Sabic Innovative Plastics IP B.v.

Other

Sabic Global Technologies B.v.

Dennis James Patrick Maria Willemse

Hans-Peter Brack

Maarten Antoon Jan Campman

Laurus Van Der Wekke

Hatem Abdallah Belfadhel

Hans Looij

Jorge A Garcia Agudo

Yohana Perez De Diego

Ricardo Godoy-Lopez

Jan Henk Kamps

Ignacio Vic Fernandez

Jan-Pleun Lens

Dennis Karlik

Martin H Oyevaar

Peter Kennedy Davis

Josef Gerardus Berndsen

Han Vermeulen

David Domingo Fuster

Gerardo Hidalgo Llinas

Miguel Angel Salomon Cheliz

Fernando Olmedo Fernandez

Martin Walde

Marianne Guyader

Laurus Ver Der Wekke

The present invention provides methods of forming carbamates, ureas, and isocyanates. In certain embodiments these methods include the step of reacting an amine with an ester-substituted diaryl carbonate to form an activated carbamate which can be further derivitized to form non-activated carbamate or a urea. The urea or carbamate can be subjected to a pyrolysis reaction to form isocyanate.

Method for making carbamates, ureas and isocyanates

A method for forming a monomeric carbonate includes the step of combining a monofunctional alcohol or a difunctional diol with an ester-substituted diaryl carbonate to form a reaction mixture. Similarly, a method for forming a monomeric ester includes the step of combining a monofunctional carboxylic acid or ester with an ester-substituted diaryl carbonate to form a reaction mixture. These methods further include the step of allowing the reaction mixtures to react to form a monomeric carbonate or a monomeric ester, respectively.

Method for making carbonates and esters

A polycarbonate is provided that contains repeat units derived from isosorbide and a residue derived from an activated diaryl carbonate. The polycarbonate hasH-NMR peaks associated with the repeat units derived from isosorbide. The polycarbonate contains no more than a maximum allowable amount of sorbitol-derived color bodies. If these color bodies are present in the polycarbonate it has aH-NMR peak associated with the color bodies. The maximum allowable amount of color bodies are present when the integrated area of theH-NMR peak associated with the color bodies divided by the integrated areas of theH-NMR peaks associated with the repeat units derived from isosorbide is 0.025.

Method of making isosorbide polycarbonate

A melt polymerized polycarbonate comprising repeat units in the polycarbonate derived from the melt polymerization of monomers (II) and/or (III), monomer (IV), and optionally monomer (VIII), wherein monomers (II) and (III) are diaryl dihydroxy compounds, monomer (IV) is a sterically hindered dihydroxy compound, and monomer (VIII) is a non-sterically hindered dihydroxy diaryl compound; wherein the mole ratio of repeat units in the polycarbonate derived from monomers [(II)+(III)]:(IV):(VIII) is 15-70:1-85:0-50, the sum of the mole percent of repeat units in the polycarbonate derived from monomers [(II)+(III)]+(IV) is greater than or equal to 50 mole %, and the sum of the mole percent of units in the polycarbonate derived from monomers [(II)+(III)]+(IV)+(VIII) is 100 mole %; and wherein the polycarbonate has an L* value that is at least 1 L* unit value higher than the same polycarbonate in which monomer (IV) is replaced by bisphenol A.

Polycarbonates, compositions made therefrom, methods of manufacture thereof, and articles therefrom

The present invention provides methods of producing high molecular weight polymer. A method of forming polycarbonate includes the step of combining in a reaction mixture a diaryl carbonate, a transesterification catalyst, an aliphatic dihydroxy compound, and a diacid compound in a reactor system. The temperature and pressure of the reactor system are adjusted to a first reactor setpoints and the reaction mixture is monitored to detect initiation of the exothermic oligomerization reaction. The reactor setpoint are adjusted to second reactor setpoints after detection of initiation of the exothermic oligomerization reaction. The reactor system is maintained at the second reactor setpoints to allow the reaction mixture to react to form an oligomer mixture. The oligomer mixture is then introduced to a polymerization reactor system operating under melt polymerization conditions sufficient to polymerize the oligomer mixture to a Mw of at least 9,000 g/mol (PC) and to remove the phenolic byproduct from the oligomer mixture to form polycarbonate.

Method of producing high molecular weight polymer

A method of making a polycarbonate is described. The method comprises melt reacting an ester-substituted diaryl carbonate and a multifunctional compound of the formula: in the presence of catalyst to form an oligomer comprising less than 2,000 ppm of an ester-linked terminal group, and melt polymerizing the oligomer to form a polycarbonate. Use of specific reaction conditions produces a polycarbonate having an Mw of greater than or equal to 25,000 g/mol as determined by gel-permeation chromatography relative to polystyrene standards. Polycarbonates comprising units derived from the multifunctional compound, including homopolycarbonates, aliphatic copolycarbonates further comprising units derived from an aromatic dihydroxy compound, and aliphatic polycarbonate-polyesters, are also disclosed, as are a thermoplastic composition and an article including the disclosed polycarbonates.

Aliphatic polycarbonates, methods of making, and articles formed therefrom

A method of forming polycarbonate includes the steps of introducing a plurality of reaction components to a reactor operating under melt polymerization conditions and removing ester-substituted phenol from the reactor. The plurality of reaction components include a dihydroxy compound, an ester-substituted diaryl carbonate, and a melt transesterification catalyst. The reaction components are introduced in a plurality of reaction component streams. A first reaction component streams includes a melt transesterification catalyst dissolved or suspended in a liquid carrier containing an ester-substituted phenol. The composition of the first reaction component stream is selected such that ester-substituted phenol is not generated as a reaction product in the first reaction component stream.

Method of forming polycarbonate

A non-reactive monomer mixture has a monomer component dispersed in a melted diaryl carbonate. The monomer component has one or more monomer compounds having a melting point below the melting point of the diaryl carbonate. Furthermore, the monomer component has less than 600 ppb alkali metal, an acid stabilizer, or both less than 600 ppb alkali metal and an acid stabilizer. The monomer compounds of the monomer component and the diaryl carbonate are present in a mole ratio of from 0.9 to 1.1. The monomer mixture is at a temperature between the melting temperature of the lowest melting monomer compound and the melting temperature of the diaryl carbonate.

Monomer solution for producing polycarbonate

A non-reactive monomer mixture contains a monomer component and a diaryl carbonate dispersed in the mixture. The monomer component includes one or more monomer compounds having a melting point below the melting point of the diaryl carbonate. The monomer component has less than 600 ppb alkali metal, an acid stabilizer, or both less than 600 ppb alkali metal and an acid stabilizer. The monomer compounds of the monomer component and the diaryl carbonate are present in a mole ratio of from 0.9 to 1.1. The monomer mixture is at a temperature between the melting temperature of the lowest melting monomer compound and less than 5&#xb0; C. above the melting point of the diaryl carbonate.

A method is provided for producing an ester-substituted phenol product stream from an ester-substituted diaryl carbonate manufacturing waste stream. The method includes the steps of obtaining a waste stream containing an ester-substituted diaryl carbonate from an ester-substituted diaryl carbonate manufacturing facility and creating a reaction mixture by combining the waste stream with a solvent and with a transesterification catalyst. The reaction mixture is maintained at a reaction pressure at or below atmospheric pressure, and at a reaction temperature for a period of time sufficient to produce ester-substituted phenol by solvolysis of the ester-substituted diaryl carbonate. Ester-substituted phenol is removed from the reaction mixtures in an ester-substituted phenol stream. The solvent, the reaction temperature, and the reaction time are selected in combination such that less than 1,000 ppm of acid-substituted phenol is present in the ester-substituted phenol stream.

Method for producing phenolic compound

A surface of a melt polymerization reactor system having residual reaction components of a melt polymerization reaction thereon can be cleaned by introducing a cleaning agent having a phenolic compound to the polymerization reactor system and into contact with the surface of the melt polymerization reactor system having the residual reaction components of a melt polymerization reaction thereon. The residual reaction components of the melt polymerization reaction include polycarbonate oligomers or polymers or their degradation products. Further, the cleaning agent is maintained in contact with the surface for a period of time and at a temperature sufficient to substantially remove the residual reaction components from the surface.

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Standdaarbuiten, Netherlands

Dennis James Patrick Maria Willemse