General Electric Company

Cyclics Corporation

Cyclis Corporation

Tohru Takekoshi

Patricia P Anderson

Steven J Winckler

Eric J Pearce

Jane M Terry

John E Kochanowski

Farid Fouad Khouri

Andrew J Caruso

Steven R Bahr

Daniel Joseph Brunelle

John Robert Campbell

Thomas L Evans

Yi-Feng Wang

Ronald L Markezich

Kevin Hsingtao Dai

Therese C Jordan

Edwin J Iwanowicz

Sterling B Brown

Jimmy Lynn Webb

Peter David Phelps

Timothy Mark Sivavec

Donald C Clagett

Clive W Reed

Erik W Walles

Howard J Klopfer

Choong Y Han

Stephen M Cooper

Darrell R Heath

Johannes Jacobus De Moor

Judith Ann Serth-Guzzo

John T Bendler

Franciscus Petrus Mercx

Paul Willey

Sunita S Baghel

The invention provides methods and formulations involving the use of promoters that accelerate the polymerization of macrocyclic polyester oligomers (MPOs). For example, in certain embodiments, the invention provides blends of macrocyclic polyester oligomer (MPO), catalyst, and promoter that are substantially stable at ambient temperature for a period of time. The blend material may be stored without premature polymerization of MPO or deactivation of catalyst. The invention also provides processes employing one-part, ready-to-polymerize blends that contain MPO, catalyst, and promoter, as well as processes in which the catalyst and promoter are used in separate streams and are contacted when it is desired to accelerate polymerization of MPO. Methods of the invention offer advantages in the manufacture of thermoplastic parts and composites, due at least in part to the unique properties of MPO.

Methods for polymerizing macrocyclic polyester oligomers using catalyst promoters

The invention provides intimate physical mixtures of macrocyclic polyester oligomer (MPO) and filler, as well as methods for their preparation and use. Improved dispersion of filler in a polymer matrix is achieved upon polymerization, and larger amounts of filler with high aspect ratio can be used. In one aspect, the invention provides mixtures of MPO with magnesium silicate. In another aspect, the invention provides a mixture of MPO, filler, and polymerization catalyst as a one-part, ready-to-polymerize material with a long shelf life. The one-part material can be used, for example, in the manufacture of parts without modification of existing processing equipment.

Intimate physical mixtures containing macrocyclic polyester oligomer and filler

The invention provides blends of macrocyclic polyester oligomer (MPO) with high-molecular-weight polymer and polymerization catalyst as friable, one-component, ready-to-polymerize materials with long shelf life. The invention also provides methods for preparation and use of the blend materials. The blends are used, for example, in the production of thermoplastics via low-pressure processes, such as rotational molding and powder coating, without modification of existing equipment. The blends are particularly useful where it is desired to exploit the ability to polymerize and crystallize MPO isothermally, but where the melt viscosity of unfilled MPO is too low for use in existing equipment.

Blends containing macrocyclic polyester oligomer and high molecular weight polymer

A water slurry process is used to prepare a prepreg and to manufacture articles from macrocyclic polyester oligomers. In one embodiment, a process for preparing a water suspension of macrocyclic polyester oligomers includes the steps of contacting a macrocyclic polyester oligomer and a polymerization catalyst with water and a surfactant, and mixing the macrocyclic polyester oligomer and polymerization catalyst with water and the surfactant thereby forming a suspension. In another embodiment, a process for impregnating macrocyclic polyester oligomers for polymerization includes the steps of providing a suspension of a macrocyclic polyester oligomer and a polymerization catalyst in water, applying the suspension to a base material, drying to remove water from the suspension, and pressing the dried suspension to a desired form. In yet another embodiment, a composition of macrocyclic polyester oligomer includes a macrocyclic polyester oligomer, a polymerization catalyst, and water. In yet another embodiment, a process for polymerizing macrocyclic polyester oligomers includes the steps of mixing a blend material having a macrocyclic polyester oligomer and a polymerization catalyst with water to form a mixture, applying the mixture to a base material, drying to remove water, heating to polymerize the macrocyclic polyester oligomer, and pressing the polymerized macrocyclic polyester oligomer to a desired form.

Macrocyclic polyester oligomers and processes for polymerizing the same

Copolymers of polycarbonates or polyarylates with polyether polymers such as polyethersulfones, polyetherketones, and polyetherimides are prepared by reaction of the polyether polymer-forming reagents, e.g., bisphenol A disodium salt and bis(4-chlorophenyl) sulfone, in the presence of the polycarbonate or polyarylate. The reaction may take place in a dipolar aprotic solvent, or in a water-immiscible aromatic solvent in the presence of a phase transfer catalyst, preferably a hexaalkylguanidinium halide. Hydroxy-terminated polyether oligomers may be produced from the copolymers by saponification of carbonate or ester groups.

Method for preparing polyether copolymers with polycarbonates and polyarylates

Xylene derivatives, such as chloro-ortho-xylene, are oxidized in the absence of solvent or added promoter in the presence of at least one metal catalyst. The primary products are chlorophthalic anhydride and chlorotoluic acid.

Method for oxidation of xylene derivatives

A blend of a macrocyclic polyester oligomer and a polymerization catalyst as a one component ready-to-use material with a long shelf life enables production of parts from macrocyclic polyester oligomers without the modification of existing equipment, thereby reducing time and cost of manufacture while expanding the application of macrocyclic polyester oligomers. In this blend material, the macrocyclic polyester oligomer remains intact in solid state at ambient conditions. Upon melting, the blend material initially forms low viscosity fluid, and then rapidly polymerizes to form high molecular weight polyesters which subsequently solidify to form crystalline polymers. In the case of certain macrocyclic polyester oligomers, for example, poly(1,4-butylene terephthalate), demolding can take place at the polymerization temperature, e.g., at about 180&deg; C. to 200&deg; C., because the resulting polyester polymer solidifies fairly rapidly at that temperature without cooling. In one aspect, the invention generally features a blend material that includes a macrocyclic polyester oligomer, a polymerization catalyst, and optionally, a filler. In another aspect, the invention generally features a process for preparing a blend material. In yet another aspect, the invention features processes such as rotational molding, resin film infusion, pultrusion, resin transfer molding, filament winding, making and using powder-coated or hot melt prepreg, compression molding, and roll wrapping, which use the blend material.

Blend material including macrocyclic polyester oligomers and processes for polymerizing the same

Copolymers of polycarbonates or polyarylates with polyether polymers such as polyethersulfones, polyetherketones, and polyetherimides are prepared by reaction of the polyether polymer-forming reagents, e.g., bisphenol A disodium salt and bis(4-chlorophenyl)sulfone, in the presence of the polycarbonate or polyarylate. The reaction may take place in a dipolar aprotic solvent, or in a water-immiscible aromatic solvent in the presence of a phase transfer catalyst, preferably a hexaalkylguanidinium halide. Hydroxy-terminated polyether oligomers may be produced from the copolymers by saponification of carbonate or ester groups.

Polyethersulfones derived from dihydroxybiphenyls or dihydroxybenzenes, especially 4,4&prime;-dihydroxybiphenyl, are isolated by crystallization from a solvent, preferably a water-immiscible aromatic solvent. Crystallization may be achieved by cooling from the reaction temperature to a temperature in the range of about 20-100&deg; C., optionally with the use of a crystallization aid such as preformed polyethersulfone crystals. The crystallized polyethersulfone is then separated by filtration and by-product salts are removed therefrom by extraction with water.

Method for isolating dihydroxybiphenyl polyethersulfones

The instant invention provides a substantially flame retardant composition comprising: (a) a thermoplastic polyester and copolyester material, a halogenated organic fire retardant, antimony oxide, organo clay, and a fluorocarbon polymer. Also provided are compositions comprising glass fibers and stabilizers. The combination of the organo clay and the fluorocarbon polymer exhibits a synergistic effect on the fire retardant properties of the instantly claimed composition. This synergistic effect helps reduce the amount of the halogenated organic fire retardant in the instantly claimed flame retardant composition.

Fire retardant blends

Growing community of inventors

Scotia, NY, United States of America

Tohru Takekoshi