Dow Global Technolgoies LLC

Blue Cube IP LLC

William W Fan

Bruce D Hook

Christian D Kneupper

Sascha Noormann

Dennis Wade Jewell

David H West

Travis Hope Larsen

Renate Patrascu

David Jean

Leming Gu

Stephen B Wallace

Marvin L Dettloff

Rui Xie

Anna Forlin

Philip J Carlberg

Mark B Wilson

Charles William Lipp

Hannah L Crampton

Heinz Groenewald

Michael D Cloeter

Stanley E Moore

Eric B Ripplinger

Yi Ling Liang

Ranate Patrascu

Perry S Basile

Dennis W Jewell

Renate P Patrascu

Sascha N Noormann

Heinz G Groenewald

Curable compositions comprising an epoxy mixture comprising a) an epoxy mixture comprising i) a first epoxy component comprising epoxy phenol novolac oligomers having a content of 2-functional monomers of less than 10 weight percent based on the total weight of the first epoxy component and having an epoxide equivalent weight in the range of 170 to 200; and ii) a second epoxy component comprising an epoxy resin having monomers with an average functionality of at least 2 and b) a hardener, are disclosed. The curable compositions can be used to prepare prepregs for hot-melt applications.

Curable epoxy compositions

A continuous process comprising a) separating an epoxy novolac resin comprising oligomers having an average functionality of greater than 2.5 and a hydrolyzable chlorine content of less than 450 ppm with a continuous evaporator apparatus to form i) a first distillate vapor fraction comprising epoxy novolac resin having more than 75 weight percent of 2 functional components and wherein the mass of the first distillate vapor fraction is in the range of from 15 to 40 weight percent of the starting epoxy novolac resin; and ii) a first bottom fraction comprising epoxy novolac resin having less than 5 weight percent of 2 functional components and having a glass transition temperature of at least 15 C higher compared to the starting epoxy novolac resin when cured; b) recovering the first bottom fraction product; and c) condensing the first distillate vapor fraction to form a first condensed distillate vapor fraction; d) separating the first condensed distillate vapor fraction with a second continuous evaporator apparatus to form i) a second distillate vapor fraction wherein the mass of the second distillate vapor fraction is in the range of from 40 to 70 weight percent of the first condensed distillate vapor fraction; and ii) a second bottom fraction; e) recovering the second bottom fraction product; and f) condensing the second distillate vapor fraction to form a second condensed distillate vapor fraction product comprising at least 98 weight percent of 2 functional components with a total chlorine content less than 900 ppm, is disclosed.

Distilled epoxy novolac resins

A continuous process comprising: a) separating a starting epoxy novolac resin comprising oligomers having an average functionality of greater than 2.5 and a hydrolyzable chlorine content of less than 450 ppm with a first continuous evaporator apparatus under a vaporization temperature in the range of from 150&#xb0; C. to 250&#xb0; C. and an absolute pressure of from 0.05 to 1 mmHg absolute to form a first vapor fraction comprising epoxy novolac resin having more than 95 weight percent of 2-functional components and wherein the mass of the first vapor fraction is in the range of from 5 to 20 weight percent of the starting epoxy novolac resin; and a first bottom fraction comprising epoxy novolac resin having a lower weight percent of 2-functional components in comparison with the weight percent of 2-functional components of the starting epoxy novolac resin; b) recovering the first bottom fraction; and c) condensing from 95 weight percent to 99.95 weight percent of the first vapor fraction at a temperature in the range of from 50&#xb0; C. to 200&#xb0; C. to form a first partially condensed vapor fraction product having at least 95 weight percent of 2-functional components and having a total chlorine content of less than 900 ppm and an uncondensed vapor product comprising halogenated impurities, is disclosed.

A process for recovering a divinylarene dioxide from a crude feed stream comprising the steps of: (a) providing an effluent reaction stream containing at least one divinylarene dioxide product and other compounds; and (b) separating/recovering the divinylarene dioxide product from the other compounds of the reaction effluent from step (a); wherein the percent recovery of the divinylarene dioxide product recovered comprises greater than about 85 percent; and wherein the percent purity of the divinylarene dioxide product recovered comprises greater than about 85 percent.

Process for recovering divinylarene dioxides

A process for preparing a divinylarene oxide including (a) reacting (i) at least one divinylarene; (ii) at least one peroxycarboximidic acid; (iii) at least one solvent; and (iv) at least one basic compound, under reaction conditions to form a reaction effluent containing a divinylarene oxide product; and then (b) evaporating the reaction effluent of step (a) to form a concentrate containing the divinylarene oxide product; and wherein the concentrate separates into two liquid phases.

Process for preparing divinylarene oxides

A multiple liquid phase composition and process for preparing an oxirane product, such as epichlorohydrin, including a reaction mixture of: (a) at least one olefin, wherein the olefin is selected from one of (i) an aliphatic olefin or substituted aliphatic olefin, with the proviso that the aliphatic olefin is not propylene, (ii) a cycloaliphatic olefin, (iii) an aromatic olefin, (iv) a cycloaromatic olefin, and (v) mixtures thereof; (b) at least one peroxide compound, (c) at least one catalyst, and (d) and a solvent mixture; wherein the solvent mixture comprises at least (i) at least one alcohol or a combination of alcohols, and (ii) at least one non-reactive co-solvent; wherein the solvents are mixed at a predetermined concentration; wherein the non-reactive co-solvent has a different boiling point than the oxirane product; and wherein the oxirane product partitions into a high affinity solvent during the reaction. The process of the present invention advantageously produces a waste stream with no significant amount of sodium chloride (NaCl). In one embodiment, the present invention includes a process for preparing epichlorohydrin from allyl chloride and hydrogen peroxide including reacting (a) an allyl chloride with (b) hydrogen peroxide, in the presence of (c) a titanium silicalite-1 (TS-1) catalyst and (d) in the presence of a predetermined amount of a mixed solvent system; wherein the mixed solvent system includes at least (i) methanol and (ii) at least one non-reactive co-solvent.

Process for producing an oxirane

A process for producing epoxide, the process including contacting an organic phase including at least one halohydrin(s) with at least one aqueous phase including a base in a plug-flow mixer/reactor system to disperse the organic phase in the aqueous phase via a mixing device imparting a power-to-mass ratio of at least 0.2 W/kg to convert at least a portion of the at least one halohydrin to an epoxide.

Process for producing epoxides

A process and apparatus are disclosed for the purification of epichlorohydrin. The process includes distilling and/or fractionating a feed stream containing epichlorohydrin, dichlorohydrin(s), and one or more other substances, subjecting at least a portion of the liquid phase effluent to a dichlorohydrin dehydrochlorination process for converting residual dichlorohydrin(s) in the liquid phase effluent to epichlorohydrin, and recovering purified epichlorohydrin from the vapor phase effluent in which the distillation/fractionation pressure and/or temperature of step (1) is adjusted to retain at least 5 weight-percent epichlorohydrin in the liquid phase effluent. The apparatus for making purified epichlorohydrin includes a dehydrochlorination apparatus, a first liquid-vapor contacting apparatus, and a second liquid-vapor contacting apparatus connected to the dehydrochlorination apparatus for recycling a distillate to the dehydrochlorination apparatus. Advantages include more efficient recovery of epichlorohydrins and reduced capital investment in recovery equipment.

Process and apparatus for producing and purifying epichlorohydrins

A process for producing epoxides, the process including: (a) feeding at least one aqueous alkali and at least one halohydrin to a reactive distillation column, wherein the reactive distillation column includes a feed zone, a top zone disposed above the feed zone, and a bottom zone disposed below the feed zone; (b) concurrently in the reactive distillation column: (i) reacting at least a portion of the halohydrin with the alkali to form an epoxide; and (ii) stripping water and the epoxide from a basic aqueous residue; (c) recovering the water and the epoxide from the reactive distillation column as an overheads fraction; (d) condensing and phase separating the overheads fraction to form an organic overheads fraction including the epoxide and an aqueous overheads fraction including water; and (e) maintaining a liquid holdup per plate in the feed zone at a residence time of 10 seconds or less.

A process for producing epoxides, the process including: (a) feeding at least one aqueous alkali and at least one halohydrin to a reactive distillation column; (b) concurrently in the reactive distillation column: (i) reacting at least a portion of the halohydrin with the alkali to form an epoxide; and (ii) stripping water and the epoxide from a basic aqueous residue; (c) recovering the water and the epoxide from the reactive distillation column as an overheads fraction; and, (d) condensing and phase separating the overheads fraction at a temperature of 50&#xb0; C. or less to form an organic overheads fraction including the epoxide and an aqueous overheads fraction including water.

Growing community of inventors

Lake Jackson, TX, United States of America

William W Fan