CA2033150A1 - Process for preparing granular polyarylene sulfides having high molecular weight - Google Patents
Process for preparing granular polyarylene sulfides having high molecular weightInfo
- Publication number
- CA2033150A1 CA2033150A1 CA002033150A CA2033150A CA2033150A1 CA 2033150 A1 CA2033150 A1 CA 2033150A1 CA 002033150 A CA002033150 A CA 002033150A CA 2033150 A CA2033150 A CA 2033150A CA 2033150 A1 CA2033150 A1 CA 2033150A1
- Authority
- CA
- Canada
- Prior art keywords
- molecular weight
- high molecular
- preparing
- polycondensation
- polyarylene sulfide
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/02—Polythioethers
- C08G75/0204—Polyarylenethioethers
- C08G75/025—Preparatory processes
- C08G75/0254—Preparatory processes using metal sulfides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/02—Polythioethers
- C08G75/0204—Polyarylenethioethers
- C08G75/0209—Polyarylenethioethers derived from monomers containing one aromatic ring
- C08G75/0213—Polyarylenethioethers derived from monomers containing one aromatic ring containing elements other than carbon, hydrogen or sulfur
- C08G75/0222—Polyarylenethioethers derived from monomers containing one aromatic ring containing elements other than carbon, hydrogen or sulfur containing nitrogen
Abstract
ABSTRACT OF THE DISCLOSURE
A process for preparing a granular polyarylene sulfide having a high molecular weight is a one-stage polycondensation process which involves subjecting a dihalogen aromatic compound to polycondensation with a source of sulfur in the presence of a polymerization aid in an organic polar solvent and setting the temperature for polycon-densation to a range from 220 °C to 248 °C for a predetermined period of time prior to completion of polycondensation up to completion of polycondensation. The resulting granular polyarylene sulfide is suitable for molding or forming into sheets, films, fibers and so on, causes less burrs when subjected to injection molding, has a high molecular weight sufficient to create the property of forming a gel, and is easy to handle.
A process for preparing a granular polyarylene sulfide having a high molecular weight is a one-stage polycondensation process which involves subjecting a dihalogen aromatic compound to polycondensation with a source of sulfur in the presence of a polymerization aid in an organic polar solvent and setting the temperature for polycon-densation to a range from 220 °C to 248 °C for a predetermined period of time prior to completion of polycondensation up to completion of polycondensation. The resulting granular polyarylene sulfide is suitable for molding or forming into sheets, films, fibers and so on, causes less burrs when subjected to injection molding, has a high molecular weight sufficient to create the property of forming a gel, and is easy to handle.
Description
PROCESS FOR PREPARING GRANULAR POLYARYLENE SULFIDES
HAVING HIGH MOLECULAR WEIGHT
BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a process for preparing a granular polyarylen~e sulfide having a high molecular weight and a controlled particle size and, more particularly, to a process ~or preparing a granular polyarylene sulfide by using a polymerization aid so as to adjust a poly-merization temperature, the granular polyarylene sulfide being suitable for the preparation of sheets, films, fibers and so on, causing less burrs to occur upon injection molding, having such a sufficiently high molecular weight as providing the property of forming a gel, and being easy to handle.
HAVING HIGH MOLECULAR WEIGHT
BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a process for preparing a granular polyarylen~e sulfide having a high molecular weight and a controlled particle size and, more particularly, to a process ~or preparing a granular polyarylene sulfide by using a polymerization aid so as to adjust a poly-merization temperature, the granular polyarylene sulfide being suitable for the preparation of sheets, films, fibers and so on, causing less burrs to occur upon injection molding, having such a sufficiently high molecular weight as providing the property of forming a gel, and being easy to handle.
2. Description of Related Art Among polyarylene sulfides such as polyphenylene sulfides, some are thermoplastic resins having partially thermosetting characteristics, which have excellent properties as engineering plastics, such as resistance to chemicals, good mechanic~al properties over a wide range of temperatures, and resistance to thermal rigidity.
Recently, demands have been made on processes for preparing polyarylene sulfides such as polyphenylene sulfides, which do not make them highly viscous by heating, which can provide them with a sufficiently high molecular weight only by polymerization, and which cannot impart color to them.
~ eretofore, th~re have been made various proposals for such demands. For example, Japanese Patent Laid-open (kokai) Publication -No. 46,228/1988 discloses a process for .
~' :
preparing a polyarylene sulfide by reacting a dihalogen aromatic compound with an alkali metal sulfide in a polar solvent, which comprises an early-stage polymerization step for forming a prepolymer ha~ing a low melting viscosity and a later-stage polymerization step for proceeding with further polymerization of the resulting prepolymer, wherein the early-stage polymerization step is carried out by reacting the dihalogen aromatic compound in such a state in which the arylene group and water are present at the rates of 0.5 mole to 3.5 moles and 0.5 mole to 5 moles, respectively, with respect to kilogram of an organic solvent in the reaction system, thereby converting the dihalogen aromatic compound at the conversion rate of 50% to 98% by mole into the prepoly~er having a melting viscosity of 5 poises to 300 poises, and the later-stage polymerization step is carried out without separation of the resulting prepolymer from the reaction system by adding water to the reaction system so as to allow the water content in the reaction system to account for 1.5 mole to 15 moles per kilogram of the organic solvent, retaining the resulting reaction system at temperatures ranging from 257C
to 290~ with stirring for at least 10 minutes and then stirring the reaction system for at least 2 hours at tempera-tures reduced to the range from appro~imately 220 C to 250 C .
This polymerization process can yield the polyarylene sulfide with a high molesular weight, which is easy to handle.
Further, for e~ample, Japanese Patent Laid-open (kokai) Publication No. 9,266/1989 discloses a polyarylene sulfide with improved burr characteristics, which is prepared by blending a non-crosslinked polyarylene thioether having a melting viscosity of 10 poises to 5 x 10~ poises and a cross--~ - ~
linked polyarylene thioether having a melting viscosity of 5 105 poises to 1 x 109 poises with a fibrous filler and/or inorganic filler.
It cannot be said, however, that the process disclosed in Japanese Patent Laid-oplen (kokai) Public~tion No.
46,228/1988 comprises at least three steps for polymerization, including the step for preparing the prepolymer and it re~uires a long reaction period of time And the polyarylene sulfide obtainable by this process has a relatively large molecular weight yet its molecular weight is not so high as demonstrating the property of forming a gel.
It is also noted that some of the polyarylene sulfides obtainable by the process disclosed in 3apanese Patent Laid-open (kokai) Publication No. 9,266/1984 contain granules at the rate of approximately 20%, yet a majority of them are in a bulky state. Therefore, they are not said to be desired in handling.
As an improvement of this process, there has been proposed the process as disclosed in Japanese Patent Laid-open (kokai) Publication No. 299,826J1989. This process is a process for preparing a crosslinked polyarylene sulfide in a granular forns, which comprises three steps including a step for converting a halogenated aromatic compound at the conversion rate of 50% to 98% by mole by using a branching agent in the presence of water in a predetermined amount at temperatures below 180~ to 235 ~ , a step for elevating the temperature of the reaction system under a particular condition so as to yield a polymer having a particular range of its melting viscosity in the presence of a particular amount of water, and a step for continuing the reaction at temperature ranging from 245~ to 290 C .
It is to be noted, however, that this process presents the problems that the steps and setting of reaction conditions are complex and the polymerization temperature in the first step is so low that the polymerization period of time becomes very long.
SUMMARY OF THE INVENTION
Therefore, the present irlvention has been completed under the circumstances as describled hereinabove and has the object to provide a simplified process for preparing a granular polyarylene sulfide, which can solve the problem that it is difficult to collect the product due to adherence to a polymerization reactor, the granular polyarylene sulfide being suitable for the molding or forming into sheets, films, fibers and so on and easy to handle, and having such a high molecular weight as providing the property of forming a gel.
In order to achieve the aforesaid object, the present invention consists of a process for preparing a granular polyarylene sulfide having a high molecular weight by polycondensing a dihalogen aromatic compound with a source of sulfur in the presence of a polymerization aid in an organic polar solvent, wherein the polycondensation temperature is so set as to range from 220~ to 248 ~ for a predetermined period of time up to the time of completion of polycondensation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described more in detail.
- Raw Materials -(1) Source of Sulfur ': ' The sulfur source to be used for the present invention may include an alkali metal sulfide, an alkali metal hydrosulfide and hydrogen sulfide.
- The alkali metal sulfide may include, for example, lithium sulfide, sodium sulfide, potassium sulfide, rubidium sulfide and cesium sulfide.
Among the sulfur sources described hereinabove, lithium sulfide and sodium sulfide are preferred, and sodium sulfide is particularly preferred.
The aforesaid alkali metal sulfides may be used singly or in combination of two or more.
It is further noted that the alkali metal sulfide may be one obtainable by the reaction of an alkali metal hydrosulfide with a base.
In other words, the alkali metal hydrosulfide may be used together with the base, in place of or in addition to the alkali metal sulfide.
Furthermore, it is to be noted that hydrogen sulfide can be used as the source of sulfur together with the base or hydrogen sulfide can be likewise used together with ~he base in addition to the alkali m2tal sulfide and/or the alkali metal hydrosulfide.
The alkali metal hydrosulfide may include, for example, lithiu~ hydrosulfide, sodium hydrosulfide, potassium hydrosulfide, rubidium hydrosulfide and cesium hydrosulfide~
Among those alkali metal hydrosulfides, sodium hydrosulfide and lithium hydrosulfide are preferred, and sodium hydrosulfide is particularly preferred.
The aforesaid ~lkali metal hydrosulfides may be used singly or in combination of two or more.
The base may be any acid receptor of an inorganic type or of an organic type, which can convert the alkali metal hydrosulfide into the alkali metal sulfiae, which can convert hydrogen sulfide into the alkali mletal hydrosulfide, or which can effectively neutrali~e or receive a hydrogen halide producible upon polycondensation o the alkali metal hyarosul-fide or hydrogen sulfide with the dihalogenated aromatic compound, as will be described hereinafter, and which does not adversely affect the object of the present invention. An alkali metal hydroxide or the like may usually be used appropriately as the base.
Specific examples of the alkali metal hydroxides may include, for example, lithium hydroxide, sodium hydro~ide, potassium hydroxide, rubidi~m hydroxide, and cesium hydroxide.
Among these alkali metal hydroxides, lithium hydro-xide and sodium hydroxide are preferred, and sodium hydroxide is particularly preferred.
The ~ase of the organic type may include, for e~ample, a metal salt of an ~ -hydroxycarboxylic acid and an alkali metal aminoalkanoate.
The aforesaid bases may be used singly or in combination of two or more.
The rate of the base may sufficiently range from 0.80 mole to 1.2 moles with respect of mole of .khe total hydrogen atoms of the alkali metal hydrosulfide and hydrogen sulfide.
As the alkali metal sulfide and the alkali metal hydrosulfide, there may be- used ones of industrial grade containing hydrated water in the amount of 2.6 moles to 9 moles per mole of them. If such industrial grade one containing smaller than 1.2 moles of hydrated water with respect to mole ' : " ' ' of the alkali metal sulfide or the alkali metal hydrosulfide is used, an appropriate amount of water may be added to the reaction system.
As described hereinabove, in accordance with the present invention, it is preferred that a small amount of water be present in the reaction system prior to polymerization because the polymerization aid such as a lithium halide, an alkali metal salt of a carboxylic acid or the like.
(2~ Dihalogen Aromatic Compounds The dihalogen aromatic compound to be used for the present invention may be any compound which is known to the art as ~seful for preparing the polyarylene sulfides.
The dihalogen aromatic compound may include, for example, a dihalobenzene such as m-dihalobenzene and p-dihalo-benzene; an alkyl-substituted dihalobenzene and a cycloalkyl-substituted dihalobenzene such as 2,3-dihalotoluene, 2,5-dihalo-toluene, 2,6-dihalotoluene, 3,4-dihalotoluene, 2,5-dihaloxylene, l-ethyl-2,5-dihalobenzene, 1,2,4,5-tetramethyl-3,6-aihalo-benzene, l-n-hexyl-2,5-dihalobenzene and 1-cyclohe~yl-2,5-di-halobenzene; an aryl-substituted dihalobenzene such as l-phenyl-2,5-dihalobenzene, 1-benzyl-2,5-dihalobenzene and l-p-toluyl-2,5-dihalobenzene; a dihalobiphenyl such as 4,4'-dihalobiphenyl;
and a dihalonaphthalene such as l,4-dihalonaphthalene, 1,5-di-halonaphthalene, and 2,S-dihalonaphthalene.
The two halogen atoms in these dihalogen aromatic compounds may be fluorine, chlorine, bromine or iodine and they may be the same as or different from each other.
Among those dihalogen aromatic compounds as described hereinabove, the dihalobenzenes are preferred, and the dichlorobenzene!s containing 70% by mole of p-dichloroben-.
.
.
zene or more is particularly preferred.
Recently, demands have been made on processes for preparing polyarylene sulfides such as polyphenylene sulfides, which do not make them highly viscous by heating, which can provide them with a sufficiently high molecular weight only by polymerization, and which cannot impart color to them.
~ eretofore, th~re have been made various proposals for such demands. For example, Japanese Patent Laid-open (kokai) Publication -No. 46,228/1988 discloses a process for .
~' :
preparing a polyarylene sulfide by reacting a dihalogen aromatic compound with an alkali metal sulfide in a polar solvent, which comprises an early-stage polymerization step for forming a prepolymer ha~ing a low melting viscosity and a later-stage polymerization step for proceeding with further polymerization of the resulting prepolymer, wherein the early-stage polymerization step is carried out by reacting the dihalogen aromatic compound in such a state in which the arylene group and water are present at the rates of 0.5 mole to 3.5 moles and 0.5 mole to 5 moles, respectively, with respect to kilogram of an organic solvent in the reaction system, thereby converting the dihalogen aromatic compound at the conversion rate of 50% to 98% by mole into the prepoly~er having a melting viscosity of 5 poises to 300 poises, and the later-stage polymerization step is carried out without separation of the resulting prepolymer from the reaction system by adding water to the reaction system so as to allow the water content in the reaction system to account for 1.5 mole to 15 moles per kilogram of the organic solvent, retaining the resulting reaction system at temperatures ranging from 257C
to 290~ with stirring for at least 10 minutes and then stirring the reaction system for at least 2 hours at tempera-tures reduced to the range from appro~imately 220 C to 250 C .
This polymerization process can yield the polyarylene sulfide with a high molesular weight, which is easy to handle.
Further, for e~ample, Japanese Patent Laid-open (kokai) Publication No. 9,266/1989 discloses a polyarylene sulfide with improved burr characteristics, which is prepared by blending a non-crosslinked polyarylene thioether having a melting viscosity of 10 poises to 5 x 10~ poises and a cross--~ - ~
linked polyarylene thioether having a melting viscosity of 5 105 poises to 1 x 109 poises with a fibrous filler and/or inorganic filler.
It cannot be said, however, that the process disclosed in Japanese Patent Laid-oplen (kokai) Public~tion No.
46,228/1988 comprises at least three steps for polymerization, including the step for preparing the prepolymer and it re~uires a long reaction period of time And the polyarylene sulfide obtainable by this process has a relatively large molecular weight yet its molecular weight is not so high as demonstrating the property of forming a gel.
It is also noted that some of the polyarylene sulfides obtainable by the process disclosed in 3apanese Patent Laid-open (kokai) Publication No. 9,266/1984 contain granules at the rate of approximately 20%, yet a majority of them are in a bulky state. Therefore, they are not said to be desired in handling.
As an improvement of this process, there has been proposed the process as disclosed in Japanese Patent Laid-open (kokai) Publication No. 299,826J1989. This process is a process for preparing a crosslinked polyarylene sulfide in a granular forns, which comprises three steps including a step for converting a halogenated aromatic compound at the conversion rate of 50% to 98% by mole by using a branching agent in the presence of water in a predetermined amount at temperatures below 180~ to 235 ~ , a step for elevating the temperature of the reaction system under a particular condition so as to yield a polymer having a particular range of its melting viscosity in the presence of a particular amount of water, and a step for continuing the reaction at temperature ranging from 245~ to 290 C .
It is to be noted, however, that this process presents the problems that the steps and setting of reaction conditions are complex and the polymerization temperature in the first step is so low that the polymerization period of time becomes very long.
SUMMARY OF THE INVENTION
Therefore, the present irlvention has been completed under the circumstances as describled hereinabove and has the object to provide a simplified process for preparing a granular polyarylene sulfide, which can solve the problem that it is difficult to collect the product due to adherence to a polymerization reactor, the granular polyarylene sulfide being suitable for the molding or forming into sheets, films, fibers and so on and easy to handle, and having such a high molecular weight as providing the property of forming a gel.
In order to achieve the aforesaid object, the present invention consists of a process for preparing a granular polyarylene sulfide having a high molecular weight by polycondensing a dihalogen aromatic compound with a source of sulfur in the presence of a polymerization aid in an organic polar solvent, wherein the polycondensation temperature is so set as to range from 220~ to 248 ~ for a predetermined period of time up to the time of completion of polycondensation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described more in detail.
- Raw Materials -(1) Source of Sulfur ': ' The sulfur source to be used for the present invention may include an alkali metal sulfide, an alkali metal hydrosulfide and hydrogen sulfide.
- The alkali metal sulfide may include, for example, lithium sulfide, sodium sulfide, potassium sulfide, rubidium sulfide and cesium sulfide.
Among the sulfur sources described hereinabove, lithium sulfide and sodium sulfide are preferred, and sodium sulfide is particularly preferred.
The aforesaid alkali metal sulfides may be used singly or in combination of two or more.
It is further noted that the alkali metal sulfide may be one obtainable by the reaction of an alkali metal hydrosulfide with a base.
In other words, the alkali metal hydrosulfide may be used together with the base, in place of or in addition to the alkali metal sulfide.
Furthermore, it is to be noted that hydrogen sulfide can be used as the source of sulfur together with the base or hydrogen sulfide can be likewise used together with ~he base in addition to the alkali m2tal sulfide and/or the alkali metal hydrosulfide.
The alkali metal hydrosulfide may include, for example, lithiu~ hydrosulfide, sodium hydrosulfide, potassium hydrosulfide, rubidium hydrosulfide and cesium hydrosulfide~
Among those alkali metal hydrosulfides, sodium hydrosulfide and lithium hydrosulfide are preferred, and sodium hydrosulfide is particularly preferred.
The aforesaid ~lkali metal hydrosulfides may be used singly or in combination of two or more.
The base may be any acid receptor of an inorganic type or of an organic type, which can convert the alkali metal hydrosulfide into the alkali metal sulfiae, which can convert hydrogen sulfide into the alkali mletal hydrosulfide, or which can effectively neutrali~e or receive a hydrogen halide producible upon polycondensation o the alkali metal hyarosul-fide or hydrogen sulfide with the dihalogenated aromatic compound, as will be described hereinafter, and which does not adversely affect the object of the present invention. An alkali metal hydroxide or the like may usually be used appropriately as the base.
Specific examples of the alkali metal hydroxides may include, for example, lithium hydroxide, sodium hydro~ide, potassium hydroxide, rubidi~m hydroxide, and cesium hydroxide.
Among these alkali metal hydroxides, lithium hydro-xide and sodium hydroxide are preferred, and sodium hydroxide is particularly preferred.
The ~ase of the organic type may include, for e~ample, a metal salt of an ~ -hydroxycarboxylic acid and an alkali metal aminoalkanoate.
The aforesaid bases may be used singly or in combination of two or more.
The rate of the base may sufficiently range from 0.80 mole to 1.2 moles with respect of mole of .khe total hydrogen atoms of the alkali metal hydrosulfide and hydrogen sulfide.
As the alkali metal sulfide and the alkali metal hydrosulfide, there may be- used ones of industrial grade containing hydrated water in the amount of 2.6 moles to 9 moles per mole of them. If such industrial grade one containing smaller than 1.2 moles of hydrated water with respect to mole ' : " ' ' of the alkali metal sulfide or the alkali metal hydrosulfide is used, an appropriate amount of water may be added to the reaction system.
As described hereinabove, in accordance with the present invention, it is preferred that a small amount of water be present in the reaction system prior to polymerization because the polymerization aid such as a lithium halide, an alkali metal salt of a carboxylic acid or the like.
(2~ Dihalogen Aromatic Compounds The dihalogen aromatic compound to be used for the present invention may be any compound which is known to the art as ~seful for preparing the polyarylene sulfides.
The dihalogen aromatic compound may include, for example, a dihalobenzene such as m-dihalobenzene and p-dihalo-benzene; an alkyl-substituted dihalobenzene and a cycloalkyl-substituted dihalobenzene such as 2,3-dihalotoluene, 2,5-dihalo-toluene, 2,6-dihalotoluene, 3,4-dihalotoluene, 2,5-dihaloxylene, l-ethyl-2,5-dihalobenzene, 1,2,4,5-tetramethyl-3,6-aihalo-benzene, l-n-hexyl-2,5-dihalobenzene and 1-cyclohe~yl-2,5-di-halobenzene; an aryl-substituted dihalobenzene such as l-phenyl-2,5-dihalobenzene, 1-benzyl-2,5-dihalobenzene and l-p-toluyl-2,5-dihalobenzene; a dihalobiphenyl such as 4,4'-dihalobiphenyl;
and a dihalonaphthalene such as l,4-dihalonaphthalene, 1,5-di-halonaphthalene, and 2,S-dihalonaphthalene.
The two halogen atoms in these dihalogen aromatic compounds may be fluorine, chlorine, bromine or iodine and they may be the same as or different from each other.
Among those dihalogen aromatic compounds as described hereinabove, the dihalobenzenes are preferred, and the dichlorobenzene!s containing 70% by mole of p-dichloroben-.
.
.
zene or more is particularly preferred.
(3) Polymerization Aids In the process according to the present invention, it is significant that the dihalogen aromatic compound is polycondensed with the sulfur source in the presence of the polymerization aid.
The polymerization aid to be employed for the present invention may include an organic acid salt or an inorganic acid salt, which is soiuble in the organic polar solvent to be used for polymerization.
Specific examples of the polymerization aids may include, for example, lithium chlor~de, lithium fluoride, lithium acetate, sodium acetate, or the like.
Among those polymerization aids, lithi~m chloride is particularly preferred.
The polymerization aid to be employed for the present invention may include an organic acid salt or an inorganic acid salt, which is soiuble in the organic polar solvent to be used for polymerization.
Specific examples of the polymerization aids may include, for example, lithium chlor~de, lithium fluoride, lithium acetate, sodium acetate, or the like.
Among those polymerization aids, lithi~m chloride is particularly preferred.
(4) Branching Agents, etc.
- In accordance with the present invention, a branching agent, such as an active-hydrogen containing, halogen aromatic compound, a polyhalogen aromatic compound containing three halogen atoms or more in one molecule and a halogen aromatic nitro compound, or the like, may appropriately be selected and be added to the reaction system.
As the active-hydrogen containing, halogen aromatic compound, there may be mentioned a halogen aromatic compound with a functional group or groups havin~ active hydrogen atom, such as an amino group, mercapto group, hydroxyl group or the like. More specifically, the active-hydrogen, containing halogen aromatic colmpound may include, for example, a dihaloani-line such as 2,6-dichloroaniline, 2,5-dichloroaniline, 2,4-di-chloroaniline ~nd 2,3-dichloroaniline, a trihaloaniline such . .
....~;
.
., - . : . ~: . :
. . , . ~ . . :
as 2,3,4-trichloroanilin~, 2,3,5-trichloroaniline, 2,4,6-tri-chloroaniline and 3,4,5-trichloroaniline, a dihaloaminodiphenyl ether such as 2,2'-diamino-4,4'-dichlorodiphenyl ether and 2,4'-diamino-2',4-dichlorodiphenyl ether, and a mixture thereof, and those in which the iamino group is replaced by the other functional group such as thiol group or hydro~yl group.
There may also be used an active-hydrogen containing, halogen aromatic compound in which hydrogen atom or atoms joined to the carbon atom or atoms forming its aromatic ring is or are replaced by another inert group or groups such~as a carbohydryl group, i.e., an alkyl group.
Among the active-hydrogen containing, halogen aromatic compounds, the active-hydrogen containing, dihalogen aromatic compound is preferred. Dichloroaniline is particularly preferred.
As the polyhalogen aromatic compound having three halogen atoms or more in one molecule, there may specifically be used 1,2,4-trichlorobenzene, 1,3,5-trichlorobenzene, and 1,4,6-trichloronaphthalene.
The halogen aromatic nitro compound may include, for example, a mono- or di-halonitrobenzene such as 2,4-dinitro-chlorobenzene or 2,5-dichloronitrobenzene, a dihalonitrodiphenyl ether such as 2-nitro-4,4'-dichlorodiphenyl ether, a dihalo-nitrodiphenyl sulfone such as 3,3'-dinitro-~,4'-dichlorodiphenyl sulfone, a mono- or di-halonitropyridine such as 2,5-dichloro 3-nitropyridine or Z-chloro-3,5-dinitropyridine, or a dihalo-nitronaphthalene.
Various characteristics of the polymers to be produced by the process according to the present invention ~ . ~ ' , ' ' ' ` ~- ' may be further improved by increasing the branching degree of the resulting polymer, further increasing the molecular weight of the resulting polymer or forming the polymer wi~h a decreased melt flowability and wit:h the property of forming a gel by using these active-hydrogen containing, halogen aromatic compound, polyhalogen aromatic compound, halogen aromatic nitro compound, or the like.
In accordance with the process of the present in~ention, these branching agent may be employed singly or in combination with two or more.
- In accordance with the present invention, a branching agent, such as an active-hydrogen containing, halogen aromatic compound, a polyhalogen aromatic compound containing three halogen atoms or more in one molecule and a halogen aromatic nitro compound, or the like, may appropriately be selected and be added to the reaction system.
As the active-hydrogen containing, halogen aromatic compound, there may be mentioned a halogen aromatic compound with a functional group or groups havin~ active hydrogen atom, such as an amino group, mercapto group, hydroxyl group or the like. More specifically, the active-hydrogen, containing halogen aromatic colmpound may include, for example, a dihaloani-line such as 2,6-dichloroaniline, 2,5-dichloroaniline, 2,4-di-chloroaniline ~nd 2,3-dichloroaniline, a trihaloaniline such . .
....~;
.
., - . : . ~: . :
. . , . ~ . . :
as 2,3,4-trichloroanilin~, 2,3,5-trichloroaniline, 2,4,6-tri-chloroaniline and 3,4,5-trichloroaniline, a dihaloaminodiphenyl ether such as 2,2'-diamino-4,4'-dichlorodiphenyl ether and 2,4'-diamino-2',4-dichlorodiphenyl ether, and a mixture thereof, and those in which the iamino group is replaced by the other functional group such as thiol group or hydro~yl group.
There may also be used an active-hydrogen containing, halogen aromatic compound in which hydrogen atom or atoms joined to the carbon atom or atoms forming its aromatic ring is or are replaced by another inert group or groups such~as a carbohydryl group, i.e., an alkyl group.
Among the active-hydrogen containing, halogen aromatic compounds, the active-hydrogen containing, dihalogen aromatic compound is preferred. Dichloroaniline is particularly preferred.
As the polyhalogen aromatic compound having three halogen atoms or more in one molecule, there may specifically be used 1,2,4-trichlorobenzene, 1,3,5-trichlorobenzene, and 1,4,6-trichloronaphthalene.
The halogen aromatic nitro compound may include, for example, a mono- or di-halonitrobenzene such as 2,4-dinitro-chlorobenzene or 2,5-dichloronitrobenzene, a dihalonitrodiphenyl ether such as 2-nitro-4,4'-dichlorodiphenyl ether, a dihalo-nitrodiphenyl sulfone such as 3,3'-dinitro-~,4'-dichlorodiphenyl sulfone, a mono- or di-halonitropyridine such as 2,5-dichloro 3-nitropyridine or Z-chloro-3,5-dinitropyridine, or a dihalo-nitronaphthalene.
Various characteristics of the polymers to be produced by the process according to the present invention ~ . ~ ' , ' ' ' ` ~- ' may be further improved by increasing the branching degree of the resulting polymer, further increasing the molecular weight of the resulting polymer or forming the polymer wi~h a decreased melt flowability and wit:h the property of forming a gel by using these active-hydrogen containing, halogen aromatic compound, polyhalogen aromatic compound, halogen aromatic nitro compound, or the like.
In accordance with the process of the present in~ention, these branching agent may be employed singly or in combination with two or more.
(5) Organic Polar Solvents As the organic polar solvent to be used for the present invention, there may be used a non-protonic organic solvent such as an amide compound, a lactam compound, a urea compound and a cyclic organophosphorus compound.
The amide compound may include, for example, N,N-di-methylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N,N-dipropylacetamide, N,N-dimethylbenzoic amide, and the like.
The lactam compound may include, for example, capro-lactam, N-methylcaprolactam, N-ethylcaprolactam, N-n-propylcap-lactam, N-isopropylcaprolactam, N-n-butylcaprolactam, N-iso-butylcaprolactam, N-cyclohexylcaprolactam, N-methyl-2-pyrroli-done, N-ethyl-2-pyrrolidone, N-n-propyl-2-pyrrolidone, N-iso-propyl-2-pyrrolidone, N-n-butyl-2-pyrrolidone, N-isobutyl-2-pyrrolidone, N-cyclohe~yl-2-pyrrolidone, N-methyl-3-methyl-2-pyrrolidone, N-ethyl-3-methyl-2-pyrrolidone, N-methyl-3,4,5-tri-methyl-2-pyrrolidone, N-methyl-2-piperidone, N-ethyl-2-piperî-done, N-isopropyl-2-piperidone, N-methyl-6-methyl-2-piperidone, N-methyl-3-ethyl-2-piperidone, and the like~
'' ` , .
.'. ' ~ ~ .
' . , - .
', . , ' ' -' : -. ' , ' ' As the urea compound may be used, for example, tetra-methyl urea, N,N'-dimethyleth~leneurea, N,N'-dimethylpropylene urea, and so on.
Th~ cyclic organophosphorus compound may include, for example l-methyl-l-oxosulphorane, l-ethyl-l-oxosulphorane, l-phenyl-l-oxosulphorane, l-metyl-l-oxophosphorane, l-n-propyl-l-oxophosphorane, l-phenyl-1-oxophosphorane, and the like.
These solvents may be employed singly or in combination of two or more.
Among those solvents, an N-alkyllact~m and an N-alkyl-pyrrolidone are preferred. Particularly preferred is N-methyl-2-pyrrolidone.
The amide compound may include, for example, N,N-di-methylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N,N-dipropylacetamide, N,N-dimethylbenzoic amide, and the like.
The lactam compound may include, for example, capro-lactam, N-methylcaprolactam, N-ethylcaprolactam, N-n-propylcap-lactam, N-isopropylcaprolactam, N-n-butylcaprolactam, N-iso-butylcaprolactam, N-cyclohexylcaprolactam, N-methyl-2-pyrroli-done, N-ethyl-2-pyrrolidone, N-n-propyl-2-pyrrolidone, N-iso-propyl-2-pyrrolidone, N-n-butyl-2-pyrrolidone, N-isobutyl-2-pyrrolidone, N-cyclohe~yl-2-pyrrolidone, N-methyl-3-methyl-2-pyrrolidone, N-ethyl-3-methyl-2-pyrrolidone, N-methyl-3,4,5-tri-methyl-2-pyrrolidone, N-methyl-2-piperidone, N-ethyl-2-piperî-done, N-isopropyl-2-piperidone, N-methyl-6-methyl-2-piperidone, N-methyl-3-ethyl-2-piperidone, and the like~
'' ` , .
.'. ' ~ ~ .
' . , - .
', . , ' ' -' : -. ' , ' ' As the urea compound may be used, for example, tetra-methyl urea, N,N'-dimethyleth~leneurea, N,N'-dimethylpropylene urea, and so on.
Th~ cyclic organophosphorus compound may include, for example l-methyl-l-oxosulphorane, l-ethyl-l-oxosulphorane, l-phenyl-l-oxosulphorane, l-metyl-l-oxophosphorane, l-n-propyl-l-oxophosphorane, l-phenyl-1-oxophosphorane, and the like.
These solvents may be employed singly or in combination of two or more.
Among those solvents, an N-alkyllact~m and an N-alkyl-pyrrolidone are preferred. Particularly preferred is N-methyl-2-pyrrolidone.
(6) ~ates of Blending The rate of the dihalogen aromatic compound may range usually from 0.95 mole to 1.30 moles, preferably from 0.g7 mole to 1.20 moles, with respect to mole of the sulfur atom in the sulfur source, when no branching agent is employed.
When the branching agent is employed, the n~mber of total moles of the dihalogen aromatic compound and the branching agent may be adjusted to range usually from 0.95 mole to 1.30 moles, preferably from 0.97 mole to 1.20 moles, with respect to mole of the sulfur atom in the sulf~lr source.
If the rate of the dihalogen aromatic compound is less than 0~95 mole with respect to mole of the sulfur atom in the sulfur source when no branching agent is employed or if the number of total moles of the dihalogen aromatîc compound and the branching agent is less than 0.95 mole with respect thereto when the branching agent is employed, on the one hand, by-products such as thiophenol may be prepared. On the other hand, if the dihalogen aromatic compound would be ~' ' '' ~ ' ' ' ' " . . ' , , - - ' ' employPd at the rate of more than 1.30 moles with respect to mole of the sul~ur atom in the sulfur source when no branching agent is employed or if the number of total moles of the dihalogen aromatic compound and the branching agent is less than 1.30 moles with respect thereto whe~ the branching agent is employed, the molecular weight of the resulting polyarylene sulfides may be reduced.
The rate of the organic polar solvent to be used may range usually from 1 mole to 30 moles, preferably from 3 moles to 15 moles, with respect to mole of the sulfur atom of the sulfur source. In this case, if the rate of the organic polar solvent would be less than one mole, on the one hand, the reaction may not proceed to a sufficient extent. If the organic polar solvent would be employed at the rate larger than ~0 moles, on the other hand, the volume efficiency may be worsened, thereby reducing productivity.
The rate of the branching a~ent to be optionally used may be in the range usually from 0.0005 mole to 0.05 mole, preferably from 0.001 mole to 0.02 mole, with respect to mole o t~e sulfur atom in the sulfur source.
The poly~erization aid may be employed at the rate ranqing usually from 0.05 mole to 2.0 moles, preferably from 0.2 mole to 1.2 moles, with respect to mole of the sulfur atom of the sulfur source. In this case, if the rate of the polymerization aid would be les~ than 0.05 mole with respect to mole of the sulfur atom in the sulfur source, on the one hand, the effect of adding the polymerization aid cannot be demonstrated to a sufficient extent, the reaction velocity may become slower, and the resulting polyarylene sulfide cannot increase its molecular weight or purity to a sufficient ~. : . . . . .
~ . . , ' ~ ' '~ ' ' ' : ' :
level~ If the polymerization aid would be employed at the rate greater than 2.0 moles, on the other hand, the effect cannot be achieved so as to comply with the use of such a large amount of the polymerization, thereby raising costs for preparation In this case, therefore, the process is disadvan-tageous in terms of economy.
- Polycondensation -The process according to the present invention can provide the polyarylene sulfides by polycondensing the dihalogen aromatic compound with the source of sulfur in the presence of the polymerization aid in the organic polar solvent, preferably in the presence of the branching agent.
A preferred example of the polycondensation involves, first, dehydrating a mixture of the sulfur source and the polymerization aid with the organic polar solvent by heating it, for example, under streams of an inert gas or under reduced pressures at a predetermined temperature for a predetermined period of time and, after the lapse of the predetermined period of time, reduciny the temperature of the reaction system, followed by adding the dihalogen aromatic compound and, if necessary, the branching agent to the reaction system and reacting the mixture at a predetermined temperature for a predetermined period of time.
The polymeri~ation to be employed for the present invention is not restricted to the aforesaid example and, for example, the polymerization aid may be added after the dehydration. It is further noted that the water content in the polyrondensation step may be usually 2.5 moles or less with respect to mole of the sulfur source, preferably 1.5 moles or less with respect to mole of the sulfur source particularly when lithium chloride is employed.
It should be noted in accordance with the present invention that the temperature for the polycondensation during the polymerization is of extreme significance. In particular~
it is significant that, in the ,polycondensation step, the temperature is set to lie in the range usually from 220 C to 248 C , preferably from 225 C to 248 ~ , for a predetermined period of time ranging from the predetermined time point prior to the completion of polycondensation up to the time point of the completion of polycondensation. If the temperature at this time would become lower than 220C , on the one hand, the reaction velocity may become too slow to be practical. If the temperature at this time would exceed 248 ~ , on the other hand, the resulting polymer may become bulky, thereby failing to yield the granular polyarylene sulfide easy in handling. It is to be noted, herein, that the terms "completion of completion" referred to hereinabove is intended to mean the stop of the operation -for polycondensation yet is not necessarily intended to mean the completion of reaction at a 100~ rate.
The period of time for which the temperature should be retained in the range of 220 ~ to 248 C may vary with the kind and the rate of each component to be employed, the kind and the rate of the polymerization aid to be employed, and so on, and cannot be determined uniformly When the reaction `time required from the start of polycondensation to the completion of polycondensation may range from U.5 hour to 20 hours, the period of time for which the polycondensation should ~e retained at the temperatures ranging from 220 C to 248 ~ may be in the range usually within 10 hours, preferably ' ~ ' ; " '~
---- ' from 10 minutes to 8 hours, prior to the completion of poly-condensation.
This period of time is determined on the basis of the fact that p-dichlorobenzene is converted at the rate ranging from 70% to 98% and that the poly~ondensation is carried out at the temperature ranging from 220 ~ to 248 C
prior to the timing at which the logarithmic number,~ I n n f the resulting polyarylene sulfide indicates usually 0.3 or larger.
It is further to be noted that, in accordance with the process according to the present invention, although the polycondensation may be carried out at the temperature ranging from 220~ to 248 C fro~ the start of the polycondensation to the completion of the polycondensation, it will take a long period of time. It is accordingly effective in terms of shortening the reaction time that the polycondensation is carried out at the temperature ranging from 250 ~ to 290 C
at the time of the start of polycondensation and the reaction temperature is lowered to 220 C to 248 C at which the poly-condensation is continued to proceed for the predetermined period of time prior to the completion of polycondensation, thereby making the resulting polyarylene sulfide higher in molecular weight and granular. The reaction temperature at 250C
to 290~C may be maintained constantly or reduced or elevated gradually in a stepwise manner or in a continuous manner. If the reaction temperature would exceed 290 C , side reactions may occur and the resulting polymer may deteriorate, thereby resulting in the causes of making the resulting polymer irregular, such as coloration or gellation.
As a reactor for polycondensation, there may be --:
employed any device which has conventionally been employed for polymerization. The kind of a stirrer is not restricted to a particular one and the effect sought to be achieved by the present invention can particularly be demonstrated by using a paddle wing or the like - Polyarylene SulEid~s -The polyarylene sulfide synthesized by the poly-merization may be isolated by separating it directly from the reaction mixture by a standard method, such as filtration, centrifugal separation or the like, or by separating it from the reaction mixture after addition of water and/or a flocculating agent such as a dilute acid.
The polymer separated is then washed usually with water, N-methylpyrrolidone (NMP),` methanol, acetone, ben~ene, toluene, or the like to remove the alkali metal halide, alkali metal sulfide, polymerization aid, hy-products and the like which adhere to the polymer.
The resulting polymer may be recovered by distilling the solvent off from the reaction mixture without separation therefrom and by washing the residue in the same manner as above. The solvent recovered may be re-used.
In accordance with the process of the present invention, the granular polyarylene sulfide having a sufficiently high molecular weight, which has a logarithmic viscosity number n i n h of 0.30 or hi~her and a melt index (MI) of O to 50 grams per 10 minutes and, in some cases, which can demonstrate the property of forming a gel and have a controlled particle size ranging from 0.5 mm to 5 mm, can be prepared by the simplified mode of steps with ease and stability. In accordance with the present invention, the form of the resulting polyarylene sulfide referred to as "granular" may be in a form of beads as well as in a form of granules.
The polyarylene sulfides prepared in the manner as described hereinabove may be subjected to desalting treatment, if needed, thereby reducing the content of a salt, such as sodium chloride, in the polymer.
The polyarylene sulfides prepared by the process according to the present invention may be formed into various products by formulating them with an appropriate amount of other polymers, fillers such as pigment, graphite, metallic powder, glass powder, quartz powder, talc, calcium carbonate, glass fibers, carbon fibers, whiskers, a stabilizer, a lubricant or the like. The resulting polyarylene sulfide can appropriately be used for various molaing materials and materials for films, fibers, mechanical parts, electronic parts, and so on.
The present invention will be described more in detail by way of examples with reference to comparative examples. It is to be understood, however, that the present invention is not considered in any respect to be limitative to the examples.
E~ample 1 A 10-liter autoclave was charged with 1,369 grams (8.14 moles) of sodium sulfide pentahydrate (NazS~ 5H20), 345 grams (8.14 m~les) of lithium chloride (LiCl), and 4,161 ml of N-methylpyrrolidone (NMP). The autoclave was heated to 195 ~ under nitrogen gas stream to distill off 1,830 ml of a mixture of water with N-methyl-2-pyrrolidone. At the same time, hydrogen sulfide gas (H2S) was distilled off into the solution ~ : ' , . ~ .
at the rate of 6.88% by mole with respect to NazS. Then the autoclave was cooled to about 100 C . To the autoclave, a mixture of 1,108 grams (7.54 moles) of p-dichlorobenzene- ~p-DCB), 8.74 grams [0.046 mole) of dichloronitrobenzene (DCNB~, and 1,500 ml of NMP was added, and the resulting mixture was subjected to polycondensation at 260C for 30 minutes and then at 245 C for 4 hours. Thereafter, the resulting poly-phenylene sulfide (PPS) in a granular form was separated through 60-mesh sieve, washed with water and then with acetone, and dried under vacuum condition. The resulting granular PPS
was found to have an average particle si~e of 4,100 microns.
The polymer after the reaction at 260 'C for 30 minutes had a logarithmic viscosity number n ; n n of 0.22 and a conversion rate of 81%.
The result is shown in Table below.
Examples 2 to 5 The polyarylene sulfides were prepa~ed in substan-tially the same manner as in Example 1, except for a pattern o~ the temperatures for polycondensation.
The results are shown in Table below.
Comparative Example 1 The polyarylene`sulfide was prepared in substantially the same manner as in E~ample 1, except for the polycondensation at 260~ It was found as a result that the stirring of the reaction system became disabled in 1.5 hours due to adherence of the polymer to the paddle wings.
Comparative Example 2 The polyarylene sulfide was prepared in substantially the same manner as in Example 1, except for using the patter of the reaction temperatures shown in Table below. It was also ',, . ~ ' found that the stirring of the reaction mixture disabled because the resulting mixture became solidified.
Reference Example The polyarylene sulfide was prepared in substantially the same m~nner as in Example 1, except for maintàining the reaction temperature constantly at 260~ excluding the timing at which p-dichlorobenzene, dichloronitrobenzene and NMP were charged The results are shown in Table below. I n instancés where the melt index is higher than 200 grams per 10 minutes, the polymer in a granular form can be prep~red without controlling the temperature.
Example 6 - The procedures were followed in substantially the same manner as in Example 1, except for using 111.0 grams (7.56 moles) of p-dichlorobenzene and 4.37 grams (0.023 mole) of 2,5-dichloronitroben~ene and carrying out polycondensation at 235~ for 5 hours.
The result is shown in Table below.
Comparative Example 3 The polyarylene sulfide was prepared in substantially the same manner as in Example 6, except for carrying out poly-condensation at 260 C for 2 hours.
The result is shown in Table below.
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When the branching agent is employed, the n~mber of total moles of the dihalogen aromatic compound and the branching agent may be adjusted to range usually from 0.95 mole to 1.30 moles, preferably from 0.97 mole to 1.20 moles, with respect to mole of the sulfur atom in the sulf~lr source.
If the rate of the dihalogen aromatic compound is less than 0~95 mole with respect to mole of the sulfur atom in the sulfur source when no branching agent is employed or if the number of total moles of the dihalogen aromatîc compound and the branching agent is less than 0.95 mole with respect thereto when the branching agent is employed, on the one hand, by-products such as thiophenol may be prepared. On the other hand, if the dihalogen aromatic compound would be ~' ' '' ~ ' ' ' ' " . . ' , , - - ' ' employPd at the rate of more than 1.30 moles with respect to mole of the sul~ur atom in the sulfur source when no branching agent is employed or if the number of total moles of the dihalogen aromatic compound and the branching agent is less than 1.30 moles with respect thereto whe~ the branching agent is employed, the molecular weight of the resulting polyarylene sulfides may be reduced.
The rate of the organic polar solvent to be used may range usually from 1 mole to 30 moles, preferably from 3 moles to 15 moles, with respect to mole of the sulfur atom of the sulfur source. In this case, if the rate of the organic polar solvent would be less than one mole, on the one hand, the reaction may not proceed to a sufficient extent. If the organic polar solvent would be employed at the rate larger than ~0 moles, on the other hand, the volume efficiency may be worsened, thereby reducing productivity.
The rate of the branching a~ent to be optionally used may be in the range usually from 0.0005 mole to 0.05 mole, preferably from 0.001 mole to 0.02 mole, with respect to mole o t~e sulfur atom in the sulfur source.
The poly~erization aid may be employed at the rate ranqing usually from 0.05 mole to 2.0 moles, preferably from 0.2 mole to 1.2 moles, with respect to mole of the sulfur atom of the sulfur source. In this case, if the rate of the polymerization aid would be les~ than 0.05 mole with respect to mole of the sulfur atom in the sulfur source, on the one hand, the effect of adding the polymerization aid cannot be demonstrated to a sufficient extent, the reaction velocity may become slower, and the resulting polyarylene sulfide cannot increase its molecular weight or purity to a sufficient ~. : . . . . .
~ . . , ' ~ ' '~ ' ' ' : ' :
level~ If the polymerization aid would be employed at the rate greater than 2.0 moles, on the other hand, the effect cannot be achieved so as to comply with the use of such a large amount of the polymerization, thereby raising costs for preparation In this case, therefore, the process is disadvan-tageous in terms of economy.
- Polycondensation -The process according to the present invention can provide the polyarylene sulfides by polycondensing the dihalogen aromatic compound with the source of sulfur in the presence of the polymerization aid in the organic polar solvent, preferably in the presence of the branching agent.
A preferred example of the polycondensation involves, first, dehydrating a mixture of the sulfur source and the polymerization aid with the organic polar solvent by heating it, for example, under streams of an inert gas or under reduced pressures at a predetermined temperature for a predetermined period of time and, after the lapse of the predetermined period of time, reduciny the temperature of the reaction system, followed by adding the dihalogen aromatic compound and, if necessary, the branching agent to the reaction system and reacting the mixture at a predetermined temperature for a predetermined period of time.
The polymeri~ation to be employed for the present invention is not restricted to the aforesaid example and, for example, the polymerization aid may be added after the dehydration. It is further noted that the water content in the polyrondensation step may be usually 2.5 moles or less with respect to mole of the sulfur source, preferably 1.5 moles or less with respect to mole of the sulfur source particularly when lithium chloride is employed.
It should be noted in accordance with the present invention that the temperature for the polycondensation during the polymerization is of extreme significance. In particular~
it is significant that, in the ,polycondensation step, the temperature is set to lie in the range usually from 220 C to 248 C , preferably from 225 C to 248 ~ , for a predetermined period of time ranging from the predetermined time point prior to the completion of polycondensation up to the time point of the completion of polycondensation. If the temperature at this time would become lower than 220C , on the one hand, the reaction velocity may become too slow to be practical. If the temperature at this time would exceed 248 ~ , on the other hand, the resulting polymer may become bulky, thereby failing to yield the granular polyarylene sulfide easy in handling. It is to be noted, herein, that the terms "completion of completion" referred to hereinabove is intended to mean the stop of the operation -for polycondensation yet is not necessarily intended to mean the completion of reaction at a 100~ rate.
The period of time for which the temperature should be retained in the range of 220 ~ to 248 C may vary with the kind and the rate of each component to be employed, the kind and the rate of the polymerization aid to be employed, and so on, and cannot be determined uniformly When the reaction `time required from the start of polycondensation to the completion of polycondensation may range from U.5 hour to 20 hours, the period of time for which the polycondensation should ~e retained at the temperatures ranging from 220 C to 248 ~ may be in the range usually within 10 hours, preferably ' ~ ' ; " '~
---- ' from 10 minutes to 8 hours, prior to the completion of poly-condensation.
This period of time is determined on the basis of the fact that p-dichlorobenzene is converted at the rate ranging from 70% to 98% and that the poly~ondensation is carried out at the temperature ranging from 220 ~ to 248 C
prior to the timing at which the logarithmic number,~ I n n f the resulting polyarylene sulfide indicates usually 0.3 or larger.
It is further to be noted that, in accordance with the process according to the present invention, although the polycondensation may be carried out at the temperature ranging from 220~ to 248 C fro~ the start of the polycondensation to the completion of the polycondensation, it will take a long period of time. It is accordingly effective in terms of shortening the reaction time that the polycondensation is carried out at the temperature ranging from 250 ~ to 290 C
at the time of the start of polycondensation and the reaction temperature is lowered to 220 C to 248 C at which the poly-condensation is continued to proceed for the predetermined period of time prior to the completion of polycondensation, thereby making the resulting polyarylene sulfide higher in molecular weight and granular. The reaction temperature at 250C
to 290~C may be maintained constantly or reduced or elevated gradually in a stepwise manner or in a continuous manner. If the reaction temperature would exceed 290 C , side reactions may occur and the resulting polymer may deteriorate, thereby resulting in the causes of making the resulting polymer irregular, such as coloration or gellation.
As a reactor for polycondensation, there may be --:
employed any device which has conventionally been employed for polymerization. The kind of a stirrer is not restricted to a particular one and the effect sought to be achieved by the present invention can particularly be demonstrated by using a paddle wing or the like - Polyarylene SulEid~s -The polyarylene sulfide synthesized by the poly-merization may be isolated by separating it directly from the reaction mixture by a standard method, such as filtration, centrifugal separation or the like, or by separating it from the reaction mixture after addition of water and/or a flocculating agent such as a dilute acid.
The polymer separated is then washed usually with water, N-methylpyrrolidone (NMP),` methanol, acetone, ben~ene, toluene, or the like to remove the alkali metal halide, alkali metal sulfide, polymerization aid, hy-products and the like which adhere to the polymer.
The resulting polymer may be recovered by distilling the solvent off from the reaction mixture without separation therefrom and by washing the residue in the same manner as above. The solvent recovered may be re-used.
In accordance with the process of the present invention, the granular polyarylene sulfide having a sufficiently high molecular weight, which has a logarithmic viscosity number n i n h of 0.30 or hi~her and a melt index (MI) of O to 50 grams per 10 minutes and, in some cases, which can demonstrate the property of forming a gel and have a controlled particle size ranging from 0.5 mm to 5 mm, can be prepared by the simplified mode of steps with ease and stability. In accordance with the present invention, the form of the resulting polyarylene sulfide referred to as "granular" may be in a form of beads as well as in a form of granules.
The polyarylene sulfides prepared in the manner as described hereinabove may be subjected to desalting treatment, if needed, thereby reducing the content of a salt, such as sodium chloride, in the polymer.
The polyarylene sulfides prepared by the process according to the present invention may be formed into various products by formulating them with an appropriate amount of other polymers, fillers such as pigment, graphite, metallic powder, glass powder, quartz powder, talc, calcium carbonate, glass fibers, carbon fibers, whiskers, a stabilizer, a lubricant or the like. The resulting polyarylene sulfide can appropriately be used for various molaing materials and materials for films, fibers, mechanical parts, electronic parts, and so on.
The present invention will be described more in detail by way of examples with reference to comparative examples. It is to be understood, however, that the present invention is not considered in any respect to be limitative to the examples.
E~ample 1 A 10-liter autoclave was charged with 1,369 grams (8.14 moles) of sodium sulfide pentahydrate (NazS~ 5H20), 345 grams (8.14 m~les) of lithium chloride (LiCl), and 4,161 ml of N-methylpyrrolidone (NMP). The autoclave was heated to 195 ~ under nitrogen gas stream to distill off 1,830 ml of a mixture of water with N-methyl-2-pyrrolidone. At the same time, hydrogen sulfide gas (H2S) was distilled off into the solution ~ : ' , . ~ .
at the rate of 6.88% by mole with respect to NazS. Then the autoclave was cooled to about 100 C . To the autoclave, a mixture of 1,108 grams (7.54 moles) of p-dichlorobenzene- ~p-DCB), 8.74 grams [0.046 mole) of dichloronitrobenzene (DCNB~, and 1,500 ml of NMP was added, and the resulting mixture was subjected to polycondensation at 260C for 30 minutes and then at 245 C for 4 hours. Thereafter, the resulting poly-phenylene sulfide (PPS) in a granular form was separated through 60-mesh sieve, washed with water and then with acetone, and dried under vacuum condition. The resulting granular PPS
was found to have an average particle si~e of 4,100 microns.
The polymer after the reaction at 260 'C for 30 minutes had a logarithmic viscosity number n ; n n of 0.22 and a conversion rate of 81%.
The result is shown in Table below.
Examples 2 to 5 The polyarylene sulfides were prepa~ed in substan-tially the same manner as in Example 1, except for a pattern o~ the temperatures for polycondensation.
The results are shown in Table below.
Comparative Example 1 The polyarylene`sulfide was prepared in substantially the same manner as in E~ample 1, except for the polycondensation at 260~ It was found as a result that the stirring of the reaction system became disabled in 1.5 hours due to adherence of the polymer to the paddle wings.
Comparative Example 2 The polyarylene sulfide was prepared in substantially the same manner as in Example 1, except for using the patter of the reaction temperatures shown in Table below. It was also ',, . ~ ' found that the stirring of the reaction mixture disabled because the resulting mixture became solidified.
Reference Example The polyarylene sulfide was prepared in substantially the same m~nner as in Example 1, except for maintàining the reaction temperature constantly at 260~ excluding the timing at which p-dichlorobenzene, dichloronitrobenzene and NMP were charged The results are shown in Table below. I n instancés where the melt index is higher than 200 grams per 10 minutes, the polymer in a granular form can be prep~red without controlling the temperature.
Example 6 - The procedures were followed in substantially the same manner as in Example 1, except for using 111.0 grams (7.56 moles) of p-dichlorobenzene and 4.37 grams (0.023 mole) of 2,5-dichloronitroben~ene and carrying out polycondensation at 235~ for 5 hours.
The result is shown in Table below.
Comparative Example 3 The polyarylene sulfide was prepared in substantially the same manner as in Example 6, except for carrying out poly-condensation at 260 C for 2 hours.
The result is shown in Table below.
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Claims (16)
1. A process for preparing a granular polyarylene sulfide having a high molecular weight, wherein a dihalogen aromatic compound is subjected to polycondensation with a source of sulfur in the presence of a polymerization aid in an organic polar solvent; and wherein the temperature for polycondensation is set to a range from 220 °C to 248 °C for a predetermined period of time prior to completion of polycondensation up -to completion of polycondensation
2. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 1, wherein said polymerization aid is at least one member selected from the group consisting of an organic salt and an inorganic salt, each being soluble in said organic polar solvent.
3 A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 1, wherein said polycondensation is carried out in the presence of a branching agent, together with said polymerization aid.
4. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 1, wherein the polycondensation is carried out at 250°C to 290 °C
up to said predetermined period of time prior to completion of polycondensation.
up to said predetermined period of time prior to completion of polycondensation.
5. A process for preparing a granular polyarylene sulfide having a high molecular weight, comprising:
a dehydration step for dehydrating a reaction system comprising a source of sulfur and an organic polar solvent in an inert gas stream or under reduced pressure by heating; and a one-stage polymerization step for polymerizing the source of sulfur with a dihalogen aromatic compound in the presence of a polymerization aid at a temperature ranging from 250°C to 290 °C ;
wherein the temperature for polycondensation is set to a range from 220 °C to 248 °C for a predetermined period of time prior to completion of polycondensation up to completion of polycondensation.
a dehydration step for dehydrating a reaction system comprising a source of sulfur and an organic polar solvent in an inert gas stream or under reduced pressure by heating; and a one-stage polymerization step for polymerizing the source of sulfur with a dihalogen aromatic compound in the presence of a polymerization aid at a temperature ranging from 250°C to 290 °C ;
wherein the temperature for polycondensation is set to a range from 220 °C to 248 °C for a predetermined period of time prior to completion of polycondensation up to completion of polycondensation.
6. A process for preparing a granular polyarylene sulfide having a high molecular weight, comprising:
a dehydration step for dehydrating a reaction system comprising a source of sulfur and an organic polar solvent in an inert gas stream under reduced pressure by heating; and a one-stage polymerization step for polymerizing the source of sulfur with a dihalogen aromatic compound in the presence of a polymerization aid at a temperature ranging from 250°C to 290 °C ;
wherein the temperature for polycondensation is set to a range from 220 °C to 248 °C prior to the point of time when a logarithmic viscosity number of the polyarylene sulfide resulting from polycondensation at the temperature at 250 °C
to 290°C reaches 0.3 or greater yet after the point of time when a conversion rate of the dihalogen aromatic compound reaches 70% to 98%.
a dehydration step for dehydrating a reaction system comprising a source of sulfur and an organic polar solvent in an inert gas stream under reduced pressure by heating; and a one-stage polymerization step for polymerizing the source of sulfur with a dihalogen aromatic compound in the presence of a polymerization aid at a temperature ranging from 250°C to 290 °C ;
wherein the temperature for polycondensation is set to a range from 220 °C to 248 °C prior to the point of time when a logarithmic viscosity number of the polyarylene sulfide resulting from polycondensation at the temperature at 250 °C
to 290°C reaches 0.3 or greater yet after the point of time when a conversion rate of the dihalogen aromatic compound reaches 70% to 98%.
7. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein a branching agent is present together with said poly-merization aid.
8. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein said polymerization aid is at least one member selected from the group consisting of an organic salt and an inorganic salt, each being soluble in said organic polar solvent.
9. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein said source of sulfur is at least one member selected from the group consisting of an alkali metal sulfide, an alkali metal hydrosulfide and hydrogen sulfide.
10. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein said source of sulfur is at least one member selected from the group consisting of lithium sulfide and sodium sulfide.
11. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein said dihalogen aromatic compound is a dihalobenzene.
12. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 6, wherein said polymerization aid is lithium chloride.
13. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 7, wherein said branching agent is at least one member selected from the group consisting of an active-hydrogen containing halogen aromatic compound, a polyhalogen aromatic compound containing three halogen atoms or more in one molecule, and a halogen aromatic nitro compound.
14. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 7, wherein said branching agent is an active-hydrogen containing dihalogen aromatic compound.
15. A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 7, wherein said branching agent is dichloroaniline.
16 A process for preparing a granular polyarylene sulfide having a high molecular weight as claimed in claim 7, wherein said organic polar solvent is a lactam compound.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1336123A JPH0672186B2 (en) | 1989-12-25 | 1989-12-25 | Method for producing granular high molecular weight polyarylene sulfide |
| JPP1-336123 | 1989-12-25 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2033150A1 true CA2033150A1 (en) | 1991-06-26 |
Family
ID=18295933
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002033150A Abandoned CA2033150A1 (en) | 1989-12-25 | 1990-12-24 | Process for preparing granular polyarylene sulfides having high molecular weight |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US5241043A (en) |
| EP (1) | EP0435209B1 (en) |
| JP (1) | JPH0672186B2 (en) |
| KR (1) | KR910011992A (en) |
| CA (1) | CA2033150A1 (en) |
| DE (1) | DE69030162T2 (en) |
| MY (1) | MY107727A (en) |
Families Citing this family (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3095559B2 (en) * | 1992-11-12 | 2000-10-03 | 東燃化学株式会社 | Particle size control method of polyarylene sulfide |
| US6331608B1 (en) | 1999-09-13 | 2001-12-18 | Phillips Petroleum Company | Process for producing poly(arylene sulfide) |
| US6437024B1 (en) | 1999-09-13 | 2002-08-20 | Phillips Petroleum Company | Menthanol extraction of polar organic compounds and modifier compounds from poly(arylene sulfide) polymer and oligomer streams |
| JP2002265603A (en) * | 2001-03-12 | 2002-09-18 | Idemitsu Petrochem Co Ltd | Method for producing polyaryrene sulfide |
| JP2002293937A (en) * | 2001-03-30 | 2002-10-09 | Petroleum Energy Center | Method for polyarylene sulfide by-product salt |
| JP4953020B2 (en) * | 2008-02-05 | 2012-06-13 | Ｄｉｃ株式会社 | Method for producing polyarylene sulfide resin |
| JP6797686B2 (en) | 2013-09-25 | 2020-12-09 | ティコナ・エルエルシー | Multi-step process for forming polyarylene sulfide |
| US9403948B2 (en) | 2013-09-25 | 2016-08-02 | Ticona Llc | Salt byproduct separation during formation of polyarylene sulfide |
| JP2016536377A (en) | 2013-09-25 | 2016-11-24 | ティコナ・エルエルシー | A scrubbing process to form polyarylene sulfides |
| JP6797687B2 (en) | 2013-09-25 | 2020-12-09 | ティコナ・エルエルシー | Polyarylene sulfide crystallization method |
| WO2015047717A1 (en) | 2013-09-25 | 2015-04-02 | Ticona Llc | Method and system for separation of a polymer from multiple compounds |
| JP2016536376A (en) | 2013-09-25 | 2016-11-24 | ティコナ・エルエルシー | Method for forming low halogen content polyarylene sulfides |
| WO2016133738A1 (en) | 2015-02-19 | 2016-08-25 | Ticona Llc | Method for forming a low viscosity polyarylene sulfide |
| WO2016133740A1 (en) | 2015-02-19 | 2016-08-25 | Ticona Llc | Method of polyarylene sulfide precipitation |
| WO2016133739A1 (en) | 2015-02-19 | 2016-08-25 | Ticona Llc | Method for forming a high molecular weight polyarylene sulfide |
| JP6783242B2 (en) | 2015-03-25 | 2020-11-11 | ティコナ・エルエルシー | How to form polyarylene sulfide with high melt viscosity |
| US11407861B2 (en) | 2019-06-28 | 2022-08-09 | Ticona Llc | Method for forming a polyarylene sulfide |
| US11319441B2 (en) | 2019-12-20 | 2022-05-03 | Ticona Llc | Method for forming a polyarylene sulfide |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5212240A (en) * | 1975-07-18 | 1977-01-29 | Matsushita Electric Ind Co Ltd | Process for preparing transparent coating compounds |
| US4089847A (en) * | 1976-03-30 | 1978-05-16 | Phillips Petroleum Company | Temperature programming in the production of arylene sulfide polymers |
| US4393197A (en) * | 1982-02-16 | 1983-07-12 | Phillips Petroleum Company | Arylene sulfide polymer preparation |
| JPH0813887B2 (en) * | 1986-08-13 | 1996-02-14 | 呉羽化学工業株式会社 | Process for producing poly (arylene sulfide) having excellent handling property |
| EP0286298B1 (en) * | 1987-03-30 | 1994-06-29 | Kureha Kagaku Kogyo Kabushiki Kaisha | Polyarylene thioether composition for molding |
| JPH07107130B2 (en) * | 1987-03-30 | 1995-11-15 | 呉羽化学工業株式会社 | Polyarylene thioether molding composition |
| JPS6425493A (en) * | 1987-07-21 | 1989-01-27 | Mitsubishi Electric Corp | Semiconductor laser device |
| DE3738142A1 (en) * | 1987-11-10 | 1989-05-18 | Bayer Ag | METHOD FOR PRODUCING POLYARYL SULFIDES WITH DEFINED ADJUSTABLE MELT VISCOSITIES |
| JP2575430B2 (en) * | 1987-12-18 | 1997-01-22 | 東ソー株式会社 | Method for producing poly (p-phenylene sulfide) |
| JP2514832B2 (en) * | 1988-05-26 | 1996-07-10 | 呉羽化学工業株式会社 | Method for producing polyarylene sulfide crosslinked polymer |
-
1989
- 1989-12-25 JP JP1336123A patent/JPH0672186B2/en not_active Expired - Fee Related
-
1990
- 1990-12-21 DE DE69030162T patent/DE69030162T2/en not_active Expired - Fee Related
- 1990-12-21 EP EP90125143A patent/EP0435209B1/en not_active Expired - Lifetime
- 1990-12-24 MY MYPI90002260A patent/MY107727A/en unknown
- 1990-12-24 KR KR1019900021660A patent/KR910011992A/en not_active Application Discontinuation
- 1990-12-24 CA CA002033150A patent/CA2033150A1/en not_active Abandoned
- 1990-12-24 US US07/632,692 patent/US5241043A/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| EP0435209A2 (en) | 1991-07-03 |
| US5241043A (en) | 1993-08-31 |
| JPH0672186B2 (en) | 1994-09-14 |
| JPH03195734A (en) | 1991-08-27 |
| EP0435209B1 (en) | 1997-03-12 |
| DE69030162D1 (en) | 1997-04-17 |
| DE69030162T2 (en) | 1997-10-02 |
| KR910011992A (en) | 1991-08-07 |
| EP0435209A3 (en) | 1991-10-02 |
| MY107727A (en) | 1996-05-30 |
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