POLYPHENYLENE ETHER RESINS OF CONTROLLED MOLECULAR WEIGHT AND PROCESS OF MANUFACTURE

Abstract: The chain length, and therefore, the molecular weight of polyphenylene ether resins prepared by the oxidative cou­ pling of phenols in the presence of a copperamine catalyst is controlled in such a process by additionally including in the reaction mixture an effective amount of a phenolic com­ pound having an acidity constant (K a ) the same as, or greater than, phenol. The additional compound can be phenol itself, or various other phenolic compounds not normally suitable as starting materials for the polymerization reaction.

Description: UNITED STATES PATENT APPLICATION OF: David Frederick Aycock FOR: POLYPHENYLENE ETHER RESINS OF CONTROLLED MOLECULAR WEIGHT AND PROCESS OF MANUFACTURE BACXGROUND OF THE INVENTION The polyphenylene ether resins (also sometimes referred to as the polyphenylene oxide resins) constitute a well known family of engineering thermoplastics which are highly regarded for their chemical and physical properties. The resins and methods for their preparation are described in the patent literature, including U.S. Patent Nos. 3,306,874 and 3,306,875 (to Allan Hay), and U.S. Patent Nos. 3,257,357 and 3,257,358 (to Gelu Stoeff Stamatoff). The polyphenylene ether resins can be prepared, as is well known, by the oxidative coupling of a phenol with oxygen in the presence of a complex copper-amine catalyst. The reaction can be carried out in a tertiary amine, for instance, which serves as a component of the catalyst as well as a solvent for the reaction mixture. Oxygen is bubbled through the reaction mixture and an exothermic reaction takes place, producing the corresponding phenylene oxide homopolymer or copolymer and by-product water. Further details are available in the Hay patents. While high molecular weight polymers have been made possible by the oxidative coupling procedure, it has been found that the molecular weight of the final'polymer is not easily controlled. One reason is that the polymer molecular weight increases slowly during the early stages of the reaction, but quite rapidly during the later staaes. Another reason is that the rate at which the molecular weight increases in the latter stages of reaction is dependent upon the amount of remaining active catalyst. The amount of active catalyst decreases during the reaction as a complex function of the initial reaction ingredients, the temperature history of the reaction, and the degree of oxygen dispersion in the reactor. These factors make it difficult to control the molecular weight of the polymer by stopping the reaction before its completion. Many of these difficulties are pointed out by Faurote and Segal in U.S. Patent No. 3,440,217. They disclose that the chain length of certain poly (phenylene oxides) can be controlled by including in the starting mixture a phenol substituted in the 4(para) position with alkyl or alkenyl groups, for example, 214,6-trimethylphenol, and then proceeding with the oxidative coupling reaction. INTRODUCTION TO THE INVENTION It has now been discovered that phenolic compounds having an acidity constant (era) equal to or greater than phenol are also effective to control the molecular weight of polyphenylene ether resins prepared by oxidative coupling. For instance, it has been found that phenols as diverse as phenol, 2,6-dibromophenol and pentafluorophenol limit the growth in molecular weight of polyphenylene ethers in much the same way as 2,4,6-trimethylphenol, a known chain stopper. As employed herein the terms "acidity constant" and "X " are used in their conventional senses and are defined herein as the equilibrium constant for the reaction of a phenol with a base (b): K = [phenoxide][bH ]/[phenol)[b) Phenols with a Ka greater than phenol,C6H5OH, includes all phenols which are more acidic than phenol. The amount of the above mentioned chain terminator employed in the process can vary widely, for example, from 0.1 to 50 percent by weight of the polymer, dependent on particular requirements. DESCRIPTION OF THE INVENTION The class of phenols which can be used as chain terminators are those which are more acidic than phenol and would include those phenols which have one or more electron withdrawing groups attached to the ring. Common electron withdrawing groups are -F, -C1, -Br, -I, -NO2, -CN, -SO2R, -COOH, -OH, and -NR3+. Illustratively, the chain terminating phenol may be selected from among phenol, 2,6-dibromophenol, pentafluoro- phenol, 4-nitrophenol, 2,4-dinitrophenol, 2,3-dichlorophenol, 2-cyanophenol, 4-carboxyphenol, 2-chloro-4-nitrophenol, 4methylsulfonylphenol, and the like. In greater detail, the present process invention is carried out by passing molecular oxygen or an oxygen containing gas through a mixture of one or more phenols in a solution which also contains the dissolved catalyst components. As taught by Hay, suitable phenolic starting materials are those having the formula EMI4.1 where X is a substituent selected from the group consisting of hydrogen, chlorine, bromine, and iodine, R is a monovalent substituent selected from the group consisting of hydrocarbon radicals and hydrocarbonoxy radicals, haloaryl radicals wherein all halogens are substituted on aromatic carbon atoms, and haloaryloxy radicals wherein all halogens are substituted on aromatic carbon atoms, R' is the same as R and, in addition, may be halogen, and R" is the sane as R and, in addition, may be hydrogen or halogen, but preferably hydrogen. The catalyst used in the process is composed of ingredients as disclosed in the above mentioned patents of Hay. In general, the catalyst is a complex composed of a copper salt and amine, having the formula R2HN - R1 - NHR2 in which R has at least two and no more than three carbon atoms separating the two nitrogen atoms and is C 2-4 a lkylenc or C 3-7 cycloalkylene, and each R2 is independently isopropyl or a C4 tertiary alkyl group having no halogens on the > -carbon atom. The copper can come from various soluble copper compounds, for example, cuprous oxide, cupric bromide, cuprous bromide, and so forth. The amine may be any of those known for the purpose, for example, a secondary monoamine, e.g., dibutyl- amine, or a combination of a hindered secondary amine (e.g., N,N'-di-tert-butylethylenediamine) and a tertiary amine with low stericrequirements (e.g., n-butyldimethylamine). If desired, the reaction mixture can include co-ingredients for the catalyst which serve to enhance the catalytic effect. Materials of this kind are disclosed, for instance, by Hay in U.S. Patent No. 3,914,266, and may comprise a trialkyl amine and bromide ion. Illustratively, the trialkyl amine may be selected from among trimethyl amine, triethyl amine, dimethyl ethylamine, diethyl methylamine, tripropyl amine, tributyl amine, dimethyl butylamine, diethyl butyl amine, ethyl dibutylamine, diethyl propylamine, tripentyl amine, trihexyl amine, and the like. The source of bromide ion may be bromine itself or any soluble bromine containing compound, preferably hydrogen bromide or an alkali metal salt such as potassium bromide or sodium bromide. The reaction can be carried out in an excess amount of the amine which functions as a solvent for the ingredients, or the reactants and catalyst components may be dissolved in some other solvent which is selected from among, for example, alcohols, ketones, hydrocarbons, chlorohydrocarbons, nitrohydrpcarbons, ethers, esters, amides, mixed ether-esters and sulfoxides. The reaction proceeds at room temperature, preferably with cooling to control the heat of reaction such that the temperature will not exceed 80"-100"C. Generally, reaction temperatures may be permitted to vary between about 0 and 500C., and preferably between about 20C and about 300C. Superatmospheric pressures of 1 to 100 psig, or higher, may be employed if desired. The reaction may be terminated and the polymer recovered from the reaction mixture by use of standard techniques such as the use of aqueous acetic acid followed by precipitation of the polymer with a suitable antisolvent such as methanol. The process may be, and preferably is, carried out continuously in a series of reactors, 'with each reactor provided with a fresh supply of catalyst. A polymer of increasing molecular weight is obtained until the desired degree of polymerization is achieved. The preferred end products, and this constitutes another aspect of the invention, are polyphenylene ether (oxide) homo- or copolymers having the formula: EMI7.1 wherein R is monovalent and selected from the group consisting of hydrocarbon 'radicals, hydrocarbonoxy radicals, haloaryl radicals wherein all halogens are substituted on aromatic carbon atoms, and haloaryloxy radicals wherein all halogens are substituted on aromatic carbon atoms, R' is the same as R and, in addition, may be halogen, and R" is the same as R and, in addition, may be hydrogen or halogen, but preferably hydrogen, and n represents the total number of monomer units and is an integer of at least about 10; and Q represents the described chain terminating compound or residue thereof. Examples include homopolymers such as poly(2, 6-dilauryl-1,4-phenylene)ether; poly(2,6-diphenyl-l,4phenylene) ether; poly(2,6-dimethoxy-1,4-phenylene)ether; poly(2,6-diethoxy-l,4-phenylene)ether; poly(2-methoxy-6ethoxy-1,4-phenylene)ether; poly(2-ethyl-6-stearyloxy-l, 4-phenylene)ether; poly(2-methyl-6-phenyl-1,4-phenylene) ether; poly (2-ethoxy-1, 4-phenylene) ether, etc. Also included within the scope of the above formula are copolymers such as poly(2,6-dimethyl-co 2,3,6-trimethyl-1,4-phenylene)ether, poly(2,6-dimethylco-2-methyl-6-butyl-1,4-phenylene)ether, etc. Preferred is poly(2,6-dimethyl-l,4-phenylene) ether, and especially those which are characterized by an intrinsic viscosity of between about 0.1 and about 0.9 deciliters per gram, in solution in chloroform at 300C. DESCRIPTION OF THE SPECIFIC EMBODIMENTS The invention is further illustrated in the following examples. These are intended only to show specific embodiments and not as a limitation on the scope of the invention. EXAMPLE 1 A polymerization was carried out in a one gallon stirred autoclave equipped with a dip tube for oxygen and internal coils for cooling and heating. To the reactor were added, in order: 1740 ml of toluene, 512 grams of 2,6xylenol dissolved in 743 ml of toluene, 20 grams of n-butyldimethylamine, 8.1 grams of di-n-butylamine, 2.5 grams of N,N'-di-tert-butylethylene diamine, 2.52 grams of 2,6dibromophenol, 15 grams of sodium bromide, 0.35 grams of cuprous oxide dissolved in 4 grams of 48 percent hydrogen bromide. Oxygen was added at 3 standard cubic feet per hour and the temperature was kept at 350C. After 30 minutes, the reaction exotherm was over and the temperature was increased to 50 C. Samples were taken periodically and precipitation was induced with methanol. The intrinsic viscosities (measured at 300C. in chloroform) of the polymer samples were as follows: EMI8.1 <tb> Time <SEP> (min.) <SEP> 35 <SEP> 40 <SEP> 45 <SEP> 60 <SEP> 80 <tb> IV <SEP> (dl/g) <SEP> .38 <SEP> .49 <SEP> .53 <SEP> .64 <SEP> .72 <tb> There was obtained a poly(2,6-dimethyl-l, 4-phenylene ether) resin having terminal groups formed from 2 ,6-dibromophenol. EXAMPLE 2 (Control) To a one gallon reactor were added, in order: 2000 ml of toluene, 459 grams of 2,6-xylenol dissolved 572 ml of toluene, 20 grams of n-butyldimethylamine, 8.1 grams of di-n-butylamine, 2.5 grams of N,N'-di-tertbutylethylene diamine, 15 grams of sodium bromide, 0.35 grams of cuprous oxide dissolved in 4 grams of 48 percent hydrogen bromide. Oxygen was added at a rate of 3 SCFH and the temperature kept at 350C. After 30 minutes, the reaction exotherm was over and the temperature was increased to 500C. The intrinsic viscosities were as follows: EMI9.1 <tb> Time <SEP> (min.) <SEP> J <SEP> 29 <SEP> 40 <SEP> 60 <tb> IV <SEP> (dl/g) <SEP> 0.62 <SEP> 0.85 <SEP> 0.95 <tb> EXAMPLE 3 Example 2 was repeated, except that 3.67 grams of pentafluorophenol were added at the beginning of the reaction. The measured intrinsic viscosities were as follows: EMI9.2 <tb> Time <SEP> (min.) <SEP> 30 <SEP> 40 <SEP> 60 <tb> IV <SEP> (dl/g) <SEP> 0.n8 <SEP> 0.59 <SEP> Q.64 <SEP> <tb> There was obtained a poly(2,6-dimethyl-l,4- phenylene ether) resin having terminal groups formed from pentafluorophenol. EXAMPLE 4 Example 2 was repeated except that 2.1 grams of phenol were added at the beginning of the reaction. The measured intrinsic viscosities were as follows: EMI10.1 <tb> Time <SEP> (min.) <SEP> 30 <SEP> 40 <SEP> 60 <tb> IV <SEP> (dl/g) <SEP> 0.55 <SEP> 0.55 <SEP> 0.60 <tb> EXAMPLE 5 (Comparison) Example 2 was repeated, except that 2.72 grams of 2,4,6-trimethylphenol were added at the beginning of the reaction. The measured intrinsic viscosities were as follows: EMI10.2 <tb> Time <SEP> (min.) <SEP> -33 <SEP> 40 <SEP> 60 <SEP> 77 <tb> IV <SEP> (dl/g) <SEP> 0.54 <SEP> 0.55 <SEP> 0.58 <SEP> 0.59 <tb> There was obtained a poly(2,6-dimethyl-l,4phenylene ether) resin having terminal groups formed from 2,4, 6-trimethylphenol. The above mentioned patents and/or publications are incorporated herein by reference. Obviously, other modifications and variations are possible in light of the above disclosure. It is to be understood, therefore, that changes may be made in the particular embodiments which are within the full intended scope of the invention defined in the appended claims.

Claims: Claims: 1. In a process for the production of polyphenylene ether resin by the oxidative coupling of a phenolic compound in the presence of a copper-amine catalyst, the improvement for controlling the molecular weight of said resin comprising conducting the reaction in the presence of a chain terminating phenolic compound, said compound being different from the phenolic starting material and having an acidity constant equal to or greater than phenol. 2. A process according to Claim 1, in which the chain terminating compound is selected from among phenolic compounds having one or more electron withdrawing groups attached to the aromatic ring. 3. A process according to Claim 2, in which the electron withdrawing group is one or more of -F, -C1, -Br, -I, NO2, -CN, -SO2R, -COOH, -OH and -NR3+, where R is lower alkyl having from one to six carbon atoms. 4. A process according to Claim 1, in which the phenolic starting material has the formula EMI11.1 where X is a substituent selected from the group consisting of hydrogen, chlorine, bromine, and iodine, R is a monovalent substituent selected from the group consisting of hydrocarbon radicals, hydrocarbonoxy radicals, haloaryl radicals wherein all halogens are substituted on aromatic carbon atoms, and haloaryloxy radicals wherein all halogens are substituted on aromatic carbon atoms, R' is the same as R, and in addition may be halogen and R" is the same as R and, in addition, may be hydrogen or halogen. 5. A process according to Claim 1, in which the phenolicstartingmaterial is 2,6-xylenol. 6. A process according to Claim 1, in which the chain terminating compound is employed in an amount within the range between 0.1 and 50 percent by weight of the polyphenylene ether resin end product. 7. A process according to Claim 1, in which the catalyst comprises an admixture of a copper compound, a hindered secondary anime, a tertiary anime with low steric requirements and a secondary monoamine. 8. A process according to Claim 1, which is carried out in an organic solvent. 9. A process according to Claim 1, in which the chain terminating compound is phenol. 10. A process according to Claim 1, in which the chain terminating compound is 2,6-dibromophenol. 11. A polyphenylene ether homopolymer or copolymer having the formula EMI12.1 wherein R is monovalent and selected from the group consisting of hydrocarbon radicals, hydrocarbonoxy radicals, haloaryl radicals wherein all halogens are substituted on aromatic carbon atoms, and haloaryloxy radicals wherein all halogens are substituted on aromatic carbon atoms, R' is the same as R and, in addition, may be halogen, and R" is the same as R and, in addition, may be hydrogen or halogen, but preferably hydrogen, and n represents the total number of monomer units and is an integer of at least about 10; and Q represents the described chain terminating compound or residue thereof.

Inventors: AYCOK, DAVID FREDERICK
Applicants: GENERAL ELECTRIC COMPANY
Application year: 1983
Main classification: C08G65
IPC codes: C08G65