CROSSLINKABLE POLYCYCLIC POLYCARBONATE OLIGOMERS AND METHODS FOR THEIR PREPARATION

Abstract: Polycyclic polycarbonate (or thiol analog) oligomers are prepared from a mixture of at least one bishaloformate with at least one tetraphenol, or thio analogs thereof. Such mix­ ture may also contain at least one dihydroxy or dimercapto compound. The oligomers are formed by the reaction of such mixtures with alkali metal hydroxides and various amines. The polycyclic oligomer mixtures may be converted to cross­ linked polycarbonates or their thiol analogs.

Description: CROSSLINKABLE POLYCYCLIC POLYCARBONATE OLIGOMERS AND METHODS FOR THEIR PREPARATION AND USE This invention relates to new polycyclic oligo meric compositions, methods for their preparation and uses thereof. In particular, it relates to crcssllnkable cyclic polycarbonate oligomers. Polycarbonates are well known polymers which have good property profiles, particularly with respect to impact resistance, electrical properties, optical clarity, dimensional rigidity and the like. These polymers are generally linear, but can be made it branched sites to enhance their properties in specific ways. Low levels of branching are generally incorporated into the resin by copolymerizing into the polymer backbone a polyfunctional reagent to yield a thermoplastic polycarbonate resin with enhanced rheological properties and melt strength which make it particularly suitable for such types of polymer processing procedures as the biow moulding of large, hollow containers and the extrusion of complex profile forms. Special manufacturing runs must be set aside to prepare these branched polycarbonate resins. Sufficiently higher levels of branching sites in the resin will cause resin chains actuality to join to each other to form partially or fully crosslinked resin networks which will no longer be thermoplastic in nature and which are expected to exhibit enhancements over corresponding linear resins I physical properties and/or in their resistance to abusive conditions, such as exposure to organic solvents. A wide variety of means have been employed to produce crosslinking In polycarbonate resins. They generally involve the incorporation of a suitably reactive chem ical group into the resin chain at its time of manufacture, as an additive to the resin after manufacture, or both. These reactive groups and the reactions they undergo are generally different from those characteristic of polycarbonate resins themselves and therefore tend to have detrimental side effects on the physical and/or chemical properties of the polymer. The conventional test used to judge the success of these means for crosslinking is to observe the formation of gels due to the crosslinked material when a resin sampie is mixed wit: a so vent, such as methylene chloride, in which normal linear polycarbonate resin is highly soluble. S prssnc:pal object of the present invention, therefore, is to provIde usefu new compositions of matter, and methods for tner preparation and use. A further object is to provide compositions which form crosslinked polycarbonates, and precursors therefor. A still further is to provide new poycarbonate compositions with advantageous properties. Other objects will in part be obvious and will in part appear hereinafter. In one of ;ts aspects, te present invention includes compositions comprising polycyclic cligomers having structural unIts of both of the formulas EMI3.1 wherein: eac K as Independently a divalent aliphatic, alicyclic or aromatic radical; each of A1 and Aê is a trivalent aromatic radical; each Y1 is independently oxygen or sulfur; and Yê is a bridging radical in which one or two atoms separate A1 from Aê. before proceeding with a detailed discussion of the invention, it may be useful to explain some terms used herein. The term "thiol analog", when used with reference to dihydroxy compounds, oligomers and polycarbonates, in- cludes monothio and dlthio compounds in which the carbonsulfur bonds are single bonds only. The terms "resin" and "reslnous composition" include polycarbonates and polymers containing this analogs of the carbonates. As will be apparent from the above, the polycyclic oligomers of this invention may contain organic carbonate, thiolcarbonate and/or dithiolcarbonate units. The various R1 values in formula I may be different but are usually the same, and may be aliphatic, allcyclic, aromatic or mixed; those which are aliphatic or alicyclic generally contain up to about 8 carbon atoms. SuItable R values include ethylene, propylene, trimethylene, tetramethylene, hexamethylene, dodecamethylene, 1,4-(2-butenylene), 1,10-(2-ethyldecylene), 1,3-cyclopentylene, 1,3-cyclohexylene, 1,4-cyclohexylene, m-phenylene, p-phenylene, 4,4'-biphenylene, 2,2-bis(4-phen- ylene)propane, benzene-1,4-dimethylene (which is a vinylog of the ethylene radical and has similar properties) and similar radicals such as those which correspond to the dihydroxy compounds disclosed by name or formula (generic or specific) in U.S. Patent 4,217.238, the disclosure of which is incorporated by reference herein Alse included are radcals containing non-hydrocarbon moieties. These may be substituents such as chloro, nitro, alkoxy and the like, and also linking radicals such as this, sulfoxy, sulfone, ester, amide, ether and carbonyl. Most often, however, all R1 radicals are hydrocar-on radicals. Preferably at least about 60% and more preferably at least about 80% of the total number of R1 values in the polycycllc oligomers, and most desirably all of said R1 values, are aromatic. The aromatic K radicals preferably have the formula (III) -A3-Y3-A4 wherein each of A3 and A is a single-ring divalent aromatic radical and Y3 is a bridging radical in which one or two atoms separate A3 from A4. The free valence bonds in formula III are usually in the meta or para positions of A3 and A4 in relation to Y3 Such R1 values may be considered as being derived from bisphenols of the formula HO-A3-Y3-A4-OH. Frecuent reference to bisphenols will be made hereinafter, but It should be understood that R1 values derived from suitable compounds other t:.an bisphenols may be employed as appropriate. 3 4 In formula III, the A3 and A4 values may be unsubstituted phenylene or substituted derivatives thereof, illustrative substituents (one cr more) being alkyl, alkenyl (e.g., cross inkable-graftable moieties such as vinyl and allyl), halo (especially chloro and/or bromo), nitro, alkoxy and the like. Unsubstituted phenylene radical are preferred. Both A3 and A4 are preferably p-phenylene, although both may be o- or m-phenylene o one o- or m-phenylene and the other p-phenylene. 3 The bridging radical, ï , is one in which one or two atoms, preferably one, separate A3 from A4. It is most often a hydrocarbon radical and particularly a saturated radical such as methylene, cyclohexylmethylene, neopentylidene, 2-[2.2.1]bicycloheptylmethylene, ethylene, ethylidene, iscpropylldene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene or adamantylidene, especially an alkyli dene radical. Also included, however, are unsaturated radicals and radicals which are entirely or partially composed of atoms other than carbon and hydrogen. Examples of such radicals are 2,2-dichloroethylidene, carbonyl, tio and sulfone. For reasons cf availability and particular suitability for the purposes of this invention, the preferred radical of formula ,II is the 2,2-bis(4-phenylene)propane radical, which is derived from bisphenol A and in which Y3 ;s isopropylidene and A3 and A4 are each p-phenylene. As noted, each 1 value is independently oxygen or sulfur. Most often all ' values are oxygen and the corresponding compositions are cyclic polycarbonate oligomer mixtures. An essential feature ci the compositions of this invention is the presence of structural units having formula II, which lead to an overall polycyclic structure. The number of rings in any individual molecule of said compositions wi oepen on the proportions of reactants and the reaction sonditions. The following molecular structures are illustrative. EMI6.1 EMI7.1 wherein m and n are integers, typically from 1 to about 11. In formula T, each 1 value may be oxygen or sulfur and all Y1 values are usually oxygen. The Yê values are bridging radicals similar to those defined hereinabove for Y3, and are usually methylene, carbonyl, thiol, sulfoxy or sulfony. The A1 and Aê values are usually trivalent single-ring aromatic radicals; they are preferably unsubstituted but may contain substituents such as those previously identified with respect to A3 and A4. The structural units of formula II may be considered as being derived from the corresponding tetraphenols and their hid analogs. Illustrative tetraphenols are bis(2,4-dihydroxy-3-methylphenyl)methane, 2,2',4,4'-tetrahydroxybiphenyl, 2,2',4,4'-tetrahydroxybenzophenone, bis (2,4-dihydroxyphenyl) sulfide, bis(2,4-dihydroxyphenyl) sul oxide and bis(2,5-dihydroxyphenyl) sulfone. Certain of these tetraphenols, particularly the bis(2,4-dihydroxy-3-alkylphenyl)methanes, are novel compounds. Therefore, another aspect of the invention is tetraphenols having the formula EMI8.1 wherein R2 is a C1-4 primary or secondary alkyl radical and especially methyl. Such tetraphenols may be prepared by reacting a 2-alkyiresorcinol with formaldehyde under acidic conditions, typically in aqueous solution and at a temperature in the range of 10-50 C. Most often, approximately equimolar amounts of 2-alkylresorcinal an acid are present and the molar ratio of 2-alkylresorcinol to formaldehyde is about 3-6:1. The following exampie is Illustrative. All parts are by weight. Example 1 To a solution cf 246.14 parts (2 moles) of 2-meth ylresorcinol in one liter of 2 N aqueous hydrochloric acid was added 32.6 parts of 38% aqueous formaldehyde solution (0.4 mole of formaldehyde). The mixture was stirred for two hours at about 20 C, whereupon a white solid precipitated. It was removed by filtration, washed several times with water and dried. The product was shown by infrared and nuclear magnetic resonance spectroscopy to be the desired bis(2,4-dihydroxy-3-methylphenyl)methane. The yield was 49.2 parts, or 50% of theoretical. The polycyclic oligomers of this invention include dimers, trimers and tetramers similar to those disclosed in the following U.S. patents: 3,155,683 3,386,954 3,274,214 3,422,119. They also Include polycyclic oligomer mixtures similar to the mixtures disclosed in copending, commonly owned application Serial No. 704,122, filed February 22, 1985, the disclosure of which is incorporated by reference herein. The polycyclic oligomer mixtures consist essentially of olicomers naving degrees cf polymerization from 2 to about 30 and preferably to about 20, with a major propor- tion being up to about 12 and a still larger proportion up to about 15. Since they are mixtures, these compositions have relatively low melting points as compared to single compounds. The pclycyclic oligomer mixtures are generally liquid at temperatures above 300 C and most often at temperatures above 225 C. The mixtures of this invention contain very low proportions of acyclic oligomers, generally undetectable amounts and very seldom more than about 5% by weight. Th ) also contain low percentages, frequently less than 30%, of polymers (linear or cyclic) having a degree of polymeriza tion greater than about 30. Such polymers are frequently Identified hereinafter as "high polymer". These properties, coupled with the relatively low melting points and viscosi- ties of the polycyclic oligomer mixtures, contribute to their utility In the invention. The polycyclic oligomers of this invention may be prepared by a condehsation reaction involving at least one compound selected from the group consisting of bishaloformates and thio analogs thereof, said compounds having the formula (VII) R1(Y1COX1 and at least one compound selected from the group consisting of tetraphenols and thiol analogs thereof, said compounds having the formula (VIII) (HY1)2A1-Yê-Aê(Y1H)2, wherein R1, A1, Aê, Y1 and Yê are as defined hereinabove and X1 chlorine or bromine. The condensation reaction typically takes place interfacially when a solution of said compounds in a substantially non-polar organic liquid is contacted with a tertiary amine from a specific class and an aqueous alkali metal hydroxide solution. Accordingly, another embodiment of the present invention is a method for preparing a composition comprising polycyclic polycarbonate or thiol analog ollgomers which comprises contacting (A) a compositions comprising a mixture of (1) at least one compound having formula VII and (2) at least one compound of formula VtI, said mixture optionally also containing (3) at least one bis(active hydrogen) compound having the formula IX) R3(Y3H)2 wherein each Y3 is independently sulfur when the corresponding R3 is aliphatic or alicyclic and oxygen or sulfur when the the corresponding R3 is aromatic, with (B) at least one oleophilic aliphatic or heterocyclic tertiary amine and (C) an aqueous alkali metal hydroxide solution having a concentration of about C.1-10 M; said contact being effected under conditions resulting in high dilution of reagent A, or the equivalent thereof, in a substantially non-polar organic liquid which forms a two-phase system with water, for a period of time sufficinet to form said polycyclic oligomers; and recovering said oligomers. Reagent A, as Indicated, is a composition comprising a mixture of compounds cf formulas V and VI (reagents -i and -2, respectively) and, optionally, compounds of formula v (reagent -3). It may also contain other com pounds, including oligomers of the formula EMI11.1 wherein R1, Y1 and X1 are as previously defined and n is a small number, typically about 1-4. While the X1 values in formulas VII and X may be chlorine cr bromine, the bischloroformates, in which X1 is chlorine, are most readily available and their use is therefore preferred. The compounds of formula VIII may be tetraphenols or mono- or polythiol analogs thereof, with the tetraphenols being preferred. (Frequent reference to bischloroformates and tetraphenols will be made hereinafter, but it should be understood that all compounds of formulas VII and VIII, respectively, are included.) Suitable bis(active hydrogen) compounds of formula IX (reagent -3) Include diols and thiol analogs thereof having divaent radicals of formula III which are different from the corresponding divalent radicals In the compound of formula VII, as well as other dihydroxyaromatic compounds ana ticl analogs thereof. Any cyclic oligomers containing divalent allphatlc radicals (or their vinylogs) flanked by two oxygen atoms are obtained from a mixture of compounds identifiable as reagent A-i. The proportion of reagent A-2 in the reaction mixture (and of its cf formula ;: n the oligomer product) depends to some extent on the amount cf crosslinking desired in the final linear polycarbonate. In general, about 0.5-10.0 mole percent (based on monomeric units in total reagent A), and especially about 1-5 mole percent, will produce z crossllnked product having the desired properties. however, it is within the scope of the invention to prepare a polycyclic oligomer product having a higher proportion of units cf formula II and to dilute it with a conventional cyclic oligomer product prior to formation of the crosslinked linear polycarbonate. Therefore, the presence of about C.5-12.0 mole percent of component -2 is contemplated. Higher proportions than about 12 mole percent may cause premature crosslinking vIa formation of branched polycarbonates, resulting in gel formation. Reagent A-3, when present, generally comprises up to about 50,0 by weight, most often up to about 20% and preferably up to about 10%, cf total reagent A. The bischloroformate may be employed in substantially pure, isolated form or as a crude bischloroformate product Suitable crude products may be prepared by any known methods for bischloroformate preparation. Typically, at least one bisphenol is reacted with phosgene in the presence of a substantially inert organic liquid, as disclosed in the following United States patents: 3,255,230 3,966,785 3,312,661 3,974,126. The disclosures of these patents are incorporated by reference herein. In addition to the bisphenol bischloroformate, such crude bischloroformate products may contain oligomer bischloroiormates containing up to 4 bisphenol units. They may also contain minor amounts of higher oligomer bischloro ormates ano of monochloroformates corresponding to any of the aformentioned bischloroformates. Higher oligomer monoand bischloroformates are preferably present, if at all, only in trace amounts. ore preferably, the preparation of the crude bis chlorofonate product takes place in the presence of aqueous alkali. The pH of the reaction mixture may be up to about 12. It is generally found, however, that the proportion of high polymer in the cyclic oligomer mixture is mlnimized by employing a crude bischloroformate product comprising a mayor amount of bisphenol bischloroformate and only minor amounts of any oligomer bischloroformates. Such products may be obtained by the method disclosed in copending, commonly assigned application Serial No. 790,909, filed October 24, 185, the disclosure of which is also incorporated by reference herein. In that method, phosgene is passed into a mixture of a substantially inert organic liquid and a bisphenol, said mixtre being maintained at a temperature within the range of about 10-;OC, the phosgene flow rate being at least 0.15 equivalent per equivalent of bisphenol per minute when the temperature is above 3O0C. An aqueous alkali metal or alkaline earth metal base solution is simultaneously introduced as necessary to maintain the pH of the aqueous phase in the range of 0.5-8. By this method, it is possible to prepare blschloroformate in high yield while using a reiatively small proportion of phosgene, typically up to about 1.1 equivalent per equivalent of bisphenol. When one cf these methods is employed, it is obvious that the crude bischloroformate product will ordin airily be obtained as a solution in a substantially non-polar organic liquid such as those disclosed hereinafter. Depend Ing on the method of preparation, it may be desirable to wash said solution with a dilute aqueous acidic solution to remove traces of base used in preparation. The tertiary amines useful as reagent B ("tertiary" in this context denoting the absence of N-H bonds) generally comprise those which are oleophilic (i.e., which are soluble in and highly active in organic media, especially those used in the oligomer preparation method of this invention), and more particularly those which are useful for the formation of polycarbonates. Reference is made, for example, to the tertiary aines disclosed in the aforementioned U.S. Patent 4,217,438 and Ir. U.S. Patent 4,368,315, the disclosure of which is also incorporated by reference herein. They include aliphatic amines such as triethylamine, tri-n-propylamine, diethyl-n-propylamine and tri-nbutylamine and highly nucleophilic heterocyclic amines such as 4-dimethylam:nopyr:dlne (which, for the purposes of this invention, contains only one active amine group). The preferred amines are those which dissolve preferentially in the organic phase of the reaction system; that is, for which the organic-aqueous partition coefficient is greater than 1. This is true because intimate contact between the amine and reagent n is essential for the formation of the cyclic oligomer mixture. For the most part, such amines contain at least about 6 and preferably about 6-14 carbon atoms. The ar,r,es most useful as reagent E are trialkylamines containing no branching on the carbon atoms in the iand 2- positions. EspecIally preferred are tri-n-alkylamines in whIch the alkyl groups contain up to about 4 carbon atoms. Triethylamine is most preferred by reason of its particular availability, low cost, and effectiveness in the preparation of products containing low percentages of linear oligomers and high polymers. Reagent C is an aqueous alkali metal hydroxide solution. It is most often lithium, sodium or potassium hydroxide, with sodium hydroxide being preferred because of its availability and relatively low cost. The concentration of said solution is about 0.2-10 M and preferably no higher than about 3 M. The fourth essential component in the cyclic oligomer preparation method of this invention is a substantially non-pclar organic liquid which fcrms a two-phase system with water. The identity of the liquid is not critical, provided it possesses the stated properties. Illustrative liquids are aromatic hydrocarbons such as toluene and xylene; substituted aromatic hydrocarbons such as chlorobenzene, o-dichlorobenzene and nitrobenzene; chlorinated aliphatic hydrocarbons such as chloroform and methylene chloride; and mixtures of the foregoing with ethers such as tetrahydrofuran. To prepare the cyclic oligomer mixture according to the above-described method, the reagents and components are maIntained in contact under conditions wherein reagent A is present in high dilution, or equivalent conditions. Actual high dilution conditions, requiring a large proportion of organic liquid, may be employed but are usually not preferred for cost ano convenience reasons. Instead, simulated high dill ion conditions known to those skilled in the art may be employed. For example, in one embodiment of the method reagent A (i.e., a combination of all constituents thereof) or reagents a and E are added gradually to a mixture of the other materials. It is within the scope of this embodiment to incorporate reagent E in the mixture to which reagent A is added, or to add it gradually, either in admixture wit reagent A or separately. Continuous or incremental addition of reagent E is frequently preferred, whereupon the cyclic oligomer mixture is obtained in relatively pure form and In high yield. Although addition of reagent A neat (i.e., without solvents) is within the scope of this embodiment, it is frequently inconvenient because many bischloroformates are solids. Therefore, it is preferably added as a solution in a portion of the organic liquid. The proportion of organic liquid used for this purpose is not critical; about 25-75% by weight, and especially about 40-60%, is preferred. The reaction temperature is generally in the range of about 0-50 C. It is most often about 0-400C and preferably 2-400C. For maximization cf the yield and purity of polycyclic oligomers as cpposed to high polymer and insoluble and/or intractable by-products, it is preferred to use not more than about 0.7 mole of reagent A (calculated as mcnomeric material) per liter of organic liquid present in the reaction system, including any liquid used to dissolve reagent S Preferably, about 0.003-0.6 mole of reagent A is used wren it consists entirely of reagents r.-l and A-2, and no more tan about 0.5 mole Is used when it contains reagent A-3. It should be noted that this is not a molar concentration in te organic liquid when reagent A is added graddaily, since said reagent is consumed as it is added to the reaction system. The molar proportions of the reagents constitute another important feature for yield and purity maximization. The preferred molar ratio of reagent E to reagent A is about 0.1-1.0:1 and most often about 0.2-0.6:1. The preferred molar ratio of reagent C to reagent A is about 1.5-3:1 and most often about 2-3:1. Recovery of the polycyclic oligomers normally means merely separatlng the same from diluent (by known methods such as vacuum evaporation) and, optionally, from high polymer and other impurities When other reagents are added to reagent C and the preferred conditIons and material proportions are otherwise employed, the polycyclic oligomers (obtained as a solution in the organic liquid) contain minimal amounts of high polymer and insoluble material. Depending on the intended use of the polycyclic oligomer mixture, the separation step may then be unnecessary. When separation is necessary, the unwanted impurities may be removed in the necessary amounts by conventional operations such as combining the solution with a non-solvent for said impurities. Illustrative nor-solvents include ketones such as acetone and methyl isobutyl ketone and esters such as methyl acetate and ethyl acetate. Acetone is a partIcularly preferred non-solvent. The preparation of the polycyclic carbonate oligomers of tis inventions is illustrated by the following examples. Examples 2-7 To a solution of 3.53 grams (10 mmcl.) of bisphenol A bischlorofomate in 10 ml. of methylene chloride was added a solution of 1 mmol. cf the desired tetraphenol in about 0.5 ml. of tetrahydrofuran. The resulting solution was added over 40 minutes at room temperature, with stir rng, to a mixture of C.25 gram (2.5 mmol.) of triethylamine, 10 ml. of 2.5 N aqueous sodium hydroxide solution (25 mmol.) and 30 ml. of methylene chloride. After the addition was complete, the organic layer was separated, washed twice with 1 N aqueous hydrochloric acid and once with water and drie. The solvent was removed by vacuum stripping and the polycyclic ollgomers and high polymer were separated by sissolution of the polycyclic cllgomers In acetone or by prec;pitation of high polymer from methylene chloride by addition of acetone. The results are given in Table I. TABLE I Yield, x Polycyclic High Example Tetraphenol oligomers polymer 2 (2. 4-dihydroxy-3- 60 32 ethylphenyl)methane 3 2,2',4,4'-Tetrahydroxy- 55 30 biphenyl 4 2,2',4,4'-Tetrahydroxybenzo- 72 26 phenone 5 Bis(2,4-dihydroxyphenyl) 55 33 sulfide 6 Bis(2,4-dihydroxyphenyl) 56 33 sulfoxide 7 Bis(2,4-dihydroxyphenyl) total 50 sulfone Example 8-9 To a solution cf 17.65 grams (50 mmol.) of bisphenol A bischloroformate in 5C ml. of methylene chloride was added a solution of 5 mmol. of the desIred tetraphenol in 2 ml. of tetrahydrofuran. The solution was added over 40 minutes, at room temperature, to a solution of 0.25 gram of triethylamlne in 150 ml. of methylene chloride. There were simultaneously added 50 ml. of 2.5 N aqueous sodium hydroxide (125 mmol.) and an additional 1 gram of trlethylamine (total 12.4 mmol.), the latter being added incrementally. The product was worked up substantially as described in Examples 2-7. The results are given in Table II. TABLE II Yield, % Polycyclic High Example Tetraphenol oligomers polymer 8 Bis(2,4-dihydroxy-3- 78 21 methylphenyl)methane 9 Bis(2,4-dihydroxyphenyl) 75 20 sulfide Examples 10-20 mixture of 45.66 grams (200 mmol.) of bisphenol and 200 ml. of methylene chloride is stirred as gaseous phosgene is passed in for 5C minutes t 0.83 grams per minute (total 42C mmol.). At the same time, 88 ml. of 5 M aqueous sodium hydroxyde (440 mmol.) is added incrementally to maintain the pH above 10.0. Stirring is continued for 15 minutes, after which the methylene chloride solution of the crude bischloroformate product is separated and washed with 0.1 M aqueous hydrochloric acid. The crude bischloroformate product is combined with bis(2,4-dihydroxy-3-methylphenyl)methane and the dihydroxy compounds or dithiols listed in Table III. In each case, the proportions of the tetraphenol and the liste dihydroxy compound or dithiol, based on total reagent A, are 10 mole percent each. The products are similar to those of Examples 2-9. TABLE III Example Dihvdroxv compound or dithiol 10 l,l-Eis(4-hydroxyphenyl)cyclohexane 11 1,1-Bis(4-hydroxyphenyl)cyclododecane 12 2,2-Bis(4-hydroxy-3,5-dimethylphenyl)propane 13 2,2-Bis(4-hydroxy-3,5-dibromphenyl)propane 14 Bis(4-hydroxyphenyl) sulfone 15 4,4'-Thiodiphenol 16 2,2-Bis(4-hydroxy-3,5-dimethylphenyl) sulfone 17 2,2-Bis(4-hydroxyphenyl)-1,1-dichloroethylene 18 Hydroquinone 19 4,4'-Bisphenyldithiol 20 ,i2-Dodecanedithiol The polycycllc oligomer mixtures of this invention are useful as Intermediates for conversion to crosslinked polycarbonates or their thiol analogs. Accordingly, the present invention includes a method for the preparation of a crosslinked resinous composition ich comprises contacting at least one of the previously defined polycyclic oligomer mixtures with a polycarbonate formation catalyst at a temperature up to about 350 C. The oligomer mixtures may frequently be employed in this method without separation of high polymer therefrom, but if desired, high polymer may be removed as previously described. The polycarbonate formation catalysts which can be used in the resin formation method: of this invention include various bases and Lewis acids. It is known that basic catalysts ay be used to prepare polycarbonates by the interfacial method, as well as by transesterification and from cyclic oligomers. Reference is made to the aforementioned U.S. Patents 3,155,683, 3,274,214, 4,217,438 and 4,368,315. Such o;talysts may also be used to polymerlze the polycyclic oligomer mixtures. Examples thereof are lithium 2,2,2-trifluoroethoxide, n-butyllithium and tetramethylammonium hydroxide. Also useful are various weakly basic salts such as sodium benzoate and lithium stearate, as well as tetraarylborates exemplified by the lithium, sodium, tetramethylammonium, tetra-n-butylammonium and tetraphenyl phosprontum tetraphenylborates and similar compounds disclosed in copending, commonly owned application Serial No. 723,672, fIled April 16, 1985, the disclosure of which is incorporated by reference herein. Lewis acios useful as polycarbonate formation catalysts include dloctyltln oxide, triethanolaminetitanium ispropoxide, tetra(2-ethylhexyl) titanate and polyvalent metal (especilly titanium and alumInum) chelates such as bisisopropoxytitanium bisacetylacetonate (commercially available under the tradename "Tyzor AA") and the bisisopro poxyaluminum salt of ethyl acetoacetate. Among the preferred catalysts are lithium stearate and bisisopropoxytitanium bisacetylacetonate. ne resin formation reaction is typically effected by merely contacting the polycyclic oligomers with the catalyst t temperatures up to 35000, preferably about 200-300 C. until polymerization has proceeded to the extent desired. Although the use of a solvent is within the scope of the invention, it is generally not preferred. In general, the amount of catalyst used is about 0.001-1.0 mole percent based on structural units in the oligomers. The preparation of cross linked resinous composi tloc according to tis invention is illustrated by the following examples. Examples 21-27 Various polycyclic oligomer compositions of the type described in Example 2-9 were dissolved in methylene chloride; in Examples 22 and 27, high polymer was removed before dissolution. An amount of tetramethylammonium tetraphenylborate to provide 0.1 mole percent based on structural units in the ollgomers was added. The methylene chloride was removed by vacuum evaporation and the samples were dried at 600 for 2 hours in a vacuum oven. They were then heated under nitrogen at 250 C until polymerization was complete. The percentage of orosslinklng was determined by extracting uncrossllnked material from the samples with methylene chloride for 12-16 hours at reflux. The results are gIven in Table IV. TABLE IV Example Identiv Mole % % crosslinked 21 Bis(2,4-dihydroxy-3- 5 93 methylphenyl)methane 22* " 5 95 23 Bis(2,4-dihydroxyphenyl) 5 70 sulfone 24 2,2',4,4'-tetrahydroxy- 5 90 biphenyl 25 2,2',4,4'-tetrahydroxy- 10 89 benzophenone 26 Bis(2,4-dihydroxyphenyl) 5 90 sulfide 27* " 5 98 *High polymer removed. The cross linked resinous compositions of this invention may optionally contain commonly known and used additives such as, for example, arti-oxidants, mineral fillers, reinforcing agents, impact modifiers, cclorants, ultraviolet radiation absorbers such as the benzophenones, benzotriazoles, and cyanoacrylates; color stabilizers such as organophosphites; hydrolytic stabilizers such as epoxides; and flame retardants. Some particularly useful reinforcing agents which may be used separately or In combination are carbon, aramid, glass and boron fibers and other reinforcements which may be coped, woven, kit, braided, wound or shaped by any conventional method. Some particularly useful flame retardants are the alkali and alkaline earth metal salts of organic sulfonlc acids.

Claims: What is claimed is: 1. A composition comprising polycyclic oligomers having structural units of both of the formulas EMI25.1 wherein: each K1 is Independently a divalent aliphatic, alicyclic or aromatic radical; each of A1 and A2 is a trivalent aromatic radical; each Y1 is independently oxygen or sulfur; and Yê is a bridging radical in which one or two atoms separate A1 from Aê. 2. A composition according to claim 1 wherein each yl is oxygen and each R has the formula II) -A3-Y3-A4 wherein each of A3 and A4 is a single-ring divalent aromatic radical and R3 is a bridging radical in which one or two atoms separate A3 from A4. 3. A composition according to claim 2 wherein each of A1 and A2 is an unsubstituted single-ring aromatic radical and Yê is methylene, carbonyl, thio, sulfoxy or sulfone. 4. A composition according to claim 3 wherein each of A3 and A is p-chenylene and Y3 is isopropylidene. 5. A composition according to claim 4 wherein a major proportion of the oligomers have degrees of polymerization up to about 12. 6. A composition according to claim 5 which contains about 0.5-10.0 mole percent of units having formula II. 7. A method for preparing a composition compris ng polycyclic polycarbonate or thiol analog oligomers which comprises contacting (A) a composition comprising a mixture of (i) at least one compound having the formula (VII) R1(Y1COX1)2 wherein each K is independently a dlvalent aliphatic, alicyclic or aromatic radical, each Y1 is independently oxygen or sulfur and X1 is chiorine or bromine, with (2) at least one compound of the formula (VIII) (HY1)2A1-Y2-A2(Y1H)2 wherein each of A1 and A2 is a trivalet aromatic radical and Y2 is a bridging radical in which one or two atoms separate A1 from A2; ; said mixture optionally also containing (3) at least one bis(active hydrogen) compound having the formula (IX) .3 wherein each i3 is Independently sulfur when the correspond- ing R3 is aliphatic or cyclic and oxygen or sulfur when the the correspondIng R3 is aromatic; with (B) at least one oleophilic aliphatic or heterocyclic tertiary amine and (C) an aqueous alkali metal hydroxide solution having a concentration c¯ about C.1-10 M; said contact being effected under conditions resulting in high dilution of reagent A, or the equivalent thereof, ln a substantially ncn-polar organic liquid which forms a two-phase system with water, for a period of time sufficient to form said polycyclic oliomers; and recovering said oligomers. 8. A method according to claim 7 wherein reagent A consists essentially of a mixture of (1) a bischloroformate cf formula VII in which Y1 is oxygen, X1 is chlorine and R1 has the formula (III) -A3-Y3-A4-, wherein each of A3 and A is a single-ring divalent aromatic radical and Y3 is a bridging radical in which one or two atoms separate A3 from A4; and (2) a tetraphenol of formula VI :n which each Y2 is oxygen. 9. A method according to claim 8 wherein each of A1 and A2 is p-phenylene and E is isopropylidene. 10. A method according to claim 9 wherein reagent E Is triethylamine, reagent C is sodium hydroxide and the organic liquid is methylene chloride. 11. A method according to claim 1 wherein reagent A-1 is a crude bischloroformate product. 12. method according to claim 11 wherein reagent A comprises about 0.5-10.0 mole percent of tetraphenols of formula VI. 13. A method for the preparation of a crosslinked resinous composltion which comprises contacting a polycyclic oligomer composition according to claim 1 with a polycarbonate formation catalyst at a temperature up to about 3500C. 14. A method according to claim 13 wherein the polycarbonate formation catalyst is a base or a Lewis acid. 15. A method according to claim 14 wherein the polycarbonate formation catalyst is lithium stearate, bisisopropoxytitanium bisacetylacetonate or a tetraarylborate. 16. A method according to claim 20 wherein each R1 has the formula (III) -A3-Y3-A4wherein each of A3 and A4 is a single-ring divalent aromatic radical and Y is 2 bridging radical in which one or two atoms separate A3 from A- 17. A method according to claim 16 wherein each of and Aê is an unsubstituted single-ring aromatic radical and Yê is methylene, carbonyl, thio, sulfoxy or sulfone. 1E. A method according to claim i7 wherein each of A1 and A2 is p-phenylene and Yê is isopropylidene. 19. A tetraphenol having the formula EMI29.1 wherein R2 is a C G primary or secondary alkyl radical. 20. A tetraphenol according to claim 19 wherein R2 is methyl.

Inventors: BRUNELLE, DANIEL JOSEPH, SHANNON, THOMAS GERARD
Applicants: GENERAL ELECTRIC COMPANY
Application year: 1986
Main classification: C08G64
IPC codes: C08F290, C08G75, C08G64, C07C69, C07C317, C07C313, C08F299, C07C67, C07C323