Novel olefin/CO copolymers

Abstract: Copolymers of carbon monoxide with at least two α-olefinically unsaturated compounds, which a) have been prepared by polymerization of carbon monoxide with one or more monomers (A) of the general formula (CH₂=CR₁)-R₂ and with one or more monomers (B) chosen from the group formed by compounds of the general formulae (CH₂=CR₁)OPO(R₃)(OR₅) and (CH₂=CR₁)PO(OR₃)(OR₅), wherein R₁ and R₂ are hydrogen atoms and/or hydrocarbyl groups and R₃ and R₅ are hydrocarbyl groups, b) have a linear structure, and c) are made up of units of the general formula -CO-(A')-and units of the general formula -CO-(B')-, wherein A' and B' represent monomer units originating, respectively, in monomers A and B used.

Description: The invention relates to novel copolymers of carbon monoxide with at least two α-olefinically unsaturated compounds. Copolymers of carbon monoxide with one or more compounds of the general formula (CH 2 =CR 1 )-R 2 , wherein R 1 , and R 2 represent hydrogen atoms and/or hydrocarbyl groups, comprise carbonyl groups as functional groups. Therefore they are referred to as polyketones. These carbonyl groups can be converted at least partly into a variety of other functional groups by means of chemical reaction. This chemical modification leads to changes in the properties of the polymers and renders the latter eligible for uses for which the original polymers were not very or not at all suitable. As examples of chemical reactions to which the polymers can be subjected may be mentioned the conversion into polyamines by way of catalytic hydrogenation in the presence of ammonia, the conversion into polyalcohols by way of catalytic hydrogenation, the conversion into polyphenols by way of condensation with phenols and the conversion into polythiols by way of catalytic hydrogenation in the presence of hydrogen sulphide. Among the copolymers of carbon monoxide with compounds of the general formula (CH 2 =CR 1 )-R 2 (for the sake of brevity referred to as A), high molecular weight linear alternating polymers composed of units of the general formula -CO-(A')-, wherein A' represents a monomer unit originating in a monomer A used, form a special class. Such copolymers can be prepared, inter alia, by using catalyst compositions based upon a) a palladium compound, b) an anion of an acid with a pKa of less than 4, and c) either a phosphorus bidentate ligand, or a nitrogen bidentate ligand, which bidentate ligands meet certain structural requirements. An investigation carried out by the Applicant into these copolymers has shown that they can be chemically modified by introducing into the monomer mixture from which they are prepared, in addition to carbon monoxide and one or more monomers A, a relatively small quantity of one or more monomers B, chosen from the group composed of the general formulae (CH 2 =CR 1 )OPO(R 3 )(OR 5 ) and (CH 2 =CR 1 )PO(OR 3 )(OR 5 ), wherein R 1 has the meaning mentioned hereinbefore and R 3 and R 5 are hydrocarbyl groups. The use of the above-mentioned catalyst compositions with such a monomer mixture affords copolymers made up of units of the general formula -CO-(A')- and units of the general formula -CO-(B')-, wherein B' represents a monomer unit originating in a monomer B used. It follows from this structure that the present copolymers are alternating copolymers, i.e. in the polymer chains every unit CO is positioned in between a unit originating from an olefinically unsaturated monomer irrespective of whether this unit is A' or B'. Because of the nature of the monomers B used, the polymers obtained comprise phosphonate groups as functional groups, in addition to the carbonyl groups originally present in the polymers. As distinct from the chemical modification described hereinbefore, in which at least part of the carbonyl groups present in the polymers are converted into other functional groups, i.e. a chemical modification after the polymerization, the use of monomers of type B as co-monomers can be regarded as a chemical modification in situ, i.e. during the polymerization. Just like the carbonyl groups, the phosphonate groups can be converted at least partly into a variety of other functional groups by chemical reaction after the polymerization. Briefly stated, the copolymers to which the invention relates can be defined as follows a) they have been prepared by polymerization of carbon monoxide with one or more compounds A and with one or more compounds B, b) they have a linear structure, and c) they are made up of units of the general formula -CO-(A')- and units of the general formula -CO-(B')-. Copolymers that meet the criteria a)-c) are novel. The present patent application therefore relates to novel copolymers of carbon monoxide with at least two α-olefinically unsaturated compounds, which polymers meet the criteria mentioned hereinbefore under a)-c). The patent application further relates to the preparation of the copolymers. Per unit -CO-(B')- the polymers of the invention preferably comprise, on an average, fewer than 2000 and in particular fewer than 1500 units -CO-(A')-. The monomers A and B that are used in the preparation according to the invention preferably contain fewer than 20, and in particular fewer than 10, carbon atoms. In the preparation of the polymers the starting mixture is preferably a polymer mixture which, in addition to carbon monoxide, comprises only a single monomer A and a single monomer B. As examples of olefinically unsaturated hydrocarbons of the general formula (CH 2 =CR 1 )-R 2 which in the preparation of the polymers are eligible for use as the monomers A, may be mentioned, inter alia, ethene, propene, butene-1, pentene-1, hexene-1, octene-1, styrene, p-methyl styrene and p-ethyl styrene. Preference is given to the use of ethene as the monomer A. As examples of phosphonic acid esters of the general formula (CH 2 =CR 1 )OPO(R 3 )(OR 5 ) eligible for use in the polymerization as the monomer B, may be mentioned, inter alia, the vinyl-methyl esters of methyl phosphonic acid and the vinyl-methyl ester of phenyl phosphonic acid. As examples of phosphonic acid esters of the general formula (CH 2 =CR 1 )PO(OR 3 )(OR 5 ) suitable for use as the monomer B, may be mentioned, inter alia, the following esters of vinyl phosphonic acid: the dimethyl ester, the diethyl ester, the methyl-phenyl ester and the diphenyl ester. Good results have been obtained by using the diethyl ester of vinyl phosphonic acid as the monomer B. As stated hereinbefore, in accordance with the nature of the monomers B used, the polymers of the invention comprise functional groups which can be at least partly converted into other functional groups by means of chemical modification. The use of phosphonic acid esters as momomers B leads to the formation of polymers comprising phosphonate groups as the functional groups. In the chemical modification of polymers prepared by using a phosphonic acid ester as monomer B, there is a distinction as to what type of phosphonic acid ester was used. The use of phosphonic acid esters of the general formula (CH 2 =CR 1 )OPO-(R 3 )(OR 5 ) leads to the formation of a polymer in which the phosphonate groups are bound to the carbon chain by an oxygen atom. Subjection of such a polymer to hydrolysis affords a polymer in which hydroxyl groups are found in the places where originally there were phosphonate groups, i.e. the polymer has been converted into a polyalcohol. The use of phosphonic acid esters of the general formula (CH 2 =CR 1 )PO(OR 3 )(OR 5 ) leads to the formation of a polymer in which the phosphonate groups are bound to the carbon chain by the phosphonic atom. Subjection of such a polymer to hydrolysis affords a polymer in which phosphonic acid groups are present in the places where originally there were phosphonate groups, i.e. the polymer has been converted into a polyphosphonic acid. For the preparation of polymers according to the invention it is preferred to use the afore-mentioned catalyst compositions comprising a phosphorus or nitrogen bidentate ligand. The palladium compound used in these catalyst compositions as component a) is preferably a palladium salt of a carboxylic acid and in particular palladium acetate. As examples of acids with a pKa of less than 4 (determined in aqueous solution at 18 °C) whose anions should be present in the catalyst compositions as components b), may be mentioned, inter alia, mineral acids, such as perchloric acid, sulphuric acid, phosphonic acid and nitrous acid, sulphonic acids, such as 2-hydroxy propane-2-sulphonic acid, para-toluenesulphonic acid, methane sulphonic acid and trifluoromethane sulphonic acid, and carboxylic acids, such as trifluoro acetic acid, trichloro acetic acid, dichloro acetic acid, difluoro acetic acid, tartaric acid and 2,5-dihydroxy benzoic acid. Preferably, the catalyst composition comprises an anion of an acid with a pKa of less than 2 as the component b) and in particular an anion of a sulphonic acid, such as para-toluenesulphonic acid, or an anion of a carboxylic acid, such as trifluoro acetic acid. In the catalyst compositions component b) is preferably present in a quantity of from 0.5 to 200, and in particular of from 1.0 to 100, equivalents per gram atom of palladium. Component b) may be introduced into the catalyst compositions either in the form of an acid or in the form of a salt. Eligible salts include non-noble transition metal salts. When component b) is used as a salt of a non-noble transition metal, preference is given to a copper salt. If component b) is used in the catalyst composition in the form of an acid or of a non-noble transition metal salt, it is preferred also to take up a quinone as a component d) in order to enhance the activity of the catalyst compositions. 1,4-Benzoquinones and 1,4-naphthaquinones are very suitable for the purpose. If desired, components a) and b) can be combined in a single compound. An example of such a compound is palladium para-tosylate. The phosphorus bidentate ligands suitable for use as components c) in the catalyst compositions have the general formula R 6 R 7 P-R-PR 8 R 9 , wherein R 6 -R 9 represent similar or dissimilar hydrocarbyl groups which may or may not be substituted with polar groups and R represents a bivalent organic bridging group which contains at least two carbon atoms in the bridge. Preference is given to phosphorus bidentate ligands wherein R 6 -R 9 represent similar or dissimilar aryl groups which may or may not be substituted with polar groups, and in particular to such phosphorus bidentate ligands in which at least one of the aryl groups has at least one polar substituent situated in a position ortho or para to phosphorus. Preference is further given to phosphorus bidentate ligands in which the polar substituents that may be present in the groups R 6 -R 9 are alkoxy groups and in particular methoxy groups. Finally, preference is given to phosphorus bidentate ligands in which the groups R 6 -R 9 are similar to one another and in which the bivalent organic bridging group contains three carbon atoms in the bridge. Examples of suitable phosphorus bidentate ligands are 1,3-bis(diphenyl-phosphino)propane, 1,3-bis[di(4-methyl-phenyl)phosphino]propane, 1,3-bis[di(4-methoxy-phenyl)phosphino]propane, 1,3-bis[di(2-methoxy-phenyl)phosphino]propane, 1,3-bis[di(2,4-dimethoxy-phenyl)phosphino]propane, 1,3-bis[di(2,6-dimethoxy-phenyl)phosphino]propane, and 1,3-bis[di(2,4,6-trimethoxy-phenyl)phosphino]propane. The use of phosphorus bidentate ligands in which at least one of the groups R 6 -R 9 is an aryl group having at least one polar substituent in a position ortho to phosphorus as the component c) offers an additional advantage in that in this case in addition to anions of acids with a pKa of less than 4, also anions of acids with a pKa of at least 4 but less than 6 are eligible for use as components b). Preferably, the phosphorus bidentate ligands are used in the catalyst compositions in a quantity of 0.1-3 and in particular of 0.75-2 mol per mol of palladium compound. Nitrogen bidentate ligands that are eligible for use in the catalyst compositions as components c) have the general formula wherein X and Y represent similar or dissimilar bridging groups, each containing three or four atoms in the bridge, at least two of which are carbon atoms. In the nitrogen bidentate ligands the bridging groups X and Y are connected by the two carbon atoms shown in the general formula. In addition to this linkage, there may exist a further junction between the bridging groups X and Y, such as is the case with 1,10-phenanthroline and compounds derived therefrom. If, in addition to carbon atoms, the bridging groups X and Y contain further atoms in the bridge, these atoms are preferably nitrogen atoms. Further, preference is given to nitrogen bidentate ligands in which the bridging groups X and Y are similar. Examples of suitable nitrogen bidentate ligands are 2,2'-bipyridyl and compounds derived therefrom and 1,10-phenanthroline and compounds derived therefrom. If a catalyst composition based upon a nitrogen bidentate ligand is used to prepare the polymers of the invention, it is preferred to use 2,2'-bipyridyl or 1,10-phenanthroline. Preferably, the nitrogen bidentate ligands are used in the catalyst compositions in a quantity of 0.5-200 and in particular 1-50 mol per mol of palladium compound. The quantity of bidentate ligand-containing catalyst composition used in the preparation of the polymers of the invention may vary within wide ranges. Per mol of olefinically unsaturated compound to be polymerized, such a quantity of catalyst is preferably used as to contain 10 -7 to 10 -3 and in particular 10 -6 to 10 -4 gram atom of palladium. The molar ratio of the olefinically unsaturated compounds relative to carbon monoxide is preferably 10:1-1:5 and in particular 5:1-1:2. In the monomer mixture from which the polymers are prepared, the ratio between the monomers A and B is preferably chosen such as to afford polymers comprising fewer than 2000 and in particular fewer than 1500 units -CO-(A')- per unit -CO-(B')-. The preparation of the copolymers of the invention by using a bidentate-ligand-containing catalyst is preferably carried out at a temperature of 20-200 °C and a pressure of 1-200 bar and in particular at a temperature of 30-150 °C and a pressure of 20-100 bar. The polymerization is preferably executed in a liquid diluent. Very suitable liquid diluents are lower alcohols, such as methanol and ethanol. The invention will now be illustrated with the aid of the following example. Example A carbon monoxide/ethene/diethyl-vinyl phosphonate terpolymer was prepared as follows. A stirred autoclave of 300 ml capacity was charged with a catalyst solution comprising: 50 ml of methanol, 0.1 mmol of palladium acetate, 2 mmol of trifluoro acetic acid, and 0.15 mmol of 1,3-bis(diphenyl-phosphino)propane. After the introduction of 10 ml of diethyl-vinyl phosphonate into the autoclave, air was removed by evacuation and ethene was introduced with pressure until a pressure of 15 bar was reached, followed by carbon monoxide, until a pressure of 45 bar was reached. Then the contents of the autoclave were brought to a temperature of 80 °C. After 5 hours the polymerization was terminated by cooling down to room temperature and releasing the pressure. The polymer formed was filtered off, washed with methanol and dried in vacuo at room temperature. 3.3 g of terpolymer having a melting point of 250 °C was obtained. With the aid of 13 C-NMR analysis it was established that the terpolymer had a linear structure and was made up of units of the formula -CO-(C 2 H 4 )- and units of the formula -CO-(C 6 H 13 O 3 P)-, and that the said units occurred randomly distributed within the terpolymer. From the data obtained by 13 C-NMR analysis it was further deduced that per unit of the formula -CO-(C 6 H 13 O 3 P)- the terpolymer comprised on average 100 units of the formula -CO-(C 2 H 4 )-.

Claims: Copolymers of carbon monoxide with at least two α-olefinically unsaturated compounds, which a) have been prepared by polymerization of carbon monoxide with one or more monomers (A) of the general formula (CH 2 =CR 1 )-R 2 and with one or more monomers (B) chosen from the group formed by compounds of the general formulae (CH 2 =CR 1 )OPO(R 3 )(OR 5 ) and (CH 2 =CR 1 )PO(OR 3 )(OR 5 ), wherein R 1 and R 2 are hydrogen atoms and/or hydrocarbyl groups and R 3 and R 5 are hydrocarbyl groups, b) have a linear structure, and c) are made up of units of the general formula -CO-(A')-and units of the general formula -CO-(B')-, wherein A' and B' represent monomer units originating, respectively, in monomers A and B used. Copolymers as claimed in claim 1, characterized in that per unit -CO-(B')- they comprise on average fewer than 1500 units -CO-(A')-. Copolymers as claimed in claim 1 or 2, characterized in that the monomers A and B used have fewer than 10 carbon atoms. Copolymers as claimed in one or more of claims 1-3, characterized in that ethene is used as monomer A. Copolymers as claimed in one or more of claims 1-4, characterized in that diethyl-vinyl phosphonate is used as monomer B. Process for the preparation of copolymers as claimed in any one of claims 1 to 5, characterized in that a mixture of carbon monoxide with one or more monomers A and with one or more monomers B is polymerized by using a catalyst composition based upon a) a palladium compound, b) an anion of an acid with a pKa of less than 4, and c) either a phosphorus bidentate ligand of the general formula R 6 R 7 P-R-PR 8 R 9 , wherein R 6 -R 9 represent similar or dissimilar hydrocarbyl groups which may or may not be substituted with polar groups and R represents a bivalent organic bridging group having at least two carbon atoms in the bridge, or a nitrogen bidentate ligand of the general formula wherein X and Y represent similar or dissimilar bridging groups, each having three or four atoms in the bridge, at least two of which are carbon atoms. Process as claimed in claim 6, characterized in that a catalyst composition is used which in addition comprises a quinone, such as a 1,4-benzoquinone or a 1,4-naphthaquinone, as a component d). Process as claimed in claim 6 or 7, characterized in that a catalyst composition is used which comprises as component c) a phosphorus bidentate ligand in which at least one of the aryl groups holds at least one polar substituent in a position ortho or para to phosphorus. Process as claimed in one or more of claims 6-8, characterized in that a catalyst composition is used which comprises as component c) a 2,2'-bypiridyl which may or may not be substituted or a 1,10-phenanthroline which may or may not be substituted.

Inventors: DRENT EIT, DRENT, EIT
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1987
Main classification: C08G67
IPC codes: C08G67