PROCESS FOR PREPARING POLYHYDROXYSTYRENE WITH A NOVOLAK TYPE STRUCTURE

Abstract: A process for preparing a polyhydroxystyrene having a novolak type structure which comprises the step of polymerizing a mixture of carboxylic acid and at least one substituted phenyl carbinol whose formula is (I), wherein (a) R1 is selected from the group consisting of H, alkyl C1-C20, substituted and unsubstituted phenyl, and C(O)R8 (where R8 is alkyl C1-C20); (b) R2 is selected from the group consisting of H and alkyl C1-C20; and (c) R3-R7 are each independently selected from the group consisting of H, alkyl C1-C20, OR9 (where R9 is H, alkyl C1-C20), esters thereof, or substituted and unsubstituted phenyl), halogen, BZT, nitro, or amino, with the proviso that at least one of R3-R7 is OR9, in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form said novolak type polymer.

Description: PROCESS FOR PREPARING POLYHYDROXYSTYRENE WITH A NOVOLAK TYPE STRUCTURE RELATED APPLICATIONS This patent application and the following patent applications are commonly owned by the same Assignee and all relate to polyhydroxystyrene: (a) U.S. Serial No. 08/406,351 filed March 17, 1995 (b) U.S. Serial No. 08/406,266 filed March 17, 1995 (c) U.S. Serial No. 08/406,350 filed March 17, 1995 BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a process for the production of polyhydroxystyrene (PHS) directly from a substituted phenyl carbinol ("carbinol") such as 4-hydroxymethyl-carbinol (HPMC) and which PHS has a novolak type structure which has utility in the electronic chemicals market such as photoresist compositions. Description of the Prior Art In the past, one ofthe ways of preparing polyhydroxystyrene (PHS) was the use of 4-hydroxystyrene (HSM) as the starting material; note European Patent Application No. 0-108- 624. 4-Hy droxy styrene is a well-known compound in the art. Although there are several known ways to prepare 4-hydroxystyrene, these known methods are not commercially feasible in the further utilization ofthe 4-hy droxy styrene. The 4- hydroxystyrene itself is difficult to isolate since it (1) readily decomposes, and (2) is toxic via skin absorption and, as a result, those skilled in the art have made numerous attempts at finding a method of synthesizing PHS in a manner which avoids using the 4-hydroxystyrene as the starting material. The following prior art references are disclosed in accordance with the terms of 37 CFR 1.56, 1.97, and 1.93 for U.S. patent office practices and procedures. U.S. 5,087,772 (issued February 11, 1992) discloses the preparation of HSM by reacting 4-acetoxystyrene (ASM) with a suitable alcohol in the presence of a catalytic amount of a suitable base. U.S. 5,340,687 discloses the alkyiation of a linear polyhydroxystyrene. European Patent Application No. 0-128-984 (publication no.) filed August 30, 1983 discloses a process for the production of para- vinyl phenol (HSM) by dehydrogenation of para- ethyl phenol. European Patent Application No. 0-108-624 (publication no.) filed November 4, 1983, discloses a process for the production of p-vinyl phenol polymer (polyhydroxystyrene polymer - PHS) by polymerizing p-vinyl (HSM) in the presence of water and iron. U.S. 4,032,513 (issued June 28, 1977) discloses a process of producing PHS by cationicaUy polymerizing HSM in the presence of a nitrile such as CH 3 CN using a cationic polymerization initiator in a homogeneous reaction system. Other prior art references which relate to the present invention include U.S. 2,276,138; U.S. 3,547,858, U.S. 4,544,704; U.S. 4,678,843; U.S. 4,689,371; U.S. 4,822,862; U.S. 4,857,601; U.S. 4,868,256; U.S. 4,877,843; U.S. 4,898,916; U.S. 4,912,173; U.S. 4,962,147; and U.S. 4,965,400. All ofthe above-cited prior art and any other references mentioned herein are incoφorated herein by reference in their entirety. SUMMARY OF THE INVENTION A process for preparing a polyhydroxystyrene having a novolak type structure which comprises the step of polymerizing a mixture of carboxylic acid and at least one substituted phenyl carbinol whose formula is: wherein (a) R, is selected from the group consisting of H, alkyl C r C 20 , substituted and unsubstituted phenyl, and C(O)R 8 (where R 8 is alkyl C,-C 20 ); (b) R 2 is selected from the group consisting of H and alkyl C,-C 2 o; and (c) R 3 -R 7 are each independently selected from the group consisting of H, alkyl C,-C 20 , OR <. (where R 9 is H, alkyl C,-C 20 , esters thereof, or substituted and unsubstituted phenyl), halogen, BZT, nitro, or amino, with the proviso that at least one of R 3 -R 7 is OR 9 , in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form said novolak type polymer, which is a unique and new PHS polymeric material having a molecular weight of from about 1 ,000 to about 500,000, preferably from about 1,000 to about 100,000 and more preferably from about 1,000 to about 30,000. DETAILED DESCRIPTION OF THE INVENTION The present invention provides a novel PHS and a novel process for preparing PHS having a novolak type structure which comprises the steps of (a) reacting at least one substituted phenyl carbinol with a carboxylic acid for a sufficient period of time and under suitable conditions of temperature and pressure to form a reaction mixture, and (b) polymerizing said reaction mixture in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form a novolak type polymer. More specifically, the present invention is directed to a unique, cost-efficient process for preparing a novolak type polymer which comprises the step of polymerizing a mixture of carboxylic acid and at least one substituted phenyl carbinol whose formula is: wherein (a) R, is selected from the group consisting of H, alkyl C r C 20 , substituted and unsubstituted phenyl, and C(O)R 8 (where R 8 is alkyl C r C 20 ); (b) R, is selected from the group consisting of H and alkyl C r C 20 ; and (c) R 3 -R 7 are each independently selected from the group consisting of H, alkyl C,-C 20 , OR 9 (where R 9 is H, alkyl C r C 20 , esters thereof, or substituted and unsubstituted phenyl), halogen, BZT, nitro, or amino, with the proviso that at least one of R 3 -R 7 is OR 9 , in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form said novolak type polymer. Substituted phenyl as used herein means phenyl substituted by at least one substituent selected from the group consisting of halogen (chlorine, bromine, fluorine, or iodine), amino, nitro, hydroxy, alkyl, alkoxy which means straight or branched chain alkoxy having 1 to 10 carbon atoms, and includes, for example, methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, secondary butoxy, tertiary butoxy, pentyloxy, isopentyloxy, hexyloxy, heptryloxy, octyloxy, nonyloxy, and decyloxy, haloalkyl which means straight or branched chain alkyl having 1 to 8 carbon atoms which is substituted by at least one halogen, and includes, for example, chloromethyl, bromomethyl, fluoromethyl, iodomethyl, 2-chloroethyl, 2-bromoethyl, 2-fluoroethyl, 3-chloropropyl, 3-bromopropyl, 3-fluoropropyl, 4-chlorobutyl, 4-fluorobutyl dichloromethyl, dibromomethyl, difluoromethyl, duodomethyl, 2,2-dichloroethyl, 2,2-dibromoethyl, 2,2-difluoroethyl, 3,3-dichloropropyl, 3,3-difluoropropyl, 4,4-dichlorobutyl, 4,4-difluorobutyl, trichloromethyl, 4,4-difluorobutyl, trichloromethyl, trifluoromethyl, 2,2,2- trifluoroethyl, 2,3,3-trifluoropropyl, 1,1,2,2-tetrafluoroethyl, and 2,2,3,3-tetrafluoropropyl. In the above definitions and throughout the present specification, alkyl means straight or branched chain alkyl having 1 to 20 carbon atoms, and includes, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, secondary butyl, tertiary butyl, pentyl, isopentyl, neopentyl, hexyl, heptyl, octyl, 2-ethylhexyl, 1,1,3 ,3 -tetramethy Ibutyl, nonyl, decyl, dodecyol, tetradecyl, nexadecyl, octadecyl, and eicosyl. In conjunction with formula I and the definitions of R 3 -R 7 , (a) "BZT" means benzotriazole and has the structural formula: and (b) halogen means Cl, Br, I, and F. As used herein, PHS (polyhydroxystyrene) includes a polymer, copolymer, or block polymer having at least some hydroxy groups in the structure. It is to be understood that there may be present and/or used other monomers which do not contain a hydroxy group. These include, without limitation, (a) substituted phenols: where x = 0-6 and y=0-6 and R 3 is the same as defined herein; and (b) substituted diarylalkyls or triarylalkyls: where n=0-2 and R 2 and R 3 are the same as defined herein. Thus, PHS can be mixtures of linear, branched, and/or grafted polymers using the monomers and/or polymers set forth herein. It has unexpectedly been found that the use of a carboxylic acid with a carbinol to form a reaction mixture and the subsequent polymerization thereof results in a new PHS having a novolak type structure. The carboxylic acid employed not only acts as a reactant, but also as a solvent. The exact theory of what causes the formation of this PHS is not exactly known. However, it is theorized that the carboxylic acid acts (or functions) in a dual capacity, i.e. as a reactant and as a solvent. The present applicant does not, however, desire to be limited by any theory. As previously mentioned, the use of a carboxylic acid is a critical feature of this invention. The carboxylic acid employed includes, without limitation, formic, acetic, propanoic, butyric, valeric, caproic, heptanoic, octanoic, nonanoic, undecanoic, isobutyric, isovaleric, cyclohexane carboxylic acid, and mixtures thereof. It is also critical that the particular carboxylic acid be a saturated carboxylic acid, i.e. a straight chain saturated carboxylic acid, a substituted saturated carboxylic acid, and/or ring carboxylic acid. The amount of carboxylic acid used is any amount which provides a molar reaction and also acts as a solvent. Thus, at least molar equivalents of carboxylic acid and carbinol are used, and excess carboxylic acid up to twenty (and greater) times the carbinol moles. The temperature, pressure, and time at which the carboxylic acid and carbinol are mixed together are not critical; however, it is desirable to employ the carboxylic acid in liquid form. Thus, the upper limit on temperature would desirably be the liquid/gas phase temperature ofthe carboxylic acid. The catalyst employed in the present invention process is critical and is selected from the group H 2 SO 4 , HCl, A1C1 3 , H 3 PO 4 , oxalic acid, SnCl 2 , BF 3 , BBr 3 , BC1 3 , para-toluene sulfonic acid, and methane sulfonic acid. Thus, Lewis acids and protic acids having a pKa of less than about 4.75 are suitable. The catalyst is used in any amount in order to facilitate the reaction, i.e. polymerization, to yield the PHS which has a novolak type structure. Such amounts generally are from about one part per million (ppm) to about 100,000 ppm, or higher. The temperature employed in the polymerization is generally less than about 120°C, more specifically from about 0°C to about 120°C. The reaction pressure may be subatmospheric, atmospheric, or superatmospheric. The length of time which this polymerization step is conducted is not critical and the only requirement is that the polymerization be conducted for a period of time sufficient to form PHS having a novolak type structure. Generally, this period is at least five minutes and may be as long as 25 hours. After the polymerization ofthe reaction mixture (i.e. carboxylic acid + carbinol + any nucleating agent), the desired end product (PHS) is recovered from the reaction product and the residual fraction containing any unreacted carbinol can be recycled as part ofthe starting material for the next cycle. The end product (PHS) may be recovered from the reaction product by any method; for example, it can be separated from the fraction contaimng the unreacted carbinol by, e.g. precipitation in water followed by filtration, or any other suitable technique. It is also within the scope ofthe present invention to utilize a nucleating agent like a seed monomer in order to prepare the reaction mixture. Such material does not have to be a carbinol falling within Formula I, nor does it have to contain any hydroxy groups. Such nucleating agents may include, without limitation, the substituted phenols and substituted triarylalkyls defined herein. It is also within the scope ofthe present invention to employ a chain terminating agent after the polymerization step. Any type of chain terminating agent may be used as long as there is no substantial adverse effect on the novolak structure ofthe PHS formed. It is also within the scope ofthe present invention to employ two or more carbinols in the reaction mixture or to use one or more carbinols in subsequent polymerizations after the initial polymerization; i.e. sequential polymerization with a different carbinol at each polymerization stage. It is also within the scope ofthe present invention to utilize a non-novolak type polyhydroxystyrene homopolymer to add to the "carbinol/carboxylic acid" reaction mixture and then subject the overall reaction mixture to alkylation/polymerization to prepare, a partial novolak type structure of polyhydroxystyrene. In addition to the use of PHS (with a novolak-type structure) in the microelectronic chemicals market, such PHS can be employed in standard novolak applications such as varnishes, aniline printing inks, raw materials for epoxy resins, copying paper, tackifiers for rubber, and crude oil separators. The following specific examples are supplied for the purpose of better illustrating the invention. These examples are not intended, however, to limit or restrict the scope ofthe invention in any way and should not be construed as providing conditions, parameters, or values which must be utilized exclusively in order to practice the present invention. EXAMPLES 1-11 The following procedure was used in all 11 examples to prepare PHS. This procedure illustrates Example 4. A three-neck three-liter flask was fitted with a condenser, thermowell, nitrogen purge, and mechanical stirrer. To the flask was added 4-hydroxyphenylmethylcarbinol (HPMC) (352.0 g, 2.55 mol) and glacial acetic acid (1051.9 g, 17.52 mol). Not all ofthe HPMC was dissolved. The suspension was cooled to 9°C using an ice bath and sulfuric acid (1.0 g) was added. The ice bath was removed and the suspension was allowed to warm, and at 19°C, all ofthe HPMC dissolved. The mixture exothermed, reaching a maximum temperature of 35°C. The reaction was stirred overnight at room temperature. The solution was poured into water (3 x 3000 mL), and the solid was isolated by filtration. The solid was washed with water (3 x 1000 mL), vacuum dried (50°C, 60 torr, 2 days), and weighed (288.7 g, 94.3%). The solid obtained is a bright white powder which is soluble in acetone, methanol, tetrahydrofuran, and aqueous base and is insoluble in non-polar organics. The weight average molecular weight is 5600 and the number average molecular weight is 3675, giving a polydispersity of 1.53. The thermal stability by TGA showed no decomposition below 200°C and the glass transition temperature is 143°C. The experimental conditions and results are shown in Tables 1, 2, 3, and 4. EXAMPLE 12 (COMPARATIVES The procedure set forth in Examples 1-11 above were utilized except in Example 12, methanol was used instead of acetic acid. Example 12 yielded the benzyl ether (4-hydroxy- phenylmethylcarbinol methyl ether) which did not form the PHS (with a novolak-like structure) upon polymerization. Thus, organic alcohols are not suitable replacements for carboxylic acids, in order to form a novolak type structure. DISCUSSION In view ofthe experimental results, it would appear that the use of a carboxylic acid (e.g. acetic acid), with the carbinol, forms, e.g. an acetate, as determined by Η NMR and by TLC analysis ofthe reaction mixture prior to polymerization. The subsequent addition ofthe catalyst (e.g. H 2 SO 4 ) promotes the formation of polyalky lated homopolymers of 4-HPMC. This overall reaction is shown in Scheme 1 as follows: SCHEME 1 AcOH " ™ °→. [(C 8 H 9 0) χ .(C 8 H 8 0) (C 8 H 7 0) z ] n χ+y+ z =l n=l-200 It was also found that 2-hy droxypheny lmethylcarbinol, 3-methyl-4-hydroxy- phenylmethylcarbinol, 4-acetoxyphenylmethylcarbinol, 3-methyl-4-acetoxyphenyl- methylcarbinol, and 4-hydroxybenzylalcohol all reacted under similar conditions to give polyalkylated polymers. In addition, it was found that poly(4-hydroxystyrene) alkylated under these conditions with 4-HPMC, Table 1. The polymerizations are shown in Tables 1, 2, 3, and 4. In all cases, the conversions were high, with no detectable remaining monomers as analyzed by TLC or GPC. The GPC analysis of these polymers are given in Table 2. The weight average molecular weight of a series of 4-HPMC polymers ranged from 5,300 to 7,000. Most ofthe polydispersities were lower than 2.00. Thermal analysis showed, for the 5,000 to 6,000 molecular weight polymers of 4-HPMC, a glass transition temperature of 143°C with no weight loss below 200°C. The alkyiation products of Example 4, using 4-HPMC, are shown in Tables 3 and 4. A comparison ofthe chemical shifts seen in the 13 C NMR as compared to the monomer and a series of model compounds, shows three expected structures ofthe para, ortho-para, and ortho-ortho-para substituted structures (Table 3). For Example 4, these structures are in an approximate ratio of 1 :1 :1; however, the x+y+z (Scheme 1) equals 1, but the individual structures are not limited to 1:1 :1 (or 1/3-1/3-1/3), thus there is no limitation on the structural ratio. It is to be understood that the remarks above contain some theory as to the formation of PHS with a novolak type structure; however, Applicant does not wish to be so limited. Table 1 Conditions for the polymerization of substituted phenyl carbinols Example Reactant Catalyst Temp. Time Yield Weight Weight eo (hrs.) (%) % Λcid % Solids 1 4-HPMC 1 H 2 SO 4 25 1 87 4.0 20 2 4-HPMC H 2 SO 4 25 1.5 85 4.0 20 3 4-HPMC H 2 SO 4 25 16 69 0.4 20 4 4-HPMC H 2 SO 4 25 16 95 0.3 25 5 4-HPMC H 2 SO 4 25 16 88 0.2 25 6 4-HPMC A1C1 3 55 16 91 0.6 21 7 4-HPMC HCl 55 16 85 0.6 20 8 MHPMC 2 H 2 SO 4 25 16 86 0.4 20 9 APMC 3 H 2 SO 4 60 1 - - - 10 2-HPMC 4 H 2 SO 4 25 16 87 0.01 18 11 HBA 5 H 2 SO 4 25 16 - 1 24 4-HPMC is 4-hydroxypheny lmethyl carbinol. 2 MHPMC is 3-methyl-4-hydroxyphenylmethyl carbinol. 3 APMC is 4-acetoxyphenylmethyl carbinol. 4 2-HPMC is 2-hydroxyphenylmethyl carbinol. 5 HBA is 4-hydroxybenzyl alcohol. Table 2 Polymerization of substituted phenyl carbinols in acetic acid. Example Reactant Catalyst M w M n PD 1 CQ 1 • 4-HPMC 2 H 2 SO 4 5,604 3,460 1.62 2 4-HPMC H 2 SO 4 6,600 3,466 1.90 4-HPMC H 2 SO 4 6,300 3,172 1.98 143 4 4-HPMC H 2 SO 4 5,600 3,675 1. 53 143 5 4-HPMC H 2 SO 4 6,900 4,564 1.52 6 4-HPMC A1C1 3 1,835 1,407 1.30 7 4-HPMC HCl 2,821 2,097 1.35 8 MHPMC 3 H 2 SO 4 3,900 2,248 1.74 9 APMC 4 H 2 SO 4 2,686 1,875 1.43 10 2-HPMC 5 H 2 SO 4 3,525 2,285 1.54 11 HBA 6 H 2 SO 4 45,700 3,242 14.09 'PD is polydispersity (MJM-). 2 4-HPMC is 4-hydroxyphenylmethyl carbinol. 3 MHPMC is 3-methyl-4-hydroxyphenylmethyl carbinol. 4 APMC is 4-acetoxyphenylmethyl carbinol. 5 2-HPMC is 2-hydroxyphenylmethyl carbinol. 6 HBA is 4-hydroxybenzyl alcohol. Table 3. Structures obtained by the polymerization of substituted phenyl carbinols. Table 4. Structures obtained by the polymerization of substituted phenyl carbinols. Although the invention has been illustrated by certain ofthe preceding examples, it is not to be construed as being limited thereby; but rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof.

Claims: CLAIMS What Is Claimed Is: 1. A process for preparing polyhydroxystyrene having a novolak type structure which comprises the steps of (a) reacting at least one substituted phenyl carbinol with a carboxylic acid for a sufficient period of time and under suitable conditions of temperature and pressure to form a reaction mixture, and (b) polymerizing said reaction mixture in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form a novolak type polymer. 2. The process as set forth in claim 1 wherein said carbinol has the formula: wherein R, is selected from the group consisting of H, alkyl C,-C 20 , substituted and unsubstituted phenyl, and C(O)R 8 (where R 8 is alkyl C,-C 20 ); R 2 is selected from the group consisting of H and alkyl C,-C 20 ; and R 3 -R 7 are each independently selected from the group consisting of H; alkyl C,- C 20 , OR, (where R is H, alkyl C,-C 20 , esters thereof, or substituted or unsubstituted phenyl), halogen, BZT, nitro and amino; with the proviso that at least one of R 3 -R 7 is OR j . 3. The process as set forth in claim 1 wherein said catalyst is a Lewis acid. 4. The process as set forth in claim 1 wherein the temperature in steps (a) and (b) is from about 0°C to about 120°C. 5. The process as set forth in claim 1 wherein said catalyst is selected from the group consisting of H 2 SO 4 , HCl, A1C1 3 , H 3 PO 4 , oxalic acid, SnCl 2 , BF 3 , BBr 3 , BC1 3 , para-toluene sulfonic acid, and methane sulfonic acid. 6. The process as set forth in claim 1 wherein said carboxylic acid is acetic acid. 7. The process as set forth in claim 1 wherein said catalyst is H 2 SO 4 . 8. The process as set forth in claim 1 wherein said carbinol is selected from the group consisting of 4-hydroxyphenylmethylcarbinol, 2-hydroxyphenylmethylcarbinol, and mixtures thereof. 9. The process as set forth in claim 1 wherein said carbinol is 3 -methy 1-4-hy droxy- phenylmethylcarbinol. 10. The process as set forth in claim 1 wherein said carbinol is 4-acetoxyphenyl- methylcarbinol. 11. The process as set forth in claim 1 wherein said carbinol is 3-methyl-4-acetoxy- phenylmethylcarbinol. 12. The process as set forth in claim 1 wherein said carbinol is selected from the group consisting of 4-hydroxybenzyl alcohol, 2-hydroxybenzyl alcohol, and mixtures thereof. 13. The product produced by the process of any ofthe preceding claims. 14. A process for preparing a polyhydroxystyrene having a novolak type structure which comprises the step of polymerizing a mixture of carboxylic acid and at least one substituted phenyl carbinol whose formula is: wherein (a) R, is selected from the group consisting of H, alkyl C,-C 20 , substituted and unsubstituted phenyl/and C(O)R g (where R 8 is alkyl C,-C 20 ); (b) R 2 is selected from the group consisting of H and alkyl C,-C 20 ; and (c) R 3 -R 7 are each independently selected from the group consisting of H, alkyl C,-C 20 , OR, (where R 9 is H, alkyl C,-C 20 , esters thereof, or substituted or unsubstituted phenyl), halogen, BZT, nitro, or amino, with the proviso that at least one of R 3 -R 7 is OR,, in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form said polyhydroxystyrene. 15. The process as set forth in claim 25 wherein (a) said catalyst is H 2 SO 4 ; (b) the temperature is from about 0°C to about 120°C; (c) the carboxylic acid is acetic acid; (d) the carbinol is a hydroxyphenylcarbinol; and (e) the novolak polymer has a polydispersity of from about 1.0 to about 2.0 and a molecular weight of from about 1000 to about 30,000. 16. The product produced by the process of claim 14 or 15. 17. The process as set forth in claim 1 wherein there are at least two carbinols in said reaction mixture in step (a). 18. The process as set forth in claim 1 wherein there are at least two carbinols used and said second and any other carbinols are individually added after the previous polymerization step in order to form a novolak type block polymer. 19. The process as set forth in claim 1 wherein there is further included step (c) of reacting said novolak type polymer with a chain terminating agent. 20. The process as set forth in claim 1 wherein there is further included in step (a) a nucleating agent. 21. The product produced by the process of claims 17, 18, 19 or 20. 22. The process of claim 1 wherein in step (a), a polyhydroxystyrene having a non- novolak type structure is added to the reaction mixture. 23. A polyhydroxystyrene having a novolak type structure which is prepared by a process which comprises the steps of (a) reacting at least one substituted phenyl carbinol with a carboxylic acid for a sufficient period of time and under suitable conditions of temperature and pressure to form a reaction mixture, and (b) polymerizing said reaction mixture in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form a said polyhydroxystyrene 24. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol has the formula: wherein R, is selected from the group consisting of H, alkyl C r C 20 , substituted and unsubstituted phenyl, and C(O)R 8 (where R g is alkyl C,-C 20 ); R 2 is selected from the group consisting of H and alkyl C r C 20 ; and R 3 -R 7 are each independently selected from the group consisting of H; alkyl C,- C 20 , OR, (where R, is H, alkyl C,-C 20 , esters thereof, or substituted or unsubstituted phenyl), halogen, BZT, nitro and amino; with the proviso that at least one of R 3 -R 7 is OR,. 25. The polyhydroxystyrene as set forth in claim 23 wherein said catalyst is a Lewis acid. 26. The polyhydroxystyrene as set forth in claim 23 wherein the temperature in steps (a) and (b) is from about 0°C to about 120°C. 27. The polyhydroxystyrene as set forth in claim 23 wherein said catalyst is selected from the group consisting of H 2 SO 4 , HCl, A1C1 3 , H 3 PO 4 , oxalic acid, SnCl 2 , BF 3 , BBr 3 , BC1 3 , para-toluene sulfonic acid, and methane sulfonic acid. 28. The polyhydroxystyrene as set forth in claim 23 wherein said carboxylic acid is acetic acid. 29. The polyhydroxystyrene as set forth in claim 23 wherein said catalyst is H 2 SO 4 . 30. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol is selected from the group consisting of 4-hydroxyphenylmethylcarbinol, 2-hydroxyphenylmethyl-carbinol, and mixtures thereof. 31. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol is 3-rnethyl-4- hydroxy-phenylmethylcarbinol . 32. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol is 4-acetoxy- phenylmethylcarbinol. 33. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol is 3-methyl-4- acetoxy-phenylmethylcarbinol. 34. The polyhydroxystyrene as set forth in claim 23 wherein said carbinol is selected from the group consisting of 4-hydroxybenzyl alcohol, 2-hydroxybenzyl alcohol, and mixtures thereof. 35. A polyhydroxystyrene having a novolak type structure which is prepared by a process for preparing a polyhydroxystyrene having a novolak type structure which comprises the step of polymerizing a mixture of carboxylic acid and at least one substituted phenyl carbinol whose formula is: wherein (a) R, is selected from the group consisting of H, alkyl C,-C 20; , substituted and unsubstituted phenyl, and C(O)R g (where R 8 is alkyl C r C 20 ); (b) R 2 is selected from the group consisting of H and alkyl C,-C 20 ; and (c) R 3 -R 7 are each independently selected from the group consisting of H, alkyl C r C 20 , OR, (where R, is H, alkyl C r C 20 , esters thereof, or substituted or unsubstituted phenyl), halogen, BZT, nitro, or amino, with the proviso that at least one of R 3 -R 7 is OR,, in the presence of a suitable catalyst for a sufficient period of time and under suitable conditions of temperature and pressure to form said polyhydroxystyrene. 36. The polyhydroxystyrene as set forth in claim 35 wherein (a) said catalyst is H 2 SO 4 ; (b) the temperature is from about 0°C to about 120°C; (c) the carboxylic acid is acetic acid; (d) the carbinol is a hydroxyphenylcarbinol; and (e) the novolak polymer has a polydispersity of from about 1.0 to about 2.0 and a molecular weight of from about 1000 to about 30,000. 37. The polyhydroxystyrene as set forth in claim 23 wherein there are at least two carbinols in said reaction mixture in step (a). 38. The polyhydroxystyrene as set forth in claim 23 wherein there are at least two carbinols used and the second and any other carbinols are individually and sequentially added after the previous polymerization step in order to form a novolak type block polymer. 39. The polymer as set forth in claim 23 wherein there is further included step (c) of reacting said novolak type polymer with a chain terminating agent. 40. The polymer as set forth in claim 23 wherein there is further included in step (a) a nucleating agent. 41. A polyhydroxystyrene having a novolak type structure and which has the general formula [(C 8 H,O) x (C 8 H 8 O) y (C 8 H 7 O) z ] π where x+y+z is 1 and n is 1-200. 42. The polyhydroxystyrene as set forth in any of claims 23-41 wherein there is substantially no cross-linking. 43. The polyhydroxystyrene as set forth in any of claims 23-42 wherein the polydispersity is less than 2.0 and the molecular weight is less than 30,000. 44. The polyhydroxystyrene of claim 23 wherein in step (a), a polyhydroxystyrene having a non-novolak type structure is added to the reaction mixture.

Inventors: SOUNIK JAMES R, SOUNIK, JAMES, R.
Applicants: HOECHST CELANESE COPORATION
Application year: 1996
Main classification: C08G61
IPC codes: C08G61, G03F7