Abstract:
Embodiments of the disclosure provide a method for removing residual BPA from a residual BPA-containing substance and a method for making a container with residual BPA removed. The method may consist of preparing a stabilization reagent, wherein water is removed from the stabilization reagent. The method may also include preparing the residual BPA-containing substance. The method may also include reacting the residual BPA-containing substance in a melt condensation process with the stabilization reagent, wherein the stabilization reagent is non-toxic.

Description:
TECHNICAL FIELD 
       [0001]    Embodiments described herein generally relate to removing residual monomers in polycarbonate, specifically Bisphenol A (BPA). 
       BACKGROUND 
       [0002]    Polycarbonates are tough, clear, and highly impact resistant thermoplastic resins. Polycarbonates have excellent properties for applications such as baby bottles and water bottles. Residual monomer, such as Bisphenol A (BPA), may leach out of the polycarbonate at certain temperatures and expose the consumer to the residual BPA. The residual BPA may disrupt the endocrine system of various mammalian species, including humans. 
         [0003]    There are known methods of adding diacid residues into polycarbonate that concern altering the physical properties of the resulting polycarbonate, but not removal of residual BPA. 
         [0004]    U.S. Pat. No. 6,747,119 discloses a method for preparing a polycarbonate by adding a free hydroxyl-containing polycarbonate to a mixture of an optionally substituted aromatic dihydroxy diacid and a symmetrically optionally activated aromatic carbonic acid diester. 
         [0005]    U.S. Pat. No. 6,307,005 discloses a method of preparing a polyestercarbonate using an interfacial polymerization reaction using a diacid. 
       SUMMARY 
       [0006]    Embodiments of the disclosure provide a method for removing residual BPA from a residual BPA-containing substance. The method may consist of preparing a stabilization reagent, wherein water is removed from the stabilization reagent. The method may also include preparing the residual BPA-containing substance. The method may also include reacting the residual BPA-containing substance in a melt condensation process with the stabilization reagent, wherein the stabilization reagent is non-toxic. 
         [0007]    Another embodiment of the disclosure may provide a method of a container with stabilized residual BPA. The method may consist of preparing a stabilization reagent. The water is removed from the stabilization reagent. The method may also include preparing a residual BPA-containing substance. The method may also include reacting the residual BPA-containing substance in a melt condensation process with the stabilization reagent. The stabilization reagent is non-toxic. The method may also include making a container from the reaction product of the residual BPA-containing substance with the stabilization reagent. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements or steps: 
           [0009]      FIG. 1  illustrates an exemplary flowchart of a method of adding a stabilization reagent to a residual Bisphenol A (BPA)-containing substance, according to an embodiment. 
           [0010]      FIG. 2  illustrates an exemplary configuration of an apparatus for adding a stabilization reagent to a residual BPA-containing substance, according to an embodiment. 
           [0011]      FIG. 3  is a representation of the reaction between BPA and glutaric acid to remove residual BPA, according to an embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    As mentioned above, the present disclosure relates to a method for removing residual monomer, specifically Bisphenol A (BPA). Diacids have been traditionally used to modify the physical properties of polycarbonates but not to reduce toxicity of polycarbonates. Even though the present disclosure focuses on removing BPA from polycarbonates, embodiments of the disclosure could apply to removing other types of unreacted monomers from polymers. 
         [0013]    Embodiments of the disclosure have found that adding selected species of diacids and carboxylic acids, herein referred to as a stabilizing reagent, result in BPA binding with minimal leaching of the stabilizing reagent. This remains true even with a stoichiometric excess of stabilizing reagent. 
         [0014]      FIG. 1  illustrates a flowchart of a method  100  of adding a stabilization reagent to a residual BPA-containing substance, according to an embodiment. The method may begin at operation  110 . In operation  110 , a residual BPA-containing substance is added to a hopper as a starting material. The hopper may refer to any holding container prior to a polymer melt reaction, but it could be any device. The residual BPA-containing substance may be any substance that contains residual BPA, e.g., BPA that is unbound by another molecule in a polymer. The residual BPA-containing substance may include a variety of different substances, e.g., epoxy resin, or, most notably, polycarbonate. The residual BPA-containing substance may be in a finished polymer state, e.g., polycarbonate recycling, or in a pelletized pre-melt state. 
         [0015]    In operation  112 , the stabilization reagent may be added to the residual BPA-containing substance. The stabilization reagent may be a reagent that reacts with BPA and represented by the following formula: A x D y A z  where A is a carboxyl group or an ester, x is zero or an integer, D is a carbon chain that contains single, double, or triple bonds, y is an integer of the value 3, 5, or 6-33, y is an integer, z is an integer. If A is an ester, then the ether linkage may be of the formula O-R, where R contains a carbon chain of C1-C6 carbon atoms, which may be either single, double, or triple bonded, and O is oxygen. 
         [0016]    The diacid or carboxylic acid must be non-toxic to humans and may be established by mg/kg in various mammalian species. An optimal selection of low toxicity diacid may have an acute dosage of greater than 6000 mg/kg for a mouse since a greater dosage threshold is required for acute toxic effects. Table 1 illustrates examples of possible diacid reactants with low toxicities. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Number of Carbon 
                   
                   
               
               
                   
                 Atoms in 
                 Toxicity (Acute) 
                   
               
               
                 Compound 
                 Carbon Chain 
                 Oral (mg/kg) 
                 Species 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Glutaric Acid 
                 C3 
                 6000 
                 Mouse 
               
               
                 Dimethyl glutarate 
                 C3 (ester) 
                 8191 
                 Rat 
               
               
                 Pimelic Acid 
                 C5 
                 7000 
                 Rat 
               
               
                 Azelaic Acid 
                 C7 
                 &gt;10000 
                 Rat 
               
               
                 Dihexyl azelate 
                 C7 (ester) 
                 16000 
                 Rat 
               
               
                 Sebabic Acid 
                 C8 
                 6000 
                 Mouse 
               
               
                 Dietyhl Sebacate 
                 C8 (ester) 
                 14500 
                 Rat 
               
               
                 Diacid 1550 
                 C21 
                 6176 
                 Rat 
               
               
                 Dodecanedioic Acid 
                 C10 
                 17000 
                 Rat 
               
               
                   
               
             
          
         
       
     
         [0017]    Table 2 illustrates examples of possible carboxylic acid reactants. In some embodiments, the carboxylic acid moieties may be more favorable due to lower cost and prevalence in naturally occurring compounds, e.g., caprylic acid naturally occurs in goat milk fat. 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                   
                   
                 Number of Carbon 
               
               
                   
                   
                 Atoms in Carbon 
               
               
                 Compound 
                 Formula 
                 Chain 
               
               
                   
               
             
             
               
                 Caprylic acid 
                 CH 3 (CH 2 ) 6 COOH 
                 C7 
               
               
                 Pelargonic acid 
                 CH 3 (CH 2 ) 7 COOH 
                 C8 
               
               
                 Capric acid 
                 CH 3 (CH 2 ) 8 COOH 
                 C9 
               
               
                 Undecylic acid 
                 CH 3 (CH 2 ) 9 COOH 
                 C10 
               
               
                 Lauric acid 
                 CH 3 (CH 2 ) 10 COOH 
                 C11 
               
               
                 Tridecylic acid 
                 CH 3 (CH 2 ) 11 COOH 
                 C12 
               
               
                 Myristic acid 
                 CH 3 (CH 2 ) 12 COOH 
                 C13 
               
               
                 Pentadecanoic acid 
                 CH 3 (CH 2 ) 13 COOH 
                 C14 
               
               
                 Palmitic acid 
                 CH 3 (CH 2 ) 14 COOH 
                 C15 
               
               
                 Margaric acid 
                 CH 3 (CH 2 ) 15 COOH 
                 C16 
               
               
                 Stearic acid 
                 CH 3 (CH 2 ) 16 COOH 
                 C17 
               
               
                 Arachidic acid 
                 CH 3 (CH 2 ) 18 COOH 
                 C19 
               
               
                   
               
             
          
         
       
     
         [0018]    The stabilization reagent may be in a water-free solvent. The water-free solvent may be selected so that it does not interact with the residual BPA-containing substance or the polymer formed from the reaction of the stabilization reagent and the residual BPA-containing substance. Other processes may be introduced to ensure that the stabilization reagent is free of water. For example, the stabilization reagent may be subjected to a drying operation. A drying operation may include preheating the stabilization reagent or pretreating with a desiccant that may be removed such as calcium sulfate, calcium chloride, or activated charcoal. In one embodiment, the preheating process may occur at a temperature that is above 100 C but below the glass transition temperature of the residual BPA-containing substance. In another embodiment, the preheating process may occur at any temperature below the degradation temperature of the stabilization reagent. 
         [0019]    The stabilization reagent may be added in a particular proportion depending on the amount of residual BPA predicted to be in the substance. For example, in polycarbonate, the BPA concentration may range from 7 mg/kg to 50 mg/kg and the polycarbonate may range in molecular weight from 10,000 g/mol to 200,000 g/mol. Therefore the mol % of stabilization reagent needed may be anywhere from 0.03 mol %-4.38 mol %. These values may be quickly determined by those with ordinary skill in the art. In another embodiment, there may be a stoichiometric excess of stabilization reagent added. For example, using the previous example, the mol % of stabilization reagent to be added may be 10 mol %. 
         [0020]    In operation  114 , the stabilization reagent and the residual BPA-containing substance may be reacted together in a melt condensation process. A melt condensation process may be a reaction that occurs between two monomers at an elevated temperature and produces water as a byproduct. The reaction between the residual BPA-containing substance and the stabilization reagent may occur during the melt phase, when the residual BPA-containing substance is converted to a molten state. The molten state is achieved by slowly elevating the temperature of the residual BPA-containing substance at or beyond the glass transition temperature of the substance. For example, if the glass transition temperature of polycarbonate is 147 C to 155 C, then the temperature may be first elevated to 147 C and then slowly increased to 155 C. The reaction may occur best at a reaction temperature range of 250 C to 350 C. In an embodiment, the residual BPA-containing substance may be melted in operation  110  before the addition of the stabilization reagent. In another embodiment, the residual BPA-containing substance and stabilization reagent are combined together before the melt phase, and then gradually heated to the reaction temperature. 
         [0021]    The reaction may occur in the absence or presence of a catalyst. An example of a catalyst may include tetramethylammonium hydroxide (TTMH) in a molar ratio of less than 1 mole TTMH to 1 mole stabilization reagent. The catalyst may be added during the melt phase in operation  114  or any time before the melt phase. The catalyst may also be premixed with the stabilization reagent in operation  112 . 
         [0022]    The reaction may ideally occur at atmospheric pressure although it may be possible in some embodiments to conduct the reaction under higher than atmospheric pressure. 
         [0023]    Additionally, any variety of plasticizers may be added during the melt phase of the reaction. The plasticizer may modify the underlying physical properties of the polymer. Ideally, plasticizers should be selected based on their ability to not leech out of the polymer or selected based on low-toxicity. 
         [0024]    In operation  116 , the melted polymer may be cooled and processed into a variety of polymer products, e.g., baby bottles, food storage containers, or water bottles. The processing may occur in a variety of different ways including blow molds, and extrusion. 
         [0025]      FIG. 2  depicts an example of an apparatus  200  that may be used to implement the reaction, according to an embodiment. The apparatus  200  may receive a residual BPA-containing substance  210 , and a stabilization reagent  212 . The receipt of the residual BPA-containing substance  210  may correspond to operation  110 . The receipt of the stabilization reagent  212  may correspond to operation  112 . 
         [0026]    The residual BPA-containing substance  210  and the stabilization reagent  212  may be received into a hopper  214 . The function of the hopper  214  may be blending the residual BPA-containing substance  210  and the stabilization reagent  212  before the melt phase, according to an embodiment. In an embodiment, after blending in a hopper  214 , the residual BPA-containing substance  210  and the stabilization reagent  212  may be reacted in a melt reaction  216 . The melt reaction  216  may correspond to operation  114 . An example of a reaction where BPA is stabilized is shown on  FIG. 3 . As an example of further processing, the melt reaction  216  may proceed to an extruder  218 . In an embodiment, the extruder  218  may take the melted product from the reaction of the residual BPA-containing substance  210  and the stabilization reagent  212  and further blend the resulting product. The extruder  218  may then under go a finishing process  220  that corresponds to operation  116  to produce a final product  222 . Examples of final products include baby bottles, water bottles, and food containers. 
         [0027]      FIG. 3  illustrates an example of the melt condensation reaction  300  that stabilizes BPA  310  in a residual BPA-containing substance, according to an embodiment. In the example, the residual BPA  310  in the substance is reacted with glutaric acid  312 , a species of diacid, in order to bind the residual BPA in the substance. The reaction may occur with or without a catalyst  316 . In the shown example, TTMH is used but other configurations are contemplated. The reaction  300  may occur in a temperature range of 250 C-350 C. In some embodiments, the temperature range may depend on the typical processing conditions of various grades of the residual BPA-containing substance  210 , e.g. polycarbonate. The temperature range may be narrowed based on an empirical determination of the specific residual BPA-containing substance  210  used in the reaction. 
         [0028]    The reaction  300  produces water  316 . The water may be removed using standard polymer processing methods. After the BPA  310  and glutaric acid  312  react at elevated temperature conditions  314 , a form of polyester carbonate  318  is produced. The polyester carbonate  318  stabilizes any leftover BPA in the residual BPA-containing substance. 
         [0029]    While the disclosed subject matter has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the subject matter, which are apparent to persons skilled in the art to which the disclosed subject matter pertains are deemed to lie within the scope and spirit of the disclosed subject matter.