Patent Publication Number: US-5298592-A

Title: Preparation of polyaryl ethers with nitrogen compound catalysts

Description:
The present invention relates to a process for preparing aromatic polyether ketones and polyether sulfones. 
     Polyaryl ethers can be prepared electrophilically as described, for example, in U.S. Pat. No. 4,709,007, U.S. Pat. No. 3,791,890 or DE 1 645 153. Nucleophilic polycondensation of bisphenols with dihaloaromatic compounds to synthesize polyaryl ethers has likewise been disclosed, for example, in U.S. Pat. No. 4,105,636 and EP 1879. Nucleophilic condensation results in high molecular weight polyaryl ether ketones only when the relatively costly difluoro compounds are employed as dihaloaromatic compounds. EP-B-1879 states that part of the difluoro monomers can be replaced by dichloro monomers. DE-A-38 29 283 describes a two-stage process for preparing polyether ketones in which, in a first stage, the total amount of bisphenol and dichloroaromatic compound and, in a second stage, the difluoroaromatic compound are employed for the condensation. 
     It is an object of the present invention to find a process for preparing polyaryl ethers from bisphenols and dichloroaromatic compounds with the addition of catalysts without using corresponding difluoro compounds. 
     We have found that this object is achieved when the polycondensation of bisphenols and dichloroaromatic compounds to give high molecular weight compounds is carried out in the presence of certain nitrogen compounds. 
     The compounds obtained with the addition according to the invention have higher molecular weights than without the addition, under conditions which are otherwise the same, as the following comparison shows. 
    
    
     The present invention particularly relates to a process for preparing polyaryl ethers of the formula I or Ia ##STR4## by condensation of at least one appropriate bisphenol with at least one appropriate aromatic dichloride in the presence of an alkali metal carbonate in a dipolar aprotic solvent, which process is carried out in the presence of a catalyst selected from the alkali metal nitrites and the group of compounds of the formula II ##STR5## where R 1  and r 3  are each hydrogen, C 7  -C 16  -phenylalkyl, C 1  -C 12  -alkoxy, fluorine, chlorine, bromine, iodine or nitro, and r 2  is nitro or nitroso, or ##STR6## where R 4  is hydrogen, C 1  -C 4  -alkyl, fluorine, chlorine, bromine or iodine. 
     If R 2  is nitro or nitroso, at least one of r 1  or R 3  must be halogen such as fluorine, chlorine, bromine or iodine. 
     the effective amount of alkali metal nitrite is, for example, from 5 to 50 mol %, based on the dichloride, preferably 10 to 40 mol % and particularly preferably 12 to 30 mol %. 
     Of the other nitrogen compounds generally from 1 to 20 mol %, based on the dichloride, preferably 2 to 15 mol % are required. 
     The polycondensation of the bisphenol with the dichloroaromatic compound otherwise substantially corresponds to the conventional process, ie. the compounds are reacted in the stoichiometric amount at from 130° to 400° C. in a dipolar aprotic solvent in the presence of an alkali metal carbonate and of the catalyst according to the invention. The resulting polyaryl ethers are composed of up to 100 mol % of units of the formula I ##STR7## and/or up to 100 mol % of units of the formula Ia ##STR8## where X,X&#39;, Q,Q&#39;, W and W&#39; can each, independently of one another, be --SO 2  --, --O--, --CO--, a bond or --CRR&#39;--, R and R&#39; are each hydrogen, C 1  -C 8  -alkyl or C 1  -C 6  -alkoxy, aryl or fluoro or chloro derivatives thereof, and p, q and r are each 0 to 1, or the nuclear-substituted C 1  -C 6  -alkyl or C 1  -C 6  -alkoxy, aryl, chloro or fluoro derivatives thereof. 
     These polyaryl ethers are prepared using, for example, the following monomers. 
     
         __________________________________________________________________________
 ##STR9##                            4,4&#39;-dihydroxydiphenyl sulfone       
 ##STR10##                           bis(4-hydroxyphenyl)methane          
 ##STR11##                           1,1-bis(4-hydroxyphenyl)ethane       
 ##STR12##                           1-phenyl-1,1-bis(4-hydroxyphenyl)-   
                                     methane                              
 ##STR13##                           bisphenyl-bis(4-hydroxyphenyl)methane
                                     7                                    
 ##STR14##                           tetramethylbisphenol A               
 ##STR15##                           4,4&#39;-dihydroxydiphenyl ether         
 ##STR16##                           4,4&#39;-dihydroxydiphenyl sulfide       
 ##STR17##                           4,4&#39;-dihydroxybenzophenone           
 ##STR18##                           bisphenol A                          
 ##STR19##                           1,4-di(4-hydroxybenzoyl)benzene      
 ##STR20##                           3,3&#39;,5,5&#39;-tetramethyl-4,4&#39;- dihydroxy
                                     diphenyl sulfone                     
 ##STR21##                           hydroquinone                         
 ##STR22##                           2,3,6-trimethylhydroquinone          
 ##STR23##                           4,4&#39;-dihydroxybiphenyl               
 ##STR24##                           3,3&#39;,5,5&#39;-tetramethyl-4,4&#39;- dihydroxy
                                     biphenyl                             
 ##STR25##                           4,4&#39;-bis(4-hydroxybenzoyl)- diphenyl 
                                     ether                                
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     Of the dihydroxy compounds listed above, hydroquinone and 4,4&#39;-dihydroxydiphenyl sulfone are particularly preferred. 
     
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 ##STR26##               4,4&#39;-dichloro- benzophenone                      
 ##STR27##               1,4-bis(4- chlorobenzoyl)- benzene               
 ##STR28##               1,5-dimethyl- 2,4-di(4- chlorophenyl- sulfonyl)- 
                         enzene                                           
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     Of the dichloro compounds listed above, 4,4&#39;-bis()4-chlorophenylsulfonyl)biphenyl and dichlorobenzophenone, and the corresponding polycondensates, are particularly preferred. 
     The following monomers with biphenyl units which are employed to prepare corresponding polymers may be mentioned, merely as representatives: 
     
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 ##STR29##                 4,4&#39;-bis-(4- chloro- phenyl- sulfonyl)-        
                           biphenyl                                       
 ##STR30##                 4,4&#39;-bis-(4- hydroxy- benzoyl)- biphenyl       
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     The abovementioned compounds can in principle be reacted together in any desired combination. 
     The reaction is particularly suitably carried out in dipolar aprotic solvents in the presence of anhydrous alkali metal carbonates. Particularly preferred solvents are N-methylpyrrolidone and, for the preparation of polyether ketones, preferably sulfone solvents, especially diphenyl sulfone. The amount of solvent is generally from 5 to 100 mol, preferably 5 to 20 mol, based on 1 mol of monomer. This results in a preferred solids content in the range from 5 to 50 % by weight, particularly preferably 10 to 40 % by weight, in the reaction mixture. 
     The water produced in the polycondensation can be removed with the aid of an entraining agent, by reducing the pressure or, preferably, by passing in nitrogen and distilling out. Suitable entraining agents are all compounds which boil in the region of the reaction temperature under atmospheric pressure and which mix with the reaction mixture without undergoing chemical reactions. 
     The reaction temperature for the preparation of polyaryl ether sulfones is generally in the range from 130° to 220° C., preferably from 150° to 210° C.; the total reaction time depends on the required degree of condensation but is generally in the range from 0.1 to 15 hours. 
     To prepare polyaryl ether ketones, generally higher temperatures in the range from 150° to 400° C., in particular 200° to 350° C., are necessary. It is advantageous to increase the temperature stepwise. 
     Following the polycondensation it is possible to stabilize free phenol end groups by reaction with an alkylating or arylating agent such as methyl chloride or 4-fluorobenzophenone. 
     The alkali metal chloride which is formed can be removed using suitable apparatus, for example clarifying filter or centrifuge. 
     It is also possible to convert the melt into a finely divided material which is extracted with a suitable solvent (eg. acetone) or a solvent mixture such as a methanol/acetone mixture, to remove residual solvent (eg. diphenyl sulfone). It is subsequently possible to remove the alkali metal chloride which has been produced by extraction with water. 
     The following preliminary remarks are necessary to explain the following examples and the table. 
     In the case of the polyaryl ether ketones, the inherent viscosity ##EQU1## is used, with the unit dl/g. 
     The measurements are carried out on a 0.5% strength solution in concentrated sulfuric acid at 250° C. 
     In the case of the polyaryl ether sulfones, the reduced viscosity ##EQU2## is used, with the unit dl/g. 
     The measurements are carried out on a 0.5 % strength solution in concentrated sulfuric acid at 25° C. 
     EXAMPLE 1 
     200 g of diphenyl sulfone, 142.10 g of 4,4&#39;-(bis(4-chlorobenzoyl)benzene, 44.00 g of hydroquinone, 42.29 g of sodium carbonate, 2.90 g of potassium carbonate and 5.1 g of potassium nitrite were introduced into a 1 1 three-neck flask with stirrer, distillation apparatus and nitrogen introduction tube, which was flushed with nitrogen. The mixture is heated at 250° C. for 2.5 h and at 330° C. for 5 h while passing in N 2 . The water is removed by distillation. The mixture is cooled and ground, and extracted with acetone and then with water. The residue is dried at 200° C. 
     In the comparative test, Example 1 is repeated but without the addition of potassium nitrite. 
     EXAMPLE 2 
     300 g of diphenyl sulfone, 151.41 g of 4,4&#39;-dichlorobenzophenone, 66.00 g of hydroquinone, 85.41 g of potassium carbonate and 7.70 g of potassium nitrite were introduced into a 1 1 three-neck flask with stirrer, distillation apparatus and nitrogen introduction tube, which was flushed with nitrogen and then heated at 200° C. for 1.5 h, at 250° C. for 1 h and at 330° C. for 3 h while passing in N 2 . The mixture is cooled and ground, and extracted with acetone and then with water. The residue is dried at 200° C. 
     A comparative test without potassium nitrite is carried out in this case too. 
     EXAMPLE 3 
     The process is carried out as described above but with heating at 200° C. for 1.5 h, at 200° C. for 1 h and at 300° C. for 1 h. Comparison without added nitrite. 
     
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                                      Polymer                             
Example  Catalyst Temperature                                             
                             η.sub.inh · (dl/g)*.sup.)       
                                      type                                
______________________________________                                    
1        KNO.sub.2                                                        
                  2.5 h 250° C.,                                   
                             1.05     PEEKK                               
                  5 h 330° C.                                      
Comparative                                                               
         -        2.5 h 250° C.,                                   
                             0.80     PEEKK                               
                  5 h 330° C.                                      
2        KNO.sub.2                                                        
                  1.5 h 200° C.,                                   
                             1.20     PEEK                                
                  1 h 250° C.                                      
                  3 h 330° C.                                      
Comparative                                                               
         --       1.5 h 200° C.,                                   
                             0.84     PEEK                                
                  1 h 250° C.                                      
                  3 h 330° C.                                      
3        KNO.sub.2                                                        
                  1.5 h 200° C.,                                   
                             0.92     PEEK                                
                  1 h 250° C.                                      
                  3 h 300° C.                                      
Comparative                                                               
         --       1.5 h 200° C.,                                   
                             0.49     PEEK                                
                  1 h 250° C.                                      
                  3 h 300° C.                                      
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 *.sup.) measured on 0.5% strength solution in concentrated H.sub.2       
 SO.sub.4 at 25° C.                                                
 
    
     EXAMPLE 4 
     259.26 g of 4,4&#39;-bis(4-chlorophenylsulfonyl)biphenyl (prepared from 4-chlorobenzenesulfonyl chloride and biphenyl in 1,2-dichlorobenzene as solvent), 125.14 g of 4,4&#39;-dihydroxydiphenyl sulfone, 76.0 g of potassium carbonate, 7.93 g of azoxybenzene and 1 1 of N-methylpyrrolidone are heated at 190° C. under nitrogen. Most of the water which has formed is distilled out within one hour. The mixture is then stirred at 190° C. for a further 5 h, and the product is removed by precipitation with water, washed and dried at 120° C. The resulting polyaryl ether has a reduced viscosity of 0.73 dl/g measured at 1 % strength solution in N-methylpyrrolidone at 25° C. 
     If the process is carried out correspondingly but without the addition of azoxybenzene, the reaction product has a reduced viscosity of 0.19 dl/g.