Abstract:
The present invention relates to the novel monomers generically identified as bis(4-hydroxyphenyl thio)benzenes, to a process for their production and to their use in the preparation of polycarbonates, polyurethanes, polyesters, polysulfones and polyethers.

Description:
SUMMARY OF THE INVENTION 
     The present invention comprises novel monomers generically identified as bis(4-hydroxyphenyl thio)benzenes of the structural formula: ##STR1## wherein 
     R 1 , R 2  and R 3 , which may be the same or different, are C 1  -C 4  -alkyl, Cl or Br, and 
     n 1 , n 2  and n 3 , which may be the same or different, are 0, 1 or 2, 
     to a process for their synthesis and to polycarbonates, polyurethanes, polyesters, polysulfones and polyethers prepared from these novel monomers. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The bis(4-hydroxyphenyl thio)benzenes of the present invention have the general structural formula: ##STR2## wherein 
     R 1 , R 2  and R 3 , which may be the same or different, are C 1  -C 4  -alkyl, Cl or Br, and 
     n 1 , n 2  and n 3 , which may be the same or different, are 0, 1 or 2. 
     A route suitable for the synthesis of the generic bis(4-hydroxyphenyl thio)benzenes is illustrated by the following general reaction scheme for the synthesis of bis(4-hydroxyphenyl thio)benzenes (n 1  -n 3  =0), the preferred monomer of the present invention: ##STR3## 
     As indicated in the above reaction scheme, 4-mercaptophenol is reacted with p-dibromobenzene in the presence of potassium carbonate and dimethylformamide to produce the preferred bis(4-hydroxphenyl thio)benzene of the present invention. The resulting monomer is recovered as a precipitate and is then separated and dried. 
     When the reaction is performed on 0.1 mol of p-dibromo benzene, only the desired monomer is formed in 87.8% yield. Scale up of the reaction on a 3.0 mol basis produced a mixture of the desired monomer and the expected by-product, 4&#39;-bromo, 4-hydroxy diphenyl sulfide, in the ratio of 55/45 weight %. ##STR4## Separation of bis(4-hydroxyphenyl thio)benzene from 4&#39;-bromo-4-hydroxy diphenyl sulfide is effected by difference in solubility. 4&#39;-bromo-4-hydroxy diphenyl sulfide being soluble in cyclohexane is removed by Soxhlet extraction of the reaction mixture. Soxhlet extraction is a well-known continuous type of extraction practiced in organic chemistry to separate a mixture having one component possessing solubility in solvent. 
     The generic bis(4-hydroxyphenyl thio)benzenes of the invention are useful as monomers or one of the comonomers in the synthesis of polycarbonates, polyurethanes, polyesters, polysulfones, polyethers and other polymers. 
     Such polycarbonates may be produced using the novel monomers of the invention by well-known methods, such as disclosed in U.S. Pat. Nos. 2,964,794; 2,970,131; 2,991,237; 2,999,835; 2,999,846; 3,028,365; 3,153,008; 3,187,065; 3,215,668 and 3,248,414, all incorporated herein by reference and in the monograph H. Schnell, Chemistry and Physics of Polycarbonates, Interscience Publishers, New York, N.Y., 1964. 
     Such polyurethanes may be produced using the novel monomers of the invention by well-known methods, such as disclosed in U.S. Pat. Nos. 2,266,777; 2,284,637; 2,284,296; 2,511,544, all incorporated herein by reference and in the text Polyurethanes: Chemistry and Technology, Vol. 1, S. H. Saunders and K. C. Frisch, Interscience Publishers, New York, N.Y., 1964. 
     Such polyesters may be produced using the novel monomers of the invention by well-known methods, such as disclosed in U.S. Pat. Nos. 2,980,650; 3,185,668; 3,185,670 and 3,268,482, all incorporated herein by reference, and in the text Polyesters (two parts), edited by Norman G. Gaylord, Interscience Publishers, New York, 1962. 
     Such polysulfones may be produced using the novel monomers of the invention by well-known methods, such as disclosed in U.S. Pat. Nos. 3,236,808; 3,236,809; 3,409,599 and 3,742,087, all incorporated herein by reference. 
     Such polyethers may be produced using the novel monomers of the invention by well-known methods, such as disclosed in U.S. Pat. Nos. 1,922,459; 2,253,723; 2,991,313 and 3,651,151, all incorporated herein by reference, and in the text Polyethers, (three parts), edited by Norman G. Gaylord, Interscience Publishers, New York, 1962. 
    
    
     The invention will be further illustrated, but is not intended to be limited by the following examples. 
     EXAMPLES 
     EXAMPLE 1 
     Synthesis of Bis(4-Hydroxyphenyl Thio)Benzene 
     4-Mercaptophenol (756 g; 6.0 moles) was added to a slurry of anhydrous potassium carbonate (910 g; 6.59 mols, 10% excess) and 7 liters of distilled dimethyl formamide contained in a 12 liter stirred resin reactor. The reaction was carried out under dry nitrogen atmosphere. The mixture was slowly heated to 60° C. at which time a yellow coloration to the reaction mixture was observed. This is due to the formation of potassium salt of 4-mercaptophenol. The reaction mixture was held at 90° C. for 3 hours. Para dibromobenzene (708 g; 3 moles) dissolved in 1.5 liters of distilled dimethyl formamide was added to the reaction mixture through an addition funnel in 1/2 hour. The reaction temperature was raised to 130° C. and maintained at this temperature for 20 hours. The reaction mixture was filtered through a Buchner funnel to remove potassium bicarbonate and unreacted potassium carbonate. The residue in the Buchner funnel was washed with 500 ml of hot dimethyl formamide. The combined filrate was divided in 3 equal portions and each portion poured into a stirred 5-gallon plastic pail containing 3 gallons of demineralized H 2  O and 175 ml of concentrated hydrochloric acid. After adjusting the pH to 6, the contents of the pail were cooled. Water from the pail was decanted. The crude product, a viscous material thus obtained, was washed two times with water--1 gallon each time. The powdery material thus obtained was filtered and washed free of acid with demineralized water. The crude product was dried under vacuum at 90° C. overnight--(m.p. 125°-130° C.). 
     The crude product obtained from the reaction (larger scale, 3 mole basis) contained bis(4-hydroxyphenyl thio)benzene and 4&#39;-bromo-4-hydroxy diphenylsulfide in the ratio of 55/45 (weight %). 
     To remove 4&#39;-bromo-4-hydroxydiphenyl sulfide, the crude reaction product was slurried with hot cyclohexane for 2 hours, and the resultant mixture was filtered. It required 3 similar extractions to separate 4&#39;-bromo-4-hydroxydiphenyl sulfide from the bis(4-hydroxyphenyl thio)benzene. 4&#39;-bromo-4-hydroxydiphenyl sulfide in white flakes (390 g)--(m.p. 78°-79° C.)--was obtained after removal of cyclohexane from the extract. The insoluble portion of 398 g was found to be 99% bis(4-hydroxyphenyl thio)benzene--(m.p. 158°-160° C.). The infrared (IR) and nuclear magnetic resonance (NMR) spectra of the bis(4-hydroxyphenyl thio)benzene and 4&#39;-bromo-4-hydroxydiphenyl sulfide were consistent with the assigned structures. Elemental analysis given below is also consistent for the two products. 
     Bis(4-Hydroxyphenyl Thio)Benzene: Molecular formula: C 18  H 14  S 2  O 2  (molecular weight 326.292); Theory: % C: 66.26; % H: 4.32; % S: 19.6; Found: % C: 64.32; % H: 3.98; % S: 18.84. 
     4&#39;-Bromo-4-Hydroxydiphenyl Sulfide: Molecular formula: C 12  H 9  BrSO (Molecular weight 281.192); Theory: % C: 51.25; % H: 3.23; % S: 11.38; % Br: 28.45; Found: % C: 51.36; % H: 3.22; % S: 11.32; % Br: 28.43. 
     EXAMPLE 2 
     Preparation of a Copolycarbonate Produced from Bisphenol A and Bis(4-Hydroxyphenyl Thio)Benzene 
     A copolycarbonate resin was prepared by reacting a mixture of the disodium salts of 2,2-bis(4-hydroxyphenyl)propane (bisphenol A) and bis(4-hydroxyphenyl thio)benzene with phosgene in accordance with the interfacial polycondensation synthesis. 5 weight % of bis(4-hydroxyphenyl thio)benzene and 95 weight % of bisphenol A, based on the weight of the diphenols, were used. The properties measured for this copolycarbonate are reported in Table 1. 
     
                       TABLE 1______________________________________      UNITS      VALUE             US              US      SI     Conv    SI      Conv______________________________________Izod Impact Strength.sup.1        J/M      ft lb/in1/8&#34; thickness                817   15.301/4&#34; thickness                145   2.71Critical Thickness        mm       mil     4.95  195Melt Index.sup.2        g/10 min         6.70Heat DeflectionTemp.sup.3Under Load °C.        3(264 psi) 1.82 MPa        °C.                 °F.                         120.8 250Tensile Properties.sup.4Tensile strength at        MPa      psi     61    8800yieldTensile strength,        MPa      psi     61    8800ultimateTensile strength,        MPa      psi     49    7100failureElongation, yield %           8Elongation, fail %            103Flexural Properties.sup.5Strength     MPa      psi     86    12422Ultimate     MPa      psi     86    12422Modulus      GPa      psi     2.3   334000FlammabilityPropertiesUL-94.sup.6                   94V-23.2 mm (1/8&#34; thickness)Oxygen Index.sup.7        %                23.9Optical Properties.sup.8% Brightness                  83.26% Yellowness Index            11.8at 550° F. molding% Haze at                     2.2550° F. molding% Yellowness at               17.4650° F. molding% Brightness at               80.5650° F. moldingMelt Viscosity,        Pa&#39;s     Poise300° C.7.2 S.sup.-1                  620   620014.4                          600   600036.0                          540   540072.00                         510   5100144                           510   5100360                           440   4400720                           360   36001440                          290   2900Melt Stability, 300° C.        Pa&#39;s     Poise5 min                         510   510035 min                        370   370065 min                        350   3500(5-65)                        160   1600Initial RV                    1.292After 65&#39; strand RV           1.279______________________________________ .sup.1 ASTM D256 .sup.2 ASTM D2138; at 300° C. and 1200 g load .sup.3 ASTM D648/72 .sup.4 ASTM D638 .sup.5 ASTM D790 .sup.6 Underwriters Laboratories, Inc. 94: Standard For Tests For Flammability Of Plastic Materials For Parts In Devices And Appliances .sup.7 ASTM D2863 .sup.8 ASTM D1003 
    
     Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.