Flow reactor synthesis of polymers

Patent metadata

Field	Value
Publication number	US-9751983-B2
Application number	US-201615261441-A
Country	US
Kind code	B2
Filing date	Sep 9, 2016
Priority date	Oct 13, 2015
Publication date	Sep 5, 2017
Grant date	Sep 5, 2017

Abstract

A flow reactor system and methods having tubing useful as polymerization chamber. The flow reactor has at least one inlet and at least one mixing chamber, and an outlet. The method includes providing two phases, an aqueous phase and a non-aqueous phase and forming an emulsion for introduction into the flow reactor.

First claim

What is claimed is:

1. A method comprising
introducing an emulsion of a monomer and an acid into a flow reactor, the flow reactor comprising a length of tubing of inner diameter between about 1 to about 1000 micrometers;
polymerizing the monomer; and
forming a salt of the polymerized monomer with the acid within the length of tubing.

2. The method of claim 1 , further comprising introducing a catalyst to the emulsion.

3. The method of claim 1 , further comprising introducing a catalyst to the flow reactor.

4. The method of claim 1 , wherein the emulsion comprises an aqueous solution of the monomer and an organic solvent solution of the acid.

5. The method of claim 1 further comprising maintaining the salt of the polymerized monomer in the length of tubing.

6. The method of claim 5 , further comprising recovering the salt of the polymerized monomer from the tubing.

7. The method of claim 6 , wherein the recovering of the salt of the polymerized monomer from the tubing is with organic solvent.

8. The method of claim 1 , further comprising maintaining the polymerized acid salt in the length of tubing and removing unreacted monomer or the acid from the tubing with water.

9. The method of claim 1 , wherein the length of tubing is coiled.

10. The method of claim 1 , wherein the tubing is a fluoropolymer.

11. The method of claim 1 , wherein the flow reactor comprises a plurality of tubing arranged in a parallel flow configuration.

12. The method of claim 1 , wherein the polymerizing is carried out in a diffusion-limiting condition.

13. The method of claim 1 , wherein the monomer is an aniline or a thiophene.

14. The method of claim 1 , wherein the acid is an organic acid selected from polystyrene sulfonate or dinonylnaphthalene sulfonic acid.

15. A method comprising
introducing an emulsion of an aniline and an organic sulfonic acid;
introducing the emulsion into a flow reactor, the flow reactor comprising a length of tubing of inner diameter between about one to about 1000 micrometers;
introducing an oxidant to the emulsion or the flow reactor; and
polymerizing the aniline in the inner diameter of the length of tubing and forming an acid salt thereof.

16. A polymerization apparatus for reacting one or more monomers producing one or more polymers, the polymerization apparatus comprising:
an amount of tubing of inner diameter between about 1 to about 1000 micrometers, the tubing including at least one inlet and at least one outlet, the amount of tubing having at least one inlet port for receiving a reactant composition and at least one outlet port;
a temperature controller sized to receive at least a portion of the tubing;
a mixing chamber, the mixing chamber having an outlet fluidically coupled to the inlet of the tubing, and an inlet;
at least one pressure unit operatively coupled to one or both of the inlet port or the outlet port of the amount of tubing, the at least one pressure unit configured to monitor, during polymerization of the one or more monomers, pressure in the amount of tubing or the difference in pressure between the inlet port and the outlet port of the amount of tubing; and
at least one fluid flow control device fluidically coupled to the inlet of the mixing chamber.

17. The polymerization apparatus of claim 16 ; wherein the tubing is wound around the temperature controller.

18. The polymerization apparatus of claim 16 ; wherein the at least one fluid control device comprises a monomer fluid flow control device and an acid fluid flow control device.

19. The polymerization apparatus of claim 16 , further comprising a second mixing chamber fluidically coupled to the outlet of the mixing chamber and the inlet of the tubing.

20. The polymerization apparatus of claim 16 , further comprising a catalyst fluid flow control device fluidically coupled to the second mixing chamber or to the tubing.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick John
• Zweig Andrew M

Classifications

• C08K5/42

  Sulfonic acids; Derivatives thereof · CPC title

• C08G73/0266 Primary

  Polyanilines or derivatives thereof · CPC title

• B01J2219/00891

  Feeding or evacuation · CPC title

• B01J2219/00889

  Mixing · CPC title

• B01J2219/00792

  One or more tube-shaped elements · CPC title