Process for producing a high molecular-weight aromatic polycarbonate resin

Patent metadata

Field	Value
Publication number	US-9822218-B2
Application number	US-201415032763-A
Country	US
Kind code	B2
Filing date	Nov 12, 2014
Priority date	Nov 15, 2013
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

The present invention is to provide a process for producing a high molecular-weight aromatic polycarbonate resin, the process includes mixing a dialcohol compound represented by the following Formula (1) with a first catalyst to obtain a catalyst composition; mixing the obtained catalyst composition with an aromatic polycarbonate prepolymer to obtain a prepolymer mixture; and obtaining a high molecular-weight aromatic polycarbonate by subjecting the obtained prepolymer mixture to heating treatment under reduced pressure condition. In the Formula (1), R 1 to R 4 each independently represent a hydrogen atom, an alkyl group and the like. Q represents a divalent group or a single bond.

First claim

The invention claimed is:

1. A process for producing a high molecular-weight aromatic polycarbonate resin, the process comprising:
providing an aromatic polycarbonate prepolymer;
mixing a dialcohol compound represented by the following Formula (1) with a first catalyst to obtain a catalyst composition;
mixing the obtained catalyst composition with the aromatic polycarbonate prepolymer to obtain a prepolymer mixture; and
obtaining a high molecular-weight aromatic polycarbonate by subjecting the obtained prepolymer mixture to heating treatment under reduced pressure conditions:

wherein, in Formula (1), R 1 to R 4 each independently represent a hydrogen atom, a halogen atom, or a linear or branched alkyl group having 1 to 5 carbon atoms; and Q represents a divalent group comprising at least one member selected from the group consisting of an aliphatic hydrocarbon group, an aromatic hydrocarbon group, an oxygen atom, a sulfur atom, a sulfonic group, a sulfoxide group, a carbonyl group, a dialkylsilyl group, and a diarylsilyl group and optionally having a substituent, or a single bond,
wherein the high molecular-weight aromatic polycarbonate resin obtained has a content of heterologous structure of less than 1100 ppm.

2. The process according to claim 1 , wherein the catalyst composition has been subjected to dehydration treatment or devolatilization treatment.

3. The process according to claim 1 , wherein the first catalyst is at least one member selected from the group consisting of alkali metal salts and alkaline earth metal salts.

4. The process according to claim 1 , wherein providing an aromatic polycarbobnate prepolymer includes subjecting an aromatic dihydroxy compound and a carbonate diester compound to polycondensation reaction in the presence of a second catalyst to obtain the aromatic polycarbonate prepolymer.

5. The process according to claim 4 , wherein the molar ratio of the first catalyst and the second catalyst is from 1:9 to 9:1.

6. The process according to claim 4 , wherein the total amount of the the first catalyst and the second catalyst is 1×10 −6 mol or less per 1 mol of the aromatic dihydroxy compound.

7. The process according to claim 4 , wherein obtaining the aromatic polycarbonate prepolymer is conducted in coexistence with a cocatalyst.

8. The process according to claim 1 , wherein the dialcohol compound is represented by the following Formula (1a):

wherein, in Formula (1a), Ra and Rb each independently represent a hydrogen atom, a halogen atom, a linear or branched alkyl group having 1 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, a cycloalkyl group having 3 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, an aryl group having 6 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, or an alkoxy group having 1 to 15 carbon atoms and optionally including an oxygen atom or a halogen atom, and Ra and Rb are optionally bonded to each other to form a ring; R 1 to R 4 each independently represent a hydrogen atom, a halogen atom, or a linear or branched alkyl group having 1 to 5 carbon atoms; and n represents an integer of 0 to 30.

9. The process according to claim 1 , wherein the dialcohol compound is represented by the following Formula (1b):

wherein, in Formula (1b), Ra and Rb each independently represent a hydrogen atom, a halogen atom, a linear or branched alkyl group having 1 to 30 carbon atoms and optionally icluding an oxygen atom or a halogen atom, a cycloalkyl group having 3 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, an aryl group having 6 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, or an alkoxy group having 1 to 15 carbon atoms and optionally including an oxygen atom or a halogen atom, and Ra and Rb are optionally bonded to each other to form a ring.

10. The process according to claim 9 , wherein the dialcohol compound is selected from the group consisting of 2-butyl-2-ethylpropane-1,3-diol, 2,2-diisobutylpropane-1,3-diol, 2-ethyl-2-methylpropane-1,3-diol, 2,2-diethylpropane-1,3-diol, and 2-methyl-2-propylpropane-1,3-diol.

11. The process according to claim 1 , further comprising removing at least part of a cyclic carbonate formed in obtaining the high molecular-weight aromatic polycarbonate to the outside of the reaction system.

12. The process according to claim 11 , wherein removing the cyclic carbonate is removing a distillate containing at least part of the cyclic carbonate formed in increasing molecular weight to the outside of the reaction system.

13. The process according to claim 11 , wherein the cyclic carbonate is a compound represented by the following Formula (2a):

wherein, in Formula (2a), Ra and Rb each independently represent a hydrogen atom, a halogen atom, a linear or branched alkyl group having 1 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, a cycloalkyl group having 3 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, an aryl group having 6 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, or an alkoxy group having 1 to 15 carbon atoms and optionally including an oxygen atom or a halogen atom, and Ra and Rb are optionally bonded to each other to form a ring; R 1 to R 4 each independently represent a hydrogen atom, a halogen atom, or a linear or branched alkyl group having 1 to 5 carbon atoms; and n represents an integer of 0 to 30.

14. The process according to claim 11 , wherein the cyclic carbonate is a compound represented by the following Formula (2b):

wherein, in Formula (2b), Ra and Rb each independently represent a hydrogen atom, a linear or branched alkyl group having 1 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, a cycloalkyl group having 3 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, an aryl group having 6 to 30 carbon atoms and optionally including an oxygen atom or a halogen atom, or an alkoxy group having 1 to 15 carbon atoms and optionally including an oxygen atom or a halogen atom, and Ra and Rb are optionally bonded to each other to form a ring.

15. The process according to claim 9 , wherein the dialcohol compound is 2-butyl-2-ethylpropane-1,3-diol.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Isahaya Yoshinori
• Hirashima Atsushi
• Harada Hidefumi
• Ito Maki
• HAYAKAWA Jun-ya
• Isobe Takehiko
• Liu Hongyu
• Furuhashi Hiroki
• Shinkai Yousuke

Classifications

• C08G64/305

  and alcohols · CPC title

• C08G64/06 Primary

  not containing aliphatic unsaturation · CPC title

• C08G64/307

  and phenols · CPC title

• C08G64/205

  characterised by the apparatus used · CPC title