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Polycarbonate compositions with improved oxidation stability and methods of manufacturing the same

A technology of polycarbonate and composition, applied in the field of polycarbonate composition with improved oxidation stability and its preparation, capable of solving problems such as easy oxidation of polycarbonate

Active Publication Date: 2021-05-04
SABIC GLOBAL TECH BV
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

However, polycarbonate is prone to oxidation and is thus known to color with time and applied heat

Method used

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  • Polycarbonate compositions with improved oxidation stability and methods of manufacturing the same
  • Polycarbonate compositions with improved oxidation stability and methods of manufacturing the same
  • Polycarbonate compositions with improved oxidation stability and methods of manufacturing the same

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0106] figure 1 An exemplary polycarbonate production process is shown. The reactants DPC and BPA are mixed in the monomer mixing unit (R010) in the presence of TBPA. The process flow continues to the first oligomerization reactor (R100). A scrubber (C100) running on top of R100 recycles DPC and BPA back to R100 and removes phenol. The equipment group (H100, V100) allows to condense the vapor product of the C100 and adjust the distillate and reflux rate as appropriate for the C100. The process flow continues to the second oligomerization reactor (R200). The process flow continues to the first polymerization reactor (R300), the second polymerization reactor (R400) and the third polymerization reactor (R500). The equipment groups (H200, H300, H400) allow to condense or sublimate the vapor streams leaving R200, R300 and R400 respectively to remove most of the phenol and send those materials to V200. These materials may contain phenol, DPC, BPA, and resulting TBPO and related...

Embodiment 2

[0110] figure 2 An alternative polycarbonate production process is shown in which stream 102 containing TBPO and DPC is directed to a purge tank. In this case, all materials from medium boilers (MB) to high boilers (HB) are cleaned. This reduces recycling of MB, DPC, TBPO and other HB back into the process. In this configuration, the amount of TBPO in DPCs run at 50 μmol TBPA / mol BPA was drastically reduced to 1–5 ppm P.

[0111] Table 4 shows the P content in DPC and PC. In the case of PC, it must be taken into account that PC also contains a certain amount of other extrusion stabilizers / processing aids Irgafos TM 168 (tris(2,4-di-tert-butylphenyl) phosphite, CAS: 31571-04-4, Mw: 646.9 g / mol) to analyze the P content. Therefore, as shown in Table 4, total P content was not directly affected by DPC re-route. The P content (ppm) during polycarbonate production is shown in figure 1 middle. The 2.95% mean confidence interval (CI) was calculated using the MS ExcelConfiden...

Embodiment 3

[0129] image 3 shown is designed to address the previously described and figure 2 Another alternative polycarbonate production process with reduced TBPO concentration shown above. A new distillation column (C300) is added to recover TBPO and DPC, both of which are then rerouted back to the process via the overhead stream (109) of column C300. It has been observed that DPC split ratios greater than 0.6 are required to see oxidation benefits in polycarbonates. The main reason for this is that the color benefit is shown in Example 2 with a DPC recovery close to 0.6, but it does not show a P content that would provide an oxidation benefit. The rationale for this is that (i) the top of C300 is not sent to C401, causing a loss of P content, and (ii) a DPC recovery higher than 0.6 is required to pull more TBPO and other phosphates from the bottoms to the tops. but found image 3 The process described in does not increase the content of TBPO and other phosphate esters in stream ...

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Abstract

A method of preparing a polycarbonate composition in a polymerization system that comprises a monomer mixing unit, an oligomerization section, and a polymerization section. The method includes melt polymerizing a dihydroxy compound with a diaryl carbonate compound in the presence of a quaternary phosphonium catalyst to produce the polycarbonate composition having a pho sphorus-containing byproduct of at least one of the quaternary phosphonium catalyst or of the diaryl carbonate compound. The method further includes recycling the phosphorus -containing byproduct into the monomer mixing unit of the polymerization system and removing the polycarbonate composition from the polymerization system. The recycle stream has a phosphorus concentration of greater than or equal to 40 ppm.

Description

[0001] Cross References to Related Applications [0002] This application claims priority to EP Application No. 18382900.1, filed December 5, 2018, and US Patent Application No. 62 / 788,202, filed January 4, 2019, both of which are incorporated herein by reference in their entirety. [0003] Background of the invention [0004] Polycarbonates are useful in the manufacture of articles and components with a wide variety of applications, such as automotive parts, electronic devices, plastic optical recording media, and optical lenses. Polycarbonates exhibit excellent mechanical properties such as impact resistance, heat resistance and transparency. However, polycarbonate is prone to oxidation and thus is known to color with time and application of heat. [0005] Polycarbonate can be produced by melt-polymerizing a dihydroxy compound and a carbonate compound in the presence of a catalyst. It has been observed that when organic quaternary phosphonium compounds such as tetrabutylpho...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C08G64/06C08G64/30
CPCC08G64/06C08G64/307
Inventor A·D·博雅斯基I·维克费尔南德斯
Owner SABIC GLOBAL TECH BV
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