Polyester polycondensation with catalyst and a catalyst enhancer

Abstract

The present invention is based upon the discovery that nontitanyl oxalates can enhance the catalytic functionality of titanyl oxalate catalysts. This invention provides a novel catalytic composition containing a titanyl oxalate catalyst and a metallic oxalate catalyst enhancer and optionally containing a metallic cocatalyst such as an antimony based catalyst. A synergistic relationship has been discovered between titanyl oxalate catalyst and the catalyst enhancer. A synergistic relationship has also been discovered between the titanyl oxalate catalyst, catalyst enhancer and a metallic cocatalyst such as antimony oxide or antimony triacetate. Also provided is an improved process of producing polyester by the polycondensation of polyester forming reactants in the presence of a catalytically effective amount of a polycondensation catalyst, wherein the improvement comprises utilizing, as the polycondensation catalyst, the novel catalyst composition containing a titanyl oxalate such as lithium titanyl oxalate and a catalyst enhancer such as a nontitanyl metallic oxalate like lithium oxalate and optionally containing a metallic catalyst such as antimony oxide or antimony triacetate. The improved process produces an improved polyester having lower acetaldehyde numbers and good color. The titanyl oxalate / catalyst enhancer composition can be used as a polycondensation catalyst in combination with other catalysts to achieve synergistic catalytic activity. Preferred is a combination of lithium or potassium titanyl oxalate, Li2 or K2TiO(C2O4)2, lithium or potassium oxalate, Li2 or K2(C2O4)2 with antimony oxide or antimony triacetate or antimony trisglycoxide.

Description

[0001] REFERENCE TO RELATED APPLICATION[0002] This application is a continuation-in-part of U.S. patent application Ser. No. 09 / 747,115, filed Dec. 22, 2000, which claims priority of U.S. Provisional Application No. 60 / 175,006, filed Jan. 7, 2000, which disclosures are incorporated herein by reference.[0003] This invention relates to synergistic combinations of titanium containing catalysts and catalyst enhancers of carboxylic acid or oxalic acid or their Li, Na, K, Rb, Cs, Be, Mg, Ca, Sr, Ba and ammonium salts that are useful for manufacturing polyesters. The synergistic combination of the titanium containing catalysts with a catalyst enhancer such as an oxalic acid, an oxalic acid salt or a carboxylic acid or a carboxylic acid salt provides fast reactions with improved properties such as reduced acetaldehyde content and good color properties for the resulting polyester at substantially reduced catalyst levels.DESCRIPTION OF THE PRIOR ART[0004] Polycondensation reactions that produ...

AI Technical Summary

Problems solved by technology

Polycondensation reactions that produce polyesters require an extremely long period of time that is significantly reduced by a suitable catalyst.

However, titanyl oxalate catalysts when used as polycondensation catalysts for polyesters have caused color problems in the resulting polyester.

However, only potassium titanyl oxalate and ammonium titanyl oxalate were used in the examples and lithium titanyl oxalate was not even listed among their preferred titanyl oxalate catalysts.

Titanium based catalysts have shown very high polycondensation activity, however; the resulted polyesters are yellowish color which will limit their applications.

Titanium compounds are not a good sole catalyst.