Polyarylene Sulfide Resin Synthesis via Sulfoxide Dealkylation
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Solution Overview
Problem
The existing methods for manufacturing polyarylene sulfide resins have limited flexibility in designing the constitutional unit and often result in resins with low molecular weights, making it difficult to achieve desired properties for various applications.
Innovation Solution
A method involving the reaction of a sulfoxide with an aromatic compound to form a poly(arylenesulfonium salt), which is then dealkylated or dearylated to produce a polyarylene sulfide resin, allowing for greater control over the constitutional unit and achieving high molecular weights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a monofunctional sulfoxide is used as raw material for homopolymerization, then the manufacturing process is simple, but the range of constitutional units that can be designed is very limited
Solution Approach 1:
The invention divides the polymer structure into two separate components: a sulfoxide portion and an aromatic compound portion. By using a bifunctional sulfoxide (with two sulfinyl groups) instead of a monofunctional one, the polymer chain is segmented into alternating units of these two components, enabling independent selection and combination of different aromatic compounds to achieve diverse constitutional units while maintaining a systematic manufacturing approach
Solution Approach 2:
The bifunctional sulfoxide acts as a universal platform that can react with multiple different aromatic compounds. The sulfinyl groups serve multiple functions: they enable polymerization, provide structural flexibility, and allow for various constitutional unit designs by simply changing the aromatic compound component while keeping the sulfoxide framework constant
2Adaptability or versatility
If a bifunctional sulfoxide is reacted with aromatic compounds in the presence of phosphorous pentoxide and trifluoromethanesulfonic acid, then a wide variety of polyarylene sulfide resins can be manufactured, but it is difficult to obtain resin with sufficiently high molecular weight
Solution Approach 1:
The invention changes the reaction parameters by using different acid catalysts (sulfonic acids, carboxylic acids, or Lewis acids) and adjusting their amounts relative to the sulfoxide. The patent specifies using 0.01-5 equivalents of acid per mole of sulfoxide, which is a significant parameter change from conventional methods. This parameter optimization enables both high molecular weight and structural diversity
Solution Approach 2:
The invention creates composite polymer structures by combining bifunctional sulfoxides with various aromatic compounds in specific ratios and configurations. The resulting polyarylene sulfide resins are composite materials with controlled molecular weights and diverse constitutional units, achieving both high molecular weight and material variety through systematic composition design
3Productivity
If dichlorobenzene is used as monomer for solution polymerization, then polyphenylene sulfide resin can be manufactured, but the concentration of halogen remaining in resin is high and severe polymerization conditions are required
Solution Approach 1:
The invention extracts and removes the harmful dichlorobenzene monomer from the polymerization system. Instead of using dichlorobenzene that leaves high halogen residues, the patent employs bifunctional sulfoxides combined with aromatic compounds, which do not introduce halogen into the polymer structure. This extraction of the harmful element eliminates the halogen contamination problem while maintaining resin manufacturability
Solution Approach 2:
The invention replaces expensive and problematic titanium/chromium/zirconium reactor materials with conventional steel reactors by using a new polymerization system that operates under milder conditions. The bifunctional sulfoxide aromatic compound system allows standard equipment to be used, eliminating the need for expensive specialized reactors while achieving the same productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a high degree of freedom in designing the constitutional unit of polyarylene sulfide resins, enabling the production of materials with enhanced heat resistance, mechanical properties, and molecular weight, suitable for diverse applications.
Implementation Method 1
reacting a sulfoxide with an aromatic compound to obtain a poly(arylenesulfonium salt)
Implementation Method 2
dealkylating or dearylating the poly(arylenesulfonium salt) to obtain a polyarylene sulfide resin
Implementation Method 3
dealkylating or dearylating the poly(arylenesulfonium salt) to obtain a polyarylene sulfide resin
Data Source
AI summary
The present invention relates to a method for manufacturing a polyarylene sulfide resin comprising: reacting a sulfoxide represented by the following formula (1) with a particular aromatic compound to obtain a poly(arylenesulfonium salt) having a particular constitutional unit; and dealkylating or dearylating the poly(arylenesulfonium salt) to obtain a polyarylene sulfide resin having a particular constitutional unit,wherein R1 represents an alkyl group having 1 to 10 carbon atoms, etc.; Ar1 and Ar2 each independently represent an arylene group optionally having a substituent; and Z represents a direct bond, etc.