Polyarylene Ether Sulfone Process With Low Cyclic Oligomers
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Solution Overview
Problem
Existing processes for producing polyarylene(ether)sulfones result in high cyclic oligomer and aromatic volatile contents, leading to processing issues in membrane production, particularly requiring subsequent purification steps and volatiles migration.
Innovation Solution
A process involving a reaction mixture of aromatic dihalogen sulfone, dihydroxy component, carbonate component in excess, and aprotic solvent, heated at a controlled rate to produce high molecular weight polyarylene(ether)sulfones with low cyclic dimer and volatile content without additional purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional production processes are used, then polyarylene(ether)sulfones can be produced, but the cyclic oligomer content becomes too high causing processing issues
Solution Approach 1:
The invention changes key process parameters including using a specific molar ratio of dihalogen sulfone to dihydroxy component (1:1.05 to 1:1.20), controlling reaction temperature (100-200°C), and selecting specific solvents to optimize the polymerization reaction and minimize cyclic oligomer formation
Solution Approach 2:
The invention extracts and removes cyclic oligomers from the reaction mixture through filtration and/or centrifugation steps, separating these unwanted byproducts from the desired polymer product to achieve low cyclic oligomer content in the final product
2Manufacturing precision
If conventional production processes are used, then polyarylene(ether)sulfones can be produced, but aromatic volatile content becomes too high leading to migration issues
Solution Approach 1:
The invention changes process parameters including reaction temperature control (100-200°C), solvent selection (aprotic solvents like NMP, DMAc, DMSO), and reaction time to minimize the formation of aromatic volatiles such as toluene and chlorobenzene during polymerization
Solution Approach 2:
The invention removes aromatic volatiles from the reaction mixture through filtration and/or centrifugation, extracting these unwanted byproducts from the polymer solution to achieve low volatile content without requiring additional purification steps
3Strength
If high molecular weight polymers are produced, then excellent mechanical properties are achieved, but cyclic dimer content increases causing filter clogging
Solution Approach 1:
The invention optimizes reaction parameters including monomer ratio (1:1.05 to 1:1.20), temperature (100-200°C), and solvent type to promote linear polymer chain growth while minimizing cyclic dimer formation, achieving high molecular weight with low cyclic content
Solution Approach 2:
The invention extracts cyclic dimers from the reaction mixture through filtration and/or centrifugation, removing these harmful byproducts that would otherwise cause filter clogging during membrane production while preserving the high molecular weight polymer
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
The process yields polymers with low cyclic dimer and volatile content, suitable for membrane production, preventing filter clogging and enhancing purity and suitability for solution processes.
Implementation Method 1
II) heating the reaction mixture RM from the start temperature T1 to the final reaction temperature TF with a rate of at least 0.4 K/min
Data Source
AI summary
This invention relates to a process for the production of polyarylene(ether)sulfones having high molecular weight and excellent purity as well as low content of undesired volatiles and a reduced content of cyclic oligomers, the polyarylene(ether)sulfones resulting from the inventive process, as well as parts made from the inventive polyarylene(ether)sulfones such as membranes.