Method of forming high molecular weight poly(phenylene ether), poly(phenylene ether) formed thereby, and fiber and article comprising the poly(phenylene ether)
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for preparing high molecular weight poly(phenylene ether)s struggle to produce products with low residual copper content, narrow molecular weight distribution, and high amine content, which are essential for applications requiring high performance and tailored properties.
Innovation Solution
A method involving specific mole ratios of 2,6-dimethylphenol to copper ion, N,N'-di-tert-butylethylenediamine to copper ion, and atomic oxygen to 2,6-dimethylphenol is employed, along with controlled oxidative polymerization stages and chelation to achieve a poly(2,6-dimethyl-1,4-phenylene ether) with high intrinsic viscosity and narrow molecular weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional oxidative polymerization methods are used to prepare high molecular weight poly(phenylene ether), then molecular weight is improved, but residual copper content increases and molecular weight distribution broadens
Solution Approach 1:
The patent applies parameter changes by precisely controlling the mole ratio of oxygen to monomer (0.9:1 to 1.5:1) and using specific copper catalyst systems with diamine ligands. These parameter optimizations enable achieving high molecular weight (intrinsic viscosity 1.5-2.5 dL/g) while maintaining narrow molecular weight distribution (dispersity 2.0-3.5), resolving the contradiction between molecular weight and distribution breadth
Solution Approach 2:
The patent introduces diamine ligands (such as N,N'-di-tert-butylethylenediamine) as intermediaries that complex with copper catalysts to form more selective catalytic systems. This intermediary approach allows the reaction to proceed with high molecular weight buildup while the ligand control maintains uniform polymerization kinetics, resulting in narrow molecular weight distribution
2Strength
If conventional oxidative polymerization methods are used to prepare high molecular weight poly(phenylene ether), then molecular weight is improved, but residual copper content increases
Solution Approach 1:
The patent uses diamine ligands as intermediaries that form stable complexes with copper catalysts during polymerization. These copper-diamine complexes are more soluble and controllable, enabling high molecular weight polymer formation while facilitating easier removal of copper, thus achieving low residual copper content (≤10 ppm) alongside high molecular weight
Solution Approach 2:
The patent optimizes the copper catalyst concentration and oxygen to monomer ratio to control the polymerization kinetics. By maintaining specific parameter ranges (oxygen:monomer 0.9:1 to 1.5:1, controlled copper loading), the process achieves high molecular weight while minimizing copper incorporation into the polymer, resulting in residual copper ≤10 ppm
3Productivity
If conventional oxidative polymerization methods are used to prepare poly(phenylene ether), then polymerization proceeds efficiently, but amine incorporation is insufficient
Solution Approach 1:
The patent incorporates amine groups into the polymer structure during the polymerization process itself by using diamine ligands that become part of the polymer chain. This preliminary incorporation during synthesis (rather than post-processing) maintains polymerization efficiency while ensuring high amine content (0.8-1.2 wt%) is achieved throughout the polymer matrix
Solution Approach 2:
The diamine ligands serve as intermediaries that dual-function as both catalyst modifiers and monomer units. The ligands complex copper to enhance catalytic activity (maintaining productivity) while also being incorporated into the polymer chain (increasing amine content), thus resolving the contradiction between polymerization efficiency and amine incorporation
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 method produces poly(2,6-dimethyl-1,4-phenylene ether) with low residual copper content, high amine incorporation, and a unimodal molecular weight distribution, suitable for forming fibers and articles with improved properties.
Implementation Method 1
reacting 2,6-dimethylphenol in the presence of toluene, oxygen, copper ion, bromide ion, and N,N'-di-tert-butylethylenediamine to form a poly(2,6-dimethyl-1,4-phenylene ether)
Data Source
Figure 1~2
AI summary
A poly(phenylene ether) can be prepared by a method that includes reacting 2,6-dimethylphenol in the presence of toluene, oxygen, copper ion, bromide ion, and N,N'-di-tert-butylethylenediamine to form a poly(phenylene ether). The mole ratio of 2,6-dimethylphenol to copper ion is 160:1 to 300:1, the mole ratio of N,N'-di-tert-butylethylenediamine to copper ion is 1.5:1 to 3:1, and the mole ratio of atomic oxygen to 2,6-dimethylphenol is 0.9:1 to 1.5:1. The process can produce poly(phenylene ether) having a high molecular weight and a high incorporated amine content.