Process for the preparation of aromatic polycarbonate

• US 6,265,524 B1
• Filed: 11/22/1999
• Issued: 07/24/2001
• Est. Priority Date: 05/26/1997
• Status: Expired due to Fees

• Current Assignee: Teijin Limited, UBE Industries Limited
• Original Assignee: Teijin Limited, UBE Industries Limited
• Inventors: Sawaki, Toru, Sasaki, Katsushi, Takemoto, Hidemi
• Primary Examiner(s): Boykin, Terressa M.
• Application Number:
  US09/424,318
• Time in Patent Office: 610 Days
• Field of Search: 528/196
• US Class Current: 528/196
• CPC Class Codes: C07C 68/00 Preparation of esters of carbonic or haloformic acids
• CPC Class Codes: C07C 69/96 Esters of carbonic or haloformic acids
• CPC Class Codes: C08G 64/307 and phenols

Abstract

A process for producing an aromatic polycarbonate through an ester interchange reaction between an aromatic carbonic acid diester and an aromatic dihydroxy compound, wherein the aromatic carbonic acid diester is obtained through the decarbonylation reaction of an aromatic oxalic acid diester represented by the following general formula (1):

wherein two Ar'"'"'s are the same or different aromatic hydrocarbon groups having 6 to 14 carbon atoms, and has a hydrolyzable halogen content of 5 ppm or less.

According to the present invention, an aromatic polycarbonate having a high molecular weight and excellent color can be easily produced without impairing ester interchange reactivity for the production of the aromatic polycarbonate by using an aromatic carbonic acid diester obtained through the decarbonylation of an aromatic oxalic acid diester and controlling the amount of hydrolyzable halogen contained in the aromatic carbonic acid diester to a value smaller than a predetermined value.

Claims

1. A process for producing an aromatic polycarbonate through an ester interchange reaction between an aromatic carbonic acid diester and an aromatic dihydroxy compound, wherein the aromatic carbonic acid diester is obtained through the decarbonylation reaction of an aromatic oxalic acid diester represented by the following general formula (1):

wherein two Ar'"'"'s are the same or different aromatic hydrocarbon groups having 6 to 14 carbon atoms, and has a hydrolyzable halogen content of 5 ppm or less.

2. The process for producing an aromatic polycarbonate according to claim 1, wherein the aromatic carbonic acid diester contains 2 ppm or less of hydrolyzable halogen.

3. The process for producing an aromatic polycarbonate according to claim 1, wherein the aromatic carbonic acid diester is represented by the following general formula (2):

wherein R₁, R₂, R₃ and R₄ are the same or different and each a hydrogen atom, alkyl group having 1 to 4 carbon atoms, phenyl group or halogen atom.

4. The process for producing an aromatic polycarbonate according to claim 1, wherein the aromatic dihydroxy compound is represented by the following general formula (3):

wherein W is —

O—

, —

S—

, —

SO—

, —

SO₂—

,

wherein n is 0 to 4, R₅ and R₆ are the same or different and each a halogen atom or a hydrocarbon group having 1 to 12 carbon atoms, R₇ and R₈ are the same or different and each a halogen atom, a hydrogen atom or a hydrocarbon group having 1 to 12 carbon atoms, and R₉ is an alkylene group having 3 to 8 carbon atoms.

5. The process for producing an aromatic polycarbonate according to claim 1, wherein the hydrolyzable halogen is derived from a catalyst used in the decarbonylation reaction of the aromatic oxalic acid diester.

6. The process for producing an aromatic polycarbonate according to claim 1, wherein the aromatic carbonic acid diester is obtained through the decarbonylation reaction of the aromatic oxalic acid diester represented by the above general formula (1), using a combination of an organic phosphorus compound and a halogen compound, or a halogen-containing organic phosphorus compound, as a catalyst.

7. The process for producing an aromatic polycarbonate according to claim 1, wherein the ester interchange reaction is carried out in the presence of at least one catalyst selected from the group consisting of alkali metal compounds, alkaline earth metal compounds and nitrogen-containing basic compounds.

8. The process for producing an aromatic polycarbonate according to claim 1, wherein an alkali metal compound and an alkaline earth metal compound are used as catalysts in a total equivalent amount of 1×

10<sup>−

8</sup> to 5×

10<sup>−

5</sup>, based on 1 mole of the aromatic dihydroxy compound in the ester interchange reaction.

9. The process for producing an aromatic polycarbonate according to claim 1, wherein a nitrogen-containing basic compound is used as a catalyst in an equivalent amount of 1×

10<sup>−

5</sup> to 1×

10<sup>−

3</sup> based on 1 mole of the aromatic dihydroxy compound in the ester interchange reaction.

10. The process for producing an aromatic polycarbonate according to claim 1, wherein the ester interchange reaction is carried out at a temperature of 160 to 300°

C.

11. The process for producing an aromatic polycarbonate according to claim 1, wherein the aromatic carbonic acid diester is obtained through the decarbonylation reaction of the aromatic oxalic acid diester and subjected to a contact treatment with hot water heated to a temperature higher than the melting point of the aromatic carbonic acid diester.

12. The process for producing an aromatic polycarbonate according to claim 11, wherein the hot water has a pH of 8 to 10.

13. The process for producing an aromatic polycarbonate according to claim 11, wherein purification by distillation is carried out before or after the above contact treatment with hot water.

14. An aromatic carbonic acid diester obtained through the decarbonylation reaction of the aromatic oxalic acid diester represented by the following general formula (1):

wherein two Ar'"'"'s are the same or different aromatic hydrocarbon groups having 6 to 14 carbon atoms, and contains 5 ppm or less of hydrolyzable halogen.

15. The aromatic carbonic acid diester of claim 14 which is used for the production of an aromatic polycarbonate.

16. An aromatic polycarbonate obtained through an ester interchange reaction between the aromatic carbonic acid diester of claim 14 and the aromatic dihydroxy compound.