Process for producing highly polymerized aromatic polycarbonate resin

• US 9,499,661 B2
• Filed: 11/15/2013
• Issued: 11/22/2016
• Est. Priority Date: 11/17/2012
• Status: Active Grant

• Current Assignee: Mitsubishi Gas Chemical Company Incorporated (Mitsubishi Electric Corporation)
• Original Assignee: Mitsubishi Gas Chemical Company Incorporated (Mitsubishi Electric Corporation)
• Inventors: Tokutake, Taichi, Isahaya, Yoshinori, Hirashima, Atsushi, Harada, Hidefumi, Ito, Maki, Hayakawa, Jun-ya, Isobe, Takehiko, Shinkai, Yousuke
• Primary Examiner(s): BUTTNER, DAVID J
• Application Number:
  US14/441,939
• Publication Number:
  US 20150274887A1
• Time in Patent Office: 1,103 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C08G 64/04 Aromatic polycarbonates
• CPC Class Codes: C08G 64/06 not containing aliphatic unsaturation
• CPC Class Codes: C08G 64/1608 saturated
• CPC Class Codes: C08G 64/30 using carbonates
• CPC Class Codes: C08G 64/307 and phenols
• CPC Class Codes: C08G 64/38 using other monomers
• CPC Class Codes: C08G 64/42 Chemical after-treatment

Abstract

The invention provides a process for producing a highly polymerized aromatic polycarbonate resin including a molecular weight-increasing step of reacting an aromatic polycarbonate prepolymer with an aliphatic diol compound represented by Formula (g2) in the presence of a transesterification catalyst to obtain a highly polymerized aromatic polycarbonate resin. In the formula, Ra and Rb each independently represent a hydrogen atom, a halogen atom, a linear or branched alkyl group, a cycloalkyl group, an aryl group or an alkoxy group, or Ra and Rb may be bonded to each other to form a ring; R₁ to R₄ each independently represent a hydrogen atom, a halogen atom or an alkyl group; and n represents an integer of 0 to 30.

Claims

1. A process for producing a highly polymerized aromatic polycarbonate resin comprising a highly polymerizing step of reacting an aromatic polycarbonate prepolymer with an aliphatic diol compound represented by the following Formula (g2) in the presence of a transesterification catalyst to obtain a highly polymerized aromatic polycarbonate resin:

2. The process according to claim 1, wherein n in Formula (g2) is an integer of 1 to 6.

3. The production process according to claim 1, wherein the aliphatic diol compound represented by Formula (g2) is an aliphatic diol compound represented by the following Formula (g3):

4. The process according to claim 1, further comprising a cyclic carbonate removal step of removing at least part of a cyclic carbonate by-produced in the molecular weight-increasing step to the outside of the reaction system, the cyclic carbonate being represented by the following Formula (h2):

5. The process according to claim 4, wherein the cyclic carbonate represented by Formula (h2) is a compound represented by the following Formula (h3):

6. The process according to claim 1, wherein the aliphatic diol compound is used in an amount of 0.01 to 1.0 mol per 1 mol of total terminal amount of the unreacted aromatic polycarbonate prepolymer in the highly polymerizing step.

7. A polycarbonate resin composition comprising the highly polymerized aromatic polycarbonate resin obtained by the process according to claim 1 and from 0.0005 to not more than 3000 ppm of a cyclic carbonate represented by the following Formula (h2):

8. A polycarbonate resin composition comprising the highly polymerized aromatic polycarbonate resin obtained by the process according to claim 1 and from 0.0005 to not more than 3000 ppm of a cyclic carbonate represented by the following Formula (h3):

9. The polycarbonate resin composition according to claim 7, further comprising not less than 3 ppm of a catalyst deactivator.

10. The polycarbonate resin composition according to claim 9, wherein the catalyst deactivator is selected from the group consisting of aromatic sulfonic acids, aromatic sulfonate esters, organic halides, alkyl sulfate salts, phosphoric acids and phosphorous acids.

11. The polycarbonate resin composition according to claim 9, wherein the catalyst deactivator is selected from the group consisting of paratoluenesulfonic acid, butyl paratoluenesulfonate, tetrabutylphosphonium dodecylbenzenesulfonate salt and tetrabutylammonium paratoluenesulfonate salt.