Method for production of high molecular weight polyester with low catalyst level and low carboxyl content

Claim 3

A method according to claim 1, wherein a reaction catalyst is added during said prepolymerization reaction.

Claim 4

A method according to claim 2, wherein said catalyst is selected from the class consisting of antimony, titanium, iron, zinc, cobalt, lead, manganese, niobium, and germanium.

Claim 5

A method according to claim 3 wherein antimony is said catalyst and wherein no greater than 100 ppm of said antimony reaction catalyst is added to said prepolymerization reaction.

Claim 6

A method according to claim 3 wherein titanium is said catalyst and wherein no greater than 5 ppm of titanium is added to said prepolymerization reaction.

Claim 7

A method according to claim 2, wherein said prepolymerization reaction comprises a dicarboxylic esterification stage, a partial polycondensation vacuum stage, and a particle separation stage; and wherein said polymerization reaction comprises a drying stage and a solid state polymerization stage.

Claim 8

A method according to claim 6, wherein said dicarboxylic esterification stage has a reaction temperature from about 240° C. to about 290° C., has a reaction pressure of at least atmospheric pressures, and has a termination when from about 90% to about 95% of said dicarboxylic compound has been esterified by said glycol; wherein said partial polycondensation vacuum stage has a reaction temperature from about 260° C. to about 290° C., has a reaction pressure of at least subatmospheric pressures, and has a termination when said polyester prepolymer has an intrinsic viscosity from about 0.15 dl/g to about 0.45 dl/g; wherein said drying stage has a temperature from about 140° C. to about 160° C., has a duration from about 30 minutes to about one hour, and has a drying gas selected from the class consisting of air, argon gas, helium gas, nitrogen gas, and combinations thereof; and wherein said solid state polymerization stage has a temperature between about 180° C. and 250° C., has a duration until said polycondensed polyester intrinsic viscosity is at least 0.60 dl/g, and has a particle suspension gas at a flow rate sufficient to suspend particles of polyester prepolymer, said suspension gas selected from the class consisting of argon gas, helium gas, nitrogen gas, and combinations thereof.

Claim 9

A method according to claim 7, wherein said atmospheric pressures reach a pressure measuring less than 1.0 mm of mercury; wherein said reaction temperature is from about 270° C. to about 285° C.; wherein said drying gas is nitrogen gas; and wherein said solid state polymerization temperature is from about 200° C. to about 240° C., said suspension gas is nitrogen gas, and said flow rate is dependent upon particle size.

Claim 10

A method according to claim 6, wherein said particle separation stage divides said prepolymer polyester into particles having -20+200 Tyler mesh size.

Claim 11

A method according to claim 9, wherein said prepolymer particles have a -35+150 Tyler mesh size.

Claim 12

A method according to claim 10, wherein said prepolymer particles have a -80+150 Tyler mesh size.

Claim 13

A method according to claim 7, wherein said polyester prepolymer is formed by said reaction of 1.0 moles of dicarboxylic compound and from about 1.20 to about 1.50 moles of glycol, said reaction occurring during said dicarboxylic esterification stage.

Claim 16

A method according to claim 7, wherein said prepolymerization reaction further comprises the stage of reacting from about 3% to about 10% excess of said glycol with said polyester prepolymer after said dicarboxylic esterification stage and before said partial polycondensation vacuum stage.

Claim 18

A method according to claim 7, wherein said dicarboxylic acid is dimethylterephthalic acid and said glycol is 1,4-butane diol.

Claim 19

A method according to claim 13, wherein said dicarboxylic acid is terephthalic acid and said glycol is ethylene glycol.

Claim 20

A method according to claim 15, wherein said dicarboxylic acid is dimethylterephthalic acid and said glycol is ethylene glycol.

Claim 21

A method according to claim 16, wherein said dicarboxylic acid is dimethylterephthalic acid and said glycol is ethylene glycol.

Claim 22

A high molecular weight, high purity polyester, comprising: a polycondensed polyester produced by a two-step polymerization, said polycondensed polyester having an intrinsic viscosity at least 0.60 dl/g and having less than 20% carboxyl end group content; said two-step polymerization comprising a melt process and a solid-state polymerization in a fluidized bed; said melt process forming a polyester prepolymer having an intrinsic viscosity from about 0.15 dl/g to about 0.45 dl/g, and having less than 20% carboxyl end group content; said prepolymer polyester formed by a reaction of a glycol and a dicarboxylic acid; said dicarboxylic acid selected from the class consisting of alkyl dicarboxylic acids having a total of from 2 to 16 carbon atoms, and aryl dicarboxylic acids containing a total of from about 8 to about 16 carbon atoms; said glycol having from 2 to 10 carbon atoms; and said solid state polymerization forming said polycondensed polyester from said polyester prepolymer.

Claim 23

A high molecular weight, high purity polyester, comprising: a polycondensed polyester produced by a two-step polymerization, said polycondensed polyester having an intrinsic viscosity at least 0.60 dl/g and having less than 20% carboxyl end group content; said two-step polymerization comprising a melt process and a solid-state polymerization in a fluidized bed; said melt process forming a polyester prepolymer having an intrinsic viscosity from about 0.15 dl/g to about 0.45 dl/g, and having less than 20% carboxyl end group content; said prepolymer polyester formed by a reaction of a glycol and a dicarboxylic acid; said dicarboxylic acid selected from the class consisting of alkyl dicarboxylic acids having a total of from 2 to 16 carbon atoms, and aryl dicarboxylic acids containing a total of from about 8 to about 16 carbon atoms; said glycol having from 2 to 10 carbon atoms; and said solid state polymerization forming said polycondensed polyester from said polyester prepolymer.

Claim 24

A high molecular weight, high purity polyester, according to claim 21, wherein a reaction catalyst is added during said melt process.

Claim 25

A high molecular weight, high purity polyester, according to claim 22 wherein said catalyst is selected from the class consisting of antimony, titanium, iron, zinc, cobalt, lead, manganese, niobium, and germanium.

Claim 26

A high molecular weight, high purity polyester, according to claim 23, wherein antimony is said catalyst and wherein no greater than 100 ppm of said antimony reaction catalyst is added to said melt process.

Claim 27

A high molecular weight, high purity polyester, according to claim 23, wherein titanium is said catalyst and wherein no greater than 5 ppm of titanium is added to said prepolymerization reaction.

Claim 28

A high molecular weight, high purity polyester, according to claim 22, wherein said melt process comprises a dicarboxylic esterification stage, a partial polycondensation vacuum stage, and a particle separation stage; and wherein said solid state polymerization comprises a drying stage and a solid state polymerization stage.

Claim 29

A high molecular weight, high purity polyester, according to claim 26, wherein said dicarboxylic esterification stage has a reaction temperature from about 240° C. to about 290° C., has a reaction pressure of at least atmospheric pressures, and has a termination when from about 90% to about 95% of said dicarboxylic compound has been esterified by said glycol; wherein said partial polycondensation vacuum stage has a reaction temperature from about 260° C. to about 290° C., has a reaction pressure of at least subatmospheric pressures, and has a termination when said polyester prepolymer has an intrinsic viscosity from about 0.15 dl/g to about 0.45 dl/g; wherein said drying stage has a temperature from about 140° C. to about 160° C., has a duration from about 30 minutes to about one hour, and has a drying gas selected from the class consisting of air, argon gas, helium gas, nitrogen gas, and combinations thereof; and wherein said solid state polymerization stage has a temperature between about 180° C. and 250° C., has a duration until said polycondensed polyester intrinsic viscosity is at least 0.60 dl/g, and has a particle suspension gas at a flow rate sufficient to suspend particles of said polyester prepolymer, said suspension gas selected from the class consisting of argon gas, helium gas, nittogen gas, and combinations thereof.

Claim 30

A high molecular weight, high purity polyester, according to claim 27, wherein said atmospheric pressures reach a pressure measuring less than 1.0 mm of mercury; wherein said reaction temperature is from about 270° C. to about 285° C.; wherein said drying gas is nitrogen gas; and wherein said solid state polymerization temperature is from about 200° C. to about 240° C., said suspension gas is nitrogen gas, and said flow rate is dependent upon particle size.

Claim 31

A high molecular weight, high purity polyester, according to claim 26, wherein said particle separation stage divides said polyester prepolymer into particles having -20+200 Tyler mesh size.

Claim 32

A high molecular weight, high purity polyester, according to claim 29, wherein said prepolymer particles have a -35+150 Tyler mesh size.

Claim 33

A high molecular weight, high purity polyester, according to claim 30, wherein said prepolymer particles have a -80+150 Tyler mesh size.

Claim 34

A high molecular weight, high purity polyester, according to claim 27, wherein said polyester prepolymer is formed by said reaction of 1.0 moles of dicarboxylic compound and from about 1.20 to about 1.50 moles of glycol, said reaction occurring during said dicarboxylic esterification stage.

Claim 35

A high molecular weight, high purity polyester, according to claims 27, 38 or 31, wherein said polyester prepolymer is formed by said reaction of 1.0 moles of dicarboxylic compound and about 1.30 moles of said glycol, said reaction occurring during said dicarboxylic esterification stage.

Claim 36

A high molecular weight, high purity polyester, according to claims 27, 38, or 31, wherein said prepolymerization reaction further comprises the stage of reacting from about 1% to about 20% excess of said glycol with said polyester prepolymer after said dicarboxylic esterification stage and before said partial polycondensation vacuum stage.

Claim 37

A high molecular weight, high purity polyester, according to claim 27, wherein said prepolymerization reaction further comprises the stage of reacting from about 3% to about 10% excess of said glycol with said polyester prepolymer after said dicarboxylic esterification stage and before said partial polycondensation vacuum stage.

Claim 38

A high molecular weight, high purity polyester, according to claims 27, 28, or 31, wherein said prepolymerization reaction further comprises the stage of adding said reaction catalyst during said partial polycondensation vacuum stage.

Claim 39

A high molecular weight, high purity polyester, according to claim 27, wherein said dicarboxylic acid is dimethylterephthalic acid and said glycol is 1,4-butane diol.

Claim 40

A high molecular weight, high purity polyester according to claim 33, wherein said dicarboxylic acid is terephthalic acid and said glycol is ethylene glycol.

Claim 41

A high molecular weight, high purity polyester, according to claim 35, wherein said dicarboxylic acid is terephthalic acid and said glycol is ethylene glycol.

Claim 42

A high molecular weight, high purity polyester, according to claim 36, wherein said dicarboxylic acid is terephthalic acid, and said glycol is ethylene glycol.

Claim 43

A polyester having color clarity and stability, comprising: a polycondensed polyester having an intrinsic viscosity at least 0.60 dl/g and having less than 20% carboxyl end group content; said polycondensed polyester formed having a reaction catalyst impurity contained therein, said reaction catalyst selected from the class consisting of antimony and titanium; and said antimony impurity being less than 100 ppm and said titanium impurity being less than 5 ppm.

Claim 44

A polyester having color clarity and stability, comprising: a polycondensed polyester having an intrinsic viscosity at least 0.60 dl/g and having less than 20% carboxyl end group content; said polycondensed polyester formed having a reaction catalyst impurity contained therein, said reaction catalyst selected from the class consisting of antimony and titanium; and said antimony impurity being less than 100 ppm and said titanium impurity being less than 5 ppm.

Claim 45

A polyester having color clarity and stability, according to claim 41, wherein said polycondensed polyester is a reaction product of a glycol and a dicarboxylic acid, said dicarboxylic acid selected from the class consisting of alkyl dicarboxylic acids having a total of from about 2 to 16 carbon atoms, and aryl dicarboxylic acid containing a total of from 8 to about 16 carbon atoms; and said glycol selected from the class consisting of glycols having from 2 to 10 carbon atoms.

Claim 46

A polyester having color clarity and stability, according to claim 42, wherein said dicarboxylic acid is dimethylterephthalic acid and said glycol is 1,4-butane diol.

Claim 47

A polyester having color clarity and stability, according to claim 42, wherein said dicarboxylic acid is terephthalic acid and said glycol is ethylene glycol.