Process for the preparation of aliphatic-aromatic polycarbonates with diphenol carbonate end groups and their use for the preparation of high-molecular, segmented, aliphatic-aromatic polycarbonate elastomers which can be processed as thermoplastics

Claim 2

A process for the preparation of an aliphatic-aromatic polycarbonate with diphenol carbonate end groups comprising conjointly reacting: (i) an aliphatic diol, the OH groups of which are in at least the α-position and γ-position relative to one another or further removed from one another, (ii) a carbonic acid bis-aryl ester, and (iii) one or more diphenols at a temperature between about 80° and 270° C. and under reduced pressure between about 200 mm Hg and 0.1 mm Hg, characterized in that n mols of aliphatic diol, m mols of diphenol and p mols of carbonic acid bis-aryl ester are employed for the preparation of 1 mol of the aliphatic-diol bis-diphenol carbonate, wherein n is a number from about 2 to 40 chosen in each case so that the product of n and of the molecular weight Mn (number average), increased by 26, of the diol employed is a number between about 300 and 10,000, m is a number between about 2 and 5 p is at least n+1, but at most (n+m)-1.

Claim 3

The process according to claim 1, wherein the reaction is carried out at a temperature between about 100° and 220° C.

Claim 4

The process of claim 1, wherein between about 0.0001 and 1% by weight of a catalyst is employed.

Claim 5

The process of claim 1, when carried out in bulk.

Claim 6

The process of claim 1, when carried out in the presence of an inert solvent.

Claim 7

The process of claim 1, wherein the carbonic acid bis-aryl ester is one having the general formula ##STR11## wherein Ar is a substituted or unsubstituted aryl radical having from about 6 to 18 carbon atoms.

Claim 8

The process of claim 1, wherein the diphenol has the general formula ##STR12## wherein X denotes a single bond, --CH 2 --, ##STR13## O, S, SO 2 , or ##STR14## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group.

Claim 9

A process for the preparation of a compound of the formula ##STR15## wherein A denotes the bivalent radical of an aliphatic diol, X denotes a single bond ##STR16## O, S, SO 2 , or ##STR17## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group and n is an integer from 2 to 40 comprising conjointly reacting (i) an aliphatic diol, the OH groups of which are in at least the α-position and γ-position relative to one another or further removed from one another, (ii) a diphenol of the general formula ##STR18## wherein X denotes a single bond, --CH 2 --, ##STR19## O, S, SO 2 or ##STR20## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group, and (iii) a carbonic acid bis-aryl ester of the general formula ##STR21## wherein Ar is a substituted or unsubstituted aryl radical having 6 to 18 carbon atoms at a temperature between about 80° and 270° C. and under reduced pressure between about 200 mm Hg and 0.1 mm Hg, characterized in that n mols of aliphatic diol, m mols of diphenol and p mols of carbonic acid bis-aryl ester are employed for the preparation of 1 mol of the Formula I compounds, wherein n is a number from about 2 to 40 chosen in each case so that the product of n and of the molecular weight Mn (number average), increased by 26, of the diol employed is a number between about 300 and 10,000, and m is a number between about 2 and 5 and p is at least n+1, but at most (n+m)-1.

Claim 10

A process for the preparation of a compound of the formula ##STR15## wherein A denotes the bivalent radical of an aliphatic diol, X denotes a single bond ##STR16## O, S, SO 2 , or ##STR17## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group and n is an integer from 2 to 40 comprising conjointly reacting (i) an aliphatic diol, the OH groups of which are in at least the α-position and γ-position relative to one another or further removed from one another, (ii) a diphenol of the general formula ##STR18## wherein X denotes a single bond, --CH 2 --, ##STR19## O, S, SO 2 or ##STR20## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group, and (iii) a carbonic acid bis-aryl ester of the general formula ##STR21## wherein Ar is a substituted or unsubstituted aryl radical having 6 to 18 carbon atoms at a temperature between about 80° and 270° C. and under reduced pressure between about 200 mm Hg and 0.1 mm Hg, characterized in that n mols of aliphatic diol, m mols of diphenol and p mols of carbonic acid bis-aryl ester are employed for the preparation of 1 mol of the Formula I compounds, wherein n is a number from about 2 to 40 chosen in each case so that the product of n and of the molecular weight Mn (number average), increased by 26, of the diol employed is a number between about 300 and 10,000, and m is a number between about 2 and 5 and p is at least n+1, but at most (n+m)-1.

Claim 11

An aliphatic diol bis-diphenol carbonate of the formula ##STR22## wherein A denotes the bivalent radical of an aliphatic diol, selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, X denotes a single bond, --CH 2 --, ##STR23## O, S, SO 2 or ##STR24## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 or C 4 alkyl group and n is an integer from 2 to 40.

Claim 12

An aliphatic diol bis-diphenol carbonate of the formula ##STR22## wherein A denotes the bivalent radical of an aliphatic diol, selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, X denotes a single bond, --CH 2 --, ##STR23## O, S, SO 2 or ##STR24## Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 or C 4 alkyl group and n is an integer from 2 to 40.

Claim 13

An aliphatic-diol bis-diphenol carbonate of the formula ##STR25## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 14

An aliphatic-diol bis-diphenol carbonate of the formula ##STR25## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 15

An aliphatic diol bis-diphenol carbonate of the formula ##STR26## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 16

An aliphatic diol bis-diphenol carbonate of the formula ##STR26## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 17

An aliphatic-diol bis-diphenol carbonate of the formula ##STR27## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 18

An aliphatic-diol bis-diphenol carbonate of the formula ##STR27## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 19

An aliphatic-diol bis-diphenol carbonate of the formula ##STR28## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 20

An aliphatic-diol bis-diphenol carbonate of the formula ##STR28## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 21

An aliphatic-diol bis-diphenol carbonate of the formula ##STR29## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 22

An aliphatic-diol bis-diphenol carbonate of the formula ##STR29## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 23

An aliphatic-diol bis-diphenol carbonate of the formula ##STR30## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 24

An aliphatic-diol bis-diphenol carbonate of the formula ##STR30## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 25

An aliphatic-diol bis-diphenol carbonate of the formula ##STR31## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 26

An aliphatic-diol bis-diphenol carbonate of the formula ##STR31## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 27

An aliphatic-diol bis-diphenol carbonate of the formula ##STR32## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 28

An aliphatic-diol bis-diphenol carbonate of the formula ##STR32## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 29

An aliphatic-diol bis-diphenol carbonate of the formula ##STR33## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 30

An aliphatic-diol bis-diphenol carbonate of the formula ##STR33## wherein A is the bivalent radical of an aliphatic diol selected from a group consisting of 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, trimethyl-1,6-hexanediol, 1,6-hexanediol, 1,12-dodecanediol, 1,12-octadecanediol, diethylene glycol, dipropylene glycol, neopentyl glycol and prepolymeric aliphatic polycarbonate diols having a M n between 300 and 3,000 prepared from diethylene glycol, 1,6-hexanediol, 1,4-butanediol or 1,12-dodecanediol, and n denotes a number from 2 to 40.

Claim 31

A process for the production of a high-molecular weight aliphatic-aromatic polycarbonate, comprising reacting an aliphatic-aromatic polycarbonate with diphenol carbonate end groups of Claim 9 with a diphenol and phosgene in a liquid mixture comprising an inert organic solvent and an alkaline aqueous solution at a temperature between about 0° C. and 80° C. at a pH value between about 9 and 14, and wherein after the addition of phosgene, polycondensation is carried out by adding from about 0.2 mol % to 10 mol %, relative to the molar amount of diphenol, of a tertiary aliphatic amine, the weight ratio of aliphatic-diol bis-diphenol carbonate to the diphenol being determined by the desired proportion of aromatic polycarbonate and the proportion of aliphatic polycarbonate in the resulting high-molecular weight aliphatic-aromatic polycarbonate elastomers.

Claim 32

The process of claim 19, wherein the reaction is carried out at a temperature between about 15° C. and 40° C.

Claim 33

The process of claim 19, wherein the diphenol has the general formula ##STR34## wherein X denotes a single bond, --CH 2 --, ##STR35## O, S, SO 2 or ##STR36## and Y 1 , Y 2 , Y 3 and Y 4 are identical or different and denote a hydrogen or halogen atom or a C 1 to C 4 alkyl group.

Claim 34

The process according to claim 19, wherein the tertiary aliphatic amine has from about 3 to about 15 C atoms per amine molecule.

Claim 35

The process according to claim 19, wherein between about 0.05 and about 2 mol %, relative to the weight of the diphenols employed, of trifunctional or more than trifunctional compounds are employed.

Claim 36

The process according to claim 19, wherein the high molecular weight aliphatic-aromatic polycarbonate is subjected to gelling, shearing or heat treatment in the course of isolation whereby the recovered polymer is multi-phase.

Claim 37

The process according to claim 19, wherein the high-molecular weight aliphatic-aromatic polycarbonate is not subjected to gelling, shearing or heat treatment in the course of isolation whereby the recovered polymer is single phase.