Process for preparing polyarylates in the presence of a diphenyl ether

Claim 2

A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 gl/gm, which process comprises reacting: (a) at least one diester derivative of a dihydric phenol having the following formula: ##STR3## wherein R is independently selected from an alkyl radical having from 1 to about 6 carbon atoms, or cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine, or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO 2 , CO, x is 0 or 1; with (b) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound, at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of catalyst.

Claim 3

A process as defined in claim 1 wherein the diester derivative of a dihydric phenol has the following formula: ##STR4##

Claim 4

A process as defined in claim 2 wherein each z is 0.

Claim 5

A process as defined in claim 1 wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.

Claim 6

A process as defined in claim 4 wherein the isophthalic acid to terephthalic acid ratio in the mixture is about 20:80 to about 100:0.

Claim 7

A process as defined in claim 1 wherein the diphenyl ether is substituted with alkyl groups, chlorine, bromine, or any substituent which does not interfere with the polyarylate forming reaction.

Claim 8

A process as defined in claim 1 wherein the polyarylate produced has a reduced viscosity of from about 0.5 to about 0.8.

Claim 9

A process as defined in claim 1 wherein the diphenyl ether is present in an amount of from about 25 to about 40 weight percent.

Claim 10

A process as defined in claim 1 wherein the temperature is between about 275° to about 295° C.

Claim 11

A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm which process comprises reacting: (a) an acid anhydride derived from an acid containing from 2 to 8 carbon atoms; (b) at least one dihydric phenol having the following formula: ##STR5## wherein Y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, R' is independently selected from a divalent saturated hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO 2 , CO, x is 0 or 1; and (c) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound, at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of a catalyst for the dihydric phenol and carboxylic acid.

Claim 12

A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm which process comprises reacting: (a) an acid anhydride derived from an acid containing from 2 to 8 carbon atoms; (b) at least one dihydric phenol having the following formula: ##STR5## wherein Y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, R' is independently selected from a divalent saturated hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO 2 , CO, x is 0 or 1; and (c) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound, at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of a catalyst for the dihydric phenol and carboxylic acid.

Claim 13

A process as defined in claim 10 wherein the acid anhydride is acetic anhydride.

Claim 14

A process as defined in claim 10 wherein the dihydric phenol has the following formula: ##STR6##

Claim 15

A process as defined in claim 12 wherein each z is 0.

Claim 16

A process as defined in claim 10 wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.

Claim 17

A process as defined in claim 14 wherein the isophthalic acid to terephthalic acid ratio in the mixture is about 20:80 to about 100:0.

Claim 18

A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm, which process comprises the following steps: I. forming a polyarylate prepolymer having a reduced viscosity of from about 0.1 to about 0.4 dl/gm, by reacting: (a) at least one diester derivative of a dihydric phenol having the following formula: ##STR7## wherein R is independently an alkyl radical having from 1 to about 6 carbon atoms or cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO 2 , CO, x is 0 or 1; with (b) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of catalyst; and II. heating the prepolymer so formed at a temperature of from about 300° to 350° C. for a period of time sufficient to form the polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/g.

Claim 19

A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm, which process comprises the following steps: I. forming a polyarylate prepolymer having a reduced viscosity of from about 0.1 to about 0.4 dl/gm, by reacting: (a) at least one diester derivative of a dihydric phenol having the following formula: ##STR7## wherein R is independently an alkyl radical having from 1 to about 6 carbon atoms or cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO 2 , CO, x is 0 or 1; with (b) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of catalyst; and II. heating the prepolymer so formed at a temperature of from about 300° to 350° C. for a period of time sufficient to form the polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/g.

Claim 20

A process as defined in claim 16 wherein the prepolymer is heated in step (II) in a vented extruder under vacuum.