Continuous, solvent-free process for preparing thermoplastic polyamides and polyesteramides

Claim 2

A continuous process for the preparation of a thermoplastic polymer characterized by the presence of a recurring amide group which process comprises the steps of: continuously feeding an organic diisocyanate and a dicarboxylic acid in substantially stoichiometric proportions to the inlet port of a continuous reactor; continuously conveying said mixture of reactants through said reactor and increasing the temperature of said mixture incrementally from an initial temperature at which evolution of carbon dioxide first commences to a final temperature at which polymer formation is substantially complete, the rate of said incremental increase in temperature being adjusted so that the carbon dioxide which is evolved continuously during the reaction can be vented completely from a plurality of vents provided at intervals throughout the said reactor; and continuously removing the resulting polymer from said reactor via a shaping zone.

Claim 3

A process according to claim 1 wherein said reactor comprises a continuous mixer-extruder.

Claim 4

A process according to claim 1 wherein the said polymer is shaped by extrusion into a continuous ribbon which is pelletized after solidification.

Claim 5

A process according to claim 1 wherein the temperature of the reaction mixture is increased incrementally from an initial value in the range of about 120° C. to about 180° C. to a final value in the range of about 250° C. to about 300° C.

Claim 6

A process according to claim 1 wherein the organic diisocyanate and the dicarboxylic acid are fed in the molten state to the inlet port of said continuous reactor.

Claim 7

A process according to claim 1 wherein the organic diisocyanate is 4,4'-methylenebis(phenyl isocyanate) and the dicarboxylic acid is selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, carboxylic acid-terminated polyesters and mixtures of any two or more such acids.

Claim 8

A continuous process for the preparation of a thermoplastic polymer characterized by the presence of a recurring amide group which process comprises the steps of: continuously feeding an organic diisocyanate and a dicarboxylic acid in substantially stoichiometric proportions to the inlet port of a screw reactor-extruder provided with a plurality of vents and equipped with a series of independently heated zones; continuously conveying said mixture of reactants through said screw reactor-extruder while increasing the temperature incrementally from an initial temperature at which evolution of carbon dioxide first commences to a final temperature at which polymer formation is substantially complete, the rate of said incremental increase in temperature being adjusted so that the carbon dioxide which is evolved continuously during the reaction can be vented completely via said vents in said screw reactor-extruder; continuously removing said polymer by extrusion in shaped form from said screw reactor-extruder.

Claim 9

A continuous process for the preparation of a thermoplastic polymer characterized by the presence of a recurring amide group which process comprises the steps of: continuously feeding an organic diisocyanate and a dicarboxylic acid in substantially stoichiometric proportions to the inlet port of a screw reactor-extruder provided with a plurality of vents and equipped with a series of independently heated zones; continuously conveying said mixture of reactants through said screw reactor-extruder while increasing the temperature incrementally from an initial temperature at which evolution of carbon dioxide first commences to a final temperature at which polymer formation is substantially complete, the rate of said incremental increase in temperature being adjusted so that the carbon dioxide which is evolved continuously during the reaction can be vented completely via said vents in said screw reactor-extruder; continuously removing said polymer by extrusion in shaped form from said screw reactor-extruder.

Claim 10

A process according to claim 7 wherein said polymer is extruded in the form of at least one continuous strand which is pelletized after solidification.

Claim 11

A process according to claim 7 wherein the temperature of the reaction mixture is increased incrementally from an initial value in the range of about 120° C. to about 180° C. to a final value in the range of about 250° C. to about 300° C.

Claim 12

A process according to claim 7 wherein the organic diisocyanate and the dicarboxylic acid are fed in the molten state to the inlet port of said screw reactor-extruder.

Claim 13

A process according to claim 7 wherein the organic diisocyanate is 4,4'-methylenebis(phenyl isocyanate) and the dicarboxylic acid is selected from the group consisting of aromatic dicarboxylic acids, aliphatic dicarboxylic acids, carboxylic acid-terminated polyesters and mixtures of any two or more such acids.

Claim 14

A process according to claim 7 werein the organic diisocyanate is 4,4'-methylenebis(phenyl isocyanate) and the dicarboxylic acid is a mixture of azelaic acid and an azelaic acid-terminated hexamethylene adipate.