Process for producing polyphenylene sulfide

Claim 2

A process for producing polyphenylene sulfide powder or granules, which comprises reacting an alkali metal sulfide compound with a polyhalogenated phenylene compound in an organic polar solvent in contact with an oxyalkylene compound, and washing the product polyphenylene sulfide with hot water, whereby polyphenylene sulfide powder or granules, having a low content of impurities composed of electrolytic components is obtained.

Claim 3

The process of claim 1 wherein the oxyalkylene compound is a compound having a hydrophile-lipophile-balance value of 1 to 19 and is represented by the general formula RO--R.sub.1 --O--.sub.n --R.sub.2 --O--.sub.m --H wherein R represents a hydrogen atom, an alkyl group having 1 to 40 carbon atoms or an aryl group having 6 to 50 carbon atoms, each of R 1 and R 2 represents an alkylene group having 2 to 4 carbon atoms, n and m are zero or an integer of at least 1, and the sum of n and m is at least 1.

Claim 4

The process of claim 1 wherein the oxyalkylene compound is a compound represented by the general formula ##STR5## wherein R 3 and R 4 represent an alkylene group having 2 to 4 carbon atoms, R 5 represents a hydrogen atom, an alkyl group having 1 to 30 carbon atoms or an aryl group, l and r are an integer of 0 to 90, the sum of l and r is an integer of 1 to 90, and p is an integer of 2 to 50.

Claim 5

The process of claim 1 wherein the alkali metal sulfide compound is lithium sulfide, sodium sulfide, potassium sulfide, rubidium sulfide, cesium sulfide or a mixture thereof.

Claim 6

The process of claim 1 wherein the polyhalogenated phenylene compound has at least two halogen atoms directly bonded to the aromatic ring.

Claim 7

A process for producing polyphenylene sulfide, powder or granules, which comprises reacting an alkali metal sulfide compound with a polyhalogenated phenylene compound in an organic polar solvent in contact with (a) an oxyalkylene compound and (b) at least one polymerization promoting salt selected from the group consisting of metal salts of organic acids, lithium halides, alkali metal carbonates, and alkali metal salts of inorganic phosphoric acid, and washing the product polyphenylene sulfide with hot water, whereby polyphenylene sulfide powder or granules having a low content of impurities composed of electrolytic components is obtained.

Claim 8

A process for producing polyphenylene sulfide, powder or granules, which comprises reacting an alkali metal sulfide compound with a polyhalogenated phenylene compound in an organic polar solvent in contact with (a) an oxyalkylene compound and (b) at least one polymerization promoting salt selected from the group consisting of metal salts of organic acids, lithium halides, alkali metal carbonates, and alkali metal salts of inorganic phosphoric acid, and washing the product polyphenylene sulfide with hot water, whereby polyphenylene sulfide powder or granules having a low content of impurities composed of electrolytic components is obtained.

Claim 9

The process of claim 6 wherein the oxyalkylene compound is a compound having a hydrophile-lipophile-balance value of 1 to 19 and is represented by the general formula RO--R.sub.1 --O--.sub.n --R.sub.2 --O--.sub.m --H wherein R represents a hydrogen atom, an alkyl group having 1 to 40 carbon atoms or an aryl group having 6 to 50 carbon atoms, each of R 1 and R 2 represents an alkylene group having 2 to 4 carbon atoms, n and m are zero or an integer of at least 1, and the sum of n and m is at least 1.

Claim 10

The process of claim 6 wherein the oxyalkylene compound is a compound represented by the general formula ##STR6## wherein R 3 and R 4 represent an alkylene group having 2 to 4 carbon atoms, R 5 represents a hydrogen atom, an alkyl group having 1 to 30 carbon atoms or an aryl group, l and r are an integer of 0 to 90, the sum of l and r is an integer of 1 to 90, and p is an integer of 2 to 50.

Claim 11

The process of claim 6 wherein the metal salts of organic acids are alkali metal, alkaline earth metal or zinc salts of organic carboxylic acids or organic sulfonic acids having a hydrocarbon group with 1 to 30 carbon atoms, or alkali metal salts of organic phosphoric acid having a hydrocarbon group with 1 to 24 carbon atoms.

Claim 12

The process of claim 1 or 6 wherein the mole ratio of the alkali metal sulfide compound to the polyhalogenated phenylene compound is 0.8-1.5:1.

Claim 13

The process of claim 1 or 6 wherein the amount of the oxyalkylene compound is 0.01 to 30% by weight based on the weight of the polyhalogenated phenylene ompound.

Claim 14

The process of claim 6 wherein the amount of the salt (b) is 0.05 to 2 moles per mole of the alkali metal sulfide compound.

Claim 15

The process of claim 1 or 2 which comprises reacting the alkali metal sulfide powder or granules compound and the polyhalogenated phenylene compound at a temperature of 150° to 290° C. for a period of 1 to 10 hours.

Claim 16

The process of claim 2 or 7 wherein the oxyalkylene compound has a hydrophile-lipophile value of from 3 to 16 and is a compound selected from the group consisting of polyoxyethylene monooctyl ether, polyoxyethylene monolauryl ether, polyoxyethylene monooctyl phenyl ether, polyoxyethylene polyoxpropylene monooctylphenyl ether, polyoxyethylene monolauryl ester, polyoxypropylene monooctyl ether, polyoxypropylene monolauryl ether, polyoxypropylene monooctylphenyl ether, polyoxypropylene monononylphenyl ether, polyoxypropylene monolauryl ether, and mixtures thereof.

Claim 17

The process of claim 3 or 8 wherein the oxyalkylene compound is selected from the group consisting of polyoxyethylenephenyl formaldehyde condensate, polyoxyethylenemethylphenyl formaldehyde condensate, polyoxyethylenenonylphenyl formaldehyde condensate, polyoxyethylenecetrylphenyl formaldehyde condensate, polyoxypropylene methyl phenyl aldehyde condensate, polyoxyproplenenonylphenyl aldehyde condensate, polyoxybutylenenonylphenyl aldehyde condensate, oxyethylenephenol formaldehyde condensate, and oxyethylenenonylphenol formaldehyde condensate.

Claim 18

A process for producing polyphenylene sulfide having a low content of impurities composed of electrolytic components which comprises adding an alkali metal sulfide hydrate, an alkali metal salt of an organic carboxylic acid as a polymerization promoter, and an alkali metal hydroxide to an organic polar solvent in an inert gaseous atmosphere at a temperature of from room temperature to 130° C., heating the resulting mixture at a temperature of 150° to 230° C. to evaporate most of the water in the mixture, cooling the resulting mixture, adding a polyhalogenated phenylene compound and an oxyalkylene compound to the mixture and maintaining the mixture at a temperature of from 150° to 290° C. for from 1 to 10 hours to produce polyphenylene sulfide, filtering the reaction mixture to recover the polyphenylene sulfide, washing the recovered polyphenylene sulfide first in boiling water and then in acetone, and drying the polyphenylene sulfide product.

Claim 19

A process for producing polyphenylene sulfide having a low content of impurities composed of electrolytic components which comprises adding an alkali metal sulfide hydrate, an alkali metal salt of an organic carboxylic acid as a polymerization promoter, and an alkali metal hydroxide to an organic polar solvent in an inert gaseous atmosphere at a temperature of from room temperature to 130° C., heating the resulting mixture at a temperature of 150° to 230° C. to evaporate most of the water in the mixture, cooling the resulting mixture, adding a polyhalogenated phenylene compound and an oxyalkylene compound to the mixture and maintaining the mixture at a temperature of from 150° to 290° C. for from 1 to 10 hours to produce polyphenylene sulfide, filtering the reaction mixture to recover the polyphenylene sulfide, washing the recovered polyphenylene sulfide first in boiling water and then in acetone, and drying the polyphenylene sulfide product.