Alternating block copolymers of polyarylene polyethers and process for their preparation

Claim 2

A substantially linear thermoplastic polyarylene polyether copolymer, or polyarylene polythioether copolymer (PAPE) represented by the formula R.sup.e --R--"PAPE"--R--R.sup.e wherein, R represents O or S in an ether linkage with R e ; R e represents a residuum selected from R 1 e X' and R 2 e RH; R 1 e X' represents a residuum of a reactive bis(haloallyl)moiety "HAM"; R 2 e represents the group ##STR6## X' represents halogen selected from the group consisting of fluorine, chlorine and bromine; X" represents an inert substituent defined hereinbelow; and, "PAPE" represents the residuum of an oligomer selected from an unsaturated alternating block copolymer represented by ["DH(T)P.sub.1 "--"DH(T)P.sub.2 "--.sub.n' --HAM--"DH(T)P.sub.3 "--.sub.n" and a regular unsaturated oligomer formed by chain extension represented by [HAM--"DH(T)P.sub.1 "--"DH(T)P.sub.2 "--HAM].sub.n'" wherein, "DH(T)P 1 " and "DH(T)P 2 " are the residues of dihydric (thio)phenols DH(T)P 1 and DH(T)P 2 which are the same or different, and "DH(T)P 3 " is the residue of a dihydric (thio)phenol DH(T)P 3 which may be the same as either DH(T)P 1 or DH(T)P 2 , or different; HAM represents the residue of a reactive bis(haloallyl) moiety selected from a bis(haloallyl)olefin having from 4 to about 20 carbon atoms including cis- or trans-dichlorobutene, a bis(haloallyl)cycloolefin having from 4 to about 8 ring carbon atoms including 1,4-bis(chloromethyl)-1,3-cyclohexadiene, a bis(haloallyl)arylene having from 8 to about 26 carbon atoms and 1,4-bis(chloromethyl)benzene; and, n', n" and n'" independently represent an integer in the range from 2 to about 100.

Claim 3

The PAPE of claim 1 wherein said dihydric phenols and dihydric thiophenols are oligomers formed from one or more dihydric phenols or dihydric thiophenols having a structure (X")(RH)Ar--X--Ar(RH)(X") or, ##STR7## wherein, R represents O or S; X represents a bond between aromatic carbon atoms or a divalent connecting radical selected from the group consisting of C═O, --O--, --S--, --S--S--, --SO 2 --, --Si-- and divalent organic hydrocarbon radicals such as alkylene, alkylidene, cycloaliphatic, or the halogen, alkyl, aryl, or like substituted alkylene, alkylidene and cycloaliphatic radicals as well as alkarylene, cycloalkyl and aromatic radicals, and a ring fused to both Ar groups; and, X" represents one or more inert substituents which if present, may each be the same or different and represent halogen, particularly chlorine or bromine; NO 2 ; alkyl having from 1 to about 18 carbon atoms, without regard for the spatial configuration such as normal, iso or tertiary; alkoxy having from 1 to about 18 carbon atoms; and, hydrogen; so that the molecular weight Mn of said PAPE is in the range from about 1000 to about 200,000.

Claim 4

The PAPE oligomer of claim 1 wherein R represents S.

Claim 5

The PAPE oligomer of claim 1 wherein said DH(T)P 1 , DH(T)P 2 and DH(T)P 3 are each independently selected from the group consisting of 2,2-bis(4-hydroxyphenyl)propane ("BPA"); 2,2-bis(4-hydroxyphenyl)silane; diphenyl sulfone; diphenyl sulfide; diphenyl ketone and diphenyl ether.

Claim 6

The PAPE oligomer of claim 4 wherein the combinations of the following DH(T)Ps are present as residua in the repeating unit: (i) 2,2-bis(4-hydroxyphenyl)propane and diphenyl sulfone; (ii) 2,2-bis(4-hydroxyphenyl)propane and dipheny ketone; (iii) 2,2-bis(4-hydroxyphenyl)propane and diphenyl ether; (iv) diphenyl sulfone and diphenyl ketone; (v) diphenyl ketone and diphenyl ether; and, (vi) diphenyl sulfone and diphenyl ether.

Claim 7

The PAPE oligomer of claim 1 wherein, said R 1 e X' represents the residuum of said bis(haloallyl)olefin; said DH(T)P 1 and DH(T)P 3 are each bisphenol A; and, said DH(T)P 2 is dichlorodiphenylsulfone.

Claim 8

A process for forming a difunctionalized substantially linear alternating block or regular thermoplastic polyarylene polyether copolymer, or polyarylene polythioether copolymer, (PAPE copolymer) having either haloallylic end groups or terminal phenol groups, comprising, (a) reacting a salt of a PAPE oligomer (segment A) formed from one or more polynuclear dihydric phenols, said PAPE oligomer having a molecular weight Mn in the range from about 1000 to about 10,000, with a ractive haloallyl moiety ("HAM") essentially quantitatively in the presence of a phase transfer catalyst ("PTC") distributed between an organic phase and an aqueous phase in an amount sufficient to solubilize said salt and substantially negate hydrolysis of said PAPE oligomer, so as to yield a functional head consisting of the residue of said HAM at each end of said PAPE copolymer, said residue being selected from the group consisting of haloallylic chain ends, and, terminal phenol groups; (b) precipitating said difunctionalized PAPE copolymer from said organic phase; and, (c) recovering said difunctionalized PAPE copolymer.

Claim 9

A process for forming a difunctionalized substantially linear alternating block or regular thermoplastic polyarylene polyether copolymer, or polyarylene polythioether copolymer, (PAPE copolymer) having either haloallylic end groups or terminal phenol groups, comprising, (a) reacting a salt of a PAPE oligomer (segment A) formed from one or more polynuclear dihydric phenols, said PAPE oligomer having a molecular weight Mn in the range from about 1000 to about 10,000, with a ractive haloallyl moiety ("HAM") essentially quantitatively in the presence of a phase transfer catalyst ("PTC") distributed between an organic phase and an aqueous phase in an amount sufficient to solubilize said salt and substantially negate hydrolysis of said PAPE oligomer, so as to yield a functional head consisting of the residue of said HAM at each end of said PAPE copolymer, said residue being selected from the group consisting of haloallylic chain ends, and, terminal phenol groups; (b) precipitating said difunctionalized PAPE copolymer from said organic phase; and, (c) recovering said difunctionalized PAPE copolymer.

Claim 10

The process of claim 7 wherein said reactive HAM represents the residue of a reactive bis(haloallyl)moiety selected from the group consisting of a bis(haloallyl)olefin to provide acyclic allylic chain ends, a bis(haloallyl)cycloolefin to provide cyclic allylic chain ends, and a bis(haloallyl)arylene to provide aryl (benzylic) allylic chain ends, so that said residue functions as a chain extending segment B to yield said regular (chain-extended) PAPE copolymer.

Claim 11

The process of claim 7 wherein said reactive HAM represents the residue, segment B, of at least one polynuclear dihydric phenol having reactive bis(haloallyl) chain ends selected from the group consisting of acyclic chain ends derived from a bis(haloallyl)olefin, cyclic allylic chain ends derived from a bis(haloallyl)cycloolefin, and aryl allylic (benzylic) chain ends derived from a bis(haloallyl)arylene, so that said residue functions as said segment B to yield said alternating block PAPE copolymer.

Claim 12

The process of claim 7 including the steps of (a) precipitating said salt from an organic solvent for said PAPE oligomer by reaction with an excess, based on the moles of --OH or --SH groups originally present in said PAPE oligomer, of an aqueous solution of an alkali metal hydroxide; (b) solubilizing said salt by adding a major molar amount of said PTC, based on the mole equivalents (mol equivs) of --OH or --SH groups originally present in said PAPE oligomer; and (c) reacting solubilized salt with said reactive HAM present in about an equimolar amount, based on the moles of --OH or --SH groups originally present in said PAPE oligomer.

Claim 13

The process of claim 10 wherein step (c) is carried out at a temperature in the range from about 10° C. to about 150° C. and at a pressure in the range from about 1 to about 20 atmospheres.

Claim 14

The process of claim 7 including the steps of (a) forming said salt in situ by contacting said PAPE oligomer with said PTCdissolved in an organic solvent for said PAPE oligomer and PTC; thereafter (b) adding about one molar equivalent of said reactive HAM for each mole of --OH or --SH groups originally present in said PAPE oligomer; then (c) adding an excess, based on the moles of --OH or --SH groups present, of an aqueous solution of an alkali metal hydroxide.

Claim 15

The process of claim 12 wherein step (c) is carried out at a temperature in the range from about 10° C. to about 150° C. and at a pressure in the range from about 1 to about 20 atmospheres.

Claim 16

The process of claim 7 wherein said PAPE alternating block or regular copolymer includes a repeating unit represented by the residuum of at least one polynuclear dihydric phenol optionally substituted with inert substituents, so that said PAPE copolymer is represented by the formula R.sup.e --R--"PAPE"--R--R.sup.e wherein, R represents O or S in an ether linkage with R e ; R e represents a residuum selected from R 1 e X' and R 2 e RH; R 1 e X' represents a residuum of a reactive bis(haloallyl) moiety "HAM"; R 2 e represents the group ##STR8## X' represents halogen selected from the group consisting of fluorine, chlorine and bromine; X" represents an inert substituent defined hereinbelow; and, "PAPE" represents the residuum of an oligomer selected from an unsaturated alternating block copolymer represented by ["DH(T)P.sub.1 "--"DH(T)P.sub.2 "].sub.n' --HAM--"DH(T)P.sub.3 "--.sub.n" and a regular unsaturated oligomer formed by chain extension represented by [HAM--"DH(T)P.sub.1 "--"DH(T)P.sub.2 "--HAM].sub.n'" wherein, "DH(T)P 1 " and "DH(T)P 2 " are the residues of dihydric (thio)phenols DH(T)P 1 and DH(T)P 2 which are the same or different, and "DH(T)P 3 " is the residue of a dihydric (thio)phenol DH(T)P 3 which may be the same as either DH(T)P 1 or DH(T)P 2 , or different; HAM represents the residue of a reactive bis(haloallyl) moiety selected from a bis(haloallyl)olefin having from 4 to about 20 carbon atoms including cis- or trans-dichlorobutene, a bis(haloallyl)cycloolefin having from 4 to about 8 ring carbon atoms including 1,4-bis(chloromethyl)-1,3-cyclohexadiene, a bis(haloallyl)arylene having from 8 to about 26 carbon atoms and 1,4-bis(chloromethyl)benzene; and, n', n" and n'" independently represent an integer in the range from 2 to about 100.

Claim 17

The process of claim 14 wherein said DH(T)P 1 , DH(T)P 2 and DH(T)P 3 are each independently selected from the group consisting of 2,2-bis(4-hydroxyphenyl)propane ("BPA"); 2,2-bis(4-hydroxyphenyl)silane; diphenyl sulfone; diphenyl sulfide; diphenyl ketone and diphenyl ether.

Claim 18

The process of claim 15 wherein the combinations of the following DH(T)Ps are present as residua in the repeating unit: (i) 2,2-bis(4-hydroxyphenyl)propane and diphenyl sulfone; (ii) 2,2-bis(4-hydroxyphenyl)propane and diphenyl ketone; (iii) 2,2-bis(4-hydroxyphenyl)propane and diphenyl ether; (iv) diphenyl sulfone and diphenyl ketone; (v) diphenyl ketone and diphenyl ether; and, (vi) diphenyl sulfone and diphenyl ether.

Claim 19

The process of claim 16 wherein, said R 1 e X' represents the residuum of said bis(haloallyl)olefin; said DH(T)P 1 and DH(T)P 3 are each bisphenol A; and, said DH(T)P 2 is dichlorodiphenylsulfone.