Method for removing volatile substances from polyphenylene ether or polyphenylene ether/styrene resin compositions

Claim 2

A process for the reduction of volatile substances in a composition comprising (a) a polyphenylene ether resin, alone, or in combination with (b) a styrene resin, said composition comprising impurities selected from styrene monomer, toluene, volatile odoriferous oxygenated species, sources of volatile odoriferous amines, mixtures of any of them and the like, said process comprising extruding said composition at a temperature above its melting point in one pass in at least two stages, each said stage comprising water injection followed by vacuum venting, the total amount of water being divided between said stages and comprising up to about 15 percent by weight of said composition whereby the devolatilization efficiency of both toluene and trimethylanisole is greater than about 70 percent in comparison with the reduction obtained with the same composition in one pass in a single stage employing the same amount of water.

Claim 3

A process as defined in claim 1 wherein said composition comprises polyphenylene ether, alone.

Claim 4

A process as defined in claim 1 wherein said polyphenylene ether resin component (a) comprises poly(2,6-dimethyl-1,4-phenylene ether), poly(2,6-dimethyl-co-2,3,6-trimethyl-1,4-phenylene ether) or a mixture thereof.

Claim 5

A process as defined in claim 1 wherein said styrene resin component (b) comprises a polystyrene homopolymer resin.

Claim 6

A process as defined in claim 1 wherein said styrene resin component (b) comprises a rubber modified styrene polymer.

Claim 7

A process as defined in claim 1 wherein said polyphenylene ether resin component (a) comprises a functionalized polyphenylene ether.

Claim 8

A process as defined in claim 6 wherein said functionalizing agent is fumaric acid, maleic anhydride, citric acid, trimellitic anhydride acid chloride or a mixture of any of the foregoing.

Claim 9

A process as defined in claim 7 wherein said functionalizing agent is maleic anhydride.

Claim 10

A process as defined in claim 1 wherein the temperature in the extruder is above about 280° C. and the water injected comprises liquid water.

Claim 11

A process as defined in claim 1 wherein the temperature in the extruder is above about 280° C. and the water injected comprises steam.

Claim 12

A process as defined in claim 1 wherein the total amount of water injected is from about 1 to about 10 percent by weight of the polymer composition.

Claim 13

A process as defined in claim 1 wherein the pressure during extrusion is in the range of about 550 to about 720 torr.

Claim 14

A process as defined in claim 1 wherein an effective amount of a nucleating agent selected from an organic or an inorganic particulate material or mixture thereof is added to the composition to induce bubble formation and increase surface area during devolatilization.

Claim 15

A process as defined in claim 13 wherein said nucleating agent comprises talc in an amount of up to about 2 percent by weight based on said composition.

Claim 16

A process as defined in claim 1 including the step of injecting carbon dioxide into the extruder in at least one injection stage.

Claim 17

A process as defined in claim 1 including setting the pressure of the vacuum vent such that the vapor velocity through the vent is kept below about 5-6 meters sec -1 .

Claim 18

A process as defined in claim 1 wherein said polyphenylene ether resin component (a) comprises from about 5 to about 95 parts by weight and said polystyrene resin component (b) comprises from about 95 to about 5 parts by weight.

Claim 19

In a process for the reduction of volatile substances in a composition comprising (a) a polyphenylene ether resin, alone, or in combination with (b) a styrene resin, said composition comprising impurities selected from styrene monomer, toluene, volatile odoriferous oxygenated species, sources of volatile odoriferous amines, mixtures of any of them, and the like; said process comprising extruding said composition at a temperature above about 280° C. in one pass in the presence of water followed by vacuum venting, the improvement which comprises carrying out the process in at least two stages each said stage comprising water injection followed by vacuum venting, the total amount of water being divided between said stages and comprising up to about 15 percent by weight of said composition, whereby the devolatilization efficiency of both toluene and trimethylanisole is greater than about 70 percent in comparison with the reductions obtained with the same composition in one pass in a single stage employing the same amount of water.

Claim 20

In a process for the reduction of volatile substances in a composition comprising (a) a polyphenylene ether resin, alone, or in combination with (b) a styrene resin, said composition comprising impurities selected from styrene monomer, toluene, volatile odoriferous oxygenated species, sources of volatile odoriferous amines, mixtures of any of them, and the like; said process comprising extruding said composition at a temperature above about 280° C. in one pass in the presence of water followed by vacuum venting, the improvement which comprises carrying out the process in at least two stages each said stage comprising water injection followed by vacuum venting, the total amount of water being divided between said stages and comprising up to about 15 percent by weight of said composition, whereby the devolatilization efficiency of both toluene and trimethylanisole is greater than about 70 percent in comparison with the reductions obtained with the same composition in one pass in a single stage employing the same amount of water.

Claim 21

A process as defined in claim 1 wherein said polyphenylene ether resin comprises a low odor polyphenylene ether resin having a 2,4,6-trimethylanisole content of less than about 50 parts per million by weight based on said resin and sources of odoriferous amine content of greater than about 10,000 parts per million based on said resin.

Claim 22

A process as defined in claim 19 wherein said low odor polyphenylene ether resin is prepared by oxidatively coupling a phenol in the presence of a catalyst in a solvent comprising a normally liquid aromatic hydrocarbon in a polymerization zone until formation of said resin and by-products are substantially complete and recovering said resin by the addition of a C 1 to C 6 alcohol to the polymer solution and recovering said aromatic hydrocarbon containing said by-products and distilling to reduce the content of said by-products and thereafter recycling said aromatic hydrocarbon essentially free of said by-products to the polymerization zone.

Claim 23

A process as defined in claim 20 wherein said phenol feed into the reactor comprises 2,6-xylenol.

Claim 24

A process as defined in claim 20 wherein said normally liquid aromatic hydrocarbon comprises toluene.

Claim 25

A process as defined in claim 20 wherein said distilling comprises distilling said aromatic hydrocarbon and said by-products to reduce the content of 2,4,6-trimethylanisole by-product present in said aromatic hydrocarbon to less than about 5 weight parts per million based on said aromatic hydrocarbon.

Claim 26

A process as defined in claim 19 wherein said polyphenylene ether resin comprises a by-product 7-methyldihydrobenzofuran content of about 0.5 to about 50 weight parts per million based on said resin.

Claim 27

A process as defined in claim 19 which also comprises step (c) comprising shaping the low odor composition.

Claim 28

A process as defined in claim 25 wherein said step (c) comprises pelletizing said low odor composition.

Claim 29

A process as defined in claim 25 wherein said step (c) comprises foaming said low odor composition.

Claim 30

A process as defined in claim 27 wherein said step (c) comprises (i) feeding said low odor composition into at least one extruder and mixing it with a blowing agent; and (ii) foaming the mixture through a die to form a shaped, foamed sheet or board having very low odor in human organoleptic tests.

Claim 31

A process as defined in claim 28 wherein said step (i) comprises feeding said composition into tandem extruders, the first extruder being adapted to melt and mix said composition and said blowing agents into the polymer melt and the second extruder is adapted for cooling the melt prior to foaming.

Claim 32

A process as defined in claim 28 wherein said blowing agent comprises a hydrocarbon, a chlorofluorocarbon, a hydrochlorofluorocarbon or a mixture thereof.

Claim 33

A process as defined in claim 30 wherein said blowing agent comprises chlorodifluoromethane.

Claim 34

A process as defined in claim 28 which also comprises adding a nucleating agent in step (i) in an amount sufficient to aid in regulating the size of foam cell and number of foam cells.

Claim 35

A process as defined in claim 25 wherein said step (c) comprises extruding said composition through a suitable die to form a solid sheet having very low odor in human organoleptic tests.

Claim 36

A process as defined in claim 25 wherein said step (c) comprises (i) adding said blowing agent directly into the extruder of step (b) to yield a low odor composition containing a liquid blowing agent under pressure; and (ii) feeding said low odor composition into an extruder equipped with a foaming die; and (iii) foaming said composition through said die to form a shaped foamed sheet or board having very low odor in human organoleptic tests.

Claim 37

A process as defined in claim 25 wherein said step (c) comprises extruding said composition through a suitable die to form an extruded article having very low odor in human organoleptic tests.

Claim 38

A process as defined in claim 25 wherein said step (c) comprises molding said composition to form a molded article having very low odor in human organoleptic tests.