Abstract: A poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resin having improved handling characteristics is prepared by a process comprising preparing in a first enclosed vessel a slurry comprising a solid poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resin and a liquid polar organic compound, and optionally water; then substantially liquifying the resin to form a mixture comprising substantially liquified resin and polar organic compound; then flashing the mixture into a second vessel having a pressure lower than the first vessel, thereby removing a portion of the polar organic compound and solidifying the resin.When the slurry further comprises water, the invention method optionally includes a venting step prior to the substantial liquification of the resin and/or a concentration step after the substantial liquification of the resin.

Abstract: In one embodiment, a process is provided for treating virgin arylene sulfide resins, wherein a heated polymer slurry, comprising a virgin arylene sulfide resin and water, is contacted by a buffer solution having a pH less than about 9.35 but greater than that necessary to result in at least a partial curing of the virgin arylene sulfide resin. In a further embodiment, a process is provided for treating a virgin arylene sulfide resin, wherein a virgin arylene sulfide resin is slurried in a buffer solution having a pH less than about 9.35 but greater than that necessary to result in at least a partial curing of the virgin arylene sulfide resin. The treating process of this invention is conducted at an elevated temperature, below the melting point of the virgin arylene sulfide resin, while in the substantial absence of a gaseous oxidizing atmosphere. The treated arylene sulfide resins are recovered from the polymer slurry in a manner which does not result in at least a partial curing of the treated resin.

Abstract: A process for producing an easily recoverable poly(arylene sulfide) polymer having a melt flow of less than 130 g/10 min., which processes comprises:a) adding a second polar organic compound to a polymerization reaction mixture during polymerization immediately prior to termination of said polymerization, wherein said polymerization reaction mixture is formed by reacting reactants comprising a dihaloaromatic compound, a sulfur source and a first polar organic compound under suitable polymerization conditions, and wherein the molar ratio of second polar organic compound added to first polar organic compound is in the range of 0.05 to 2; and thereafterb) terminating said polymerization; andc) recovering said polymer.

Abstract: According to this invention, improved results in terms of molecular weight and percent yield of aromatic sulfide/sulfone polymers are achieved by the employment of a low level modifying agent within a specific range in the polymerization reaction mixture. The modifying agent employed is a salt of an amino carboxylic acid. The salt can be employed as an already existing salt of an amino carboxylic acid or can be formed in situ by employing either an amino carboxylic acid and a base; or a lactam and a base.

Abstract: A process is provided for preparing more granular (i.e., higher bulk density) particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resins having associated therewith improved processability and thermal stability, without generating pressures significantly greater than those generated during polymerization reactions of particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resins.

Abstract: In a first embodiment, arylene sulfide resins are provided by contacting, in a polymerization mixture, during a polymerization process, reactants comprising: an alkali metal sulfide, an organic amide, an alkali metal carboxylate, water and a monomer source which comprises at least one dihaloaromatic compound. The amount of alkali metal carboxylate present during the polymerization process ranges from about 0.01 to about 0.03 mole per each mole of sulfur present in the resulting arylene sulfide resin. The total amount of water present during the polymerization process ranges from about 1.02 to about 2.1 moles per each mole of sulfur present in the resulting arylene sulfide resin.

Abstract: In one embodiment, the inventive process comprises: (a) preparing a first slurry comprising a first particulate PAS resin and a polar organic compound, (b) heating the first slurry to a temperature in the range of about 20.degree. C. (68.degree. F.) and about 40.degree. C. (104.degree. F.) below the liquid-to-solid phase transitional temperature of the first particulate resin, and (c) rapidly cooling the first slurry to below about 50.degree. C. (122.degree. F.) below the liquid-to-solid phase transitional temperature of the first particulate resin in the polar organic compound to form a second slurry, comprising the polar organic compound and a polymeric mixture comprising a novel particulate high molecular weight PAS resin and a minor amount of a particulate low molecular weight PAS resin.

Abstract: A poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resin having improved handling characteristics is prepared by a process comprising preparing in a first enclosed vessel a slurry comprising a solid poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resin and a liquid polar organic compound, and optionally water; then substantially liquifying the resin to form a mixture comprising substantially liquified resin and polar organic compound; then flashing the mixture into a second vessel having a pressure lower than the first vessel, thereby removing a portion of the polar organic compound and solidifying the resin.When the slurry further comprises water, the invention method optionally includes a venting step prior to the substantial liquification of the resin and/or a concentration step after the substantial liquification of the resin.

Abstract: The invention is a process to provide more granular, higher bulk density particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resins having associated therewith improved handling.The process for treating a first slurry comprising a solid particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resin dispersed in a liquid medium comprising a polar organic compound, comprises: (a) liquifying the first solid particulate resin in the first slurry to form a first mixture comprising a liquified resin and the polar organic compound; (b) adding, to the first mixture, a sufficient amount of at least one separaton agent to produce a second mixture, and (c) reducing the temperature of the second mixture sufficiently to solidify the liquified resin to form a second slurry comprising a polar organic compound and a second solid particulate resin having a bulk density greater than the first solid particulate resin would if recovered.

Abstract: A process for preparing poly(arylene sulfide sulfone) by contacting a dihaloaromatic sulfone, an organic amide, a sulfur-containing compound, water, and an alkali metal carboxylate, wherein the molar ratio of the alkali metal carboxylate to the sulfur-containing compound is about 0.002:1 to less than 0.05:1.

Abstract: In one embodiment, the inventive process comprises: (a) preparing a first slurry comprising a first particulate PAS resin and a polar organic compound, (b) heating the first slurry to a temperature in the range of about 20.degree. C. (68.degree. F.) to about 40.degree. C. (104.degree. F.) below the liquid-to-solid phase transitional temperature of the first particulate resin, and (c) rapidly cooling the first slurry to below about 50.degree. C. (122.degree. F.) below the liquid-to-solid phase transitional temperature of the first particulate resin in the polar organic compound to form a second slurry, comprising the polar organic compound and a polymeric mixture comprising a novel particulate high molecular weight PAS resin and a minor amount of a particulate low molecular weight PAS resin.

Abstract: A method for recovering a crystalline poly(arylene sulfide) from a slurry comprising a particulate poly(arylene sulfide), a polar organic compound, and water, said method comprising:(a) substantially liquefying said particulate poly(arylene sulfide) to form a liquid mixture comprising said substantially liquified poly(arylene sulfide) and said polar organic compound;(b) contacting said liquid mixture with a vaporized separation agent in an amount sufficient to effect a separation between said poly(arylene sulfide) and said polar organic compound;(c) reducing the temperature of said liquid mixture sufficiently to solidify said substantially liquified poly(arylene sulfide) to form a slurry comprising a particulate poly(arylene sulfide); and(d) recovering said particulate poly(arylene sulfide) from said slurry.

Abstract: A process is provided for preparing more granular (i.e., higher bulk density) particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resins having associated therewith improved processability and thermal stability, without generating pressures significantly greater than those generated during polymerization reactions of particulate poly(arylene sulfide ketone) or poly(arylene sulfide diketone) resins.

Abstract: A method of making a poly(arylene sulfide/sulfone) resin comprises heating amorphous poly(arylene sulfide/sulfone) resin at an elevated temperature but below the melting temperature of the resin in a vacuum environment so that extrudate made from the resin is smooth and has reduced gas bubble content. The invention also relates to poly(arylene sulfide/sulfone) resin made in accordance with the method.

Abstract: A method is provided for recovering poly(arylene sulfide) from a mixture comprising a liquid-phase poly(arylene sulfide) and a polar organic compound, wherein the liquid mixture is contacted by an amount of a liquid, vaporized, or mixed phase separation agent at least sufficient to effect or enhance a phase separation of the liquid-phase poly(arylene sulfide) component from the polar organic compound. The poly(arylene sulfide) resins recovered according to this invention generally exhibit uniform particle size and do not tend to adhere to vessel walls during the recovery.

Abstract: A method for producing a poly(arylene sulfide/sulfone) polymer is provided which comprises: contacting reactants comprising a dihalogenated aromatic sulfone, an alkali metal sulfide, a polar organic compound, at least one base, an alkali metal carboxylate, and, optionally water, under suitable conditions to initiate a polymerization reaction; thereafter adding an amount of water while maintaining polymerization conditions; then terminating the reaction; and recovering the polymer.The invention method provides for a polymer product wherein the production of low molecular weight product is minimized and high molecular weight yield is maximized.

Abstract: A process is provided for preparing a polymeric resin comprising the steps of: (a) preparing a first slurry, wherein the solid component thereof comprises a first particulate resin selected from the group consisting of poly(arlene sulfide ketone)s and poly(arylene sulfide diketone)s, and wherein the liquid component thereof comprises a polar organic compound; (b) substantially liquifying the first particulate resin to form a mixture comprising the substantially liquified first particulate resin and the polar organic compound; and (c) reducing the temperature of the mixture sufficiently to solidify the substantailly liquified resin and form a second slurry, wherein the solid component thereof comprises a second polymeric resin. The filterability of the slurry containing the second polymeric resin is superior to that of the first slurry.

Abstract: A method is provided for recovering poly(arylene sulfide) from a liquid reaction mixture, comprising a liquid-phase poly(arylene sulfide) and a polar organic compound which can also function as a solvent for the polymer, and water. The liquid reaction mixture is contacted by an amount of a vaporized phase separation agent at least sufficient to effect or enhance a phase separation of the liquid-phase poly(arylene sulfide) component from the polar organic compound. The poly(arylene sulfide resins recovered according to this invention exhibit greater particle size than those recovered according to prior art methods, and do not tend to adhere to vessel walls during recovery.

Abstract: A process is provided for the production of aromatic sulfide/sulfone polymers which involves contacting under suitable polymerization reaction conditions: (1) at least one dihaloaromatic sulfone, (2) at least one organic amide, (3) at least one alkali metal hydrosulfide, (4) water, and (5) at least one member selected from the group consisting of (a) alkali metal carbonates and (b) mixtures of alkali metal carbonates with alkali metal hydroxides wherein said mixtures have at least about 0.5 mole percent alkali metal carbonate.

Abstract: A process is provided for removing solid and liquid impurities from a particulate arylene sulfide polymer recovered from a polymerization reaction mixture slurry, without significantly discoloring the resulting washed polymer. The process of this invention comprises the steps of: (a) preparing a first slurry, wherein the solid component thereof comprises a particulate arylene sulfide polymer recovered from a reaction mixture slurry, and wherein the liquid component thereof comprises a mixture of water and a reducing agent; (b) heating the first slurry to a temperature of at least about 185.degree. C. (365.degree. F.) but below the melting point of the particulate polymer, to wash the polymer contained therein; (c) cooling the first slurry to a temperature below about 100.degree. C. (212.degree. F.), to form a second slurry, wherein the solid component thereof comprises a washed particulate arylene sulfide polymer; and (d) recovering the washed particulate arylene sulfide polymer from the second slurry.