Abstract: This disclosure relates to a method for producing and using catalysts in the production of bisphenols, and in particular to a method for producing catalysts which contain attached mercaptan promoters, and using these catalysts in the production of bisphenol-A and its derivatives.

Abstract: An ultraviolet radiation absorbing layer formed over a polymeric substrate is disclosed herein. The layer is a doped metal oxide coating. The layer exhibits excellent weatherability and UV absorbing properties. The layer is preferably deposited by arc plasma deposition or by sputtering.

Abstract: A method and system are provided that efficiently compound high levels of inorganic filler, processing fluid and silicone polymer at a commercial rate into homogeneous filled and devolatilized silicone compositions. In the method, filled silicone compositions are compounded by compounding a filler, processing fluid and silicone polymer in a first compounding apparatus to produce a first dispersed composition and simultaneously compounding a filler, processing fluid and silicone polymer in a second compounding apparatus that shares a common extruder shaft with the first compounding apparatus to produce a second dispersed composition. The system comprises a first compounding apparatus and a sequential second compounding apparatus that shares a common shaft with the first compounding apparatus.

Abstract: Extrusion of a mixture of an ester-substituted diaryl carbonate, such as bis(methyl salicyl) carbonate, a dihydroxy aromatic compound such as bisphenol A and a transesterification catalyst such as tetrabutylphosphonium acetate (TBPA) affords polycarbonate having a weight average molecular weight of greater than 20,000 daltons. The extruder is equipped with one or more vacuum vents to remove by-product ester-substituted phenol. Similarly, a precursor polycarbonate having ester-substituted phenoxy endgroups, for example methyl salicyl endgroups, when subjected to extrusion affords a polycarbonate having a significantly increased molecular weight relative to the precursor polycarbonate. The reaction to form a higher molecular weight polycarbonate may be catalyzed by residual transesterification catalyst present in the precursor polycarbonate, or by a combination of any residual catalyst and an additional catalyst such as TBPA introduced in the extrusion step.

Abstract: The invention relates to substantially single phase silicone copolycarbonates suitable for use in optical articles such as digital versatile disks. The silicone copolycarbonates contain residues of silicone containing and nonsilicone containing bisphenols and have properties particularly suited for use in high density optical data storage media. The invention further relates to the preparation and properties of substantially single phase silicone copolycarbonates having either a blocky or a random structure. The structure of the compositions of the invention is determined by the method of preparation used and may be used to control physical properties.

Abstract: Polymer are removed from organic solvent-polymer mixtures by preparing a liquid-liquid dispersion of finely dispersed solvent droplets containing polymer in water, adding this liquid-liquid dispersion to a stirred vessel containing water or other suitable liquid and rapidly evaporating the solvent to produce a slurry of the polymer in a liquid from which the solid polymer particles are recovered.

Abstract: The acid catalyzed condensation of phenol with acetone in the presence of a thiol promoter to produce bisphenol A is found to occur with greater overall selectivity when the catalyst employed is an amine modified acidic resin catalyst. Amine modified acidic resin catalysts are prepared from acidic resins such as sulfonated polystyrene by neutralization of a portion of the acidic functional groups present with an amine such as pyridine. Where the thiol promoter is itself an amine the use of an amine such as pyridine as the modifying agent reduces the amount of thiol promoter required to achieve high selectivity.

Abstract: This invention relates to a method for preparing diaryl esters, comprising the step of reacting a mixture comprising diaryl carbonate and a dicarboxylic acid, wherein 2.005 to 2.2 molar equivalents of diaryl carbonate per molar equivalent of dicarboxylic acid are provided.

Abstract: High yields of ester-substituted diary carbonates such as bis-methyl salicyl carbonate were obtained by the condensation of ester-substituted phenols with phosgene in the presence of a phase transfer catalyst (PTC) and optionally a tertiary amine catalyst in a solvent free reaction system comprising an aqueous phase held at a pH of 8.3 or higher. The optimized conditions of the present invention use an excess of ester-substituted phenol relative to phosgene and high conversion of phosgene to ester-substituted diaryl carbonate is observed. The product ester-substituted diaryl carbonate may be conveniently isolated as a solid by filtration or as a liquid in which the excess ester-substituted phenols serves as solvent. The method represents an attractive route for the manufacture of bis methyl salicyl carbonate and ester-substituted diaryl carbonates generally.

Abstract: Hydroxyarylalkenes, particularly the ones constituting cashew nut shell liquid, are converted to (hydroxyalkyl)phenols, particularly 3-(8-hydroxy-noctyl)phenol, by ozonolysis followed by reduction, preferably with a hydride such as sodium borohydride. No protective acylation of the hydroxyarylalkenes is necessary. The resulting (hydroxyalkyl)phenols are useful for the preparation of polycarbonates.

Abstract: Polycarbonate copolymers have been prepared by solid state polymerization (SSP). A mixture comprising partially crystalline BPA polycarbonate oligomer having a weight average molecular weight of 10,000 daltons and a source of additional structural units and optionally a catalyst is reacted under SSP conditions to afford a copolycarbonate. Sources of additional structural units include high and low molecular weight polycarbonates incorporating repeat units not derived from BPA and various bisphenols such as BPI, BPM and tetramethyl BPA.

Abstract: This invention relates to a method for removing impurities from a brine solution, the brine solution comprising a water soluble chelating agent, the method comprising the steps of: a) adjusting the pH of the brine solution to a pH of from about 2 to about 4; b) passing the brine solution through a first functionalized resin; the first functionalized resin having functional groups capable of removing multivalent metal cations from the brine solution; c) adjusting the pH of the brine solution to a pH of from about 9 to about 11.5; and d) passing the brine solution through a second functionalized resin; the second functionalized resin having functional groups capable of removing alkaline earth metal cations from the brine solution.

Abstract: This invention relates to polymer-organoclay composite compositions comprising an thermoplastic organic polymer bearing amine groups, an organoclay containing quaternary ammonium ions incorporating at least two alkyl or cycloalkyl groups; and optionally one or more additional thermoplastic polymers, impact modifying agents and compatibilizing agents. The performance characteristics of the polymer-organoclay composite compositions are found to be closely linked to the structure of the ammonium cation present in the organoclay used. The compositions are suitable for use in the manufacture of molded articles.

Abstract: High yields of ester-substituted diary carbonates such as bis-methyl salicyl carbonate were obtained by the condensation of methyl salicylate with phosgene in the presence of a phase transfer catalyst (PTC) in an interfacial reaction system in which the pH of the aqueous phase was greater than 9.3. Using the method of the present invention conversions of greater than 99% were obtained whereas under standard conditions using triethylamine as the catalyst conversions were limited to 70-75% of the methyl salicylate starting material even with a 20 mole % excess of added phosgene. The optimized conditions of the of the present invention use only a slight excess of phosgene and represent an attractive route for the manufacture of bis methyl salicyl carbonate and ester-substituted diaryl carbonates generally.

Abstract: Extrusion of a mixture of an ester-substituted diaryl carbonate, such as bis-methyl salicyl carbonate, a dihydroxy aromatic compound such as bisphenol A and a transesterification catalyst such as tetrabutyl phosphonium acetate (TBPA) affords polycarbonate having a weight average molecular weight of greater than 20,000 Daltons. The extruder is equipped with one or more vacuum vents to remove by-product ester-substituted phenol. Similarly, a precursor polycarbonate having ester-substituted phenoxy endgroups, for example methyl salicyl endgroups, when subjected to extrusion affords a polycarbonate having a significantly increased molecular weight relative to the precursor polycarbonate. The reaction to form a higher molecular weight polycarbonate may be catalyzed by residual transesterification catalyst present in the precursor polycarbonate, or by a combination of any residual catalyst and an additional catalyst such as TBPA introduced in the extrusion step.

Abstract: This invention relates to a process and apparatus for the continuous preparation of mono and bis-chloroformate products of halogenated dihydroxy compounds by an interfacial process. The mono and bis-chloroformate products may optionally be converted to capped oligomers.

Abstract: Silylmethanethiols have been found to be useful promoters in the acid catalyzed condensation reaction between phenol and acetone to afford bisphenol A. Silylmethanethiols provide improvements in both the rate and selectivity of bisphenol A formation relative to known thiol promoters such as 3-mercaptopropionic acid or hexanethiol.

Abstract: Acidic impurities in dihydroxyaromatic compounds such as bisphenol A, as illustrated by sulfonic acids and mercaptocarboxylic acids, can have an adverse effect on the molecular weight of a polycarbonate prepared therefrom by transesterification. The same is true of acidic impurities in diaryl carbonates such as diphenyl carbonate, as illustrated by salicylic acid and ferric chloride. The reagents are analyzed for these impurities. Based on the analysis, the reagents are discarded or recycled, or a compensatory amount of alkali metal hydroxide is employed as a catalyst in the reaction.

Abstract: A melt method of preparing polycarbonate having a predetermined number average molecular weight and percent endcapping is described. A computerized process model is used to determine the reaction parameters to be employed in order to furnish the product polycarbonate possessing the desired Mn and %EC. Reaction parameters of importance include a suitable starting molar ratio of diaryl carbonate to dihydroxy aromatic compound, the most appropriate reaction time, reaction temperature and pressure ranges. The target polycarbonate is then prepared using reaction parameters indicated by the process model in a reactor which forms an element of the process model. Characteristics of the reactor which may be included in the process model include agitation rate and reflux ratio during the distillative removal of hydroxy aromatic compound formed as a by-product during the polymerization.

Abstract: This invention provides a method for preparing polycarbonates, which utilizes polycondensation catalysts which are derivatized pyridyl triazinyl pyridyl macromolecules with the general formula Ax+y[(Triazinyl-Pyridyl)By−x], where A is certain alkali metals, B contains a charge balancing sulfonate, carboxylate, or phosphonate group. We have found that this new class of catalysts provide excellent polymerization rates for the preparation of Bisphenol A polycarbonate from the melt polymerization of diphenyl carbonate and Bisphenol A. Moreover, the catalysts of the invention were found to be very selective in substantially reducing the level of branching side reaction, i.e., formation of Fries product, normally associated with the melt polycarbonate process.