Abstract: Different methods for the preparation of high purity NaAlCl4 are disclosed. The methods includes charging a feed having an intimate mixture of aluminum chloride, sodium chloride, and aluminum metal, to a reactor at an initial temperature less than about 80° C., carrying out a solid state reaction to form a solid NaAlCl4 at an intermediate temperature less than about 145° C., melting the formed solid NaAlCl4 at an elevated temperature greater than about 150° C. to produce molten phase NaAlCl4, holding the reactor at a raised temperature greater than about 165° C. to substantially complete formation of colorless NaAlCl4 and filtering the reactor contents at a final temperature greater than about 165° C.

Abstract: Different methods for the preparation of high purity NaAlCl4 are disclosed. The methods includes charging a feed having an intimate mixture of aluminum chloride, sodium chloride, and aluminum metal, to a reactor at an initial temperature less than about 80° C., carrying out a solid state reaction to form a solid NaAlCl4 at an intermediate temperature less than about 145° C., melting the formed solid NaAlCl4 at an elevated temperature greater than about 150° C. to produce molten phase NaAlCl4, holding the reactor at a raised temperature greater than about 165° C. to substantially complete formation of colorless NaAlCl4 and filtering the reactor contents at a final temperature greater than about 165° C.

Abstract: Bis(halophthalimides) are prepared in mixture in an organic liquid such as ortho-dichlorobenzene or anisole, by a reaction at a temperature of at least 150° C. between at least one diamine compound and at least one halophthalic anhydride in the presence of imidization catalyst. The reaction mixture is maintained at about 15% by weight solids content and rich in the halophthalic anhydride by constantly monitoring the reaction mixture using analytical methods such as high performance liquid chromatography. The product mixture may be directly employed in the direct preparation of polyetherimides, and similar slurries may be employed to prepare other polyether polymers.

Abstract: A method for preparing a metal salt of a hydroxy-substituted aromatic compound is described. The method comprises contacting in an aqueous medium at least one hydroxy-substituted aromatic compound with a base comprising a metal cation to provide a mixture comprising water and a metal salt of said hydroxy-substituted aromatic compound. The aqueous metal salt is then contacted with a substantially water-immiscible solvent at a temperature greater than the boiling point of water at the prevailing pressure to provide a slurry comprising the metal salt of the hydroxy-substituted aromatic compound and a vapor stream comprising the water-immiscible solvent and water. The components of the vapor stream are separated using a vapor handling system comprising a partial reflux condenser to provide a water-rich component and a water immiscible solvent-rich component.

Abstract: Disclosed herein is a method comprising: (a) adding an aqueous solution comprising a quaternary ammonium salt to an organic solvent in a vessel under an inert atmosphere, thereby forming a first mixture comprising the quaternary ammonium salt and the solvent; and (b) mixing the first mixture at a temperature and for a time sufficient to remove water and a portion of the solvent from the first mixture, wherein the mixing is performed in an inert atmosphere and the temperature is less than the decomposition temperature of the quaternary ammonium salt.

Abstract: Polyether polymers, such as polyetherimides, are prepared by the reaction of a dihydroxy-substituted aromatic hydrocarbon alkali metal salt, such as bisphenol A disodium salt, with a bis(N-(chlorophthalimido))aromatic compound, such as 1,3- and/or 1,4-bis(N-(4-chlorophthalimido))benzene, in a solvent such as o-dichlorobenzene and in the presence of a phase transfer catalyst such as a hexaalkylguanidinium chloride. Several embodiments may be employed to improve the method. They comprise employing substantially dry reagents, employing a high solids level in solvent, beginning with an excess of bis(N-(chlorophthalimido))-aromatic compound and incrementally adding alkali metal salt, employing alkali metal salt of small particle size, and using reagents of high purity.

Abstract: Disclosed herein is a method comprising: (a) adding an aqueous solution comprising a quaternary ammonium salt to an organic solvent in a vessel under an inert atmosphere, thereby forming a first mixture comprising the quaternary ammonium salt and the solvent; and (b) mixing the first mixture at a temperature and for a time sufficient to remove water and a portion of the solvent from the first mixture, wherein the mixing is performed in an inert atmosphere and the temperature is less than the decomposition temperature of the quaternary ammonium salt.

Abstract: A method of making a polyether polymer comprises reacting a salt of a dihydroxy-substituted aromatic hydrocarbon with a substituted aromatic compound of formula (I) Z(A1—X1)2 ??(I) in the presence of a catalyst to form an intermediate polymer having endgroups, wherein the molar ratio of the salt of a dihydroxy-substituted aromatic hydrocarbon to the substituted aromatic compound is less than 1, Z is an activating radical, A1 is an aromatic radical and X1 is fluoro, chloro, bromo or nitro; determining the additional amount of the salt of a dihydroxy-substituted aromatic hydrocarbon needed to form a final polyether polymer with a predetermined molecular weight and adding the additional amount of the salt of a dihydroxy-substituted aromatic hydrocarbon to the intermediate polymer.

Abstract: Disclosed is a method for preparing an alkali metal salt of a hydroxy-substituted hydrocarbon which comprises the steps of (i) contacting in solvent media at least one hydroxy-substituted hydrocarbon with a base comprising an alkali metal cation; and (ii) devolatilizing the solvent media comprising alkali metal salt by adding or spraying the solvent media into a substantially water-immiscible organic solvent, said solvent being at a temperature greater than the boiling point of solvent media at the prevailing pressure. In one embodiment the solvent media comprises water, and optionally at least one water-soluble protic organic solvent.

Abstract: Aromatic polyethers are prepared by displacement polymerization reaction in the presence of a water-immiscible solvent with boiling point at atmospheric pressure of greater than 110° C. and a density ratio to water of greater than 1.1:1 at 20-25° C. The polyethers are purified by processes comprising aqueous extraction, or filtration, or a combination thereof.

Abstract: Aromatic polyethers are prepared by displacement polymerization reaction in the presence of a water-immiscible solvent with density ratio to water in a range of between about 0.9:1 and about 1.1:1 measured at a temperature in a range of between about 20° C. and about 25° C. The polyethers are purified by processes comprising aqueous extraction, or filtration, or a combination thereof.

Abstract: Aromatic polyethers are prepared by displacement polymerization reaction in the presence of a water-immiscible solvent with boiling point at atmospheric pressure of greater than 110° C. and a density ratio to water of greater than 1.1:1 at 20-25° C. The polyethers are purified by processes comprising aqueous extraction, or filtration, or a combination thereof.

Abstract: An improved thermal barrier coating for metal substrates such as superalloys is disclosed. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods are also described. In general, they involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

Abstract: An improved thermal barrier coating for metal substrates such as superalloys is provided. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

Abstract: A method for making polyarylene ethers comprises the step of melt polymerizing phenolic monomers in the presence of oxygen and oxidative coupling catalysts without employing environmentally unfriendly solvents.