Elimination of monocarbonate from polycarbonate

Abstract

A polycarbonate composition, and process for making same, wherein the monocarbonate and dicarbonate content is eliminated or limited to negligibly low levels by withholding introduction of chain terminator to the reaction mixture until the reaction of dihydroxy and carbonic acid derivative starting materials has run substantially to completion.

What is claimed is: .[.1. A composition comprising a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, which composition is free of monocarbonate..]..[.2. A composition comprising a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, which composition contains only a negligible, insignificant amount of monocarbonate..]..[.3. A composition comprising a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains only a negligible, insignificant amount of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.4. A composition comprising a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains less than 100 ppm of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.5. A composition comprising a carbonate polymer which is the product of the reaction of a dihydroxy compound, other than Bisphenol-A, with a carbonic acid derivative and a chain terminator containing a hydroxy group, which composition contains less than 100 ppm of monocarbonate..]..[.6. A composition comprising a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, other than para-t-butyl phenol, which composition contains less than 100 ppm of monocarbonate..]..[.7. The composition of claim 1, 2 or 5 wherein the chain terminator is para-t-butyl phenol, phenol or 4-(tert-ocyl) phenol..]..[.8. The composition of claim 1, 2 or 6 wherein the dihydroxy compound is Bisphenol-A, Bisphenol-A-P, Tetrabromo Bisphenol-A or Tetramethyl Bisphenol-A..]..[.9. The composition of claim 1 or 2 wherein the dihydroxy compound is Bisphenol-A and the chain terminator is 
     
        para-t-butyl phenol..].10. .[.A.]. .Iadd.An interfacial .Iaddend.process for making polycarbonate comprising .Iadd.the steps in sequence of .Iaddend. .[.(a) forming a reaction mixture which comprises a dihydroxy compound, a carbonic acid derivative, a solvent, and sufficient base to bring about the formation of polycarbonate, and   (b) employing in said reaction mixture a chain terminator, containing a hydroxy group, such that monocarbonate does not form.].   (.Iadd.a) forming a reaction mixture which comprises a dihydroxy compound, phosgene, and organic solvent, and sufficient aqueous base to bring about the formation of polycarbonate;   (b) employing in said reaction mixture a chain terminator, containing a hydroxy group, such that monocarbonate forms only in an amount less than 100 ppm by adding said chain terminator to the reaction mixture when the reaction between said dihydroxy compound and said phosgene to form polycarbonate is complete;   (c) cooling the reaction mixture; and   (d) adding a chain coupling catalyst to the polycarbonate forming reaction   
     
     
        mixture.Iaddend.. .[.11.  A process for making polycarbonate comprising (a) forming a reaction mixture which comprises a dihydroxy compound, a carbonic acid derivative, a solvent, and sufficient base to bring about the formation of polycarbonate, and   (b) employing in said reaction mixture a chain terminator, containing a hydroxy group, such that monocarbonate forms only in a negligible,   
     
     
        insignificant amount..]..[.12.  A process for making polycarbonate comprising (a) forming a reaction mixture which comprises Bisphenol-A, phosgene, a solvent, and sufficient base to bring about the formation of polycarbonate, and   (b) employing para-t-butyl phenol in said reaction mixture such that monocarbonate forms only in a negligible, insignificant amount, and dicarbonate in excess of Z ppm does not form where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight   
     
     
        average molecular weight of said polycarbonate..]..[.13.  A process for making polycarbonate comprising (a) forming a reaction mixture which comprises a dihydroxy compound, a carbonic acid derivative, a solvent, and sufficient base to bring about the formation of polycarbonate, and   (b) employing in said reaction mixture a chain terminator, containing a hydroxy group, such that monocarbonate forms only in an amount less than   
     
     
        100 ppm..]..[.14.  A process for making polycarbonate comprising (a) forming a reaction mixture which comprises Bisphenol-A, phosgene, a solvent, and sufficient base to bring about the formation of polycarbonate, and   (b) employing para-t-butyl phenol in said reaction mixture such that monocarbonate forms only in an amount less than 100 ppm and dicarbonate in excess of Z ppm does not form where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average   
     
     
        molecular weight of said polycarbonate..].15. The process of claim 10.[., 11 or 13.]. wherein the dihydroxy compound is Bisphenol-A, Bisphenol-A-P, Tetrabromo Bisphenol-A or Tetramethyl Bisphenol-A. .[.16. In the manufacture of polycarbonate which is the product of contacting a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, a process for preventing the formation of monocarbonate, comprising the steps in sequence of (a) contacting said dihydroxy compound with said carbonic acid derivative in a reaction mixture containing a solvent and sufficient base to give such reaction mixture a pH of greater than about 10, thereby forming polycarbonate, and   (b) adding said chain terminator to said reaction mixture when the heat of said reaction has increased to a constant level..]..[.17. In the manufacture of polycarbonate which is the product of contacting a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, a process for limiting the formation of monocarbonate to a negligible, insignificant amount, comprising the steps in sequence of   (a) contacting said dihydroxy compound with said carbonic acid derivative in a reaction mixture containing a solvent and sufficient base to give such reaction mixture a pH of greater than about 10, thereby forming polycarbonate, and   (b) adding said chain terminator to said reaction mixture when the heat of   
     
     
        said reaction has increased to a constant level..]..[.18.  In the manufacture of polycarbonate which is a product of contacting Bisphenol-A with phosgene and para-t-butyl phenol, a process for limiting the formation of monocarbonate to a negligible, insignificant amount and limiting the formation of dicarbonate to no more than Z ppm, where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said polycarbonate, comprising the steps in sequence of (a) contacting Bisphenol-A with phosgene in a reaction mixture containing a solvent and sufficient base to give such reaction mixture a pH of greater than about 10, thereby forming polycarbonate, and   (b) adding para-t-butyl phenol to said reaction mixture when the heat of said reaction has increased to a constant level..]..[.19. In the manufacture of polycarbonate which is the product of contacting a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, a process for limiting the formation of monocarbonate to less than 100 ppm, comprising the steps in sequence of   (a) contacting said dihydroxy compound with said carbonic acid derivative in a reaction mixture containing a solvent and sufficient base to give such reaction mixture a pH of greater than about 10, thereby forming polycarbonate, and   (b) adding said chain terminator to said reaction mixture when the heat of said reaction has increased to a constant level..]..[.20. In the manufacture of polycarbonate which is a product of contacting Bisphenol-A with phosgene and para-t-butyl phenol, a process for limiting the formation of monocarbonate to less than 100 ppm and limiting the formation of dicarbonate to no more than Z ppm, where Z is given by log 10  (Z)=14.045216-2.4921524 log 10  (Mw), and "Mw" is the weight average molecular weight of said polycarbonate, comprising the steps in sequence of   (a) contacting Bisphenol-A with phosgene in a reaction mixture containing a solvent and sufficient base to give such reaction mixture a pH of greater than about 10, thereby forming polycarbonate, and   (b) adding para-t-butyl phenol to said reaction mixture when the heat of said reaction has increased to a constant level..]..[.21. The process of claim 16, 17 or 19 wherein the dihydroxy compound is Bisphenol-A, Bisphenol-A-P, Tetrabromo Bisphenol-A or Tetramethyl Bisphenol-A..]..[.22. The process of claim 16, 17 or 19 wherein the chain terminator is para-t-butyl phenol, phenol or di(p-t-butyl) phenol..]..[.23. The process of claim 16, 17 or 19 wherein the dihydroxy compound is Bisphenol-A and the chain terminator is para-t-butyl phenol..]..[.24. The composition produced by the process of claim 10..]..[.25. The composition produced by the process of claim 11..]..[.26. The composition produced by the process of claim 12..]..[.27. The composition produced by the process of claim 13..]..[.28. The composition produced by the process of claim 14..]..[.29. The composition produced by the process of claim 15..]..[.30. The composition produced by the process of claim 16..]..[.31. The composition produced by the process of claim 17..]..[.32. The composition produced by the process of claim 18..]..[.33. The composition produced by the process of claim 19..]..[.34. The composition produced by the process of claim   
     
     
        20..]..[.35.  The composition produced by the process of claim 21..]..[.36. The composition produced by the process of claim 22..]..[.37. The composition produced by the process of claim 23..]..[.38. A molded article comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, which article contains only a negligible, insignificant amount of monocarbonate..]..[.39. A molded article comprised of a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains only a negligible, insignificant amount of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.40. A molded article comprised of a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains less than 100 ppm of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.41. A molded article comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound, other than Bisphenol-A, with a carbonic acid derivative and a chain terminator containing a hydroxy group, which article contains less than 100 ppm of monocarbonate..]..[.42. A molded article comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, other than para-t-butyl phenol, which article contains less than 100 ppm of monocarbonate..]..[.43. A compact disc free of "ghosting" imperfections comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing hydroxy group, which compact disc contains only a negligible, insignificant amount of monocarbonate..]..[.44. A compact disc free of "ghosting" imperfections comprised of a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains only a negligible, insignificant amount of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.45. A compact disc comprised of a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which contains less than 100 ppm of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2,4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said composition..]..[.46. A compact disc comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound, other than Bisphenol-A, with a carbonic acid derivative and a chain terminator containing hydroxy group, which compact disc contains less than 100 ppm of monocarbonate..]..[.47. A compact disc comprised of a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, other than para-t-butyl phenol, which compact disc contains less than 100 ppm of monocarbonate..]..[.48. A composition comprising a carbonate polymer which is the product of the reaction of a dihydroxy compound with a carbonic acid derivative and a chain terminator containing a hydroxy group, which composition is purified of monocarbonate..]..[.49. A composition comprising a carbonate polymer which is the product of the reaction of Bisphenol-A with phosgene and para-t-butyl phenol, and which is purified of monocarbonate and contains no more than Z ppm of dicarbonate where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average 
     
     
        molecular weight of said composition..]..Iadd.50.  The process of claim 10 wherein polycarbonate is formed by passing the reaction mixture through inline mixers in a tubular reactor. .Iaddend..Iadd.51. The process of claim 10 wherein polycarbonate is formed at a pH of at least about 10. .Iaddend..Iadd.52. The process of claim 10 wherein polycarbonate is formed at a pH of about 11 to about 14. .Iaddend..Iadd.53. The process of claim 10 further comprising a step (b') of adding base to the reaction mixture after the addition thereto of chain terminator and prior to cooling the reaction mixture. .Iaddend..Iadd.54. The process of claim 10 wherein step (c) is performed in a stirred tank reactor. .Iaddend..Iadd.55. The process of claim 10 wherein step (c) is performed by flashing the reaction mixture in a stirred tank reactor. .Iaddend..Iadd.56. The process of claim 10 further comprising a step (c') of adding an organic solvent to the 
     
     
        reaction mixture after cooling the reaction mixture. .Iaddend..Iadd.57. The process of claim 10 wherein the chain terminator is para-t-butyl 
     
     
        phenol, phenol or t-octyl phenol. .Iaddend..Iadd.58.  The process of claim 10 wherein the dihydroxy compound is Bisphenol-A and the chain terminator is para-t-butyl phenol. .Iaddend..Iadd.59. The process of claim 10 wherein 
     
     
        the chain coupling catalyst is triethylamine. .Iaddend..Iadd.60.  The process of claim 10 wherein, in step (b), a chain terminator containing a hydroxy group is employed in said reaction mixture such that dicarbonate in excess of Z ppm does not form where Z is given by log 10  (Z)=14.045216-2.4921524log 10  (Mw), and "Mw" is the weight average molecular weight of said polycarbonate. .Iaddend..Iadd.61. The process of claim 10 wherein, in step (b), the reaction between the dihydroxy compound and phosgene is complete when the heat of the reaction has increased to a constant level. .Iaddend.