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1. WO2018134734 - REDUCED COLOR POLYCARBONATE COMPOSITIONS, METHODS OF MANUFACTURE, AND ARTICLES THEREOF

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[ EN ]

CLAIMS

1. A method of preparing a polycarbonate composition, comprising:

melt polymerizing in a olymerization unit a dihydroxy compound of formula (3):


wherein Ra and Rb are each independently a halogen, C1-12 alkoxy, or C1-12 alkyl; p and q are each independently integers of 0 to 4; Xa is a substituted or unsubstituted C3_i8 cycloalkylidene; a C1-25 alkylidene of the formula -C(Rc)(Rd) - wherein Rc and Rd are each independently hydrogen, C1-12 alkyl, C1-12 cycloalkyl, C7-12 arylalkyl, C1-12 heteroalkyl, or cyclic C7-12 heteroarylalkyl; or a group of the formula -C(=Re)- wherein Re is a divalent C1-12 hydrocarbon group;

with a diaryl carbonate compound of formula (A)


wherein each n is independently an integer of 1 to 3 and each R1 is independently a linear or branched, optionally substituted Ci_34 alkyl, Ci_34 alkoxy, Cs_34 cycloalkyl, C7_34 alkylaryl, C6-34 aryl, a halogen radical, or -C(=0)OR' wherein R' is H, linear or branched Ci_34 alkyl, Ci_34 alkoxy, Cs_34 cycloalkyl, C7_34 alkylaryl, or C6-34 aryl; and

removing a stream of color inducing species containing an isopropenyl phenyl-containing group from the polymerization unit, to form a polycarbonate composition;

wherein the polycarbonate composition has a color inducing species containing an isopropenyl phenyl-containing group level less than or equal to 170 ppm.

2. The method of claim 1, wherein the color inducing species containing an isopropenyl phenyl-containing group level is less than or equal to 100 ppm.

3. The method of claim 1 or 2, wherein the color inducing species containing an isopropenyl phenyl-containing group comprises isopropenyl phenol, an isopropenyl phenol dimer, an isopropenyl phenol trimer, an isopropenyl phenol oligomer, an isopropenyl phenyl carbonate, or a combination comprising at least one of the foregoing.

4. The method of any of the preceding claims, wherein the color inducing species containing an isopropenyl phenyl-containing group has a boiling point higher than that of phenol and lower than that of DPC.

5. The method of any one or more of claims 1 to 3, wherein the color inducing species containing an isopropenyl phenyl-containing group has a boiling point higher than that of DPC.

6. The method of any one or more of the preceding claims, wherein the dihydroxy compound is bisphenol A and the diaryl carbonate compound is diphenyl carbonate.

7. The method of any one or more of the preceding claims, wherein the

polymerization unit comprises an oligomerization section and a polymerization section, and wherein the color inducing species containing an isopropenyl phenyl-containing group is removed from the oligomerization section.

8. The method of claim 7, wherein the oligomerization section further comprises an extraction column that extracts phenol from the oligomerization section and returns the dihydroxy compound, the diaryl carbonate compound or a mixture thereof, to the

oligomerization section, the removing comprising removing a color inducing species containing an isopropenyl phenyl-containing group from the extraction column.

9. The method of claim 8, wherein removing is by a side feed from the extraction column.

10. A polycarbonate prepared by the method of any of claims 1 to 9, wherein the polycarbonate has

a color inducing species containing an isopropenyl phenyl-containing group

concentration of 170 ppm or below, or

a yellowness index of less than or equal to 2, as measured by ASTM method D1925, or a difference in yellowness index of less than or equal to 4, after thermal aging of a molded part in a temperature of 135°C for 1500 hours, as measured by ASTM method D1925, in comparison to the yellowness index before thermal aging.

11. The polycarbonate of claim 10, wherein the wherein the polycarbonate has a color inducing species containing an isopropenyl phenyl-containing group

concentration of 100 ppm or below.

12. An article comprising the polycarbonate of claim 10.

13. The article of claim 12, wherein the article is a sheet, a film, a multilayer sheet, a multilayer film, a molded part, an extruded profile, a fiber, a coated part, or a foam.

14. A polycarbonate having a molecular weight of 18,000 to 70,000 grams/mole, as measured by gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column and calibrated to bisphenol A homopolycarbonate references;

concentration of Fries branching species of less than or equal to 2500 mg/kg, a yellowness index of less than or equal to 2, as measured by ASTM method D1925, or a difference in yellowness index of less than or equal to 4, after thermal aging of a molded part in a temperature of 135°C for 1500 hours, as measured by ASTM method D1925, in comparison to the yellowness index before thermal aging;

prepared by melt transesterif ing a dihydroxy compound of formula (3):


wherein Ra and Rb are each independently a halogen, C1-12 alkoxy, or C1-12 alkyl; p and q are each independently integers of 0 to 4; Xa is a substituted or unsubstituted C3-18

cycloalkylidene; a C1-25 alkylidene of the formula -C(Rc)(Rd) - wherein Rc and Rd are each independently hydrogen, C1-12 alkyl, C1-12 cycloalkyl, C7_i2 arylalkyl, C1-12 heteroalkyl, or cyclic C7_i2 heteroarylalkyl; or a group of the formula -C(=Re)- wherein Re is a divalent C1-12 hydrocarbon group;

with a diaryl carbonate compound of formula (A)


wherein each n is independently an integer of 1 to 3 and each R1 is independently a linear or branched, optionally substituted Ci_34 alkyl, Ci_34 alkoxy, Cs_34 cycloalkyl, C7_34 alkylaryl, C6-34 aryl, a halogen radical, or -C(=0)OR' wherein R' is H, linear or branched C1-34 alkyl, C1-34 alkoxy, Cs_34 cycloalkyl, C7_34 alkylaryl, or C6-34 aryl in a polymerization unit; and removing a color inducing species containing an isopropenyl phenyl-containing group from the

polymerization unit.