Process for producing polyester with metal phosphonic acid complex catalysts

Abstract

Disclosed is a method for the preparation of a polyester, which method comprises in a first step, reacting a dicarboxylic acid or a C 1 -C 4 dicarboxylic diester with a diol at a suitable temperature and pressure to effect esterification or transesterification to prepare a precondensate and in a second step, reacting the precondensate to effect polycondensation at a suitable temperature and pressure to prepare a high molecular weight polyester, where a metal phosphonic acid complex compound of the formula is employed in the first step, in the second step or in both the first and second steps as a reaction catalyst; and wherein n is 0, 1, 2, 3, 4, 5 or 6; p is an integer from 1 to 30; M is a metal selected from the group consisting of Li, Na, K, Cs, Be, Ca, Mg, Sr, Ba, Al, Sb, Cd, Mn, Fe, Co, Ni, Cu and Zn; v is the valency of the metal M and is 1, 2 or 3; q is an integer from 1 to 20 where q=2p/v; and R 1 is hydrogen, straight or branched chain alkyl of 1 to 36 carbon atoms, straight or branched chain alkenyl of 1 to 36 carbon atoms, cycloalkyl of 5 to 8 carbon atoms or aryl of 6 to 10 carbon atoms; or is said alkyl, alkenyl, cycloalkyl or aryl substituted by one to four hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino groups. The metal complex catalyst compound is in particular

1 . A method for the preparation of a polyester, which method comprises 
 in a first step, reacting a dicarboxylic acid or a C 1 -C 4  dicarboxylic diester with a diol at a suitable temperature and pressure to effect esterification or transesterification to prepare a precondensate and    in a second step, reacting the precondensate to effect polycondensation at a suitable temperature and pressure to prepare a high molecular weight polyester,    where a metal phosphonic acid complex compound of the formula                          is employed in the first step, in the second step or in both the first and second steps as a reaction catalyst; and    wherein    n is 0, 1, 2, 3, 4, 5 or 6;    p is an integer from 1 to 30;    M is a metal selected from the group consisting of Li, Na, K, Cs, Be, Ca, Mg, Sr, Ba, Al, Sb, Cd, Mn, Fe, Co, Ni, Cu and Zn;    v is the valency of the metal M and is 1, 2 or 3;    q is an integer from 1 to 20 where q=2p/v; and    R 1  is hydrogen, straight or branched chain alkyl of 1 to 36 carbon atoms, straight or branched chain alkenyl of 1 to 36 carbon atoms, cycloalkyl of 5 to 8 carbon atoms or aryl of 6 to 10 carbon atoms; or is said alkyl, alkenyl, cycloalkyl or aryl substituted by one to four hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino groups.    
     
     
         2 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6;  
 p is an integer from 1 to 30 where p=(v·q)/2;  
 M is a metal selected from the group consisting of Li, Na, K, Cs, Be, Ca, Mg, Sr, Ba, Al, Sb, Cd, Mn, Fe, Co, Ni, Cu and Zn;  
 v is the valency of the metal M and is 1, 2 or 3;  
 q is an integer from 1 to 20 where q=2p/v; and  
 R 2  and R 3  are independently hydrogen, hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino; and  
 R 4  is hydrogen or straight or branched chain alkyl of 1 to 8 carbons atoms.  
 
     
     
         3 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6;  
 p is an integer from 1 to 30 where p=(v·q)/2;  
 M is a metal selected from the group consisting of Li, Na, K, Cs, Be, Ca, Mg, Sr, Ba, Al, Sb, Cd, Mn, Fe, Co, Ni, Cu and Zn;  
 v is the valency of the metal M and is 1, 2 or 3;  
 q is an integer from 1 to 20 where q=2p/v; and  
 R 4  is hydrogen or straight or branched chain alkyl of 1 to 8 carbons atoms.  
 
     
     
         4 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       where 
 p is an integer from 1 to 30 where p=(v·q)/2;  
 M is a metal selected from the group consisting of Li, Na, K, Cs, Be, Ca, Mg, Sr, Ba, Al, Sb, Cd, Mn, Fe, Co, Ni, Cu and Zn;  
 v is the valency of the metal M and is 1, 2 or 3; and  
 q is an integer from 1 to 20 where q=2p/v.  
 
     
     
         5 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6;  
 p is an integer from 3 to 30;  
 q is an integer from 2 to 20 where q=2p/3; and  
 R 1  is hydrogen, straight or branched chain alkyl of 1 to 36 carbon atoms, straight or branched chain alkenyl of 1 to 36 carbon atoms, cycloalkyl of 5 to 8 carbon atoms or aryl of 6 to 10 carbon atoms; or is said alkyl, alkenyl, cycloalkyl or aryl substituted by one to four hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino groups.  
 
     
     
         6 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6;  
 R 1  is hydrogen, straight or branched chain alkyl of 1 to 36 carbon atoms, straight or branched chain alkenyl of 1 to 36 carbon atoms, cycloalkyl of 5 to 8 carbon atoms or aryl of 6 to 10 carbon atoms; or is said alkyl, alkenyl, cycloalkyl or aryl substituted by one to four hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino groups.  
 
     
     
         7 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6;  
 R 2  and R 3  are independently hydrogen, hydroxyl, halogen, straight or branched chain alkoxy of 1 to 8 carbon atoms, straight or branched chain alkyl of 1 to 8 carbon atoms or amino; and  
 R 4  is hydrogen or straight or branched chain alkyl of 1 to 8 carbons atoms.  
 
     
     
         8 . A method according to  claim 1  where the metal phosphonic acid complex compound is of the formula  
       
         
           
           
               
               
           
         
       
       wherein 
 n is 0, 1, 2, 3, 4, 5 or 6; and  
 R 4  is hydrogen or straight or branched chain alkyl of 1 to 8 carbons atoms.  
 
     
     
         9 . A method according to  claim 1  where the aluminum phosphonic acid complex compound is  
       
         
           
           
               
               
           
         
       
     
     
         10 . A method according to  claim 1  where a dicarboxylic acid is reacted with a diol to prepare a precondensate and where the dicarboxylic acid is terephthalic acid, isophthalic acid, o-phthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4′-dicarboxylic acid, succinic acid, maleic acid, glutaric acid, adipic acid, sebacic acid or a mixture thereof.  
     
     
         11 . A method according to  claim 1  where a dicarboxylic diester is reacted with a diol to prepare a precondensate and where the dicarboxylic diester is a C1-C4 dialkyl diester of terephthalic acid, isophthalic acid, o-phthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4′-dicarboxylic acid, succinic acid, maleic acid, glutaric acid, adipic acid, sebacic acid or a mixture thereof.  
     
     
         12 . A method according to  claim 10  where the diacid is terephthalic acid, isophthalic acid or 2,6-naphthalene dicarboxylic acid.  
     
     
         13 . A method according to  claim 11  where the diester is dimethyl terephthalate.  
     
     
         14 . A method according to  claim 1  where the diol is ethylene glycol, diethylene glycol, triethylene glycol, propane-1,3-diol, propane-1,2-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, 1,4-cyclohexanedimethanol, 3-methylpentane-2,4-diol, 2-methylpentane 1,4-diol, 2,2-diethylpropane-1,3-diol, 1,4-di-(hydroxyethoxy)benzene, 2,2-bis(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis-(3-hydroxyethoxyphenyl)propane, 2,2-bis-(4-hydroxypropoxyphenyl)ethane or a mixtures thereof.  
     
     
         15 . A method according to  claim 1  where the diol is ethylene glycol, 1,4-cyclohexanedimethanol or butane-1,4-diol.  
     
     
         16 . A method according to  claim 1  where the polyester is poly(ethylene terephthalate), poly(ethylene 2,6-naphthalene-2,6-dicarboxylate) or poly(1,4-butylene terephthalate).  
     
     
         17 . A method according to  claim 1  where the first step is performed at a temperature from about 200 to about 300° C.  
     
     
         18 . A method according to  claim 1  where the second step is performed at a temperature from about 250 to about 300° C. and at a pressure from about 10 to about 0.1 torr.  
     
     
         19 . A method according to  claim 1  where the catalyst is employed at a level from about 1 to about 1500 ppm by weight, based on the weight of dicarboxylic acid or dicarboxylic diester and diol.  
     
     
         20 . A method according to  claim 1  where the catalyst is employed at a level from about 1 to about 1000 ppm by weight, based on the weight of dicarboxylic acid or dicarboxylic diester and diol.