Preparation of a high molecular weight poly(arylene sulfide ketone)

Abstract

A process, and product produced therefrom, for preparing a high molecular weight poly(arylene sulfide ketone) from the reaction product of an alkali metal bisulfide with an alkali metal hydroxide, employing molar excess of alkali metal bisulfide with respect to the alkali metal hydroxide. A process, and product produced therefrom, for preparing a high molecular weight poly(arylene sulfide ketone) employing an alkali metal sulfide and an alkali metal hydrosulfide, wherein the alkali metal .[.sulfide.]. .Iadd.hydrosulfide .Iaddend.is added in a molar excess with respect to the alkali metal .[.hydrosulfide.]. .Iadd.sulfide.Iaddend..

I claim: 
     
       1. A method for preparing a poly(arylene sulfide ketone) comprising: contacting in a reaction mixture (a) at least one polyhalobenzophenone, employing about .[.1.004:1 to about 1.038:1 molar ratios.]. .Iadd.0.004 to about 0.038 molar excess .Iaddend.of alkali metal hydrosulfide relative to said polyhalobenzophenone, and at least one of (b) or (c), wherein (b) is at least one alkali metal sulfide and at least one alkali metal hydrosulfide, and (c) is at least one alkali metal hydroxide and at least one alkali metal hydrosulfide, under polymerization conditions effective for producing the poly(arylene sulfide ketone);   
     
     
       2. The method of claim 1, wherein the polyhalobenzophenone comprises a dihalobenzophenone, and the reaction mixture includes a polar reaction medium. 
     
     
       3. The method of claim 2, employing .[.the.]. .Iadd.about 0.01 to about 0.035 molar excess of said .Iaddend.alkali metal hydrosulfide .[.in a ratio of about 1.01:1 to about 1.035:1.]. relative to said polyhalobenzophenone, .Iadd.and said .Iaddend.alkali metal hydroxide .[.and.]. .Iadd.or said .Iaddend.alkali metal sulfide. 
     
     
       4. The method of claim 2, wherein the alkali metal hydrosulfide comprises sodium hydrosulfide, the alkali metal hydroxide comrpises sodium hydroxide, the dihalobenzophenone comprises 4,4'dichlorobenzophenone, and the polar reaction medium comprises N-methyl-2-pyrrolidone. 
     
     
       5. The method of claim 4, wherein the poly(arylene sulfide ketone) is represented by repeating units of the structural formula: ##STR4## 
     
     
       6. The method of claim 1, wherein the poly(arylene sulfide ketone) comprises poly(phenylene sulfide ketone). 
     
     
       7. The method of claim 6, employing said (c), wherein said alkali hydrosulfide is sodium hydrosulfide, and said alkali metal hydroxide is sodium hydroxide. 
     
     
       8. The method of claim 6, wherein the poly(phenylene sulfide ketone) exhibits an inherent viscosity of at least about 0.48 measured at 30° C. in a #200 viscometer using an 0.5 weight percent solution in concentrated H 2  SO 4 . 
     
     
       9. The method of claim 8, wherein the poly(phenylene sulfide ketone) exhibit an inherent viscosity of about 0.55 to about 0.77. 
     
     
       10. The method of claim 1, wherein the polymerization conditions include a temperature of about 175° C. to about 350° C., a pressure of about 0 psig to about 200 psig, and a reaction time of about 1 hour to about 72 hours. 
     
     
       11. The method of claim 1, employing said (b), wherein the alkali metal hydrosulfide is present in a .[.stoichiometric.]. .Iadd.molar .Iaddend.excess of about .[.1.004:1 to about 1.038:1.]. .Iadd.0.004 to about 0.038 .Iaddend.over the alkali metal sulfide. 
     
     
       12. The method of claim 11, wherein the alkali metal .[.sulfide.]. .Iadd.hydrosulfide .Iaddend.is brought together with the akali metal .[.hydrosulfide at.]. .Iadd.sulfide in .Iaddend.a molar .[.ratio.]. .Iadd.excess .Iaddend.of about .[.1.01:1 to about 1.035:1.]. .Iadd.0.01 to about 0.035.Iaddend..