United States Patent Office Patented Mar
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3,799,916 United States Patent Office Patented Mar. 26, 1974 1. 2 with the alkyl haloformate present, which necessitates 3,799,916 using at least a stoichiometrically equivalent amount of WNYTL CHLORDE BASED POLYMERS PREPARED hydrogen peroxide amounting to not less than 1 mole BY N-STUNITATORS IN ACD MEDUM Michael Langsam, Allentown, Pa., assignor to Air of hydrogen peroxide for each two moles of alkyl halo Products and Chemicals, Inc., Allentown, Pa. formate. No Drawing. Filed June 19, 1972, Ser. No. 264,044 Although the process described in U.S. 3,022,281 did Int. C. C08f3/30, 15/06, 15/30 provide a solution to the problems of special storage and U.S. C. 260-87.1 10 Claims uncontrolled reaction rate, by eliminating the use of pre-manufactured peroxydicarbonates, other difficulties arose making the process less than satisfactory. It was ABSTRACT OF THE DISCLOSURE 10 found that polymers manufactured accordingly were not Granular vinyl chloride based polymers are manu in the desired granular form, but instead were of a fibrous factured in the presence of a peroxydicarbonate free consistency. Furthermore, it was discovered that other radical catalyst, which is prepared in-situ in an acid re commercially important resins, such as vinyl chloride action mixture. By initiating and maintaining polymeriza 5 vinyl acetate copolymers could not be successfully pre tion at a pH constantly maintained below 7 the need for pared in commercially acceptable quality, apparently due excess haloformate may be avoided without sacrificing to alkaline hydrolysis. product quality. Another approach to the problem is described in U.S. Pat. 3,575,945, which suggests using a stoichiometric ex BACKGROUND OF THE INVENTION cess of alkyl haloformate over hydrogen peroxide in order 20 to ensure preparation of the more commercially desirable The invention relates to a process for preparing com polymer granules. Here, as with the earlier described mercially desirable vinyl chloride based polymers, such process, the initial pH of the aqueous phase of the re as vinyl chloride homopolymers (PVC) and copolymers action mixture is always above 7. However, this more containing vinyl chloride and other comonomers, where recent process, though specifying an initial pH of 8.5 to in a peroxydicarbonate free-radical initiator is formed 25 11.7, gradually drifts to a pH below 7 as polymeriza in-situ while the reaction mixture is maintained at a pH tion proceeds, due to the generation of hydrogen halide below 7. The peroxydicarbonates prepared in the polym and the absence of an alkaline buffering agent. In spite erization process may be identified by the formula: of generally improved product quality, this later process 30 (U.S. 3,575,945) lacked desired flexibility, in terms of proportional ranges of reactants needed for in-situ prepa Ro-5-oo--or, ration of the peroxydicarbonate initiator. Here, as with wherein R1 and R2 are alkyl or alkenyl radicals. the earlier in-situ process, certain vinyl chloride based By constantly maintaining the pH of the reaction mix copolymers could not be readily prepared with acceptable ture in the acidic range from the time polymerization 35 quality. commences the ratio of organic haloformate to aqueous British Pat. 1,262,706, as in the case of the later U.S. soluble peroxide needed to prepare the catalyst can be patent, also provides for a process of manufacturing vinyl varied considerably without adversely affecting quality chloride polymers by in-situ mechanism using peroxydi of the resulting polymer. carbonate free-radical catalysts. Polymerization is also Polymerization of vinyl based monomers, such as vinyl 40 initiated in alkaline medium and subsequently falls to an chloride may be accomplished by means of a free-radical acid pH as the reaction progresses. polymerization initiator in a suspension, emulsion or bulk It has now been discovered that high quality granular polymerization system. Polymerization, itself, is initiated vinyl chloride based polymers can be prepared by means by the generation of free-radicals arising from the de which entail conducting polymerization at an initial pH composition of various organic peroxides, such as benzoyl 45 below 7 and maintaining it in the acid range throughout peroxide, lauroyl peroxide and the like. Peroxydicar the cycle. Furthermore, a broad, flexible range of re bonate type free-radical catalysts, as with other organic actants can be successfully employed for the in situ manu peroxy catalysts, if not given special handling by storing facture of the catayst without adversely affecting poly at sufficiently low temperatures or... if not metered into mer quality. The vinyl chloride based polymers are pre the reactor under carefully controlled conditions, can 50 pared by manufacturing peroxydicarbonate free-radical result in an uncontrollable rate of reaction endangering catalysts in the presence of at least one monomer, said both operators and equipment as well as adversely affect catalyst having the formula: ing the final product. Because peroxydicarbonate free-radical initiators stand O O out as a particularly preferred group of polymerization 55 R10-0-00--or, catalysts, one approach taken in correcting the foregoing wherein R1 and R2 are alkyl or alkenyl groups having problems was to produce such initiators in-situ rather from 1 to 7 carbon atoms. than by adding the pre-manufactured catalyst to the re Accordingly, it is a principal object of the present in actor. This process is described in U.S. Pat. 3,002,281, vention to provide a process for manufacturing high qual which provides for conducting the process in an alkaline 60 ity granular vinyl chloride based polymers wherein the medium above a pH 7 for binding the hydrogen halide polymerization initiator is prepared in-situ in a reaction liberated from the reaction of the peroxide and an alkyl mixture constantly maintained at a pH below 7. haloformate. The basic medium is maintained by use of It is a further object of the instant invention to provide an alkaline buffering agent suitable for producing and a flexible process allowing wide variation of proportional sustaining the pH above 7. This proces further provides 65 amounts of reactants for preparing in-situ peroxydicar for a sufficient amount of hydrogen peroxide to react bonate free-radical catalysts for polymerizing vinyl chlo 3,799,916 3 4. ride based monomers, without adversely affecting prod formate. The aqueous soluble peroxide may be, for exam uct quality. ple, hydrogen peroxide, alkali metal peroxides like so A still further object is to provide a process for manu dium and potassium or acid peroxides e.g. peracetic facturing vinyl chloride based copolymers by employing acid, performic acid, etc. The requirements in selecting a peroxydicarbonate free-radical catalyst, which catalyst, an appropriate peroxide are not critical, however, they itself, can be prepared in the reaction mixture. must, nevertheless, be miscible with the aqueous phase These and other objects, features and advantages of of the polymerization system. this invention will become apparent to those skilled in The haloformates may be represented by the formula: the art after a reading of the following more detailed description. O PREFERRED EMBODIMENTS OF O THE INVENTON Ro-5-x Broadly, the invention is directed to a process for pre paring vinyl chloride based polymers with a dialkyl or wherein R is alkyl or alkenyl and X is halogen, such dialkenyl peroxydicarbonate free-radical initiator, which as fluorine, chlorine, bromine or iodine. Alkyl and alkenyl, is prepared in-situ during polymerization of the mon in most instances, refer to radicals having from 1 to about omers. The process is adaptable to polymerization sys 7 carbon atoms, which may be both branched and straight tems having a water phase and a monomer phase in which chained groups, like methyl, ethyl, propyl, isopropyl, n each of the reactants required for preparing the catalyst 20 butyl, t-butyl, penty1, hexyl, allyl, propenyl and the like. is soluble in one of the two mentioned phases. However, higher radicals such as nonyl and lauryl are In carrying out the process, the peroxydicarbonate cat also included in this group. alyst is formed during the polymerization of one or more The following table illustrates but a few of the halo monomers by reacting a water soluble peroxide with an formates falling within the purview of the above formula: alkyl or alkenyl haloformate. The peroxide reactant is 25 soluble in the water phase and the haloformate is soluble TABLE I in the monomer phase. Included in the reaction mixture, R: X before polymerization commences, is an acidifier which CH3 - ----------------------------------- C maintains the aqueous phase of the mixture at a pH be C2H5 ---------------------------------- C low 7. The pH of the mixture remains acidic throughout 30 CH- was so wa way war mem.8 m me it mix a m i r vro - r * - we we I the reaction cycle. Because hydrogen halide is generated i-Cahi - --------------------------------- Br during the formation of the catalyst, additional acidifier t-C4Hg ----------------------------------- C is not needed to maintain the pH constantly below 7. CoH13 ----------------------------------- C However, most conveniently, an acid buffering agent can CH3- saw a sers w is a wers as alia a was a sm am am a mm ame a mass am no or rid no to row C be employed. 35 C2H5- ---------------------------------- F The peroxydicarbonate initiator decomposes after being Cahs ---------------------------------- Cl formed in the presence of the monomers, thus providing the necessary free-radicals to bring about polymerization C oH21 aws - a - - - - - A was a was sea a nea at am more mix mm ami me mi mum am-www. C of the monomers. The reaction commences by elevating In-situ preparation of the peroxydicarbonate catalysts the mixture to above ambient temperatures. 40 may be accomplished by incorporating the peroxide re As previously indictaed, the instant process finds wide actant into the aqueous phase of the reaction mixture spread use in polymerization systems containing both and the particular haloformate into the oil or monomer water and oil or monomer phases wherein vinyl based phase of the polymerization system.