(12) Patent Application Publication (10) Pub. No.: US 2004/0171772 A1 Huffer Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2004/0171772 A1 Huffer Et Al US 2004.0171772A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2004/0171772 A1 Huffer et al. (43) Pub. Date: Sep. 2, 2004 (54) METHOD FOR PRODUCING Publication Classification HOMOPOLYMERS AND COPOLYMERS OF ISOBUTENE (51) Int. Cl." ........................................................ C08F 2/00 (52) U.S. Cl. ............................ 526/64; 526/348.7; 526/82 (76) Inventors: Stephan Huffer, Ludwigshafen (DE); Hans Peter Rath, Grunstadt (DE); (57) ABSTRACT Gabriele Lang, Mannheim (DE); Jens Kremeskotter, Mannheim (DE); Elmar Homo- and copolymers of isobutene are prepared by con Stockelmann, Grunstadt (DE) tinuous cationic polymerization of isobutene or mixtures of isobutene with ethylenically unsaturated comonomers in the Correspondence Address: presence of an initiator System comprising: Nixon & Vanderhye i) a Lewis acid Selected from covalent metal-halogen 1100 North Glebe Road compounds and covalent Semimetal-halogen com Arlington, VA 22201-4714 (US) pounds and (21) Appl. No.: 10/476,701 ii) at least one aprotic organic compound I having at least one functional group FG which forms a car (22) PCT Filed: May 24, 2002 bocation or a cationic complex with the Lewis acid under polymerization conditions (86) PCT No.: PCT/EP02/05731 in an organic Solvent inert with respect to the Lewis acid, by (30) Foreign Application Priority Data a proceSS in which the polymerization is carried out in a tubular flow-through reactor which has a plurality of curves May 25, 2001 (DE)........................................ 101.25583.7 having an alternating direction of curvature. 1 3 Patent Application Publication Sep. 2, 2004 Sheet 1 of 5 US 2004/0171772 A1 Figure 1 : 3 3C Figure 2: Patent Application Publication Sep. 2, 2004 Sheet 2 of 5 US 2004/0171772 A1 Figure 3: O.:---- D2 Figure 4: Patent Application Publication Sep. 2, 2004 Sheet 4 of 5 US 2004/0171772 A1 Figure 6: 3 %O 6 3C US 2004/0171772 A1 Sep. 2, 2004 METHOD FOR PRODUCING HOMOPOLYMERS and copolymers of isobutene, it is an object of the present AND COPOLYMERS OF SOBUTENE invention to provide a continuous proceSS for the preparation of these polymers. 0001. The present invention relates to a continuous pro ceSS for the preparation of homo- and copolymers of 0008 We have found that this object is achieved, Sur isobutene by cationic polymerization of isobutene or mix prisingly, by polymerizing isobutene or mixtures of tures of isobutene with ethylenically unsaturated comono isobutene with ethylenically unsaturated comonomers con mers which copolymerize with isobutene under the condi tinuously in a helical tube reactor in the presence of an tions of a cationic polymerization. initiator System Suitable for the living cationic polymeriza tion. 0002 Polyisobutene and its copolymers are used in a variety of ways, for example for the preparation of fuel and 0009. The present invention thus relates to a process for lubricant additives, as elastomers, as adhesives for adhesive the preparation of homo- and copolymers of isobutene by raw materials, as a base component of Sealing and stopping continuous cationic polymerization of isobutene or mixtures compounds, in coating Systems, in particular those having a of isobutene with ethylenically unsaturated comonomers in barrier action for water vapor, and in chewing gum compo the presence of an initiator System comprising: Sitions. Block copolymers of isobutene with Vinylaromatic 0010 i) a Lewis acid selected from covalent metal monomers have, for example, elastomeric properties and halogen compounds and covalent Semimetal-halo high-gas tightness. gen compounds and 0003. The cationic polymerization of isobutene is fre 0011 ii) at least one aprotic organic compound I quently effected by boron trifluoride catalysis, in particular having at least one functional group FG which forms by polymerization of isobutene in the presence of boron a carbocation or a cationic complex with the Lewis trifluoride complex catalysts. Processes for this purpose acid under polymerization conditions have been described comprehensively in the prior art (cf. for 0012 in an organic solventinert with respect to the Lewis example DE-A 27 02 604, EP-A 145 235, EP-A 481 297, acid, wherein the polymerization is carried out in a helical EP-A 671. 419, EP-A 628 575, EP-A 807 641 and WO tube reactor. 99/31151). 0013 Helical tube reactors are disclosed in WO 0004 Kennedy et al. describe the homo- and copolymer 98/08602, which is hereby incorporated by reference for ization of isobutene under the conditions of a living cationic further details. A person skilled in the art understands a polymerization (cf. J. P. Kennedy et al. in U.S. Pat. No. helical tube reactor as meaning a curved, tubular flow 4,946,899, U.S. Pat. No. 4,327,201, U.S. Pat. No. 5,169,914, through reactor having a Substantially circular or ellipsoidal EP-A 206 756, EP-A 265 053 and comprehensively in J. P. (tube) croSS Section, wherein said reactor (or the reaction Kennedy, B. Ivan, Designed Polymers by Carbocationic tube) has a plurality of curves directly in Succession and Macromolecular Engineering, Oxford University Press, having an alternating direction of curvature. New York 1991). The initiator system used for the cationic 0014. The direction of curvature is reversed preferably no polymerization comprises, as a rule, at least one Lewis later than when that distance of the center of gravity of the acid-metal halide complex as a catalyst and at least one tube croSS-Sectional area which has been passed through organic compound which forms a carbocation or a cationic from the beginning of a curve is 200 times the tube diameter. complex with the Lewis acid under the reaction conditions. The curve may comprise up to three revolutions about the 0005 Although the living cationic polymerization leads axis of curvature. to polymerS having high molecular uniformity and more 0015. In the case of an ellipsoidal cross section of the over, in contrast to the boron trifluoride complex catalysis, also permits the Specific preparation of block copolymers reactor, tube diameter is understood as meaning the mean and of terminally functionalized polymers, it has only been value of major and minor axes. of academic importance to date. This is presumably due, on 0016 Curves having an alternating direction of curvature the one hand, to the fact that it is difficult to control and, on is to be understood here as meaning a Sequence of curved the other hand, to its high requirement with respect to the tube segments, the respective next tube segment (Section of purity of the reagents used. the tube between two Successive reversals of curvature, for example the Sections between two points of interSection of 0006 Because it is difficult to control, the living cationic axes in FIG. 1 to 4 of WO 98/08602) leading in a different polymerization is usually carried out as a batch process. The direction, preferably the opposite direction, to the preceding reaction vessels used are the Stirred kettles customary for one, i.e. there is a reversal of the direction of curvature with this purpose. In addition, the prior German patent applica each curved tube Segment. tions P10061715.8 and P10061727.1 propose the use of conventional, helically wound tubular reactors, as also used, 0017 Preferably, the reversal of the direction of curva for example, in the polymerization of isobutene underboron ture occurs no later than when that distance of the center of trifluoride catalysis, for a continuous embodiment of the gravity of the tube cross-sectional area which has been passed through from the beginning of a curve is 150, in proceSS. particular 100, preferably 80, particularly preferably 50, 30 0007. The Applicant's own experiments have shown that or 25, times the tube diameter. This distance is in general at the molecular uniformity of the polymers obtained by living least 5, in particular from 10 to 150, especially from 10 to cationic polymerization, in particular when the reaction is 100, preferably from 10 to 80, particularly preferably from carried out continuously, is unsatisfactory. Since the molecu 10 to 50, from 10 to 40 or from 10 to 30, times the tube lar uniformity is an important quality criterion for homo diameter. US 2004/0171772 A1 Sep. 2, 2004 0.018. A curve may comprise not only a partial revolution in the application, for example in the form of tubes or rods. but also one revolution or up to two or three revolutions In the case of a winding about 2 parallel axes, for example, about the axis of curvature. The angle covered by the normal the arrangement shown in FIGS. 1, 2 and 5 results. If a vector of the main direction of flow of a curve until a change winding is implemented about a plurality of axes preferably in the direction of curvature is thus in general s 10800, arranged in a plane, a band-like or wall-like design results, preferably s720°, particularly preferably s5 3600°. as shown in FIGS. 3 and 4. 0019. The curves are preferably substantially sinusoidal 0027 According to another preferred embodiment of the curves. In the present case, Sinusoidal curves are to be process, a helical tube reactor which is designed as a understood as meaning all types of, preferably periodically winding about a plurality of axes passing Substantially repeating, curves Substantially in a plane. The following through the Vertices of a polygon, in particular an equilateral description relates to the graph (Sinusoidal curve) described polygon, and perpendicular to its Surface is used. The by the path of the center of gravity of the tube diameter of polygon may have an even or, preferably, an uneven number the curved tube. The ratio of amplitude of curvature (greatest of vertices, in particular at least 3 or 5 and preferably 7, 9 or distance from the graph to a Straight line passing through 11 (cf.
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