Method of preparing ester-substituted diaryl carbonates

Organic compounds -- part of the class 532-570 series – Organic compounds – Carbonate esters

Reexamination Certificate

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C558S270000

Reexamination Certificate

active

10984318

ABSTRACT:
The present invention relates to an interfacial method of preparing ester-substituted diaryl carbonates. The method includes the steps of: forming a reaction mixture comprising phosgene, an ester-substituted phenol, an organic solvent, and a catalyst selected from the group consisting of a tertiary amine catalyst and a phase transfer catalyst, said reaction mixture having an organic phase and an aqueous phase, wherein said aqueous phase has a brine strength; allowing the reaction mixture to react wherein during the reaction, (i) the aqueous phase has a pH, and the pH is adjusted, if necessary, by the addition of an alkali metal hydroxide solution in amounts such that the pH is greater than or equal to 9.0 during at least some portion of the reaction, and (ii) the brine strength of the aqueous phase is adjusted, if necessary, by varying the concentration of the alkali metal hydroxide solution being added to maintain the pH such that the brine strength is between 15% and a saturated brine solution during at least some portion of the reaction: thereby forming an ester-substituted diaryl carbonate, wherein the reaction mixture is formed with less than 15% water of formulation, and wherein the brine strength is maintained at or above 15% and the pH is maintained at or above 9 for a sufficient portion of the process that the ester-substituted diaryl carbonate is formed with a conversion of at least 90% and a selectivity of at least 98%.

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