Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From phenol – phenol ether – or inorganic phenolate
Reexamination Certificate
2002-05-23
2003-12-09
Boykin, Terressa M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From phenol, phenol ether, or inorganic phenolate
C428S208000, C428S208000, C428S208000, C428S208000, C428S364000, C428S480000
Reexamination Certificate
active
06660826
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to polyester carbonates, to a process for the production of the polyester carbonates, to spin finishes for synthetic fibers containing the polyester carbonates as lubricants and to the use of the polyester carbonates as lubricants in spin finishes for synthetic fibers.
Immediately after the fiber forming process, manmade fibers are provided with finishes which are essential to the subsequent processing of the fibers. These finishes (cf. Ullmann's Encyclopädie der technischen Chemie, Vol. 23, pages 7-9, Verlag Chemie, Weinheim 1983) provide the fibers with the necessary surface slip between the fibers themselves and between the fibers and the guide elements of the spinning machines. In addition, spin finishes are generally expected to satisfy the following requirements: fiber cohesion, antistatic effect, good wetting of the fiber, heat resistance, no corrosion of metals, no deposits on the stretching and texturing elements, ready removability from the fibres and physiological compatibility. Since the spin finishes can enter the wastewater during their removal from the fibers, for example before dyeing, it is also desirable that they and above all the lubricants present in them in large quantities be readily biodegradable.
The lubricants in the spin finishes are supposed above all to provide the fibers with the necessary surface slip. In addition, the lubricants should be heat-resistant, non-corrosive, easy to remove from the fiber and physiologically safe so that the requirements the spin finishes are expected to meet are satisfied. Typical lubricants for spin finishes are vegetable, animal and mineral oils or even synthetic esters, silicones, polyethers, ethoxylated fatty acids and the like (cf. Ullmann's Encyclopädie der technischen Chemie, Vol. 23, pages 7-9, Verlag Chemie, Weinheim 1983).
In addition, spin finishes for synthetic fibers are expected to withstand severe heat stress as encountered in the texturing of polyester and polyamide fibers. Accordingly, heat-resistant ester oils, i.e. esters of higher fatty acids with long-chain fatty alcohols, are often used as lubricants in such spin finishes. Other suitable lubricants besides heat-resistant ester oils are polyethylene oxide/polypropylene oxide block copolymers which are known to the expert as “pluronics”. Pluronics are capable of depolymerizing completely at relatively high temperatures. This is of particular advantage in texturing because deposits on filaments and texturing elements are avoided. However, a disadvantage is that fragments of the pluronics, for example aldehydes, escape into the atmosphere during texturing which is harmful to man and the environment. In addition, pluronics have the serious disadvantage that they are virtually non-biodegradable.
German patent application DE-A41 13 889 describes water-soluble, biodegradable polycarbonates and their use as lubricants for synthetic yarns. These polycarbonates must contain
a) at least one polyalkylene glycol ether block,
b) at least one optionally ethoxylated fatty alcohol containing 6 to 22 carbon atoms and
c) a carbonic acid residue connecting a) to b).
Although these polycarbonates show acceptable thermal behavior, their surface slip properties—particularly at relatively high speeds in the machine processing of synthetic fibers—are in need of improvement.
European patent application EP-A-421 298 describes lubricant compositions which contain carbonic acid polyol esters and which are distinguished by their lubricating effect and low smoke emission. Industrial transmission oils, engine oils, lubricants for refrigerators and lubricants for fibers are mentioned as applications. The invention is particularly concerned with CFC-containing lubricant compositions for refrigerators.
U.S. Pat. No. 4,314,00 describes polycarbonates of a lower alcohol and one or more polyoxyalkylene blocks which may be used as lubricants for spin finishes. Although these polycarbonates show excellent solubility in water, their surface slip properties are unsatisfactory.
European patent application EP-A-146 234 relates to polycarbonates which may be obtained by reacting alcohols with cyclic carbonates in a decarboxylation reaction and which may be alkoxylated in a subsequent step. They are also suitable for use as lubricants in spin finishes.
Now, the problem addressed by the present invention was to provide spin finishes for synthetic fibers which would contain lubricants with improved properties in relation to known compounds. These lubricants would have good surface slip properties and would be readily soluble in water. In addition, the lubricants would have low friction coefficients on polyester fibers, particularly under the rigorous conditions of friction texturing.
It has been found that certain polyester carbonates satisfy the requirements mentioned above.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment, the present invention relates to polyester carbonates corresponding to general formula (I):
in which
R
1
and R
5
independently of one another represent linear or branched, saturated or unsaturated alkyl groups containing 6 to 21 carbon atoms,
R
2
and R
4
independently of one another represent alkyl groups containing 2 to 4 carbon atoms,
R
3
represents a saturated or unsaturated, linear or branched difunctional hydrocarbon radical containing 1 to 22 carbon atoms,
k has a value of 0 or 1 to 50,
l has a value of 1 to 300,
n has a value of 2 to 50 and
m has a value of 2 to 50.
The polyester carbonates of formula (I) according to the invention are preferably produced by reacting alkoxylated carboxylic acids with diols in the presence of dialkyl carbonates and basic catalysts. Accordingly, the present invention also relates to a process for the production of polyester carbonates corresponding to formula (I), characterized in that alkoxylated carboxylic acids corresponding to formula (II):
R
6
—CO
2
—(R
7
O)
a
—H (II)
are reacted with diols corresponding to formula (III):
HO—R
8
—OH (III)
and dialkyl carbonates corresponding to formula (IV):
R
9
O—CO—OR
10
(IV)
where R
6
is an alkyl group containing 6 to 21 carbon atoms, R
7
is a C
2
H
4
and/or C
3
H
6
group, R
8
is a difunctional alkyl group containing 1 to 22 carbon atoms and R
9
and R
10
independently of one another represent a methyl or ethyl group and a is a number of 2 to 50, in the presence of basic catalysts at temperatures of 60 to 200° C.
The reaction of compounds (II) to (IV) is preferably carried out by simultaneously reacting the three reactants. The more readily volatile alcohol of the carbonate (for example methanol or ethanol) is distilled off during the reaction, optionally together with excess dialkyl carbonate. As known to the expert, other lower-order polymers, for example dimer fatty acid ethoxylates, exist alongside the compounds of formula (I) under the described reaction conditions. In a preferred embodiment, the process according to the invention is carried out by reacting the starting compounds of formulae (II) to (IV) in a molar ratio of about 1:1:1 or in a molar ratio of about 2:1:2 in the manner described above in order to obtain the desired compounds of formula (I). Molar ratios of 2:1:4 are particularly preferred.
The starting compounds of the reaction, i.e. alkoxylated carboxylic acids of formula (II), are compounds known per se which may be prepared by any of the reactions of fatty acids with alkoxides known to the expert for this purpose. Carboxylic acids of formula (II) where the alkyl group R
6
contains 6 to 21 carbon atoms and the fatty acid has been reacted with 2 to 50 moles alkoxide are particularly preferred for the purposes of the present invention. Suitable acids for the alkoxylation are, for example, heptanoic, octanoic, nonanoic, decanoic, undecanoic, dodecanoic, tridecanoic, tetradecanoic, pentadecanoic, hexadecanoic, heptadecanoic, octadecanoic, octadecane-12-oleic, nonadecanoic and eicosanoic acid. Besides the saturated fatty acids described here, it is also possib
Becker Wolfgang
Bialas Norbert
Birnbirch Paul
Mathis Raymond
Tenhaef Rolf
Boykin Terressa M.
Cognis Deutschland GmbH & Co. KG
Drach John E.
Trzaska Steven J.
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