Polyester polycarbonates of particular diphenols

Details Polyester polycarbonates of particular diphenols Polyester polycarbonates of particular diphenols

2002-08-20

2004-02-24

Boykin, Terressa (Department: 1711)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

From phenol, phenol ether, or inorganic phenolate

C264S176100, C264S219000, C369S047360, C369S059110, C528S198000

Reexamination Certificate

active

06696543

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to thermoplastic molding compositions and in particular to compositions that contain polyester polycarbonates.
SUMMARY OF THE INVENTION
Polyestercarbonate resin is disclosed having a molecular structure that contains units derived from dicarboxylic acids and units derived from at least one diphenol selected from the group consisting of formula (IIa) and (IIb)
in which R
1
to R
7
each independently of the others represents hydrogen, halogen, a C
1
- to C
12
-alkyl radical, a C
6
- to C
19
-aryl radical, a C
7
- to C
12
-aralkyl radical. Also disclosed are the processes for their preparation, and their use in the production of molded articles and extrudates.
BACKGROUND OF THE INVENTION
In the course of new developments of optical data carriers, the requirements made of the carrier material are becoming increasingly more demanding and require the targeted development of new materials, for example, with the aim of achieving lower birefringence and lower water absorption, especially for the shorter writing and reading wavelengths which are to be expected in the future and which represent new challenges.
Low birefringence and low water absorption are not the only important properties for the substrate materials of optical data carriers; however, a combination of further properties that is as optimum as possible is required, such as high transparency, dimensional stability under heat, flowability, strength, high purity, low density, low contents of inhomogeneities or particulates and, especially, low costs of raw material and production.
Currently proposed materials for such applications fail to meet one or more of those requirements, and there is therefore a need for new materials for higher storage densities.
Polyester polycarbonates of linear or cyclic difunctional aliphatic carboxylic acids, diphenols and carbonate precursors are described, for example, in EP-A 433 716, U.S. Pat. No. 4,983,706 and U.S. Pat. No. 5,274,068, which describe various processes for their synthesis. It is known to the person skilled in the art that the incorporation of dicarboxylic acids leads to a lowering of the glass transition temperature and to an increase in flowability. For use as substrate materials, however, the lowered glass transition temperature means a limitation on the usability of the disks, because their climate resistance is reduced thereby. In addition, owing to the polar ester groups, such products have high water absorption, which is disadvantageous for use in optical data storage media. As EP-A 433 716 teaches, the carboxylic acids known for polyester polycarbonates can be incorporated in a significant amount in the interfacial process only by means of a complex, multi-stage procedure.
Polyester polycarbonates of linear and longer-chain dicarboxylic acids, in particular, also exhibit an undesirable tendency to crystallize, which has a particularly adverse effect in the case of very slow cooling, which may be necessary for the forming of very fine structures and to avoid process-related birefringence.
Dimer fatty acids as possible acid components in polyester polycarbonates are listed, for example, in DE-A 43 06 961, U.S. Pat. No. 5,134,220 and EP-A 443 058. A more precise definition of the acids to be used is not given. However, thermooxidative problems occur with non-hydrogenated dimer fatty acids. In addition, the customary commercial products contain more than 3 mol % of carboxylic acids having a basicity of three or more, which leads to a high viscosity at zero rate of shear, which is undesirable in the forming of microstructures such as pits or grooves. For that reason, such polyester polycarbonates have generally been regarded hitherto as unsuitable for substrates for optical data storage media.
Particular copolycarbonates based on spirobischromans and other diphenols are described in JP-A 10251395 and JP-A 08123050 as binders for photoreceptors. Spirobischroman-based polymers, for example polyethers or polycarbonates, are disclosed in JP-A 3162413, the latter spirochroman types are composed solely of hydroquinone and acetone, that is to say they have a strict 1,4 linkage.
The products described in the literature are polymers that have too high a glass transition temperature for use as the substrate material for optical data storage media.
Accordingly, the object underlying the invention is to provide polyester polycarbonates that do not have the disadvantages mentioned above but, in particular, have improved optical properties and may readily be prepared.
DETAILED DESCRIPTION OF THE INVENTION
Surprisingly, that object is achieved by polyester carbonates which are prepared by one of the conventional preparation processes for polycarbonates, characterized in that there are used in the preparation, in addition to the conventional carbonic acid derivatives, also dicarboxylic acids of formula (I)
HOOC—T—COOH  (I)
wherein T represents a branched or linear, saturated or unsaturated alkyl, arylalkyl or cycloalkyl moiety of from 8 to 40 carbons, preferably saturated linear alkyldicarboxylic acids having from 8 to 40 carbons, particularly preferably having from 12 to 36 carbons,
and, optionally proportionately in addition to the conventional diphenols, particular diphenols of formula (IIa) and/or (IIb)
in which
R
1
to R
7
each independently of the others represents hydrogen, halogen, a C
1
- to C
12
-alkyl radical, preferably a C
1
- to C
3
-alkyl radical, particularly preferably methyl, a C
6
- to C
19
-aryl radical, preferably a phenyl radical, a C
7
- to C
12
-aralkyl radical, preferably phenyl-C
1
- to C
4
-alkyl, particularly preferably hydrogen, halogen, preferably chlorine or bromine.
“Proportionately” in this context means that the particular diphenols of formulae IIa and IIb represent a proportion >0% of the total amount of diphenols used.
If no further conventional diphenols are used, the proportion of diphenols of formulae IIa and IIb is 100% of the diphenols used. In all other cases, the sum of the molar amounts of each of the individual diphenols is 100%. In such mixtures of diphenols, the proportion of diphenols of formulae IIa and IIb is preferably >10 mol %, particularly preferably >20 mol % and most particularly preferably >25 mol %. All conventional diphenols are suitable as diphenols used additionally in combination with the diphenols of formulae IIa and IIb.
Suitable dicarboxylic acids according to the invention are fatty acids, particularly preferably hydrogenated dimer fatty acids.
Examples of dicarboxylic acids of formula (I), or mixtures of such fatty acids, are
sebacic acid,
dodecanedioic acid,
hydrogenated dimer fatty acids, such as, for example, Pripol 1009 from Uniqema.
Pripol 1009 from Uniqema is a mixture of hydrogenated dimer fatty acids which, according to Uniqema, has approximately the following composition:
Structure
Data
(different isomers in each case)
Uniqema
ca. 30%

ca. 50%


ca. 15-20%

Dodecanedioic acid and Pripol 1009 are particularly preferred.
A small amount of mono- and poly-functionalized fatty acids may also be present. Products having very small contents of such components, especially having small contents of acids having a functionality of three or more, are especially suitable for the preparation of the polyester polycarbonates according to the invention. Preference is given, therefore, to dimer fatty acids having a content of less than approximately 1.5%, determined by gas chromatography, of acids having a functionality of three or more. The invention also includes mixtures of dimer fatty acids with other difunctional carboxylic acids having from 4 to 40 carbon atoms, such as adipic acid, sebacic acid, &agr;,&ohgr;-dodecanedicarboxylic acid, terephthalic acid, cis- or trans-9-octadecene-&agr;,&ohgr;-dicarboxylic acid, or hydroxycarboxylic acids having from 4 to 40 carbon atoms, such as salicylic acid or p-hydroxybenzoic acid.
Within the scope of the invention, the dimer fatty alcohols obtained from dimer fatty acids by reduction, or mixtures of ester

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