Production of thermally stabilized aromatic polyesters

Claim 2

A bulk polymerization process for preparing a thermally stable wholly aromatic polyester comprising: heat condensing wholly aromatic precursors to form a prepolymer; incorporating into the reaction mixture a phosphite compound, after substantial formation of the prepolymer and before advancing the prepolymer, in an amount of between about 0.05 to 0.5 parts per hundred by weight; and advancing the prepolymer to form a thermally stable wholly aromatic polyester having the required degree of polymerization.

Claim 3

The process of claim 1 wherein the phosphite compound is incorporated into the reaction mixture in an amount effective for substantially maximizing thermal stability as characterized by rate of weight loss at 400° C. in air of a molding of the polyester.

Claim 4

The process of claim 2 wherein the amount of the phosphite incorporated into the reaction mixture is in inverse relation to the purity of the precursors.

Claim 5

The process of claim 1 wherein the phosphite is incorporated into the reaction mixture in the amount of about 0.1 to 0.25 parts per hundred.

Claim 6

The process of claim 2 wherein the phosphite is incorporated into the reaction mixture in the amount of about 0.125 parts per hundred.

Claim 7

The process of claim 1 wherein the addition of the phosphite compound takes place at the point of about 95% conversion.

Claim 8

The process of claim 1 wherein the advancing is at a temperature of at least about 340° C.

Claim 9

The process of claim 1 wherein the phosphite compound is incorporated into the reaction mixture in melt form.

Claim 10

The process of claim 1 wherein the polyester comprises recurrent moieties selected from the following formulas: ##STR7## where X is O, S, CO, NH, or SO 2 ; n is zero or one; and p+q+r+s+t+u is about 3 to 800.

Claim 11

The process of claim 1 wherein the aromatic polyester is an oxybenzoyl polyester.

Claim 12

The process of claim 10 wherein the precursors comprise an aromatic dicarboxylic acid, a hydroxycarboxylic acid and a aromatic diol.

Claim 13

The process of claim 11 wherein the precursors comprise terephthalic acid, hydroxybenzoic acid and dihydroxybiphenyl.

Claim 14

The process of claim 10 wherein the polyester is an oxybenzoyl polyester containing units of the formula: ##STR8## where p is about 3 to 600.

Claim 15

The process of claim 10 wherein the oxybenzoyl polyester is of the formula ##STR9## wherein R 1 is benzoyl, lower alkanoyl or hydrogen, R 2 is hydrogen, benzyl, lower alkyl or phenyl and p about 3 to 600.

Claim 16

The process of claim 1 wherein the polyester comprises recurrent moieties selected from the following formulas: ##STR10## where X is O or SO 2 ; m is zero or one; n is zero or one; q:r is about 10:15 to 15:10; p:q is about 1:100 to 100:1; p+q+r is about 3 to 600; the carbonyl groups of the moiety of formula VII or VIII are linked to the oxy groups of the moiety of formula VII or IX; and the oxy groups of the moiety of formula VII or IX are linked to the carbonyl groups of the moiety of formula VII or VIII.

Claim 17

The process of claim 1 wherein the polyester comprises recurrent units of the following formula: ##STR11##

Claim 18

The process of claim 1 wherein the phosphite compound is selected from the group consisting of aryl phosphite, alkyl phosphite, alkyl-aryl phosphite, diphosphite and polyphosphite.

Claim 19

The process of claim 17 wherein the phosphite compound is an organic phosphite.

Claim 20

The process of claim 18 wherein the phosphite compound is distearyl pentaerythritol diphosphite.

Claim 21

A bulk polymerization process for preparing a thermally stable wholly aromatic polyester comprising: heat condensing wholly aromatic precursors to form a prepolymer; incorporating into the reaction mixture a phosphite compound, after substantial formation of the prepolymer and before advancing the prepolymer, in an amount which is in inverse relation to the purity of the precusors and which is effective for substantially maximizing thermal stability as characterized by rate of weight loss at 400° C. in air of a molding of the polyester; and advancing the prepolymer to form a thermally stable wholly aromatic polyester having the required degree of polymerization.

Claim 22

A bulk polymerization process for preparing a thermally stable wholly aromatic polyester comprising: heat condensing wholly aromatic precursors to form a prepolymer; incorporating into the reaction mixture a phosphite compound, after substantial formation of the prepolymer and before advancing the prepolymer, in an amount which is in inverse relation to the purity of the precusors and which is effective for substantially maximizing thermal stability as characterized by rate of weight loss at 400° C. in air of a molding of the polyester; and advancing the prepolymer to form a thermally stable wholly aromatic polyester having the required degree of polymerization.

Claim 23

A bulk polymerization process for preparing a thermally stable wholly aromatic polyester comprising: heat condensing terephthalic acid, hydroxybenzoic acid and dihydroxybiphenyl in molar ratios of about 1:2:1 respectively, to form an oxybenzoyl prepolymer; incorporating distearyl pentaerythritol diphosphite into the reaction mixture at the point of about 95% conversion, in an amount of about 0.1 to 0.25 parts per hundred by weight; and advancing the oxybenzoyl prepolymer at a temperature of at least about 340° C. to form an oxybenzoyl polyester having the required degree of polymerization; whereby thermal stability of the polyester is substantially maximized as characterized by rate of weight loss at 400° C. in air of a molding of the polyester.

Claim 24

A bulk polymerization process for preparing a thermally stable wholly aromatic polyester comprising: heat condensing terephthalic acid, hydroxybenzoic acid and dihydroxybiphenyl in molar ratios of about 1:2:1 respectively, to form an oxybenzoyl prepolymer; incorporating distearyl pentaerythritol diphosphite into the reaction mixture at the point of about 95% conversion, in an amount of about 0.1 to 0.25 parts per hundred by weight; and advancing the oxybenzoyl prepolymer at a temperature of at least about 340° C. to form an oxybenzoyl polyester having the required degree of polymerization; whereby thermal stability of the polyester is substantially maximized as characterized by rate of weight loss at 400° C. in air of a molding of the polyester.

Claim 25

The process of claim 11 wherein formation of the wholly aromatic precursors is by alkanoylation with an acid anhydride.

Claim 26

The process of claim 18 wherein said organic phosphite is selected from the group consisting of distearyl pentaerythritol diphosphite, trisnonylphenyl phosphite, bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, diisodecyl pentaerythritol diphosphite and triphenyl phosphite.

Claim 27

A molding composition prepared according to the process of claim 1.

Claim 28

A molded article comprising the molding composition of claim 24.