Multi-stage process for forming polyarylene sulfides

摘要

A multi-stage process and system for formation of a polyarylene sulfide is described. The multi-stage process can include at least three separate formation stages that can take place in three different reactors. The first stage of the formation process can include reaction of an alkali metal sulfide with an organic amide solvent to form a complex including a hydrolysis product of the solvent and an alkali metal hydrogen sulfide. The second stage of the formation process can include reaction of the complex formed in the first stage with a dihaloaromatic monomer to form a prepolymer, and the third stage can include further polymerization of the prepolymer with additional monomers to form the final product.

主权项

1. A multi-stage method for forming a polyarylene sulfide comprising:
providing a complex that includes an alkali metal organic amine carboxylic acid salt and an alkali metal hydrogen sulfide; carrying out a first polymerization reaction in a first reactor during which the complex is reacted with a dihaloaromatic monomer in the presence of an organic amide solvent to form a polyarylene sulfide prepolymer, wherein the first reactor is maintained at a pressure of from about 500 to about 1,600 kilopascals for at least a portion of the first polymerization reaction; thereafter, carrying out a second polymerization reaction in a second reactor during which the polyarylene sulfide prepolymer is reacted with a dihaloaromatic monomer and a sulfur-containing monomer to form the polyarylene sulfide; and removing vapor from the second reactor to maintain a pressure of less than about 1,500 kilopascals for at least a portion of the second polymerization reaction.