Maleic anhydride polyester resin

Separation of benzene/cyclohexane mixture is investigated most extensively. This is not surprising because separation of this mixture is very important in practical terms. Benzene is used to produce a broad range of valuable chemical products styrene (polystyrene plastics and synthetic rubber), phenol (phenolic resins), cyclohexane (nylon), aniline, maleic anhydride (polyester resins), alkylbenzenes and chlorobenzenes, drugs, dyes, plastics, and as a solvent. Cyclohexane is used as a solvent in the plastics industry and in the conversion of the intermediate cyclohexanone, a feedstock for nylon precursors such as adipic acid. E-caprolactam, and hexamethylenediamine. Cyclohexane is produced mainly by catalytic hydrogenation of benzene. The unreacted benzene is present in the reactor s effluent stream and must be removed for pure cyclohexane recovery. 

Used as fibres, particularly in textiles and film. Many other polyester polymers are of importance, e.g. unsaturated polyester resins from phthalic anhydride, propylene glycol and maleic anhydride used with reinforcement in boats, cars, etc. (alkyd resins). U.S. production 1983 1-7 megatonnes. 

Chlorendic Acid. Chlorendic acid [115-28-6] and its anhydride [115-27-5] are widely used flame retardants. Chlorendic acid is synthesized by a Diels-Alder reaction of maleic anhydride and hexachlorocyclopentadiene (see CyclopentadlENE and dicyclopentadiente) in toluene followed by hydrolysis of the anhydride using aqueous base (60). The anhydride can be isolated directly from the reaction mixture or can be prepared in a very pure form by dehydration of the acid. The principal use of chlorendic anhydride and chlorendic acid has been in the manufacture of unsaturated polyester resins. Because the esterification rate of chlorendic anhydride is similar to that of phthalic anhydride, it can be used in place of phthalic anhydride in commercial polyester... 

Glycols and epoxides react with maleic anhydride to give linear unsaturated polyesters (61,62). Ethylene glycol and maleic anhydride combine to form the following repeating unit. This reaction is the first step in industrially important polyester resin production (see Polyesters, unsaturated). 

Unsaturated polyester resins prepared by condensation polymerization constitute the largest industrial use for maleic anhydride. Typically, maleic anhydride is esterified with ethylene glycol [107-21-1] and a vinyl monomer or styrene is added along with an initiator such as a peroxide to produce a three-dimensional macromolecule with rigidity, insolubiUty, and mechanical strength. 

Maleic anhydride itself has few, if any, consumer uses but its derivatives are of significant commercial interest (161). The distribution of end uses for maleic anhydride is presented in Table 9 for the year 1992 (182). The majority of the maleic anhydride produced is used in unsaturated polyester resin (see Polyesters, unsaturated). Unsaturated polyester resin is then used in both glass-reinforced appHcations and in unreinforced appHcations as shown in Table 10 (183). 

The second largest use at 21% is for unsaturated polyester resins, which are the products of polycondensation reactions between molar equivalents of certain dicarboxyhc acids or thek anhydrides and glycols. One component, usually the diacid or anhydride, must be unsaturated. A vinyl monomer, usually styrene, is a diluent which later serves to fully cross-link the unsaturated portion of the polycondensate when a catalyst, usually a peroxide, is added. The diacids or anhydrides are usually phthahc anhydride, isophthahc acid, and maleic anhydride. Maleic anhydride provides the unsaturated bonds. The exact composition is adjusted to obtain the requked performance. Resins based on phthahc anhydride are used in boat hulls, tubs and spas, constmction, and synthetic marble surfaces. In most cases, the resins contain mineral or glass fibers that provide the requked stmctural strength. The market for the resins tends to be cychcal because products made from them sell far better in good economic times (see Polyesters,unsaturated). 

Uses. About 35% of the isophthahc acid is used to prepare unsaturated polyester resins. These are condensation products of isophthahc acid, an unsaturated dibasic acid, most likely maleic anhydride, and a glycol such as propylene glycol. The polymer is dissolved in an inhibited vinyl monomer, usually styrene with a quinone inhibitor. When this viscous hquid is treated with a catalyst, heat or free-radical initiation causes cross-linking and sohdification. A range of properties is possible depending on the reactants used and their ratios (97). 

Novel polyester compositions have also been derived from dicyclopentadiene [77-73-6] (DCPD), which can enter into two distinct reactions with maleic anhydride to modify properties for lower cost. These compositions have effectively displaced o-phthaUc resins in marine and bathtub laminating apphcations. 

Other minor raw materials are used for specific needs. Eumaric acid [110-17-8] the geometric isomer of maleic acid, is selected to maximize thermal or corrosion performance and is the sole acid esterified with bisphenol A diol derivatives to obtain optimum polymer performance. CycloaUphatics such as hydrogenated bisphenol A (HBPA) and cyclohexanedimethanol (CHDM) are used in selective formulations for electrical apphcations. TetrahydrophthaUc anhydride [85-43-8] (THPA) can be used to improve resiUence and impart useful air-drying properties to polyester resins intended for coating or lining apphcations. 

Polyester resins can also be rapidly formed by the reaction of propylene oxide (5) with phthaUc and maleic anhydride. The reaction is initiated with a small fraction of glycol initiator containing a basic catalyst such as lithium carbonate. Molecular weight development is controlled by the concentration of initiator, and the highly exothermic reaction proceeds without the evolution of any condensate water. Although this technique provides many process benefits, the low extent of maleate isomerization achieved during the rapid formation of the polymer limits the reactivity and ultimate performance of these resins. 

The temperature of esterification has a significant influence on isomerization rate, which does not proceed above 50% at reaction temperatures below 150°C. In resins produced rapidly by using propylene oxide and mixed phthaUc and maleic anhydrides at 150°C, the polyester polymers, which can be formed almost exclusively in the maleate conformation, show low cross-linking reaction rates with styrene. 

Dicylopentadiene Resins. Dicyclopentadiene (DCPD) can be used as a reactive component in polyester resins in two distinct reactions with maleic anhydride (7). The addition reaction of maleic anhydride in the presence of an equivalent of water produces a dicyclopentadiene acid maleate that can condense with ethylene or diethylene glycol to form low molecular weight, highly reactive resins. These resins, introduced commercially in 1980, have largely displaced OfXv o-phthahc resins in marine apphcations because of beneficial shrinkage properties that reduce surface profile. The inherent low viscosity of these polymers also allows for the use of high levels of fillers, such as alumina tfihydrate, to extend the resin-enhancing, fiame-retardant properties for apphcation in bathtub products (Table 4). 

Prior to 1975, benzene was catalytically oxidized to produce maleic anhydride, an intermediate in synthesis of polyester resins, lubricant additives, and agricultural chemicals. By 1986 all commercial maleic anhydride was derived from oxidation of / -butane. It is expected that / -butane will remain the feedstock of choice for both economic and environmental reasons. 

Polyesters. Unsaturated polyester resins based on DCPD, maleic anhydride, and glycols have been manufactured for many years. At least four ways of incorporating DCPD into these resins have been described (45). The resins are mixed with a cross-linking compound, usually styrene, and final polymerization is accompHshed via a free-radical initiator such as methyl ethyl ketone peroxide. 

The largest user of phenol in the form of thermosetting resins is the plastics industry. Phenol is also used as a solvent and in the manufacture of intermediates for pesticides, pharmaceuticals, and dyestuffs. Styrene is used in the manufacture of synthetic rubber and polystyrene resins. Phthalic anhydride is used in the manufacture of DMT, alkyd resins, and plasticizers such as phthalates. Maleic anhydride is used in the manufacture of polyesters and, to some extent, for alkyd resins. Minor uses include the manufacture of malathion and soil conditioners. Nitrobenzene is used in the manufacture of aniline, benzidine, and dyestuffs and as a solvent in polishes. Aniline is used in the manufacture of dyes, including azo dyes, and rubber chemicals such as vulcanization accelerators and antioxidants. 

Oxidation of n-hutane to maleic anhydride is becoming a major source for this important chemical. Maleic anhydride could also be produced by the catalytic oxidation of n-butenes (Chapter 9) and benzene (Chapter 10). The principal use of maleic anhydride is in the synthesis of unsaturated polyester resins. These resins are used to fabricate glass-fiber reinforced materials. Other uses include fumaric acid, alkyd resins, and pesticides. Maleic acid esters are important plasticizers and lubricants. Maleic anhydride could also be a precursor for 1,4-butanediol (Chapter 9). 

Maleic anhydride is important as a chemical hecause it polymerizes with other monomers while retaining the double bond, as in unsaturated polyester resins. These resins, which represent the largest end use of maleic anhydride, are employed primarily in fiber-reinforced plastics for the construction, marine, and transportation industries. Maleic anhydride can also modify drying oils such as linseed and sunflower. 

Unsaturated polyesters are a group of polymers and resins used in coatings or for castings with styrene. These polymers normally have maleic anhydride moiety or an unsaturated fatty acid to impart the required unsaturation. A typical example is the reaction between maleic anhydride and ethylene glycol ... 

A further type of ester resin is the unsaturated polyester where the unsaturation is built into the backbone by the use of maleic anhydride ... 

Since anhydrides are much more reactive than carboxylic acids, reaction kinetics is controlled by the second step. The scope and apphcations of this reaction are the same as direct polyesterification but are practically limited to the synthesis of unsaturated polyesters and alkyd resins from phtliahc and maleic anhydrides (see Sections 2.4.2.1 and 2.4.23). 

Alkyd resin synthesis. This synthesis consists of two steps. In the first step, a triglyceride oil is reacted at ca. 250°C with polyols, such as glycerol or pentaery-thritol, in tire presence of a basic catalyst to form a monoglyceride. In the second step, phthalic anhydride, with or without another dibasic acid such as maleic anhydride, is added to the reaction medium and reacted at high temperature. The resulting product is a branched polyester (Scheme 2.56). 

A description is given of a comparative study of the glycolysis of PETP waste soft drinks bottles by various mixtures of EG and DEG with subsequent polyesterification of the glycolysed products by maleic anhydride in order to obtain unsaturated polyesters suitable for the production of varnishes. The processing characteristics such as viscosity, exotherm temperatures of curing, compatibility of resins with monomers was investigated with respect to the type and amount of reactive monomers. The mechanical properties of varnishes produced were analysed. 13 refs. 

About 60% of the propylene oxide made is polymerized to polypropylene glycol and other polyethers for use in polyurethane foams and adhesives. Propylene glycol is also widely used in polyester resins based on maleic anhydride. 

The largest single use of maleic anhydride is in the preparation of unsaturated polyester resins. It is first esterihed with a polyalcohol (two or more hydroxyls) and then the double bond is copolymerized (crosslinked) with a vinyl monomer such as styrene to form a rigid structure. Such resins are usually reinforced with hberglass (FRP). Maleic anhydride is also used to make oil additives and agricultural chemicals. 

Unsaturated polyester resins based on maleic anhydride are widely used in coatings to manufacture boat hulls and truck caps and a variety of other uses where a smooth, weatherproof, hard-surfaced material is desired. Because these resin types are inherently brittle, hberglass is frequently added for reinforcement. Consumphon of unsaturated polyesters in the U.S. is well over a billion pounds per year, with about 50% going into construction and the marine industry. 

The polyester resin can be obtained by heating maleic anhydride and glycol at 150-200°C for 6-16 hours... 

Development of the third class, i.e. unsaturated polyester resins, remained rather slow until the late 1930s, but after commercial production of maleic anhydride by catalytic oxidation of benzene began in 1933, maleic anhydride and fumaric acid rapidly became the most important sources of unsaturated groups in polyesters. The mechanism of drying of these resins on their own and with the addition of drying oils (i.e. unsaturated compounds such as linseed oil) was... 

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