Step-growth polymerizations polycarbonates

Nearly all of the polymers produced by step-growth polymerization contain heteroatoms and/or aromatic rings in the backbone. One exception is polymers produced from acyclic diene metathesis (ADMET) polymerization.22 Hydrocarbon polymers with carbon-carbon double bonds are readily produced using ADMET polymerization techniques. Polyesters, polycarbonates, polyamides, and polyurethanes can be produced from aliphatic monomers with appropriate functional groups (Fig. 1.1). In these aliphatic polymers, the concentration of the linking groups (ester, carbonate, amide, or urethane) in the backbone greatly influences the physical properties. 

Condensation polymers result from formation of ester or amide linkages between difunctional molecules. Condensation polymerization usually proceeds by step-growth polymerization, in which any two monomer molecules may react to form a dimer, and dimers may condense to give tetramers, and so on. Each condensation is an individual step in the growth of the polymer, and there is no chain reaction. Many kinds of condensation polymers are known. We discuss the four most common types polyamides, polyesters, polycarbonates, and polyurethanes. 

Step-growth polymerization is a very important method for the preparation of some of the most important engineering and specialty polymers. Polymers such as polyamides [7], poly(ethylene terephthalate) [8], polycarbonates [9], polyurethanes [10], polysiloxanes [11], polyimides [12], phenol polymers and resins, urea, and melamine-formaldehyde polymers can be obtained by step-growth polymerization through different types of reactions such as esterification, polyamidation, formylation, substitution, and hydrolysis. A detailed list of reaction types is shown in Table 3.2. 

In bulk polymerization, the only components of the formulation are monomers and the catalyst or initiator. When the polymer is soluble in the monomer, the reaction mixture remains homogeneous for the whole process. Examples of homogeneous bulk polymerization are the production of low-density polyethylene (LDPE), general purpose polystyrene and poly(methyl methacrylate) produced by free-radical polymerization, and the manufacture of many polymers produced by step-growth polymerization including poly(ethylene terephthalate), polycarbonate and nylons. In some cases (e.g., in the production of HIPS and acrylonitrile-butadiene-styrene (ABS) resins), the reaction mixture contains a preformed... 

Step-growth polymerization of phosgene and a diol gives a polycarbonate (Section 16.4C)... 

Step-Growth Polymerization of a Diacyl Chloride and a Diol Gives a Polycarbonate (Section 29.5C)... 

Important polymers that are produced by polyaddition are polyamide 6 (nylon) and all kinds of polyurethanes. In polycondensation one mol of a small molecule (typically H2O) is liberated per step of chain growths, important polymers that are produced by polycondensation are polyamide 6.6, poly(ethylene terephthalate) (PET), polycarbonate, polyarylate, and polysulfide. Step growth polymerization is usually slow, equilibrium limited and isothermal to slightly exothermic. Polyaddition and polycondensation reactions of monomers with three or more reactive end groups lead to three-dimensionally crosslinked resins. 

TPE (co)polymers from step-growth polymerization processes can be used as compatibilizers for melt blending of the respective polymers, e.g., polyesters with polyamides or polycarbonate. The interfacial chemical reactions between... 

The field of step-growth polymers encompasses many polymer structures and polymerization reaction types. This chapter attempts to cover topics in step-growth polymerization outside of the areas reviewed in the other introductory chapters in this book, i.e., poly(aryl ethers), dendritic polymers, high-temperature polymers and transition-metal catalyzed polymerizations. Polyamides, polyesters, polycarbonates, poly(phenylene sulfides) and other important polymer systems are addressed. The chapter is not a comprehensive review but rather an overview of some of the more interesting recent research results reported for these step-growth polymers, including new polymerization chemistries and mechanistic studies. 

As with polyesters, the amidation reaction of acid chlorides may be carried out in solution because of the enhanced reactivity of acid chlorides compared with carboxylic acids. A technique known as interfacial polymerization has been employed for the formation of polyamides and other step-growth polymers, including polyesters, polyurethanes, and polycarbonates. In this method the polymerization is carried out at the interface between two immiscible solutions, one of which contains one of the dissolved reactants, while the second monomer is dissolved in the other. Figure 5.7 shows a polyamide film forming at the interface between an aqueous solution of a diamine layered on a solution of a diacid chloride in an organic solvent. In this form interfacial polymerization is part of the standard repertoire of chemical demonstrations. It is sometimes called the nylon rope trick because of the filament of nylon produced by withdrawing the collapsed film. 

Condensation polymers, which are also known as step growth polymers, are historically the oldest class of common synthetic polymers. Although superseded in terms of gross output by addition polymers, condensation polymers are still commonly used in a wide variety of applications examples include polyamides (nylons), polycarbonates, polyurethanes, and epoxy adhesives. Figure 1.9 outlines the basic reaction scheme for condensation polymerization. One or more different monomers can be incorporated into a condensation polymer. 

The functional groups that typically participate in this type of polymerization are carboxyl, amine, and alcohol groups. Examples of step growth polymers include polyesters and nylons, which are often spun into fibers used to manufacture carpeting and fabrics, and polycarbonates, which are converted into compact discs, jewel cases, and the large bottles used in water coolers. 

This line of research was also extended to the solid-state polymerization of polycarbonate (Gross et al., 1999, 2000). Solid-state polymerizations involve the heating of a low-molecular-weight, semicrystalline step-growth... 

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