Method for manufacturing 1,4-bis (4-phenoxybenzoylbenzene) at an elevated temperature
A method for manufacturing 1,4-bis 4-phenoxybenzoyl) benzene, including: providing a reactant mixture including terephthaloyl chloride and diphenyl ether in a solvent; adding a Lewis acid to the reactant mixture, so as to obtain a product mixture; wherein the temperature of the reactant mixture is greater than 5° C. during at least part of the step of adding the Lewis acid to the reactant mixture.
1. A method for manufacturing 1,4-bis(4-phenoxybenzoyl)benzene, comprising:
providing a reactant mixture comprising terephthaloyl chloride and diphenyl ether in a solvent; and
adding a Lewis acid to the reactant mixture, so as to obtain a product mixture;
wherein the temperature of the reactant mixture is greater than 5° C. during at least part of the step of adding the Lewis acid to the reactant mixture.
2. The method of claim 1 , wherein the Lewis acid is aluminum trichloride.
3. The method of claim 1 , wherein the temperature of the reactant mixture is at least 15° C. during at least part of the step of adding the Lewis acid to the reactant mixture.
4. The method of claim 1 , wherein the temperature of the reactant mixture is at least 30° C. after 20% by weight of Lewis acid that has been added to the reactant mixture, relative to the total weight of Lewis acid added to the reactant mixture.
5. The method of claim 1 wherein the temperature of the reactant mixture increases during the step of adding the Lewis acid to the reactant mixture, from an initial temperature to a final temperature.
6. The method of claim 5 , wherein the initial temperature is from 0 to 80° C.
7. The method of claim 5 , wherein the final temperature is at least 30° C.
8. The method of claim 1 , wherein the temperature of the reactant mixture does not exceed 100° C. during the step of adding the Lewis acid.
9. The method of claim 1 , wherein the solvent is ortho-dichlorobenzene.
10. The method of claim 1 , wherein a temperature difference between a final temperature and an initial temperature is from 1 to 120° C.
11. The method of claim 1 , wherein the solvent is a separate solvent from the diphenyl ether.
12. The method of claim 1 , wherein the concentration of terephthaloyl chloride relative to a sum of the solvent, the terephthaloyl chloride, the diphenyl ether and the Lewis acid is from 2 to 25%.
13. The method of claim 1 , wherein the concentration of diphenyl ether relative to a sum of the solvent, the terephthaloyl chloride, the diphenyl ether and the Lewis acid is from 2 to 42%.
14. The method of claim 1 , wherein the weight ratio of terephthaloyl chloride to diphenyl ether introduced into the reactor is from 0.05 to 0.6.
15. The method of claim 1 , further comprising steps of:
mixing the product mixture with a protic solvent so as to provide a product slurry; and
separating 1,4-bis(4-phenoxybenzoyl)benzene from the product slurry and optionally washing.
16. A method of making a polyether ketone ketone polymer, comprising:
manufacturing 1,4-bis(4-phenoxybenzoyl)benzene according to the method of claim 1 ; and
reacting said 1,4-bis(4-phenoxybenzoyl)benzene with at least one difunctional aromatic acyl chloride.
17. A method for manufacturing 1,4-bis(4-phenoxybenzoyl)benzene, comprising:
providing terephthaloyl chloride, diphenyl ether, a solvent and a Lewis acid;
reacting the terephthaloyl chloride with the diphenyl ether in the solvent, and in the presence of the Lewis acid, so as to obtain a product mixture, wherein the temperature of the reacting mixture is greater than 5° C. during at least part of the duration of the reaction; and
recovering the product mixture comprising a 1,4-bis(4-phenoxybenzoyl)benzene-Lewis acid complex.