Randomly branched bisphenol A polycarbonates. I. Molecular weight distribution modeling,interfacial synthesis,and characterization

Randomly branched bisphenol A polycarbonates (PCs) were prepared by interfacial polymerization methods to explore the limits of gel‐free compositions available by the adjustment of various composition and process variables. A molecular weight distribution (MWD) model was devised to predict the MWD, G, and weight‐average molecular weight per arm (M_w /arm) values based on the composition variables. The amounts of the monomer, branching agent, and chain terminator must be adjusted such that the weight‐average functionality of the phenolic monomers (F_OH ) was less than 2 to preclude gel formation in both the long‐ and short‐chain branched (SCB) PCs. Several series of SCB and long‐chain branched PCs were prepared, and those lacking gels showed molecular weights measured by gel permeation chromatography–UV and gel permeation chromatography–LS consistent with model calculations. In SCB PCs, the minimum M_w /arm that could be realized without gel formation depended on both composition (molecular weight, terminator type) and process (terminator addition point, coupling catalyst) variables. The minimum M_w /arm achieved in the low molecular weight series studied ranged from ～3300 to ～1000. The use of long chain alkyl phenol terminators gave branched PCs with lower glass‐transition temperatures but a higher gel‐free minimum M_w /arm. SCB PCs where M_w /arm was less than ～M_c spontaneously cracked after compression molding, a result attributed to their lack of polymer chain entanglements. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 560–570, 2000