WO2010122881A1 - 固体状ポリグリコール酸系樹脂組成物の製造方法 - Google Patents
固体状ポリグリコール酸系樹脂組成物の製造方法 Download PDFInfo
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- WO2010122881A1 WO2010122881A1 PCT/JP2010/055751 JP2010055751W WO2010122881A1 WO 2010122881 A1 WO2010122881 A1 WO 2010122881A1 JP 2010055751 W JP2010055751 W JP 2010055751W WO 2010122881 A1 WO2010122881 A1 WO 2010122881A1
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- resin composition
- polyglycolic acid
- acid resin
- solid
- pga
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
- C08G63/06—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from hydroxycarboxylic acids
- C08G63/08—Lactones or lactides
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/88—Post-polymerisation treatment
- C08G63/90—Purification; Drying
Definitions
- the present invention relates to a method for producing a solid polyglycolic acid resin composition, and more particularly to a method for producing a solid polyglycolic acid resin composition having excellent thermal stability.
- Polyglycolic acid-based resins are attracting attention as biodegradable polymer materials that have a low environmental impact because they are excellent in microbial degradability and hydrolyzability.
- This polyglycolic acid resin is molded into a granular polyglycolic acid resin composition such as pellets through the steps of melt-kneading, cooling and solidifying, and granulating by adding a heat stabilizer, extrusion molding and injection Used in various molding processes such as molding.
- Patent Document 1 a polyglycolic acid resin composition in which a molten polyglycolic acid resin composition having a reduced glycolide content is cooled by an aqueous cooling medium such as water. It is disclosed that the hydrolysis of the polyglycolic acid resin can be suppressed even when the molten polyglycolic acid resin composition is water-cooled.
- the resulting molded product may be colored. It was.
- the present invention has been made in view of the above-described problems of the prior art, and an object of the present invention is to provide a method for producing a solid polyglycolic acid-based resin composition having excellent thermal stability in which coloring due to heat hardly occurs.
- the present inventors have colored by heat when the solid polyglycolic acid resin composition obtained by cooling with water is used for molding processing involving heating. Is found to be sodium ions contained in the solid polyglycolic acid resin composition, and further, coloring due to heat is caused by sodium ions contained in the cooling water in the cooling step.
- the present invention has been completed by finding that it is generated when the amount of sodium ions in the solid polyglycolic acid resin composition absorbed by the resin composition exceeds a predetermined amount.
- the method for producing a solid polyglycolic acid resin composition of the present invention comprises producing a solid polyglycolic acid resin composition including a cooling step of cooling the molten polyglycolic acid resin composition with an aqueous medium.
- a method In the cooling step, the molten polyglycolic acid resin composition is brought into contact with the aqueous medium so that the sodium ion concentration in the obtained solid polyglycolic acid resin composition is less than 100 mass ppb. This is a cooling method.
- the aqueous medium used in the present invention is preferably ion-exchanged water, more preferably ion-exchanged water having a sodium ion concentration of less than 30 ppm by mass, particularly ion-exchanged water obtained by treatment with a hydrogen ion-type ion exchange resin. preferable.
- the molten polyglycolic acid resin composition in the cooling step, is ion-exchanged so that the water content of the obtained solid polyglycolic acid resin composition is less than 500 ppm by mass. It is preferable to cool by bringing it into contact with water, and it is more preferable to cool the polyglycolic acid resin composition in the molten state by bringing it into contact with mist ion-exchanged water.
- the solid polyglycolic acid resin composition thus obtained may be granulated.
- the present inventors infer as follows. That is, in the method for producing a solid polyglycolic acid resin composition of the present invention, an aqueous medium having a low sodium ion concentration is contacted as a cooling medium, or the aqueous medium is absorbed by the polyglycolic acid resin composition during cooling. Since the aqueous medium is brought into contact with the aqueous medium so that the amount thereof is reduced, the polyglycolic acid-based resin composition absorbs less sodium ions upon contact with the aqueous medium. It is presumed that the solid polyglycolic acid resin composition obtained is not concentrated on the surface of the acid resin composition and does not color even when heated.
- the sodium ion concentration in the obtained solid polyglycolic acid-based resin composition can be reduced without performing treatment for removing sodium ions after the cooling step, and coloring due to heat can be achieved. It becomes possible to produce a solid polyglycolic acid-based resin composition excellent in thermal stability that hardly occurs.
- the molten polyglycolic acid resin composition used in the present invention contains at least a polyglycolic acid resin (hereinafter referred to as “PGA resin”).
- PGA resin composition contains at least a polyglycolic acid resin (hereinafter referred to as “PGA resin”).
- PGA resin polyglycolic acid resin
- the molten PGA-based resin composition may be a thermal stabilizer and / or carboxyl. Those containing a base sealant are preferred.
- the molten state containing various additives such as plasticizers, heat ray absorbers, ultraviolet absorbers and pigments, and various fillers such as glass fibers, carbon fibers, metal fibers, natural fibers, synthetic fibers and inorganic particles.
- various additives such as plasticizers, heat ray absorbers, ultraviolet absorbers and pigments, and various fillers such as glass fibers, carbon fibers, metal fibers, natural fibers, synthetic fibers and inorganic particles.
- various additives such as plasticizers, heat ray absorbers, ultraviolet absorbers and pigments, and various fillers such as glass fibers, carbon fibers, metal fibers, natural fibers, synthetic fibers and inorganic particles.
- various fillers such as glass fibers, carbon fibers, metal fibers, natural fibers, synthetic fibers and inorganic particles.
- PGA-based resin compositions can also be used.
- PGA resin The PGA resin used in the present invention is represented by the following formula (1): — [O—CH 2 —C ( ⁇ O)] — (1)
- a glycolic acid homopolymer consisting only of glycolic acid repeating units represented by the formula hereinafter referred to as “PGA homopolymer”, including a ring-opened polymer of glycolide which is a bimolecular cyclic ester of glycolic acid), And a polyglycolic acid copolymer containing a glycolic acid repeating unit (hereinafter referred to as “PGA copolymer”).
- PGA-type resin may be used individually by 1 type, or may use 2 or more types together.
- Copolymers used together with glycolic acid monomers in preparing the PGA copolymer include ethylene oxalate (ie, 1,4-dioxane-2,3-dione), lactides, lactones (eg, ⁇ -Propiolactone, ⁇ -butyrolactone, ⁇ -pivalolactone, ⁇ -butyrolactone, ⁇ -valerolactone, ⁇ -methyl- ⁇ -valerolactone, ⁇ -caprolactone, etc.) carbonates (eg trimethylene carbonate, etc.), ethers ( For example, cyclic monomers such as 1,3-dioxane, ether esters (eg, dioxanone), amides (eg, ⁇ -caprolactam); lactic acid, 3-hydroxypropanoic acid, 3-hydroxybutanoic acid, 4-hydroxy Hydroxy acids such as butanoic acid and 6-hydroxycaproic acid A substantially equimolar mixture of an aliphatic dio
- the content of the glycolic acid repeating unit represented by the formula (1) is preferably 70% by mass or more, more preferably 80% by mass or more, and further preferably 90% by mass or more. 100 mass% is particularly preferable.
- the content of the glycolic acid repeating unit is less than the lower limit, heat resistance and gas barrier properties tend to decrease.
- sodium ions are not contained in the PGA resin used, but coloration due to heat does not occur. If it is the range, a trace amount sodium ion may be contained. Examples of such sodium ions include those caused by contamination during the production of a PGA-based resin.
- the weight average molecular weight of the PGA resin is preferably 30,000 to 800,000, more preferably 50,000 to 500,000.
- the weight average molecular weight of the PGA-based resin is less than the lower limit, the mechanical strength of the PGA-based resin molded product tends to be lowered. On the other hand, when it exceeds the upper limit, melt extrusion and molding tend to be difficult.
- the weight average molecular weight is a polymethylmethacrylate conversion value measured by gel permeation chromatography (GPC).
- heat stabilizer examples include a phosphate ester having a pentaerythritol skeleton structure (or a cyclic neopentanetetrayl structure) and a (sub) phosphate alkyl ester having at least one hydroxyl group and at least one alkyl ester group. At least one phosphorus compound selected from the group consisting of, specifically, a phosphorus compound described in WO 2004/087813 is preferable.
- the addition amount of such a heat stabilizer is preferably 0.003 to 3 parts by mass, more preferably 0.005 to 1 part by mass with respect to 100 parts by mass of the PGA resin.
- the addition amount of the heat stabilizer When the addition amount of the heat stabilizer is less than the lower limit, the obtained solid PGA resin composition tends to be colored by heat. On the other hand, when the addition amount exceeds the upper limit, the addition effect tends to be saturated, and cooling. Sometimes it elutes into the aqueous medium, leading to contamination of the cooling medium.
- the heat stabilizer used does not contain sodium ions, but coloration due to heat does not occur. If it is the range, a trace amount sodium ion may be contained. Examples of such sodium ions include those caused by contamination during the production of a heat stabilizer.
- a thermal stabilizer having a sodium ion concentration of 0 mass ppb or more and less than 100 mass ppb in the present invention.
- the carboxyl group-capping agent used in the present invention has a function of capping a carboxyl group and is known as a water resistance improver for aliphatic polyesters such as polylactic acid (for example, JP-A-2001-261797).
- carbodiimide compounds including monocarbodiimide and polycarbodiimide such as N, N-2,6-diisopropylphenylcarbodiimide, 2,2′-m-phenylenebis (2- Oxazoline), 2,2′-p-phenylenebis (2-oxazoline), 2-phenyl-2-oxazoline, styrene / isopropenyl-2-oxazoline, and the like, 2-methoxy-5,6-dihydro- Oxazine compounds such as 4H-1,3-oxazine, N-glycidylphthaly De, cyclohexene oxide, and the like epoxy compounds such as triglycidyl isocyanurate.
- carboxyl group-capping agents may be used alone or in combination of two or more. Of such carboxyl group-capping agents, carbodiimide compounds and epoxy compounds are preferred.
- the addition amount of the carboxyl group sealing agent is preferably 0.01 to 10 parts by weight, more preferably 0.1 to 2 parts by weight, and more preferably 0.3 to 1 part by weight with respect to 100 parts by weight of the PGA resin. Particularly preferred.
- the addition amount of the carboxyl group-capping agent is less than the lower limit, the water resistance of the obtained solid PGA resin composition tends to be lowered.
- the upper limit is exceeded, the addition effect is saturated and obtained.
- the resulting solid PGA resin composition tends to be colored.
- the carboxyl group-capping agent to be used does not contain sodium ions.
- a trace amount of sodium ions may be included as long as it does not occur. Examples of such sodium ions include those caused by contamination during the production of a carboxyl group-capping agent.
- molten PGA resin composition used in the present invention, various additives such as a heat stabilizer and a carboxyl group blocking agent are added to a PGA resin obtained by a conventionally known method as necessary, and this mixture is added. It can be manufactured by melt-kneading.
- the heating temperature during melt kneading is preferably 230 to 280 ° C, more preferably 240 to 270 ° C. If the heating temperature is less than the lower limit, the effects of adding various additives such as a heat stabilizer and a carboxyl group-capping agent tend not to be sufficiently exhibited. On the other hand, if the heating temperature exceeds the upper limit, a solid PGA resin composition is obtained. Tends to be colored.
- the melt kneading method is not particularly limited, and examples thereof include a method using a stirrer, a continuous kneader, and an extruder. Among them, a short time treatment is possible, and a smooth transition to the subsequent cooling process is possible. From the viewpoint of being, a method using an extruder (particularly, a twin-screw kneading extruder) is preferable.
- a solid PGA-based resin composition with little coloring can be obtained efficiently, a method described in International Publication No. 2007/086563, that is, ring-opening polymerization of glycolide to synthesize a partial polymer, A polymer obtained by continuously introducing a melt of this partial polymer into a biaxial agitator to obtain a partially pulverized solid polymer, followed by solid-phase polymerization of the solid pulverized polymer of this partial polymer. It is preferable to produce a molten PGA resin composition by a method of adding a heat stabilizer to the mixture and melt-kneading.
- the glycolide content in the molten PGA resin composition is reduced to 0 by the method described in International Publication No. 2007/034805. It is preferable to set it to 6 mass% or less, and it is more preferable to set it to 0.3 mass% or less.
- the present invention is a method for obtaining a solid PGA resin composition by cooling the molten PGA resin composition thus obtained with an aqueous medium. That is, in the method for producing a solid PGA resin composition of the present invention, a molten PGA system is used so that the sodium ion concentration in the finally obtained solid PGA resin composition is less than 100 mass ppb. The resin composition is brought into contact with the aqueous medium and cooled (cooling step). Thereafter, if necessary, the obtained solid PGA resin composition is granulated using a pelletizer, a crusher, or the like to obtain a granular PGA resin composition such as a pellet.
- the sodium ion concentration in the finally obtained solid PGA resin composition is preferably 50 mass ppb or less, more preferably 30 mass ppb or less, and 20 mass It is particularly preferably ppb or less, and most preferably 10 mass ppb or less.
- the molten PGA resin composition is brought into contact with an aqueous medium as described above to cool and solidify, thereby reducing the sodium ion concentration in the PGA resin composition, Further, even when sodium ions in the aqueous medium are absorbed into the PGA resin composition and the sodium ion concentration increases, the increase amount (that is, in the solid polyglycolic acid resin composition obtained in the cooling step).
- the difference (Cs ⁇ Cm) between the sodium ion concentration (Cs) and the sodium ion concentration (Cm) in the molten polyglycolic acid resin composition is preferably 30 mass ppb or less. Preferably it can be 20 mass ppb or less, Most preferably, it can be 10 mass ppb or less. Thereby, it becomes possible to suppress the coloring by the heat
- a method of contacting the molten PGA resin composition with the aqueous medium a method of immersing the molten PGA resin composition in the aqueous medium, an aqueous solution using a sprayer or the like to the molten PGA resin composition
- Examples thereof include a method of spraying a medium and bringing a mist-like aqueous medium into contact, and a method of bringing a vapor of the aqueous medium into contact with a molten PGA resin composition. More specifically, the molten PGA resin composition discharged from the extruder is immersed in a bath filled with an aqueous medium, and the molten PGA resin composition discharged from the extruder is conveyed by a conveyor. Examples thereof include a method of spraying an aqueous medium with a sprayer while spraying or spraying vapor of the aqueous medium.
- ion-exchanged water As the aqueous medium used in the present invention, ion-exchanged water is preferable.
- ion-exchanged water tap water or industrial water is treated with a cation exchange resin such as a hydrogen ion type ion exchange resin or a sodium ion type ion exchange resin. Is mentioned.
- the sodium ion concentration in the ion-exchanged water is not particularly limited, but is preferably less than 30 ppm by mass, more preferably less than 20 ppm by mass, and particularly preferably less than 10 ppm by mass.
- Examples of such ion exchange water having a low sodium ion concentration include ion exchange water treated with a hydrogen ion type ion exchange resin.
- the contact method between the molten PGA resin composition and the ion-exchanged water is not particularly limited.
- the method for contacting the molten PGA resin composition with ion-exchanged water has a water content of the obtained solid PGA resin composition of less than 500 ppm by mass (preferably 250).
- the contact method is limited to a mass ppm).
- Examples of the contact method for reducing the water content include a method of bringing a molten PGA resin composition into contact with mist ion exchange water or water vapor of ion exchange water.
- ion exchange water having a sodium ion concentration within the above range is made into a mist using a sprayer or the like and brought into contact with the molten PGA resin composition.
- the temperature of the aqueous medium is not particularly limited as long as it is a temperature at which the molten PGA resin composition can be cooled, and is usually 5 ° C. to 100 ° C., and is preferably near room temperature from the viewpoint of economy and cooling efficiency. It is not necessary to cool the aqueous medium in order to suppress an increase in temperature due to contact with the molten PGA resin composition. In particular, in the case where granulation such as pelletization is performed after cooling, it is preferable to proceed with crystallization of the PGA resin composition in this cooling step in order to proceed smoothly.
- the temperature of the aqueous medium is set to PGA.
- the glass transition temperature (Tg) of the resin composition is preferably within a range of ⁇ 30 ° C.
- the contact time between the molten PGA resin composition and the aqueous medium is not particularly limited as long as the molten PGA resin composition can be sufficiently cooled, but sodium ions produced by the PGA resin composition are not limited. From the viewpoint of reducing the amount of absorption, it is preferable that it is as short as possible.
- the contact by immersion is preferably 1 to 20 seconds, and more preferably 2 to 15 seconds.
- the contact by spraying it depends on the spraying amount per unit time. For example, when cooling 200 g of a molten PGA resin composition with an aqueous medium having a spraying amount of 100 to 3000 g / min, 2 to 60 seconds is preferable. 5 to 30 seconds is more preferable.
- a reactor comprising a jacket-structured main body provided with a reaction tube (made of SUS304) having an inner diameter of 24 mm and two jacket-structured metal plates (made of SUS304) was prepared.
- a reaction tube made of SUS304
- two jacket-structured metal plates made of SUS304
- the temperature of the liquid mixture is maintained at 100 ° C. from the upper opening of the reaction tube. It was transferred as it was.
- the other metal plate hereinafter referred to as “upper plate” was attached and the reaction tube was sealed. Thereafter, a heat medium oil at 170 ° C. was circulated through the main body and a jacket of two metal plates and held for 7 hours to synthesize a polyglycolic acid resin (PGA resin).
- PGA resin polyglycolic acid resin
- the heat medium oil circulating in the jacket was cooled to cool the reaction apparatus to near room temperature. Thereafter, the lower plate was removed, and the PGA resin mass was taken out from the lower opening of the reaction tube.
- the yield is almost 100%.
- the obtained PGA resin lump was pulverized with a pulverizer, and the sodium ion concentration of the obtained PGA resin pulverized product was measured. As a result, it was 10 mass ppb.
- the weight average molecular weight (polymethylmethacrylate conversion) in GPC measurement of the obtained PGA resin was 225000.
- Preparation Example 2 A cation in industrial water was converted to a sodium ion in the same manner as in Preparation Example 1 except that a sodium ion type strongly acidic cation exchange resin having a sodium sulfonate group was used instead of the hydrogen ion type strongly acidic cation exchange resin. To obtain ion-exchanged water B. When the sodium ion concentration in this ion-exchanged water B was measured, it was 39.1 mass ppm.
- Example 1 Heat stabilizer ("ADEKA STAB AX-71" manufactured by ADEKA Corporation, almost equimolar mixture of mono and distearyl acid phosphates, sodium ion concentration: 200 parts by mass with respect to 100 parts by mass of the PGA resin pulverized product obtained in the above synthesis example ppb) 0.03 parts by mass were added.
- 10 sections provided between the supply unit and the discharge unit and the temperature of the die are 200 ° C, 230 ° C, 260 ° C, 270 ° C, 270 ° C, 270 ° C, 270 ° C, 250 in order from the supply unit.
- melt kneading extrusion is performed, and has a single strand hole of the extruder
- the strand of the molten PGA resin composition was discharged from the die.
- the discharged strand is immediately placed on a mesh conveyor and transferred at 10 m / min.
- the ion-exchanged water A having a water temperature of about 20 ° C.
- the obtained solid PGA resin composition strands were pelletized using a pelletizer equipped with a rotary cutter while being pulled at a constant speed.
- Table 1 shows the measurement results of the water content and sodium ion concentration of the obtained pellet-shaped PGA resin composition, and the results of the thermal stability test. The water content and sodium ion concentration of the PGA resin composition are not changed by pelletization.
- Example 2 A pellet-like PGA resin composition was obtained in the same manner as in Example 1 except that the ion-exchanged water B was sprayed instead of the ion-exchanged water A to cool the strands of the molten PGA resin composition.
- Table 1 shows the measurement results of the water content and sodium ion concentration of the pellet-like PGA resin composition, and the results of the thermal stability test. Table 1 also shows calculated values of the concentration of sodium ions contained in the molten PGA resin composition before cooling.
- Example 3 A pellet-like PGA resin composition was obtained in the same manner as in Example 1 except that a PGA resin pulverized product having a sodium ion concentration of 80 mass ppb was used instead of the PGA resin pulverized product having a sodium ion concentration of 10 mass ppb.
- Table 1 shows the measurement results of the water content and sodium ion concentration of the pellet-like PGA resin composition, and the results of the thermal stability test. Table 1 also shows calculated values of the concentration of sodium ions contained in the molten PGA resin composition before cooling.
- Example 4 A pellet-like PGA resin composition was obtained in the same manner as in Example 2 except that a pulverized PGA resin having a sodium ion concentration of 80 mass ppb was used instead of the pulverized PGA resin having a sodium ion concentration of 10 mass ppb.
- Table 1 shows the measurement results of the water content and sodium ion concentration of the pellet-like PGA resin composition, and the results of the thermal stability test. Table 1 also shows calculated values of the concentration of sodium ions contained in the molten PGA resin composition before cooling.
- Example 5 In the same manner as in Example 1, melt kneading extrusion was performed using a twin-screw kneading extruder, and the melted PGA resin composition strands were discharged from a die having a single strand hole of the extruder. The discharged strand was introduced into a water bath filled with ion-exchanged water A at about 40 ° C. and immersed for 10 seconds to cool and solidify the strand of the molten PGA resin composition.
- the strand of the obtained solid PGA resin composition was pulled out of the water bath and pelletized using a pelletizer equipped with a rotary cutter in the same manner as in Example 1.
- Table 1 shows the measurement results of the water content and sodium ion concentration of the obtained pellet-shaped PGA resin composition, and the results of the thermal stability test.
- Table 1 also shows calculated values of the concentration of sodium ions contained in the molten PGA resin composition before cooling.
- Example 1 A pellet-like PGA resin composition was used in the same manner as in Example 5 except that the strand of the molten PGA resin composition was cooled using a water bath filled with ion exchange water B at about 40 ° C. instead of ion exchange water A. Got. Table 1 shows the measurement results of the water content and sodium ion concentration of the pellet-like PGA resin composition, and the results of the thermal stability test. Table 1 also shows calculated values of the concentration of sodium ions contained in the molten PGA resin composition before cooling.
- Example 4 and Comparative Example 1 the sodium ion concentration of the PGA resin composition was increased by cooling, but this was an opportunity for sodium to be mixed into the PGA resin composition in the process from the start of kneading to strand discharge. Therefore, it is assumed that sodium ions were absorbed during cooling with ion exchange water. Further, since the temperature in the melt-kneading extrusion process is 200 to 270 ° C., it is presumed that the moisture content of the pellet is also the amount of moisture absorbed during cooling with ion-exchanged water.
- an extreme increase in the sodium ion concentration in the cooling step during the production of the solid PGA resin composition is suppressed, and a solid PGA resin composition having a low sodium ion concentration is obtained. It is possible to suppress the coloring of the solid PGA resin composition due to heat.
- the granular PGA resin composition obtained by the present invention is excellent in thermal stability, it is useful as a raw material of a molded product produced by a molding method involving heating such as extrusion molding or injection molding.
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Abstract
Description
前記冷却工程において、得られる固体状ポリグリコール酸系樹脂組成物中のナトリウムイオン濃度が100質量ppb未満となるように、前記溶融状態のポリグリコール酸系樹脂組成物を前記水性媒体と接触させることにより冷却する方法である。
本発明に用いるPGA系樹脂としては、下記式(1):
-[O-CH2-C(=O)]- (1)
で表されるグリコール酸繰り返し単位のみからなるグリコール酸の単独重合体(以下、「PGA単独重合体」という。グリコール酸の2分子間環状エステルであるグリコリドの開環重合体を含む。)、前記グリコール酸繰り返し単位を含むポリグリコール酸共重合体(以下、「PGA共重合体」という。)などが挙げられる。このようなPGA系樹脂は、1種を単独で使用しても2種以上を併用してもよい。
本発明に用いる熱安定剤としては、ペンタエリスリトール骨格構造(またはサイクリックネオペンタンテトライル構造)を有するリン酸エステルおよび少なくとも1つの水酸基と少なくとも1つのアルキルエステル基を有する(亜)リン酸アルキルエステルからなる群から選択される少なくとも1種のリン化合物、具体的には国際公開第2004/087813号に記載のリン化合物が好ましい。このような熱安定剤の添加量としては、PGA系樹脂100質量部に対して0.003~3質量部が好ましく、0.005~1質量部がより好ましい。熱安定剤の添加量が前記下限未満になると得られる固体状PGA系樹脂組成物が熱により着色する傾向にあり、他方、前記上限を超えるとその添加効果が飽和する傾向にあり、また、冷却時に水性媒体へ溶出し、冷却媒体の汚染に繋がることがある。
本発明に用いるカルボキシル基封止剤としては、カルボキシル基を封止する作用を有し、ポリ乳酸などの脂肪族ポリエステルの耐水性向上剤として知られているもの(例えば、特開2001-261797号公報に記載のもの)を一般に用いることができ、例えば、N,N-2,6-ジイソプロピルフェニルカルボジイミドなどのモノカルボジイミドおよびポリカルボジイミドを含むカルボジイミド化合物、2,2’-m-フェニレンビス(2-オキサゾリン)、2,2’-p-フェニレンビス(2-オキサゾリン)、2-フェニル-2-オキサゾリン、スチレン・イソプロぺニル-2-オキサゾリンなどのオキサゾリン化合物、2-メトキシ-5,6-ジヒドロ-4H-1,3-オキサジンなどのオキサジン化合物、N-グリシジルフタルイミド、シクロヘキセンオキシド、トリグリシジルイソシアヌレートなどのエポキシ化合物などが挙げられる。これらのカルボキシル基封止剤は1種を単独で使用しても2種以上を併用してもよい。このようなカルボキシル基封止剤のうち、カルボジイミド化合物およびエポキシ化合物が好ましい。
本発明に用いる溶融状態のPGA系樹脂組成物は、従来公知の方法により得られるPGA系樹脂に熱安定剤やカルボキシル基封止剤などの各種添加剤を必要に応じて添加し、この混合物を溶融混練することによって製造することができる。
本発明は、このようにして得られた溶融状態のPGA系樹脂組成物を水性媒体により冷却して固体状のPGA系樹脂組成物を得る方法である。すなわち、本発明の固体状PGA系樹脂組成物の製造方法においては、最終的に得られる固体状PGA系樹脂組成物中のナトリウムイオン濃度が100質量ppb未満となるように、溶融状態のPGA系樹脂組成物を前記水性媒体に接触させて冷却する(冷却工程)。その後、必要に応じて、得られた固体状のPGA系樹脂組成物を、ペレタイザーやクラッシャーなどを用いて粒状化することによってペレット状などの粒状のPGA系樹脂組成物を得ることができる。
試料約10gを精秤し、濃硫酸2.5mlと過酸化水素水2mlを添加して湿式分解させた後、イオン交換水を加えて50mlにメスアップし、高周波誘導結合プラズマ-原子発光分析法(ICP-AES)によりナトリウムイオン濃度を測定した。
ペレット状のPGA樹脂組成物1~2gを精秤し、気化装置付カールフィッシャー水分計を用いて気化温度220℃で試料中の水分量を測定し、含水率を算出した。
ペレット状のPGA樹脂組成物3gを専用シャーレに敷き詰め、分光色差計((有)東京電色製「TC-1800」)を用いて標準光C、2度視野および表色系の条件で反射光測定法により黄色度(YI)を測定した。次に、このペレット状のPGA樹脂組成物を、アルミニウム板で挟んだ直径25mm、厚さ3mmの金型に入れ、290℃のヒートプレス機上で1分間加熱した後、この温度で2MPaの圧力を加えて30分間保持した。その後、室温まで冷却し、円板状のPGA樹脂成形物を得た。この成形物の黄色度(YI)を上記条件で測定し、加熱前後の黄色度の変化量を求めた。
攪拌機を備えるスチームジャケット構造の密閉可能なSUS製容器(容量:56L)にグリコリド22500gおよび二塩化スズ2水和物0.68g(30質量ppm)を仕込み、容器内の全プロトン濃度が0.13モル%となるように水1.49gを添加した。なお、前記容器内の全プロトンは容器内の雰囲気中の水分(湿気)のプロトンを含むものであり、前記水の添加量はこの容器内の雰囲気中の水分量(0.11g)を考慮して決定した。その後、容器を密閉し、攪拌しながらジャケットにスチームを循環させて容器内の混合物の温度が100℃になるまで加熱して混合物を溶融し、均一な液状混合物を得た。
スルホン酸基を有する水素イオン型強酸性陽イオン交換樹脂を充填したカラムに、工業用水を流通させて工業用水中の陽イオンを水素イオンに交換し、イオン交換水Aを得た。このイオン交換水A中のナトリウムイオン濃度を測定したところ、0.012質量ppmであった。
前記水素イオン型強酸性陽イオン交換樹脂の代わりにスルホン酸ナトリウム基を有するナトリウムイオン型強酸性陽イオン交換樹脂を用いた以外は、調製例1と同様にして工業用水中の陽イオンをナトリウムイオンに交換し、イオン交換水Bを得た。このイオン交換水B中のナトリウムイオン濃度を測定したところ、39.1質量ppmであった。
前記合成例で得たPGA樹脂粉砕物100質量部に対して熱安定剤((株)ADEKA製「アデカスタブAX-71」、モノおよびジステアリルアシッドホスフェートのほぼ等モル混合物、ナトリウムイオン濃度:200質量ppb)0.03質量部を添加した。この混合物を、供給部から排出部までの間に設けた10個の区間およびダイの温度を供給部から順に200℃、230℃、260℃、270℃、270℃、270℃、270℃、250℃、240℃、230℃、230℃に設定した二軸混練押出機(東芝機械(株)製「TEM-41SS」)に供給して溶融混練押出を行い、押出機の単一ストランド孔を有するダイスから溶融状態のPGA樹脂組成物のストランドを排出した。排出したストランドを直ちにメッシュコンベアに載せて10m/分で移送し、ダイスから20cm離れた場所でこのストランドの上方から噴霧機を用いて水温約20℃の前記イオン交換水Aを噴霧し、1000g/分の前記イオン交換水Aと前記ストランドとを10秒間接触させて溶融状態のPGA樹脂組成物のストランドを冷却して固化させた。
溶融状態のPGA樹脂組成物中のNa+濃度={(PGA樹脂中のNa+濃度)×(PGA樹脂の量)+(熱安定剤中のNa+濃度)×(熱安定剤の量)}/{(PGA樹脂の量)+(熱安定剤の量)}
により算出した。その結果も合わせて表1に示す。
イオン交換水Aの代わりにイオン交換水Bを噴霧して溶融状態のPGA樹脂組成物のストランドを冷却した以外は実施例1と同様にしてペレット状のPGA樹脂組成物を得た。このペレット状のPGA樹脂組成物の含水率およびナトリウムイオン濃度の測定結果、ならびに熱安定性試験の結果を表1に示す。また、冷却前の溶融状態のPGA樹脂組成物に含まれるナトリウムイオンの濃度の計算値も表1に示す。
ナトリウムイオン濃度が10質量ppbのPGA樹脂粉砕物の代わりにナトリウムイオン濃度が80質量ppbのPGA樹脂粉砕物を用いた以外は実施例1と同様にしてペレット状のPGA樹脂組成物を得た。このペレット状のPGA樹脂組成物の含水率およびナトリウムイオン濃度の測定結果、ならびに熱安定性試験の結果を表1に示す。また、冷却前の溶融状態のPGA樹脂組成物に含まれるナトリウムイオンの濃度の計算値も表1に示す。
ナトリウムイオン濃度が10質量ppbのPGA樹脂粉砕物の代わりにナトリウムイオン濃度が80質量ppbのPGA樹脂粉砕物を用いた以外は実施例2と同様にしてペレット状のPGA樹脂組成物を得た。このペレット状のPGA樹脂組成物の含水率およびナトリウムイオン濃度の測定結果、ならびに熱安定性試験の結果を表1に示す。また、冷却前の溶融状態のPGA樹脂組成物に含まれるナトリウムイオンの濃度の計算値も表1に示す。
実施例1と同様に二軸混練押出機を用いて溶融混練押出を行い、押出機の単一ストランド孔を有するダイスから溶融状態のPGA樹脂組成物のストランドを排出した。排出したストランドを約40℃のイオン交換水Aを満たした水浴中に導入し、10秒間浸漬させて溶融状態のPGA樹脂組成物のストランドを冷却して固化させた。
イオン交換水Aの代わりに約40℃のイオン交換水Bを満たした水浴を用いて溶融状態のPGA樹脂組成物のストランドを冷却した以外は実施例5と同様にしてペレット状のPGA樹脂組成物を得た。このペレット状のPGA樹脂組成物の含水率およびナトリウムイオン濃度の測定結果、ならびに熱安定性試験の結果を表1に示す。また、冷却前の溶融状態のPGA樹脂組成物に含まれるナトリウムイオンの濃度の計算値も表1に示す。
Claims (8)
- 溶融状態のポリグリコール酸系樹脂組成物を水性媒体により冷却する冷却工程を含む固体状ポリグリコール酸系樹脂組成物の製造方法であって、
前記冷却工程において、得られる固体状ポリグリコール酸系樹脂組成物中のナトリウムイオン濃度が100質量ppb未満となるように、前記溶融状態のポリグリコール酸系樹脂組成物を前記水性媒体と接触させることにより冷却する固体状ポリグリコール酸系樹脂組成物の製造方法。 - 前記冷却工程において得られる固体状ポリグリコール酸系樹脂組成物中のナトリウムイオン濃度(Cs)と前記溶融状態のポリグリコール酸系樹脂組成物中のナトリウムイオン濃度(Cm)との差(Cs-Cm)が30質量ppb以下である、請求項1に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 前記水性媒体がイオン交換水である、請求項1または2に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 前記イオン交換水中のナトリウムイオン濃度が30質量ppm未満である、請求項3に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 前記イオン交換水が、水素イオン型イオン交換樹脂で処理することによって得られたものである、請求項4に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 前記冷却工程において、得られる固体状ポリグリコール酸系樹脂組成物の含水率が500質量ppm未満となるように、前記溶融状態のポリグリコール酸系樹脂組成物をイオン交換水と接触させることにより冷却する、請求項3~5のうちのいずれか一項に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 前記冷却工程において、前記溶融状態のポリグリコール酸系樹脂組成物を霧状のイオン交換水と接触させることにより冷却する、請求項6に記載の固体状ポリグリコール酸系樹脂組成物の製造方法。
- 請求項1~7のうちのいずれか一項に記載の製造方法により得られた固体状ポリグリコール酸系樹脂組成物を粒状化する、粒状ポリグリコール酸系樹脂組成物の製造方法。
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US9109428B2 (en) | 2009-04-21 | 2015-08-18 | W. Lynn Frazier | Configurable bridge plugs and methods for using same |
US9062522B2 (en) | 2009-04-21 | 2015-06-23 | W. Lynn Frazier | Configurable inserts for downhole plugs |
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