WO2015182567A1 - 懸濁重合用分散安定剤、ビニル系重合体の製造方法及び塩化ビニル樹脂 - Google Patents
懸濁重合用分散安定剤、ビニル系重合体の製造方法及び塩化ビニル樹脂 Download PDFInfo
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- WO2015182567A1 WO2015182567A1 PCT/JP2015/064983 JP2015064983W WO2015182567A1 WO 2015182567 A1 WO2015182567 A1 WO 2015182567A1 JP 2015064983 W JP2015064983 W JP 2015064983W WO 2015182567 A1 WO2015182567 A1 WO 2015182567A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F8/00—Chemical modification by after-treatment
- C08F8/28—Condensation with aldehydes or ketones
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
- C08F14/02—Monomers containing chlorine
- C08F14/04—Monomers containing two carbon atoms
- C08F14/06—Vinyl chloride
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F16/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical
- C08F16/02—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical by an alcohol radical
- C08F16/04—Acyclic compounds
- C08F16/06—Polyvinyl alcohol ; Vinyl alcohol
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/16—Aqueous medium
- C08F2/20—Aqueous medium with the aid of macromolecular dispersing agents
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F214/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
- C08F214/02—Monomers containing chlorine
- C08F214/04—Monomers containing two carbon atoms
- C08F214/08—Vinylidene chloride
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F216/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical
- C08F216/02—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical by an alcohol radical
- C08F216/04—Acyclic compounds
- C08F216/06—Polyvinyl alcohol ; Vinyl alcohol
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
- C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L27/04—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
- C08L27/06—Homopolymers or copolymers of vinyl chloride
Definitions
- the present invention relates to a dispersion stabilizer for use in suspension polymerization of vinyl monomers, and more particularly to a dispersion stabilizer for use in suspension polymerization of vinyl chloride monomers.
- the present invention relates to a dispersion stabilizer for suspension polymerization in which a vinyl chloride resin having good polymerization stability and excellent physical properties is obtained, and a vinyl chloride resin produced using the dispersion stabilizer.
- An industrial method for producing a vinyl chloride resin is to disperse a vinyl monomer such as vinyl chloride in an aqueous medium in the presence of a dispersion stabilizer, and perform polymerization using an oil-soluble polymerization initiator. In general, it is carried out by batch suspension polymerization.
- Factors in the polymerization process that govern the quality of vinyl chloride resin include polymerization rate, ratio of aqueous medium to monomer, polymerization temperature, type and amount of polymerization initiator, type of polymerization tank, stirring speed, and dispersion stabilizer. Examples include the type and amount, and among them, the influence of the dispersion stabilizer is very large.
- the role of the dispersion stabilizer in suspension polymerization to obtain a vinyl chloride resin is to disperse the monomer in an aqueous medium to form stable droplets, and to uniformize the size of the droplets that repeat dispersion and coalescence.
- the purpose is to control the cohesiveness of the polymerized particles.
- polyvinyl alcohol resins hereinafter, polyvinyl alcohol may be abbreviated as PVA
- cellulose derivatives either alone or in appropriate combination.
- Polymers are most widely used. However, it is difficult to say that these sufficiently satisfy the above-mentioned required performance, and various studies are being continued at present.
- Non-Patent Document 1 as a dispersion stabilizer for suspension polymerization of vinyl chloride, a viscosity average polymerization degree of 2000, a saponification degree of 88 mol% or 80 mol%, PVA having a high emulsifying power, viscosity A method is described in which PVA is used which has an average degree of polymerization of 600 to 700 and a degree of saponification of about 70 mol%, and precipitates at the polymerization temperature of the vinyl chloride resin.
- Patent Document 1 discloses a polymerization degree obtained by adding sodium acetate to PVA obtained by saponifying polyvinyl acetate obtained by polymerization in the presence of aldehydes and the like, followed by heat treatment.
- a method of using PVA having a saponification degree of 1500 or less and a saponification degree of 90 mol% or less and having a carbonyl group and a vinylene group in two or three chains as a dispersion stabilizer for suspension polymerization of vinyl chlorides is shown. Yes.
- Patent Document 2 discloses that the absorbance at a wavelength of 280 nm and a wavelength of 320 nm of a 0.1 wt% aqueous solution, which is an index representing the vinylene group content in the molecule, is a certain value or more, and the ratio is a certain value or more. Certain PVAs are indicated as dispersion stabilizers for suspension polymerization of vinyl chlorides.
- Patent Document 1 and Patent Document 2 is a PVA that has been subjected to heat treatment, and when the suspension polymerization of vinyl chloride is performed using the heat-treated PVA, the polymerization stability is improved. However, it is hard to say that a satisfactory effect is obtained. In order to improve the polymerization stability, it is necessary to use strongly heat-treated PVA, but in PVA that has been strongly heat-treated, yellowing of PVA occurs, and thus the hue of the obtained vinyl chloride resin (PVC resin) becomes worse. Further, since the block character becomes high, there is a problem that the dispersion performance is lowered and it is difficult to obtain a porous vinyl chloride resin.
- Patent Document 3 ethylene-modified PVA
- Patent Document 4 PVA having 1,2-diol in the side chain
- Patent Document 5 PVA having a C2-C20 hydroxyalkyl group
- various modified PVAs have been investigated as dispersion stabilizers.
- an effect that is not necessarily satisfactory in terms of polymerization stability is not obtained.
- Patent Document 6 PVA esterified with a carboxylic acid having an unsaturated double bond
- the present invention is excellent in polymerization stability when used for polymerization of vinyl chloride resin, has few coarse particles, has little fish eye after resin molding, has good plasticizer absorbability, and hue. It is an object of the present invention to provide a dispersion stabilizer capable of obtaining an excellent vinyl chloride resin and to provide a high-quality vinyl chloride resin produced using the dispersion stabilizer.
- the present inventors have obtained a side chain obtained by acetalizing the polyvinyl alcohol polymer (A) with a monoaldehyde having an olefinic unsaturated double bond.
- the present inventors have found that the above problems can be solved by using a dispersion stabilizer containing a polyvinyl alcohol polymer (B) having a double bond, and completed the present invention through further research.
- the present invention relates to the following dispersion stabilizers and the like.
- a polyvinyl alcohol polymer (B) having a double bond in a side chain obtained by acetalizing a polyvinyl alcohol polymer (A) with a monoaldehyde having an olefinic unsaturated double bond.
- a dispersion stabilizer for suspension polymerization [2] The amount of modification of the polyvinyl alcohol polymer (B) having a double bond in the side chain by a monoaldehyde having an unsaturated double bond is 0.01 per monomer unit of the polyvinyl alcohol polymer (A).
- the dispersion stabilizer for suspension polymerization as described in [1] above, which is ⁇ 20 mol%.
- [3] The suspension according to [1] or [2], wherein the polyvinyl alcohol polymer (B) has a saponification degree of 60 to 99.9 mol% and an average polymerization degree of 300 to 5000.
- Dispersion stabilizer for turbid polymerization [4] The dispersion stabilizer for suspension polymerization according to any one of [1] to [3], wherein the polyvinyl alcohol polymer (B) has a block character of 0.5 or less.
- [5] A vinyl polymer characterized by suspension-polymerizing a vinyl monomer using the dispersion stabilizer for suspension polymerization described in any one of [1] to [4]. Production method.
- [6] A vinyl chloride resin produced by suspension polymerization of a vinyl chloride monomer using the dispersion stabilizer for suspension polymerization described in any one of [1] to [4].
- the dispersion stabilizer for suspension polymerization of the present invention since it is possible to stably polymerize, it is excellent that the resin is blocked due to unstable polymerization and the scale adhesion to the inner wall of the polymerization tank is reduced. The effect which was able to be produced can be produced.
- the dispersion stabilizer for suspension polymerization of the present invention is extremely excellent in dispersion stability of the vinyl chloride monomer in an aqueous medium, so that suspension polymerization can be excellently stabilized with a small amount of use. it can. For this reason, the obtained vinyl chloride resin has few coarse particles, sharp particle size distribution, good hue, high bulk specific gravity, and is porous, so it has good plasticizer absorbability and its porosity is uniform.
- the dispersion stabilizer for suspension polymerization of the present invention since the yellowing of the polyvinyl alcohol polymer contained in the dispersion stabilizer is remarkably reduced, the hue and transparency derived from the hue of the dispersion stabilizer can be reduced. It is extremely useful because it can produce a high-quality vinyl chloride resin with significantly reduced degradation of properties.
- the dispersion stabilizer for suspension polymerization of the present invention is obtained by acetalizing a polyvinyl alcohol polymer (A) with a monoaldehyde having an olefinically unsaturated double bond, and a polyvinyl alcohol system having a double bond in the side chain. It contains a polymer (B).
- the monoaldehyde having an olefinically unsaturated double bond used in the present invention is not particularly limited.
- Dialdehydes and polyhydric aldehydes are not preferred because the polyvinyl alcohol polymer (B) obtained by acetalization may be insolubilized.
- Monoaldehydes that do not contain olefinic unsaturated double bonds such as aliphatic aldehydes such as formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, valeraldehyde, hexanal, and aromatic aldehydes such as benzaldehyde and tolualdehyde during acetalization Can also be used together.
- the polyvinyl alcohol polymer used in the dispersion stabilizer of the present invention (hereinafter, the polyvinyl alcohol polymer may be abbreviated as PVA polymer) (A) is not particularly limited.
- a PVA polymer (A) obtained by saponifying the polymer can be used.
- the vinyl ester polymer can be obtained by polymerizing a vinyl ester monomer.
- the polymerization method is not particularly limited and may be a conventionally known method. Examples include bulk polymerization, solution polymerization, suspension polymerization, emulsion polymerization, and the like, and a saponification reaction performed after controlling the polymerization degree or after polymerization.
- solution polymerization using methanol as a solvent or suspension polymerization using water or water / methanol as a dispersion medium is preferable, but not limited thereto.
- the vinyl ester monomer that can be used for the polymerization is not particularly limited, and examples thereof include vinyl acetate, vinyl formate, vinyl propionate, vinyl caprylate, and vinyl versatate. Vinyl acetate is preferred from an industrial point of view.
- the vinyl ester monomer may be copolymerized with another monomer as long as the effects of the present invention are exhibited.
- monomers that can be used include, but are not limited to, ⁇ -olefins such as ethylene, propylene, N-butene, and isobutylene; acrylic acid and its salts, methyl acrylate, ethyl acrylate, acrylic acid N Acrylic esters such as -propyl, i-propyl acrylate, N-butyl acrylate, i-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate; methacrylic acid and Salts thereof: methyl methacrylate, ethyl methacrylate, N-propyl methacrylate, i-propyl methacrylate, N-butyl methacryl
- a chain transfer agent may be allowed to coexist for the purpose of adjusting the degree of polymerization of the resulting vinyl ester polymer.
- the chain transfer agent include, but are not limited to, aldehydes such as acetaldehyde, propionaldehyde, butyraldehyde, and benzaldehyde; ketones such as acetone, methyl ethyl ketone, hexanone, and cyclohexanone; mercaptans such as 2-hydroxyethanethiol and dodecyl mercaptan.
- the addition amount of the chain transfer agent is determined according to the chain transfer constant of the chain transfer agent to be added and the degree of polymerization of the target vinyl ester polymer, but is generally 0.1% relative to the vinyl ester monomer. ⁇ 10% by weight is desirable.
- a PVA polymer (A) can be produced by saponifying the vinyl ester polymer obtained as described above.
- the saponification reaction method of the vinyl ester polymer is not particularly limited and may be a conventionally known method.
- a conventionally known basic catalyst such as sodium hydroxide, potassium hydroxide, sodium methoxide, or p-
- An alcoholysis or hydrolysis reaction using an acidic catalyst such as toluenesulfonic acid can be applied.
- Examples of the solvent used in the saponification reaction include alcohols such as methanol and ethanol; esters such as methyl acetate and ethyl acetate; ketones such as acetone and methyl ethyl ketone; aromatic hydrocarbons such as benzene and toluene; These can be used alone or in combination of two or more. Among them, it is convenient and preferable to perform the saponification reaction in the presence of sodium hydroxide, which is a basic catalyst, using methanol or a mixed solution of methanol and methyl acetate as a solvent.
- alcohols such as methanol and ethanol
- esters such as methyl acetate and ethyl acetate
- ketones such as acetone and methyl ethyl ketone
- aromatic hydrocarbons such as benzene and toluene
- the saponification degree of the PVA polymer (A) is not particularly limited, but the saponification degree of the PVA polymer (A) obtained by the method for measuring the saponification degree of PVA defined in JIS K 6726 is not limited. , Preferably 60 mol% to 99.9 mol%, more preferably 65 mol% to 99.9 mol%. If the degree of saponification is too low, it will be difficult to dissolve in water and may not function as a dispersion stabilizer in an aqueous medium.
- the degree of polymerization of the PVA polymer (A) is not particularly limited, but the degree of polymerization obtained by the method for measuring the average degree of polymerization of PVA defined in JIS K 6726 is preferably 300 to 5000, more preferably 350 to 4000, more preferably 400 to 2500. If the degree of polymerization of the PVA polymer (A) is too low, the dispersion performance as the dispersion stabilizer of the present invention may be lowered. If the degree of polymerization is too high, an aqueous solution when dissolved in water. Since the viscosity becomes high, handling becomes difficult, and the viscosity of the dispersion medium becomes too high during suspension polymerization, which may adversely affect the polymerization.
- the block character of the residual acetate group of the PVA polymer (A) is preferably 0.5 or less, more preferably 0.3 to 0.5, and further preferably 0.35 to 0.45. is there.
- the block character ( ⁇ ) of the residual acetate group is an index indicating the distribution of the residual acetate group of the PVA polymer, and is obtained by analyzing three peaks appearing in the methylene region in the 13C-NMR spectrum. .
- the three peaks correspond to three 2-unit chain structures corresponding to (OH, OH), (OH, OAc), (OAc, OAc), and the absorption intensity is proportional to the three structures. ing.
- the block character ( ⁇ ) is represented by the following formula (1).
- This block character takes a value between 0 and 2, and the closer to 0, the higher the blockiness of the residual vinegar group distribution, the closer to 1, the higher the randomness, and the closer to 2, the higher the alternation. It shows that.
- the blockiness of the residual acetic acid group affects the dispersibility of vinyl monomers such as vinyl chloride monomers.
- this block character its measurement method and the like are described in detail in pages 246 to 249 of Non-Patent Document 1 and Macromolecules, 10, 532 (1977).
- the block character exceeds 0.5, the plasticizer absorbability of the vinyl polymer obtained by suspension polymerization using the vinyl alcohol polymer decreases.
- the block character is lower than 0.3, the handleability of the aqueous solution of the vinyl alcohol polymer is deteriorated.
- the block character of the residual acetic acid group of the PVA polymer (A) is the type of saponification catalyst and solvent used when the vinyl ester polymer is saponified to produce the PVA polymer (A). Etc. can be adjusted.
- a block character will increase when the obtained PVA-type polymer (A) is heated, excessive heating is not preferable.
- the method for acetalizing the PVA polymer (A) with a monoaldehyde having an olefinic unsaturated double bond is not particularly limited.
- a known acetalization method can be used.
- the method for example, (i) a method in which a monoaldehyde is dissolved in an aqueous PVA polymer (A) and reacted under an acid catalyst, and then neutralized with a basic substance to obtain a PVA polymer (B)
- monoaldehyde is directly added, or a liquid in which monoaldehyde is dissolved or dispersed in methanol, ethanol, propanol or other alcohol or water is added; Examples include a method in which an acid catalyst is added to react, neutralize with a basic substance after the reaction, and an excess solvent is dried to obtain a PVA polymer (B).
- the obtained aqueous solution of the PVA polymer can be used for suspension polymerization as it is.
- the method of reacting in the slurry state of (ii) is easy to handle because the PVA polymer can be obtained as a solid.
- the method of making the PVA polymer (A) into an aqueous solution, the method of neutralization, dissolution, dispersion and drying are not particularly limited, and conventional methods can be used. .
- the acid catalyst is not particularly limited.
- inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid; formic acid, acetic acid, oxalic acid, p-toluenesulfonic acid, etc.
- the organic acid of these can be mentioned.
- the basic substance used for neutralization is not particularly limited, and examples thereof include alkali metal hydroxides such as sodium hydroxide and potassium hydroxide; alkali metal carbonates such as sodium carbonate and potassium carbonate. it can.
- the PVA polymer (A) may be used alone, or two or more PVA polymers (A) having different characteristics may be mixed and used.
- the PVA polymer (A) having a double bond in the side chain is obtained by acetalizing the PVA polymer (A) obtained as described above with a monoaldehyde having an olefinic unsaturated double bond. Is obtained.
- the PVA polymer (B) is a monomer of the PVA polymer (A) whose modification amount by the monoaldehyde having an unsaturated double bond introduced by acetalization of the PVA polymer (A) is The amount is preferably 0.01 to 20 mol%, more preferably 0.05 to 15 mol%, and particularly preferably 0.1 to 10 mol% per unit.
- the method for measuring the amount of modification with a monoaldehyde having an unsaturated double bond is not particularly limited.
- the PVA polymer (B) is dissolved in a d6-DMSO solvent, and this is dissolved in 1H-NMR. And a method of analyzing a signal derived from a double bond, a method of measuring and obtaining unreacted monoaldehyde by high performance liquid chromatography or gas chromatography, and the like.
- the saponification of the PVA-type polymer (B) calculated
- the degree of conversion is preferably 60 mol% to 99.9 mol%, more preferably 65 mol% to 99.9 mol%. If the degree of saponification is too low, it will be difficult to dissolve in water and may not function as a dispersion stabilizer in an aqueous medium.
- the saponification degree of the PVA polymer (B) can be adjusted by the saponification degree of the PVA polymer (A) as the raw material. When the PVA polymer (A) is acetalized with monoaldehyde, it is preferable that water is contained in the reaction system because the change in the degree of saponification of the PVA polymer during the acetalization reaction is small.
- the degree of polymerization of the PVA polymer (B) is not particularly limited, but the degree of polymerization determined by the average polymerization degree measurement method of PVA defined in JIS K 6726 is preferably 300 to 5000, more preferably 350 to 4000, more preferably 400 to 2500. If the degree of polymerization of the PVA polymer (B) is too low, the dispersion performance as the dispersion stabilizer of the present invention may be lowered. If the degree of polymerization is too high, an aqueous solution when dissolved in water. Since the viscosity becomes high, handling becomes difficult, and the viscosity of the dispersion medium becomes too high during suspension polymerization, which may adversely affect the polymerization.
- the degree of polymerization of the PVA polymer (B) can be adjusted by the degree of polymerization of the PVA polymer (A) as the raw material.
- the block character of the residual acetic acid group of the PVA polymer (B) is 0.5 or less, preferably 0.3 to 0.5, more preferably 0.35 to 0.45. When the block character exceeds 0.5, the plasticizer absorbability of the vinyl polymer obtained by suspension polymerization using the PVA polymer (B) decreases. When the block character is lower than 0.3, the handleability of the aqueous solution of the vinyl alcohol polymer is deteriorated.
- the block character of the residual acetic acid group of the PVA polymer (B) can be adjusted by the block character of the PVA polymer (A) as the raw material. Furthermore, when the PVA polymer (A) is acetalized with a monoaldehyde, it is preferable to contain water in the reaction system because the change in the block character of the PVA polymer during the acetalization reaction can
- the suspension polymerization is performed by adding a vinyl monomer insoluble in an aqueous medium and an oil-soluble polymerization initiator to an aqueous medium and stirring to form fine droplets containing the vinyl monomer.
- This is a polymerization mode in which polymerization is performed in the droplets.
- an aqueous medium which can be used here,
- the mixed solvent of water, the aqueous solution containing various additive components, the organic solvent and water which are compatible with water, etc. are mentioned.
- the above PVA polymer (B) in the present invention can be used as a dispersion stabilizer when suspension polymerization of a vinyl monomer is performed.
- the vinyl monomer is not particularly limited.
- vinyl monomers to which suspension polymerization is generally applied such as vinyl chloride, vinylidene chloride, styrene, acrylic acid ester, methacrylic acid ester, vinyl acetate, acrylonitrile, etc.
- Monomers are preferable, and vinyl chloride monomers are particularly preferable.
- the vinyl chloride monomer include a vinyl chloride monomer, and a mixture of a vinyl chloride monomer and another monomer copolymerizable therewith.
- vinylidene chloride vinyl acetate, ethylene, propylene, acrylic acid, acrylic acid ester, methacrylic acid, methacrylic acid ester, styrene, vinyl alkoxysilane, Examples thereof include monomers such as maleic acid, hydroxyalkyl acrylate, allyl sulfonic acid, and vinyl sulfonic acid.
- the dispersion stabilizer of the present invention can be suitably used for homopolymerization of vinyl chloride by suspension polymerization, and one kind selected from known monomers copolymerizable with vinyl chloride by suspension polymerization. It can also be used for binary or higher multi-component copolymerization of the above and vinyl chloride, and particularly preferably used as a dispersion stabilizer in the copolymerization of vinyl chloride and vinyl acetate by suspension polymerization. it can.
- the polymerization initiator in the suspension polymerization of the vinyl monomer may also be a known one, for example, a percarbonate such as diisopropyl peroxydicarbonate, di-2-ethylhexyl peroxydicarbonate, diethoxyethyl peroxydicarbonate, etc.
- a percarbonate such as diisopropyl peroxydicarbonate, di-2-ethylhexyl peroxydicarbonate, diethoxyethyl peroxydicarbonate, etc.
- perester compounds such as benzoyl peroxide, t-butylperoxyneodecanoate, ⁇ -cumylperoxyneodecanoate, t-butylperoxydecanoate, acetylcyclohexylsulfonyl peroxide, 2, 4, Peroxides such as 4-trimethylpentyl-2-peroxyphenoxyacetate, 2,2′-azobisisobutyronitrile, azobis-2,4-dimethylvaleronitrile, azobis (4-methoxy-2,4-dimethyl Azo compounds such as valeronitrile), Emissions benzoyl peroxide, lauroyl peroxide and the like, further, can also be used in combination of potassium persulfate thereto, ammonium persulfate, hydrogen peroxide or the like.
- the main role of the dispersion stabilizer in the suspension polymerization of vinyl monomers is to stabilize the droplets composed of the vinyl monomer and its polymer, and the polymer particles produced by the droplets
- the dispersion stabilizer of the present invention is excellent in dispersion performance, so that stable droplets can be formed with a small amount of use. It is possible to prevent the formation of lumps by the above fusion.
- the phrase “droplet is stable” means that fine and almost uniform droplets are stably dispersed in a dispersion medium for suspension polymerization.
- the amount of the dispersion stabilizer of the present invention is not particularly limited, but is usually 5 parts by weight or less with respect to 100 parts by weight of the vinyl monomer. 0.005 to 1 part by weight is preferable, and 0.01 to 0.2 part by weight is more preferable.
- the dispersion stabilizer of the present invention is also generally used by dissolving it in a dispersion medium for suspension polymerization in advance using a conventional method before charging the vinyl monomer, in the same manner as the ordinary dispersion stabilizer. .
- the dispersion stabilizer in the suspension polymerization of the vinyl monomer may be used alone, but other dispersion stabilizers may be used in combination.
- the stabilizer include known dispersion stabilizers used in suspension polymerization of vinyl monomers such as vinyl chloride in an aqueous medium, such as an average polymerization degree of 100 to 4500 and a saponification degree of 30 to 100 mol.
- % PVA and modified PVA polymers other than the present invention water-soluble cellulose ethers such as methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, water-soluble polymers such as gelatin, sorbitan monolaurate, sorbitan trioleate, glycerin tristearate, Oil-soluble emulsions such as ethylene oxide propylene oxide block polymers, polyoxyethylene glycerin oil , And water soluble emulsifiers such as sodium laurate. Of these other dispersants, one of them may be used, or two or more of them may be used simultaneously.
- the dispersion stabilizer it is preferable to use a combination of two or more PVA polymers having different degrees of polymerization and saponification as the dispersion stabilizer, and one or more of them are used as the dispersion stabilizer of the present invention. It is preferable to use a certain PVA polymer (B). More preferably, a PVA polymer having a high dispersion stability having a polymerization degree of 1700 or more and a PVA polymer having a polymerization degree of 1000 or less are used in combination, and at least one of them is used as the PVA polymer weight of the present invention. Combined (B).
- dispersion aids In suspension polymerization using the dispersion stabilizer of the present invention, various known dispersion aids can be used in combination.
- a dispersion aid a low saponification degree PVA having a saponification degree of preferably 30 to 60 mol%, more preferably 30 to 50 mol% is used.
- PVA having an average degree of polymerization of preferably 160 to 900, more preferably 200 to 500 is used.
- various known additives may be used in combination in the suspension polymerization of vinyl compounds such as a chain transfer agent, a polymerization inhibitor, a pH adjuster, a scale inhibitor, and a crosslinking agent.
- the polymerization temperature in suspension polymerization is not limited and can be arbitrarily selected according to the type of vinyl monomer to be used, the polymerization conditions, the target polymerization yield, etc. Usually, the internal temperature is 30 to 80 ° C. It is preferable that The polymerization time is not particularly limited, and may be set as appropriate according to the degree of polymerization of the target polymer.
- the vinyl chloride resin obtained by the production method of the present invention described above has a sharp particle size distribution of polymer particles, a high bulk specific gravity, and a good plasticizer absorbability, so that it can be easily processed into various molded products. In addition, there are few fish eyes when molded, and the hue is good.
- the evaluation method of the vinyl chloride polymer (vinyl chloride resin) in this example is shown below.
- the average particle size, the amount of scale adhesion, the content of coarse particles, the bulk specific gravity, the plasticizer absorbability, the fish eye, and the initial colorability were evaluated as follows.
- ⁇ Average particle size, coarse particle content> The particle size distribution was measured with a low tap type vibrating sieve (using a JIS sieve), and the average particle size was determined. From the measured particle size distribution, the content of coarse particles of 60 mesh on was expressed in%. The smaller the number, the smaller the coarse particles, the sharper the particle size distribution, and the better the polymerization stability. In Tables 2 and 4 described later, the content is indicated as # 60 on.
- ⁇ Plasticizer absorbability> Put the obtained resin in a cylindrical container filled with glass fiber at the bottom, add an excess of dioctyl phthalate (hereinafter abbreviated as DOP), and let it stand for 30 minutes. After removing excess DOP by centrifugation, the weight of the resin was measured, and the amount of DOP absorbed per 100 parts of the polymer was calculated. The larger the DOP absorption amount, the better the plasticizer absorbability and the better the moldability.
- DOP dioctyl phthalate
- COH-300A chromaticity / turbidity measuring device
- Example 1 Synthesis of PVA polymer (A)
- a reactor equipped with a stirrer, condenser, nitrogen gas inlet and initiator inlet was charged with 450 parts of methanol and 550 parts of vinyl acetate monomer in advance, and the temperature was raised to 60 ° C. while nitrogen gas was circulated in the system.
- 25 parts of a 1% methanol solution of 2,2′-azobis (4-methoxy-2,4-dimethylvaleronitrile) was added as an agent to initiate polymerization.
- the system was maintained at 60 ° C., and 35 parts of a 1% methanol solution of 2,2′-azobis (4-methoxy-2,4-dimethylvaleronitrile) was started while flowing nitrogen gas through the system. Immediately after that, it was continuously added over 4 hours. After 4.5 hours from the start of polymerization, the system was cooled when the reaction yield of vinyl acetate reached 85%, and the polymerization was completed. While methanol vapor was added to the resulting reaction product, the remaining vinyl acetate monomer was distilled off to obtain a 45% methanol solution of polyvinyl acetate.
- the analysis values of this PVA polymer (B) were a saponification degree of 72.5 mol%, a polymerization degree of 800, and a block character of 0.41. Further, when dissolved in d6-DMSO solvent and subjected to 1H-NMR measurement, signals derived from double bonds were observed at 5.8, 5.4, and 5.2 ppm. The amount of modification of acrolein to the PVA polymer (B) determined from this signal intensity was 0.9 mol%.
- Examples 2 to 9 A suspension of vinyl chloride was used in the same manner as in Example 1 except that the PVA polymer (B) synthesized in the same manner as in Example 1 was used except that a monoaldehyde having an unsaturated double bond shown in Table 1 was used. Polymerization was performed to obtain a vinyl chloride polymer. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2.
- Examples 10-13 The amount of methanol used for the polymerization, the amount of 2,2′-azobis (4-methoxy-2,4-dimethylvaleronitrile) added, the reaction yield, the amount of methyl acetate used for the saponification reaction, and the sodium hydroxide solution
- a vinyl chloride polymer was obtained by suspension polymerization of vinyl chloride. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2.
- Examples 14-15 Acetaldehyde was used as a continuous transfer agent in the polymerization, the amount of methanol used, the amount of vinyl acetate used, the amount of 2,2′-azobis (4-methoxy-2,4-dimethylvaleronitrile) added, the reaction yield, and Except for changing the amount of methyl acetate used in the saponification reaction and the amount of sodium hydroxide solution used appropriately so as to obtain a PVA polymer (A) having the degree of polymerization, saponification degree and block character shown in Table 1.
- Example 2 A PVA polymer synthesized in the same manner as in Example 1 except that the PVA polymer (A) synthesized by the same method as in Example 1 and a monoaldehyde having an unsaturated double bond shown in Table 1 were used. Using the coalesced (B), suspension polymerization of vinyl chloride was carried out in the same manner as in Example 1 to obtain a vinyl chloride polymer. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2.
- Example 16 100 parts by weight of the same PVA polymer (A) powder as in Example 15 was immersed in a solution of 1 part by weight of acrolein in 500 parts by weight of methanol, and then p-toluenesulfonic acid 50% by weight methanol. 6.5 parts by weight of the solution was added, and the reaction was performed at a temperature of 40 ° C. for 2 hours. Subsequently, it neutralized with 7.5 weight part of 10 weight% sodium hydroxide aqueous solution. Subsequently, after removing the solvent by centrifugation, the PVA polymer (B) was obtained by drying at 80 ° C. for 4 hours under a nitrogen atmosphere.
- the analysis values of this PVA polymer (B) were a saponification degree of 72.7 mol%, a polymerization degree of 800, and a block character of 0.42. Further, when dissolved in d6-DMSO solvent and subjected to 1H-NMR measurement, signals derived from double bonds were observed at 5.8, 5.4, and 5.2 ppm. The amount of modification of acrolein to the PVA polymer (B) determined from this signal intensity was 0.9 mol%.
- vinyl chloride suspension polymerization was performed under the same conditions as in Example 1 to obtain a vinyl chloride polymer. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2.
- Example 17 0.1 part by weight of acrolein was added to 100 parts by weight of a 10% by weight aqueous solution of the PVA polymer (A) similar to Example 15, and 0.65 part by weight of a 50% by weight aqueous solution of p-toluenesulfonic acid was added. The reaction was carried out at a temperature of 2 ° C. for 2 hours. Subsequently, 0.75 weight part of 10 weight% sodium hydroxide aqueous solution was added and neutralized, and the aqueous solution of the PVA-type polymer (B) was obtained.
- the analysis values of this PVA polymer (B) were a saponification degree of 72.1 mol%, a polymerization degree of 800, and a block character of 0.40.
- the dispersion stabilizer of the present invention has excellent polymerization stability when used for the polymerization of vinyl chloride resin, so that there are few coarse particles and little fish eye after resin molding. It was confirmed that a vinyl chloride resin having good plasticizer absorbability and excellent hue can be obtained.
- Comparative Examples 1-6 As shown in Table 1, suspension polymerization of vinyl chloride was carried out in the same manner as in Example 1 except that the powder of PVA polymer (A) was used as it was as a dispersion stabilizer instead of PVA polymer (B). To obtain a vinyl chloride polymer.
- the PVA polymer (A) has a desired polymerization degree, saponification degree, and block character among the PVA polymers (A) used in Examples 1 to 16. Were used respectively.
- the evaluation results of the obtained vinyl chloride polymer are shown in Table 2. In Comparative Examples 1 and 5, the vinyl chloride polymer could not be obtained because the vinyl chloride was blocked and could not be polymerized.
- Comparative Example 7 As shown in Table 1, Example 1 was used except that the PVA polymer (A) produced according to the method in Example A column of Patent Document 1 was used as the dispersion stabilizer instead of the PVA polymer (B). In the same manner as above, suspension polymerization of vinyl chloride was performed to obtain a vinyl chloride polymer. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2. In Comparative Example 7, uniform polymer particles cannot be obtained due to the presence of coarse particles, stable polymerization cannot be achieved, the amount of plasticizer absorbed, the hue is poor, and there are many fish eyes and a good vinyl chloride polymer cannot be obtained. There wasn't.
- Comparative Example 8 As shown in Table 1, instead of the PVA polymer (B), the PVA polymer (A) esterified with a carboxylic acid having an unsaturated double bond produced according to the method of Example 1 of Patent Document 6 was used. Except for the use as a dispersion stabilizer, suspension polymerization of vinyl chloride was carried out in the same manner as in Example 1 to obtain a vinyl chloride polymer. The evaluation results of the obtained vinyl chloride polymer are shown in Table 2. In Comparative Example 8, there were coarse particles and uniform polymer particles could not be obtained, a large amount of scale was deposited, stable polymerization could not be achieved, and a good vinyl chloride polymer could not be obtained because of many fish eyes. .
- Examples 18-19 A PVA polymer (B) synthesized in the same manner as in Example 16 except that the same PVA polymer (A) as in Example 15 and a monoaldehyde having an unsaturated double bond shown in Table 3 were used. The suspension polymerization of vinyl chloride was performed under the conditions shown below.
- a polymerization machine pressure-resistant autoclave having an internal volume of 100 liters was charged with 45 kg of deionized water, and further, with respect to the vinyl chloride monomer, 700 ppm of the PVA polymer (B) of the present invention shown in Table 3 100 ppm of saponified polyvinyl alcohol (saponification degree 88 mol%, polymerization degree 2400), partially saponified polyvinyl alcohol (saponification degree 55 mol%, polymerization degree 220) 150 ppm, and t-butylperoxyneodecanate 500 ppm were added. Next, after degassing the inside of the polymerization apparatus to 40 mmHg, 45 kg of vinyl chloride monomer was charged and stirring was started.
- the polymerization temperature was 57 ° C., and this temperature was maintained until the polymerization was completed.
- the polymerization conversion rate reached 90%, the reaction was terminated, and unreacted monomers in the polymerization machine were collected. Then, the polymer slurry was taken out of the system and dehydrated and dried to obtain a vinyl chloride polymer.
- Table 4 shows the evaluation results of the vinyl chloride polymer.
- Example 20 Using the same PVA polymer (A) as in Example 14 and using the PVA polymer (B) synthesized in the same manner as in Example 16 using a monoaldehyde having an unsaturated double bond shown in Table 3. In the same manner as in Example 18, suspension polymerization of vinyl chloride was performed to obtain a vinyl chloride polymer. Table 4 shows the evaluation results of the obtained vinyl chloride polymer.
- the dispersion stabilizer of the present invention is excellent in polymerization stability when used for polymerization of vinyl chloride resin, it has less coarse particles and less fish eye after resin molding. It was confirmed that a vinyl chloride resin having good plasticizer absorbability and excellent hue can be obtained.
- Comparative Examples 9-10 As shown in Table 3, the same PVA polymer (A) powder as in Examples 1 and 15 was used as it was as a dispersion stabilizer, and vinyl chloride suspension polymerization was carried out in the same manner as in Example 18 to obtain vinyl chloride heavy polymer. Coalescence was obtained. Table 4 shows the evaluation results of the obtained vinyl chloride polymer. In Comparative Example 9, vinyl chloride polymer particles could not be obtained because vinyl chloride was blocked and could not be polymerized. In Comparative Example 10, there were coarse particles and uniform polymer particles could not be obtained, the amount of scale adhered was not stable, and stable polymerization could not be obtained, and a good vinyl chloride polymer could not be obtained with many fish eyes. .
- Comparative Example 11 As shown in Table 3, by using the PVA polymer (A) produced according to the method in Example A column of Patent Document 1 as a dispersion stabilizer, suspension polymerization of vinyl chloride was conducted in the same manner as in Example 18, A vinyl polymer was obtained. Table 4 shows the evaluation results of the obtained vinyl chloride polymer particles. In Comparative Example 11, the plasticizer absorption amount and hue were poor, there were coarse particles and uniform polymer particles could not be obtained, and good vinyl chloride polymer particles with many fish eyes could not be obtained.
- Comparative Example 12 As shown in Table 3, a PVA polymer (A) esterified with a carboxylic acid having an unsaturated double bond produced according to the method of Example 1 of Patent Document 6 was used as a dispersion stabilizer, as in Example 18. Then, vinyl chloride suspension polymerization was performed to obtain a vinyl chloride polymer. Table 4 shows the evaluation results of the vinyl chloride polymer particles. In Comparative Example 12, uniform polymer particles were not obtained due to coarse particles, and the amount of scale adhered was large, so that stable polymerization could not be performed.
- Examples 21-22 Using the same PVA polymer (B) as in Examples 10 and 11 as shown in Table 3, suspension polymerization of vinyl chloride was performed under the conditions shown below. A polymerization machine (pressure-resistant autoclave) having an internal volume of 100 liters was charged with 45 kg of deionized water, and further, 550 ppm of the PVA polymer (B) of the present invention shown in Table 3 with respect to the vinyl chloride monomer.
- a polymerization machine pressure-resistant autoclave having an internal volume of 100 liters was charged with 45 kg of deionized water, and further, 550 ppm of the PVA polymer (B) of the present invention shown in Table 3 with respect to the vinyl chloride monomer.
- the dispersion stabilizer of the present invention has excellent polymerization stability when used in suspension polymerization of a vinyl chloride resin, so that it can be blocked due to unstable polymerization. It was confirmed that vinyl chloride polymer particles having a reduced scale adhesion, a small number of coarse particles, a sharp particle size distribution, and an excellent hue and plasticizer absorbability can be obtained.
- Comparative Examples 13-14 As shown in Table 3, the same powder of PVA polymer (A) as in Examples 21 to 22 was used as a dispersion stabilizer as it was, and suspension polymerization of vinyl chloride was carried out in the same manner as in Example 21. Coalescence was obtained. Table 4 shows the evaluation results of the vinyl chloride polymer particles. In Comparative Examples 13 to 14, there are coarse particles and uniform polymer particles cannot be obtained, the amount of scale adhesion is large, stable polymerization cannot be performed, and a good vinyl chloride polymer with many fish eyes cannot be obtained. There wasn't.
- the dispersion stabilizer of the present invention has excellent polymerization stability when used during suspension polymerization of a vinyl chloride resin, blocking and scale adhesion due to unstable polymerization are reduced, resulting in coarse particles. Polymer particles having a small and sharp particle size distribution and excellent in hue and plasticizer absorbability can be obtained, which is extremely useful industrially.
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Abstract
Description
<1>得られる塩化ビニル系樹脂粒子の粒度分布をシャープにすること、
<2>得られる塩化ビニル系樹脂粒子を多孔質にし、可塑剤吸収性を大きくして成形加工性を良くすること、
<3>得られる塩化ビニル系樹脂粒子の空隙率を一定の範囲にし、残存モノマーの除去を容易にすること、
<4>得られる塩化ビニル系樹脂粒子の嵩比重を上げ、塩化ビニル系樹脂の加工性を向上させること、
等が挙げられる。
等に例示されるように、種々の変性PVAが分散安定剤として検討されている。しかしながら、これらの分散安定剤を用いて塩化ビニルの懸濁重合を行った場合も、重合安定性の点で必ずしも満足すべき効果が得られていない。
[1]オレフィン系不飽和二重結合を有するモノアルデヒドによりポリビニルアルコール系重合体(A)をアセタール化して得られる、側鎖に二重結合を有するポリビニルアルコール系重合体(B)を含有することを特徴とする懸濁重合用分散安定剤。
[2]側鎖に二重結合を有するポリビニルアルコール系重合体(B)の、不飽和二重結合を有するモノアルデヒドによる変性量が、ポリビニルアルコール系重合体(A)のモノマーユニットあたり0.01~20モル%であることを特徴とする前記[1]に記載の懸濁重合用分散安定剤。
[3]ポリビニルアルコール系重合体(B)のケン化度が60~99.9モル%、平均重合度が300~5000であることを特徴とする前記[1]又は[2]に記載の懸濁重合用分散安定剤。
[4]ポリビニルアルコール系重合体(B)のブロックキャラクターが0.5以下であることを特徴とする前記[1]~[3]のいずれか1項に記載の懸濁重合用分散安定剤。
[5]前記[1]~[4]のいずれか1項に記載の懸濁重合用分散安定剤を使用してビニル系単量体を懸濁重合することを特徴とするビニル系重合体の製造方法。
[6]前記[1]~[4]のいずれか1項に記載の懸濁重合用分散安定剤を使用して塩化ビニル系単量体を懸濁重合することにより製造される塩化ビニル樹脂。
また、本発明の懸濁重合用分散安定剤は、水性媒体中での塩化ビニル系単量体の分散安定性にきわめて優れるため、少量の使用で、懸濁重合を優れて安定化させることができる。このため、得られる塩化ビニル系樹脂は、粗大粒子が少なく粒度分布がシャープで、色相が良く、嵩比重が高く、多孔質であるため可塑剤吸収性が良く、その多孔質性が均一であるため樹脂成形後のフィッシュアイが少ない。
さらに、本発明の懸濁重合用分散安定剤によれば、分散安定剤に含有されるポリビニルアルコール系重合体の黄変が顕著に低減されるため、分散安定剤の色相に由来する色相や透明性の低下が顕著に低減された高品質の塩化ビニル系樹脂を製造できるために極めて有用である。
本発明の懸濁重合用分散安定剤は、オレフィン系不飽和二重結合を有するモノアルデヒドによりポリビニルアルコール系重合体(A)をアセタール化して得られる、側鎖に二重結合を有するポリビニルアルコール系重合体(B)を含むことを特徴とする。
また、アセタール化の際、ホルムアルデヒド、アセトアルデヒド、プロピオンアルデヒド、ブチルアルデヒド、バレルアルデヒド、ヘキサナール等の脂肪族アルデヒド、ベンズアルデヒド、トルアルデヒド等の芳香族アルデヒド等のオレフィン系不飽和二重結合を含まないモノアルデヒドを併用することもできる。
本発明の分散安定剤に使用されるポリビニルアルコール系重合体(以下、ポリビニルアルコール系重合体をPVA系重合体と略記することがある)(A)は、特に限定されないが、例えば、ビニルエステル系重合体をケン化反応することにより得られるPVA系重合体(A)を使用することができる。
該ビニルエステル系重合体は、ビニルエステル系単量体を重合することにより得ることができる。重合方法としては、特に限定されず、従来公知の方法に従って良いが、例えば、塊状重合、溶液重合、懸濁重合、乳化重合等が挙げられ、重合度の制御や重合後に行うケン化反応のことを考慮すると、メタノールを溶媒とした溶液重合、あるいは、水又は水/メタノールを分散媒とする懸濁重合が好ましいが、これらに限定されるものではない。
PVA系重合体(A)の重合度が低くなりすぎると、本発明の分散安定剤としての分散性能が低下するおそれがあり、また、重合度が高くなりすぎると、水に溶解した際の水溶液粘度が高くなるため、取扱いにくくなるとともに、懸濁重合の際に分散媒の粘度が高くなりすぎ、重合に悪影響を及ぼす場合がある。
ここで、残存酢酸基のブロックキャラクター(η)とは、PVA系重合体の残存酢酸基の分布を示す指標であり、13C-NMRスペクトル中のメチレン領域に現れる3本のピークの解析により求められる。前記の3本のピークは、(OH、OH)、(OH、OAc)、(OAc、OAc)に相当する3個の2単位連鎖構造に相当し、その吸収強度は3個の構造に比例している。ブロックキャラクター(η)は、下記式(1)で表される。
〔式中、(OH、OAc)は、OH基とOAc基が隣接する2単位連鎖構造(OH、OAc)の割合を表し、13C-NMRスペクトルのメチレン炭素の強度比より求められる。また、式中、(OH)は、ケン化度を表し、(OAc)は、残存酢酸基の割合を表し、それぞれモル分率で表される。〕
ブロックキャラクターが0.5を越える場合には、ビニルアルコール系重合体を用いた懸濁重合により得られるビニル系重合体の可塑剤吸収性が低下する。ブロックキャラクターが0.3より低い場合、該ビニルアルコール系重合体の水溶液の取扱い性が悪化する。
0.5以下のブロックキャラクターを得るためには、メタノールと酢酸メチルとの混合溶液を溶媒として用い、塩基性触媒をケン化触媒に用いるアルカリケン化を行うのが簡便であり好ましい。酸性触媒を用いる酸ケン化では高いブロックキャラクターが高くなりすぎるため好ましくない。
また、得られたPVA系重合体(A)を加熱するとブロックキャラクターが増加するため、過度の加熱は好ましくない。
本発明において、PVA系重合体(A)を、オレフィン系不飽和二重結合を有するモノアルデヒドによりアセタール化させる方法については特に制限はない。公知のアセタール化方法を用いることができる。
その方法として、例えば、(i)水溶液としたPVA系重合体(A)にモノアルデヒドを溶解し酸触媒下で反応させ、その後塩基性物質で中和しPVA系重合体(B)を得る方法;(ii)スラリー状又は粉末状のPVA系重合体(A)に、モノアルデヒドを直接添加、あるいはモノアルデヒドをメタノール、エタノール、プロパノール等のアルコールもしくは水に溶解又は分散させた液体を添加し、酸触媒を加えて反応させ、反応後塩基性物質で中和し、さらに余分な溶媒を乾燥してPVA系重合体(B)を得る方法等が挙げられる。(i)の方法は、得られたPVA系重合体の水溶液をそのまま懸濁重合に使用することができる。(ii)のスラリー状態で反応させる方法は、PVA系重合体を固体として得ることができるため取り扱いやすい。尚、(i)及び(ii)の方法において、PVA系重合体(A)を水溶液とする方法、中和、溶解、分散及び乾燥の方法は、特に限定されず、常法を用いることができる。
また、中和に用いる塩基性物質としては、特に制限されないが、例えば、水酸化ナトリウム、水酸化カリウム等のアルカリ金属水酸化物;炭酸ナトリウム、炭酸カリウム等のアルカリ金属炭酸塩等を挙げることができる。
上述のようにして得られたPVA系重合体(A)を、オレフィン系不飽和二重結合を有するモノアルデヒドによりアセタール化することにより、側鎖に二重結合を有するPVA系重合体(B)が得られる。
本発明において、不飽和二重結合を有するモノアルデヒドによる変性量を測定する方法は、特に限定されないが、例えば、PVA系重合体(B)をd6-DMSO溶媒に溶解させ、これを1H-NMRにより測定し、二重結合に由来するシグナルを解析する方法、あるいは高速液体クロマトグラフィーやガスクロマトグラフィーにより未反応モノアルデヒドを測定し求める方法等が挙げられる。
PVA系重合体(B)のケン化度は、この原料であるPVA系重合体(A)のケン化度で調整することができる。PVA系重合体(A)をモノアルデヒドでアセタール化する際に、反応系に水を含有させるとアセタール化反応中のPVA系重合体のケン化度の変化が少ないので好ましい。
PVA系重合体(B)の重合度が低くなりすぎると、本発明の分散安定剤としての分散性能が低下するおそれがあり、また、重合度が高くなりすぎると、水に溶解した際の水溶液粘度が高くなるため、取扱いにくくなるとともに、懸濁重合の際に分散媒の粘度が高くなりすぎ、重合に悪影響を及ぼす場合がある。
PVA系重合体(B)の残存酢酸基のブロックキャラクターは0.5以下であり、好ましくは0.3~0.5であり、さらに好ましくは0.35~0.45である。ブロックキャラクターが0.5を越える場合には、PVA系重合体(B)を用いた懸濁重合により得られるビニル系重合体の可塑剤吸収性が低下する。ブロックキャラクターが0.3より低い場合、該ビニルアルコール系重合体の水溶液の取扱い性が悪化する。
PVA系重合体(B)の残存酢酸基のブロックキャラクターは、この原料であるPVA系重合体(A)のブロックキャラクターで調整することができる。さらに、PVA系重合体(A)をモノアルデヒドでアセタール化する際に、反応系に水を含有させるとアセタール化反応中のPVA系重合体のブロックキャラクターの変化を少なくすることができるので好ましい。
次に、上記したPVA系重合体(B)からなる本発明の分散安定剤の使用ないし該分散安定剤を使用したビニル系単量体の懸濁重合によるビニル系重合体の製造方法について説明する。
なお、液滴が安定するとは、細かくかつほぼ均一なサイズの液滴が懸濁重合の分散媒体中に安定して分散することを意味する。
なお、以下の実施例及び比較例において「%」及び「部」は、特にことわりのない限り、「質量%」及び「質量部」を意味する。
(塩化ビニル重合体の評価)
塩化ビニル重合体について、平均粒子径、スケール付着量、粗大粒子含有量、嵩比重、可塑剤吸収性、フィッシュアイ、及び初期着色性を、次のようにして評価した。
ロータップ式振動篩(JIS篩を使用)により粒度分布を測定し、平均粒子径を求めた。測定した粒子径分布より、60メッシュオンの粗大粒子の含有量を%で表した。数字が小さいほど粗大粒子が少なくて粒度分布がシャープであり、重合安定性に優れていることを示す。尚、後述の表2及び4において、該含有量は#60オンと示す。
重合体スラリーを重合槽から取り出した後の重合槽の内壁におけるスケールの付着状態を目視観察し、以下の基準で評価した。
◎:スケールの付着がほとんどない
〇:スケールの付着が少ない
×:白色のスケール付着が著しい
JIS K-6721に準拠して測定した。嵩比重が大きいほど、押出し速度が向上し、加工性が良いことを示す。
底にグラスファイバーを詰めた円筒状容器に得られた樹脂を入れ、過剰のジオクチルフタレート(以下、DOPと略記する)を加え、30分放置することによって樹脂にDOPを浸透させた後、3000rpmで遠心分離することによって余分なDOPを除去した後、樹脂の重量を測定して、重合体100部あたりのDOP吸収量を算出した。DOP吸収量が大きいほど、可塑剤吸収性がよく、成形加工性に優れることを示す。
得られた樹脂100部、ジオクチルフタレート30部、三塩基性硫酸鉛1部、ステアリン酸鉛1.5部、二酸化チタン0.2部、カーボンブラック0.1部を150℃で4分間溶融混錬し、厚さ0.3mmのシートを作製し、100mm×100mmあたりのフィッシュアイ(0.4mm以上の透明粒子)の数を測定した。
得られた樹脂100部、Ba-Zn系複合安定剤2部、エポキシ化大豆油2部、DOP38部を150℃で10分間溶融混錬し、厚さ0.8mmのシートを作製した。次に、このシート片を7枚重ね、180℃で5分間プレスし、厚み5mmの積層シートを得た。この積層シートの透明性及び初期着色性を色度・濁度測定器(COH-300A、日本電色工業社製)を用いて測定し、黄色度(YI)で評価した。
(PVA系重合体(A)の合成)
攪拌機、コンデンサー、窒素ガス導入口及び開始剤投入口を備えた反応槽に、予めメタノール450部及び酢酸ビニルモノマー550部を仕込み、系内に窒素ガスを流通させながら60℃に昇温し、開始剤として2,2’-アゾビス(4-メトキシ-2,4-ジメチルバレロニトリル)の1%メタノール溶液を25部添加し、重合を開始した。
重合中は系を60℃に保持し、系内に窒素ガスを流しつつ、さらに2,2’-アゾビス(4-メトキシ-2,4-ジメチルバレロニトリル)の1%メタノール溶液35部を重合開始直後から4時間にわたって連続的に加えた。重合開始から4.5時間後、酢酸ビニルの反応収率が85%になった時点で系を冷却し、重合を終了した。得られた反応物にメタノール蒸気を加えながら、残存する酢酸ビニルモノマーを留出し、ポリ酢酸ビニルの45%メタノール溶液を得た。
次に、上記で得られたポリ酢酸ビニルの45%メタノール溶液500部に、酢酸メチル70部、水酸化ナトリウムの3%メタノール溶液30部を加えてよく混合し、40℃でケン化反応を行い、得られたゲル状物を粉砕した後に乾燥して、ケン化度72.0モル%、平均重合度800、ブロックキャラクター0.39のPVA系重合体(A)の粉末を得た。
上記で得られたPVA系重合体(A)の粉末100重量部を、アクロレイン1重量部をメタノール400重量部に溶解させた溶液に60分間浸漬した後、1N塩酸水溶液25重量部を添加し、40℃の温度で2時間反応を行った。次いで、1N水酸化ナトリウム水溶液25重量部で中和した。次いで、遠心分離により溶媒を除去した後、窒素雰囲気下にて80℃で4時間乾燥しPVA系重合体(B)を得た。このPVA系重合体(B)の分析値は、ケン化度72.5モル%、重合度800で、ブロックキャラクターは、0.41であった。また、d6-DMSO溶媒に溶解させて1H-NMR測定を行ったところ、5.8、5.4、5.2ppmに二重結合由来のシグナルが観測された。このシグナル強度から求めたアクロレインのPVA系重合体(B)への変性量は0.9モル%であった。
上記で得られたPVA系重合体(B)を、分散安定剤として用いて、以下に示す条件にて塩化ビニルの懸濁重合を行った。
耐圧のステンレス製重合器に、脱イオン水900部及び上記で得られたPVA系重合体(B)を0.5部仕込んだ。次に、真空ポンプで重合器内を50mmHgとなるまで減圧し、脱気した後、塩化ビニル単量体700部を仕込み、さらに重合開始剤としてt-ブチルパーオキシネオデカノエート0.42部を仕込んだ後、攪拌を行い、昇温を開始した。重合器の内容物の温度を57℃に維持しながら懸濁重合を行い、塩化ビニルの重合転化率が88%に達した時点で重合反応を停止した。そして、未反応単量体を減圧トラップにより回収した後、重合体スラリーを重合器から抜き出し、脱水、乾燥して塩化ビニル重合体(塩化ビニル樹脂)を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
表1に示す不飽和二重結合を有するモノアルデヒドを用いた以外は実施例1と同様にして合成されたPVA系重合体(B)を用い、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
重合に用いるメタノールの使用量、2,2’-アゾビス(4-メトキシ-2,4-ジメチルバレロニトリル)の添加量、反応収率、及び鹸化反応に用いる酢酸メチルの量及び水酸化ナトリウム溶液の使用量を、表1に示す重合度、ケン化度及びブロックキャラクターを有するPVA系重合体(A)が得られるように適宜変えた以外は実施例1と同様の方法で合成したPVA系重合体(A)、及び表1に示す不飽和二重結合を有するモノアルデヒドを用いた以外は実施例1と同様にして合成されたPVA系重合体(B)を用い、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
重合でアセトアルデヒドを連載移動剤として使用し、メタノールの使用量、酢酸ビニルの使用量、2,2’-アゾビス(4-メトキシ-2,4-ジメチルバレロニトリル)の添加量、反応収率、及び鹸化反応に用いる酢酸メチルの量及び水酸化ナトリウム溶液の使用量を、表1に示す重合度、ケン化度及びブロックキャラクターを有するPVA系重合体(A)が得られるように適宜変えた以外は実施例1と同様の方法で合成したPVA系重合体(A)、及び表1に示す不飽和二重結合を有するモノアルデヒドを用いた以外は実施例1と同様にして合成されたPVA系重合体(B)を用い、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
実施例15と同様のPVA系重合体(A)の粉末100重量部を、アクロレイン1重量部をメタノール500重量部に溶解させた溶液に40分間浸漬した後、p-トルエンスルホン酸50重量%メタノール溶液6.5重量部を添加し、40℃の温度で2時間反応を行った。次いで、10重量%水酸化ナトリウム水溶液7.5重量部で中和した。次いで、遠心分離により溶媒を除去した後、窒素雰囲気下にて80℃で4時間乾燥しPVA系重合体(B)を得た。このPVA系重合体(B)の分析値は、ケン化度72.7モル%、重合度800で、ブロックキャラクターは、0.42であった。また、d6-DMSO溶媒に溶解させて1H-NMR測定を行ったところ、5.8、5.4、5.2ppmに二重結合由来のシグナルが観測された。このシグナル強度から求めたアクロレインのPVA系重合体(B)への変性量は0.9モル%であった。
上記PVA系重合体(B)を分散安定剤として用いて、実施例1と同様の条件にて塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
実施例15と同様のPVA系重合体(A)の10重量%水溶液100重量部にアクロレイン0.1重量部を加え、p-トルエンスルホン酸50重量%水溶液0.65重量部を添加し、40℃の温度で2時間反応を行った。次いで、10重量%水酸化ナトリウム水溶液0.75重量部を加え中和し、PVA系重合体(B)の水溶液を得た。このPVA系重合体(B)の分析値は、ケン化度72.1モル%、重合度800で、ブロックキャラクターは、0.40であった。また、d6-DMSO溶媒に溶解させて1H-NMR測定を行ったところ、5.8、5.4、5.2ppmに二重結合由来のシグナルが観測された。このシグナル強度から求めたアクロレインのPVA系重合体(B)への変性量は0.9モル%であった。
上記PVA系重合体(B)を分散安定剤として用いて、実施例1と同様の条件にて塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
表1に示すように、PVA系重合体(B)の代わりにPVA系重合体(A)の粉末をそのまま分散安定剤として用いた以外は、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。尚、比較例1~6において、PVA系重合体(A)は、実施例1~16で使用されたPVA系重合体(A)のうち所望の重合度、ケン化度及びブロックキャラクターを有するものをそれぞれ使用した。
得られた塩化ビニル重合体の評価結果を表2に示す。比較例1及び5では、塩化ビニルがブロック化して重合を行うことができなかったために、塩化ビニル重合体を得ることはできなかった。比較例2~4及び6では、粗大粒子があり均一な重合体粒子が得られず、スケール付着量も多く安定な重合ができず、また、フィッシュアイも多く良好な塩化ビニル重合体を得ることはできなかった。
表1に示すように、PVA系重合体(B)の代わりに特許文献1の実施例A欄の方法に従い製造したPVA系重合体(A)を分散安定剤として用いた以外は、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
比較例7では、粗大粒子があり均一な重合体粒子が得られず、安定な重合ができず、可塑剤吸収量、色相が悪く、フィッシュアイも多く良好な塩化ビニル重合体を得ることはできなかった。
表1に示すように、PVA系重合体(B)の代わりに特許文献6の実施例1の方法に従い製造した不飽和二重結合を有するカルボン酸でエステル化したPVA系重合体(A)を分散安定剤として用いた以外は、実施例1と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表2に示す。
比較例8では、粗大粒子があり均一な重合体粒子が得られず、スケール付着量も多く安定な重合ができず、また、フィッシュアイも多く良好な塩化ビニル重合体を得ることはできなかった。
実施例15と同様のPVA系重合体(A)及び表3に示す不飽和二重結合を有するモノアルデヒドを用いた以外は実施例16と同様にして合成されたPVA系重合体(B)を用いて、以下に示す条件にて塩化ビニルの懸濁重合を行った。
内容積100リットルの重合機(耐圧オートクレーブ)に、脱イオン水45kgを入れ、更に、塩化ビニル単量体に対して、表3に示した本発明のPVA系重合体(B)700ppm、部分ケン化ポリビニルアルコール(ケン化度88モル%、重合度2400)100ppm、部分ケン化ポリビニルアルコール(ケン化度55モル%、重合度220)150ppm、t-ブチルパーオキシネオデカエート500ppmを投入した。次に、重合機内を40mmHgまで脱気した後、塩化ビニル単量体を45kg仕込み、攪拌を開始した。重合温度は57℃とし、重合終了までこの温度を保持した。
重合転化率が90%に達した時点で反応を終了し、重合機内の未反応単量体を回収した後、重合体スラリーを系外に取り出し、脱水乾燥し、塩化ビニル重合体を得た。塩化ビニル重合体の評価結果を表4に示す。
実施例14と同様のPVA系重合体(A)を用い、表3に示す不飽和二重結合を有するモノアルデヒドを用い実施例16と同様にして合成されたPVA系重合体(B)を用い、実施例18と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。得られた塩化ビニル重合体の評価結果を表4に示す。
表3に示すように実施例1、15と同様のPVA系重合体(A)の粉末をそのまま分散安定剤として用い、実施例18と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。
得られた塩化ビニル重合体の評価結果を表4に示す。比較例9では、塩化ビニルがブロック化して重合を行うことができなかったために、塩化ビニル重合体粒子を得ることはできなかった。比較例10では、粗大粒子があり均一な重合体粒子が得られず、スケール付着量も多く安定な重合ができず、また、フィッシュアイも多く良好な塩化ビニル重合体を得ることはできなかった。
表3に示すように特許文献1の実施例A欄の方法に従い製造したPVA系重合体(A)を分散安定剤として用い、実施例18と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。
得られた塩化ビニル重合体粒子の評価結果を表4に示す。
比較例11では、可塑剤吸収量、色相が悪く、粗大粒子があり均一な重合体粒子が得られず、フィッシュアイも多く良好な塩化ビニル重合体粒子を得ることはできなかった。
表3に示すように特許文献6の実施例1の方法に従い製造した不飽和二重結合を有するカルボン酸でエステル化したPVA系重合体(A)を分散安定剤として用い、実施例18と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。
塩化ビニル重合体粒子の評価結果を表4に示す。
比較例12では、粗大粒子があり均一な重合体粒子が得られず、またスケール付着量も多く安定な重合ができなかった。
表3に示すように実施例10、11と同様のPVA系重合体(B)を用いて、以下に示す条件にて塩化ビニルの懸濁重合を行った。
内容積100リットルの重合機(耐圧オートクレーブ)に、脱イオン水45kgを入れ、更に、塩化ビニル単量体に対して、表3に示した本発明のPVA系重合体(B)550ppm、部分ケン化ポリビニルアルコール(ケン化度72モル%、重合度700)250ppm、部分ケン化ポリビニルアルコール(ケン化度55モル%、重合度220)150ppm、t-ブチルパーオキシネオデカエート500ppmを投入した。次に、重合機内を40mmHgまで脱気した後、塩化ビニル単量体を45kg仕込み、攪拌を開始した。重合温度は57℃とし、重合終了までこの温度を保持した。
重合転化率が90%に達した時点で反応を終了し、重合機内の未反応単量体を回収した後、重合体スラリーを系外に取り出し、脱水乾燥し、塩化ビニル樹脂を得た。得られた塩化ビニル重合体の評価結果を表4に示す。
表3に示すように実施例21~22と同様のPVA系重合体(A)の粉末をそのまま分散安定剤として用い、実施例21と同様にして塩化ビニルの懸濁重合を行い、塩化ビニル重合体を得た。
塩化ビニル重合体粒子の評価結果を表4に示す。比較例13~14では、粗大粒子があり均一な重合体粒子が得られず、スケール付着量も多く安定な重合ができず、また、フィッシュアイも多く良好な塩化ビニル重合体を得ることはできなかった。
Claims (6)
- オレフィン系不飽和二重結合を有するモノアルデヒドによりポリビニルアルコール系重合体(A)をアセタール化して得られる、側鎖に二重結合を有するポリビニルアルコール系重合体(B)を含有することを特徴とする懸濁重合用分散安定剤。
- 側鎖に二重結合を有するポリビニルアルコール系重合体(B)の、不飽和二重結合を有するモノアルデヒドによる変性量が、ポリビニルアルコール系重合体(A)のモノマーユニットあたり0.01~20モル%であることを特徴とする請求項1に記載の懸濁重合用分散安定剤。
- ポリビニルアルコール系重合体(B)のケン化度が60~99.9モル%、平均重合度が300~5000であることを特徴とする請求項1又は2に記載の懸濁重合用分散安定剤。
- ポリビニルアルコール系重合体(B)のブロックキャラクターが0.5以下であることを特徴とする請求項1~3のいずれか1項に記載の懸濁重合用分散安定剤。
- 請求項1~4のいずれか1項に記載の懸濁重合用分散安定剤を使用してビニル系単量体を懸濁重合することを特徴とするビニル系重合体の製造方法。
- 請求項1~4のいずれか1項に記載の懸濁重合用分散安定剤を使用して塩化ビニル系単量体を懸濁重合することにより製造される塩化ビニル樹脂。
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US15/313,766 US10301402B2 (en) | 2014-05-28 | 2015-05-26 | Dispersion stabilizer for suspension polymerization, production method for vinyl-based polymer, and vinyl chloride resin |
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Cited By (16)
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WO2017094698A1 (ja) * | 2015-12-04 | 2017-06-08 | 日本酢ビ・ポバール株式会社 | 懸濁重合用分散助剤およびそれを用いるビニル系重合体の製造方法、並びに塩化ビニル樹脂 |
JP2017105997A (ja) * | 2015-12-04 | 2017-06-15 | 日本酢ビ・ポバール株式会社 | 懸濁重合用分散助剤およびそれを用いるビニル系重合体の製造方法、並びに塩化ビニル樹脂 |
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Also Published As
Publication number | Publication date |
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CN106414511B (zh) | 2018-10-26 |
EP3150639A4 (en) | 2017-12-27 |
CN106414511A (zh) | 2017-02-15 |
JP6546586B2 (ja) | 2019-07-17 |
TWI656136B (zh) | 2019-04-11 |
US20170198068A1 (en) | 2017-07-13 |
EP3150639B1 (en) | 2020-04-08 |
TW201602137A (zh) | 2016-01-16 |
US10301402B2 (en) | 2019-05-28 |
EP3150639A1 (en) | 2017-04-05 |
SG11201609700RA (en) | 2016-12-29 |
JPWO2015182567A1 (ja) | 2017-04-20 |
ES2798498T3 (es) | 2020-12-11 |
CN106414511B9 (zh) | 2019-07-19 |
SG10201810409YA (en) | 2018-12-28 |
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