JP2006225602A - Method for producing polyamide resin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a melt polymerization process for producing a polyamide resin with a high quality and a high degree of polymerization in a homogenous quality, stably in an industrial scale with reduced cost, and usable for substituting a solid phase polymerization. <P>SOLUTION: The invention relates to the method for producing the polyamide resin comprising feeding a molten raw intermediate of polymer from a material feeding port into a polymerizing chamber, discharging from holes of a porous plate and falling down along a supporting body installed in the polymerization chamber at a temperature between -10&deg;C to +60&deg;C of the melting point of the crystal of the intermediate of polymer, and polymerizing under reduced pressure in a polymerizing condition satisfying the requirement of (A) or (B). The requirements; (A); The surface area S<SB>1</SB>of the falling down polyamide resin along the supporting body and the area S<SB>2</SB>of the supporting body contacting with the polyamide resin satisfy following relation, S<SB>1</SB>/S<SB>2</SB>&gt;1. (B); The residence time of the polyamide resin at the bottom of the reaction chamber is 10 sec to 1 hr. <P>COPYRIGHT: (C)2006,JPO&amp;NCIPI

Description

  The present invention relates to a high-quality polyamide resin and a method for producing the same.

Various polyamide resins represented by polyhexamethylene adipamide (nylon 66 resin) have characteristics such as excellent heat resistance and mechanical properties. In addition to clothing fibers, fibers and films for industrial materials It is widely used for injection moldings for various uses as sheets and engineering plastics. For these uses, a high-quality one having a high degree of polymerization and little coloring is required. In addition, it is desired to be industrially stable and to be manufactured with good productivity and low cost.
Normally, a polyamide resin with a high degree of polymerization is a solid phase in which pellets of a medium degree of polymerization are first produced by melt polymerization and then heated in an inert gas stream for a long time or under reduced pressure to increase the degree of polymerization. It manufactures by superposition | polymerization (for example, refer patent document 1). Despite the need for a long and complicated manufacturing process and high manufacturing cost, solid-phase polymerization is carried out because it is difficult to cause a thermal decomposition reaction because it is polymerized below the melting point, and it is difficult to color, This is because a high-quality resin can be produced with a high degree of polymerization.

On the other hand, attempts have been made so far to produce a polyamide resin having a high degree of polymerization at low cost only by melt polymerization without performing solid phase polymerization.
Since the polycondensation reaction of the polyamide resin is basically based on the amidation equilibrium reaction of the following formula 1, it is necessary to quickly remove water generated as a by-product in the polymerization apparatus in order to make the polycondensation reaction proceed effectively. .
[Formula 1]
-NH ₂ + -COOH → -CONH- + H ₂ O

Therefore, for example, a lateral taper roll thin film evaporator that can effectively remove moisture by forming a thin film of a reaction solution to increase the surface area and renewing the surface with high efficiency (see, for example, Patent Document 2). ), Horizontal uniaxial stirring type apparatus (see, for example, Patent Documents 3 to 6), and horizontal biaxial stirring type apparatus (for example, see Patent Documents 7 to 10). However, in such a stirring type apparatus, the melt viscosity of the polyamide resin extremely increases with the polymerization, so that it is difficult to renew the surface of the polyamide resin having a high polymerization degree, and also due to the increase in liquid temperature and high shear force caused by stirring. Since the molecular chain of the polymer is also cut, it is difficult to produce a polyamide resin having a sufficiently high molecular weight. In addition, since the rotational drive portion cannot be completely sealed, it is impossible to prevent a minute amount of air from leaking, and coloring of the resin cannot be avoided. When sealing liquid is used to prevent air leakage, mixing of the sealing liquid is unavoidable, and deterioration of the resin quality is unavoidable. In addition, even if the sealing performance is high at the beginning of operation, there are serious maintenance problems such as a decrease in sealing performance while the operation is continued for a long time.
In addition to using a device that accelerates the polycondensation reaction by the rotational drive part as described above, a method of effectively removing moisture by forming a thin film while gravity dropping the polymerization intermediate from the upper part of the polymerization reactor, and performing polymerization Has also been proposed.

For example, there is a technology in which a polycondensation reaction is performed by degassing volatiles while flowing down a polyamide resin polymerization intermediate along a wall surface or a support of a polymerization vessel (see, for example, Patent Documents 11 to 15). However, such an apparatus has a deaeration part (a part that forms a thin film on the wall surface to reduce the water in the polymer) and a liquid retention part (the polymer stays at the bottom of the polymerization vessel and is in equilibrium with the water in the polymer). In the above Patent Documents 11 to 13, the polymer flow in the liquid retention part is a complete mixing tank, and a polyamide resin having a uniform polymerization degree cannot be obtained. Since it stays at a high temperature for a long time, degradation of quality such as formation of gelled products and deterioration of hue is unavoidable. In Patent Document 14, an attempt is made to produce a polyamide resin having a uniform degree of polymerization by providing a stirring blade in the liquid retention part, but by providing a rotational drive part in the lower part of the polymerization vessel, air leaks. There is a problem that the quality is further deteriorated. Patent Document 15 is a technique in which a polycondensation reaction is performed under reduced pressure in a polymerization apparatus having a guide contact drop-fall polymerization reaction zone after an inert gas absorption apparatus absorbs an inert gas in a polyamide resin polymerization intermediate. However, even with this method, when the resin is retained in the liquid retaining part for a long time, a polyamide resin having a uniform polymerization degree cannot be obtained, and quality degradation such as formation of gelled products and deterioration of hue is unavoidable. .
As described above, the conventional melt polymerization technology cannot replace the solid phase polymerization technology, and cannot produce a high-quality, high-polymerization polyamide resin industrially stably and with high productivity.

JP-T-2001-5007048 Japanese Patent Publication No.49-33358 Japanese Patent Publication No. 45-16473 Japanese Patent Laid-Open No. 10-259242 JP-A-11-130869 JP-A-11-130870 JP-A-48-84781 Japanese Patent Publication No. 50-15275 Japanese Patent Publication No. 50-21514 Japanese Patent Publication No.53-15753 US Pat. No. 3,361,537 US Pat. No. 3,477,094 US Patent No. 3044993 Japanese Patent Publication No. 50-9834 Republished patent WO99 / 65970

  The present invention aims to provide a melt polymerization technique that can replace a solid-phase polymerization technique and produce a high-quality, high-polymerization degree polyamide resin with a uniform quality and industrial stability at a low cost. .

As a result of diligent research to solve the above problems, the present inventors have supplied a polyamide resin polymerization intermediate in a molten state from a raw material supply port to a polymerization vessel and discharged it from a hole in a perforated plate. We have developed a polymerization method based on a novel principle by polymerizing under reduced pressure while dropping alongside, and that a polyamide resin with a high degree of polymerization can be obtained without retaining the polymer in the liquid retention part for a long time. I found it. Further, when the polymerization method of the present invention is used, melt polymerization at a low reaction temperature, which could not be achieved by the conventional polymerization method, becomes possible.
We have further studied and combined with a method of extracting the polymer without retaining the polymer in the liquid retention part of the polymerizer for a long time, so that high-quality and high-polymerization polyamide resin can be obtained with uniform quality and stable on an industrial scale. The inventors have found that it can be manufactured and have come to make the present invention.

That is, the present invention is as follows.
(1) The polyamide resin polymerization intermediate is supplied to the polymerization vessel from the raw material supply port in a molten state, discharged from the holes of the perforated plate, and then dropped along the surface of the support installed in the polymerization vessel. However, the polymerization intermediate is a method of polymerizing under reduced pressure at a crystal melting point of −10 ° C. or higher and a crystal melting point + 60 ° C. or lower, which satisfies the following conditions (A) and (B): And a method for producing a polyamide resin,
(A) the area in which the surface area S ₁ and the support of the polyamide resin falling along a support and a polyamide resin are in contact S ₂ satisfies the relationship of _{S 1 /} S 2> 1.
(B) The residence time of the polymerized polyamide resin at the bottom of the polymerization vessel is in the range of 10 seconds to 1 hour.
(2) When discharging the polyamide resin staying at the bottom of the polymerization vessel, the upper end line in contact with the inner wall surface of the polymerization vessel is a line L, and the volume U and bottom of the polymerization vessel below the line L The method for producing a polyamide resin according to (1), wherein the ratio (V / U) of the volume V of the polymer staying in is controlled in the range of 0.00001 to 0.95,
(3) The method for producing a polyamide resin according to (1) or (2), wherein the molecular weight of the polyamide resin polymerization intermediate is 1.5 to 3.0 in terms of relative viscosity,
(4) A polyamide resin produced by the production method according to any one of (1) to (3),
(5) A polyamide resin having a relative viscosity of 2.5 to 6.0 produced by the production method according to any one of (1) to (3),
(6) A molded product produced from the polyamide resin according to (4) or (5).

  Using the production method of the present invention, high-quality and high-polymerization polyamide resin can be replaced by solid-state polymerization technology, and can be produced with uniform quality and industrially stable by low-cost melt polymerization. Is possible.

The present invention will be specifically described below in the order of (A) the principle of the polymerization method, (B) the description of the polyamide resin polymerization intermediate, (C) the description of the polymerization vessel, and (D) the description of the polymerization method.
(A) Principle of polymerization method:
In the polymerization method of the present invention, the polyamide resin polymerization intermediate is supplied in a molten state from the raw material supply port to the polymerization vessel, and is discharged from the hole of the perforated plate, and then is dropped under reduced pressure while being dropped by gravity along the support. This is a polymerization method.
As will be described later, when the structure of the polymerization vessel and the polymerization method satisfy appropriate conditions, the polymerization intermediate falling along the support body contains a large amount of bubbles, and the polymer bubbles as the polymerization proceeds. It has a ball-like (bulk) structure and exhibits a behavior of rolling down toward the bottom of the polymerization vessel.

As a result, the contact area of the polymer liquid phase with the gas phase and the effect of renewing the surface of the polymer liquid are dramatically increased, water generated as a by-product due to the polycondensation reaction can be efficiently removed from the polymerization intermediate, and the polymerization rate is increased. Increase dramatically. As a result, it is possible to produce a polyamide resin having a high degree of polymerization without retaining the polymer in the liquid retention part for a long time, and further, it is possible to perform melt polymerization at a low polymerization temperature that could not be achieved by conventional polymerization methods. Have
In the present invention, since the polyamide resin contains a large amount of foam, even if the degree of polymerization is increased, the fluidity on the support and the bottom of the polymerization vessel is good, and since it does not stay for a long time at these places, the hue deteriorates and the gel Is unlikely to occur. Further, when a highly polymerized polyamide resin is extracted from the polymerization vessel, a high shearing force is not easily generated, and there is little deterioration in quality due to a rise in liquid temperature or molecular chain breakage.
Furthermore, there is an advantage that a high-quality polyamide resin can be produced with a low content of impurities such as oligomers and thermal decomposition products.

(B) Description of the polyamide resin polymerization intermediate:
The polyamide resin polymerization intermediate used in the present invention is not particularly limited as long as it is a polymerization intermediate having an amide bond (—NHCO—) in the main chain. More specifically, well-known raw materials used for producing a polymer having an amide bond (—NHCO—) in the main chain, such as a polymerizable amino acid, a polymerizable lactam, or a polymerizable It is a polymerization intermediate obtained by using a salt or mixture of diamine and dicarboxylic acid and these polymerizable oligomers as raw materials, and is a polyamide resin having a lower degree of polymerization than the polyamide resin of the product. The polymerization intermediate may contain an oligomer or a monomer. The production method of the polymerization intermediate is, for example, a conventionally known vertical stirring polymerizer, a horizontal stirring reactor having a uniaxial or biaxial stirring blade, a naturally flowing thin film polymerizer having a shelf, an inclined It is prepolymerized to a desired degree of polymerization by using a thin film polymerization apparatus that naturally flows down a plane, an apparatus such as a wet wall tower, a kneader, a melt kneader, or the like, or a combination of these apparatuses. Further, the polymerization form may be either a batch type or a continuous type.

  Polyamide resins preferably used in the present invention are polycaprolactam (nylon 6), polytetramethylene adipamide (nylon 46), polyhexamethylene adipamide (nylon 66), polyhexamethylene sebacamide (nylon 610), poly Hexamethylene dodecamide (nylon 612), polyundecamethylene adipamide (nylon 116), polyundecalactam (nylon 11), polydodecalactam (nylon 12), polytrimethylhexamethylene terephthalamide (nylon TMHT), poly Hexamethylene isophthalamide (nylon 6I), polynonanemethylene terephthalamide (9T), polyhexamethylene terephthalamide (6T), polybis (4-aminocyclohexyl) methane dodecamide (nylon PAC 12), polybis (3-methyl-aminocyclohexyl) methane dodecamide (nylon dimethyl PACM12), polymetaxylylene adipamide (nylon MXD6), polyundecamethylene hexahydroterephthalamide (nylon 11T (H)), and these Among them, a polyamide copolymer containing at least two different polyamide raw materials, a mixture thereof, and the like.

Specific examples of the polymerizable amino acid which is the polyamide resin raw material include 6-aminocaproic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, and paraaminomethylbenzoic acid. In the present invention, these polymerizable amino acids may be used alone or in combination of two or more.
Specific examples of polymerizable lactams include butyl lactam, pivalolactam, caprolactam, capryl lactam, enantolactam, undecanolactam, and dodecanolactam. In the present invention, one kind of these polymerizable lactams may be used, or two or more kinds thereof may be used in combination.

  Examples of the diamine of a salt or mixture of a polymerizable diamine and a dicarboxylic acid include, for example, tetramethylene diamine, hexamethylene diamine, undecamethylene diamine, dodecamethylene diamine, 2-methylpentamethylene diamine, nonane methylene diamine, 2,2, 4-trimethylhexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, 5-methylnonamethylenediamine, 2,4-dimethyloctamethylenediamine, metaxylylenediamine, paraxylylenediamine, 1,3-bis ( Aminemethyl) cyclohexane, 3,8-bis (aminomethyl) tricyclodecane, 1-amino-3-aminomethyl-3,5,5-trimethylcyclohexane, bis (4-aminocyclohexyl) methane, bis (3- Methyl-4 Aminocyclohexyl) methane, 2,2-bis (4-aminocyclohexyl) propane, bis (aminopropyl) piperazine, and the like aminoethylpiperazine. In the present invention, these polymerizable diamines may be used alone or in combination of two or more.

  Examples of the dicarboxylic acid of the polymerizable diamine / dicarboxylate include malonic acid, dimethylmalonic acid, succinic acid, glutaric acid, adipic acid, 2-methyladipic acid, trimethyladipic acid, pimelic acid, and 2,2-dimethylglutar. Acid, 3,3-diethylsuccinic acid, azelaic acid, sebacic acid, suberic acid, dodecanedioic acid, eicodioic acid, terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, 2-chloroterephthalic acid, 2-methylterephthalic acid, 5- Examples include methyl isophthalic acid, 5-sodium sulfoisophthalic acid, hexahydroterephthalic acid, hexahydroterephthalic acid, and diglycolic acid. In the present invention, these polymerizable dicarboxylic acids may be used singly or in combination of two or more.

Moreover, the copolymer in which different bonds, such as an ester bond, an amide bond, and a carbonate bond, exist in random or block form may be sufficient. Specific examples of such copolymers include polyester amides.
In addition, all of these polymerization intermediates include those obtained by previously copolymerizing polyalkylene glycols such as polyethylene glycol, polypropylene glycol, and polytetramethylene glycol.
For a specific method for producing the above-mentioned polymerization intermediate, for example, “Polymer Synthesis, vol. 1, second edition”, 1992 (published by Academic Press, Inc., USA) can be referred to.

  The relative viscosity of the polymerization intermediate suitable for the present invention is a value measured at 25 ° C. at a concentration of 1% in 98% sulfuric acid evaluated according to JIS-K6810, preferably 1.5 to 3.0, more preferably 1.7 to 2.7, most preferably 2.0 to 2.5. In order to prevent the polymerization intermediate discharged from the holes in the perforated plate of the polymerization vessel from foaming and scattering violently and adhering to the inner wall of the polymerization vessel to contaminate the polymerization vessel, the relative viscosity is 1.5 or more. It is preferable that the relative viscosity is 1.7 or more in order to drastically increase the polymerization rate while maintaining the state containing a large amount of bubbles as described above. It is still more preferable that it is above. On the other hand, in order to suppress deterioration in quality due to the resin staying in the polymerization vessel for a long period of time, the polymerization intermediate preferably has a relative viscosity of 3.0 or less. In order to polymerize, since it is better that the amount of by-produced water is large, the relative viscosity is more preferably 2.7 or less, and further preferably 2.5 or less.

(C) Description of polymerization vessel:
The polymerization apparatus of the present invention supplies the above polymerization intermediate to the polymerization apparatus in a molten state, discharges it from the hole of the perforated plate, and then melts polycondensation under reduced pressure while dropping along the support. It is the apparatus characterized by performing.
(C-1) Perforated plate:
The perforated plate is a plate-like body having a plurality of through holes. By using the perforated plate, it is possible to suppress the drift of the polymerization intermediate and to prevent local retention in the polymerization vessel, and to produce a high-quality and homogeneous polyamide resin.

The thickness of the porous plate structure is not particularly limited, but is usually in the range of 0.1 to 300 mm, preferably 1 to 200 mm, more preferably 5 to 150 mm. The perforated plate can withstand the pressure of the supply chamber of the melt polymerization intermediate, and when the support of the polymerization chamber is fixed to the perforated plate, the perforated plate has sufficient strength to support the weight of the support and the falling polymerization intermediate. It is necessary and reinforced by ribs or the like is one of the preferable modes.
The holes of the perforated plate are usually selected from shapes such as a circle, an ellipse, a triangle, a slit, a polygon, and a star. Cross-sectional area of the hole is usually 0.01～100Cm ^2, preferably 0.05～10Cm ^2, particularly preferably from 0.1 to 5 cm ^2. It also includes providing a nozzle or the like connected to the hole.

The space | interval of a hole is 1-500 mm normally by the distance of the center of a hole, Preferably it is 10-100 mm. The hole of the porous plate may be a hole penetrating the porous plate or may be a case where a tube is attached to the porous plate. Further, it may be tapered. It is preferable to determine the size and shape of the holes so that the pressure loss when the polymerization intermediate passes through the porous plate is 0.1 to 50 kg / cm ² .
The number of holes in the perforated plate is not particularly limited, and varies depending on conditions such as reaction temperature and pressure, the amount of catalyst, the range of molecular weight to be polymerized, and the like, but when a polymer is usually produced, for example, 10 to 10 ⁵ pieces, and more preferably from 50 to 10 ^4, more preferably from required ¹⁰ 2 to 10 ³ holes.

The material of the perforated plate is usually preferably a metal material such as stainless steel, carbon steel, hastelloy, nickel, titanium, chromium, or other alloy.
Examples of the method of discharging the polymerization intermediate through such a perforated plate include a method of dropping by a liquid head or its own weight, or a method of pressing and extruding using a pump or the like. In order to suppress this, it is preferable to extrude using a pump having a measuring ability such as a gear pump.
In addition, it is preferable to provide a filter in the flow path upstream of the porous plate. The filter can remove foreign substances that block the holes of the perforated plate. The type of the filter is appropriately selected so that foreign matters having a diameter larger than the pore diameter of the perforated plate can be removed and the filter is not damaged by the passage of the polymerization intermediate.

(C-2) Support:
The polymerization intermediate discharged from the holes of the perforated plate falls along the support. At this time, assuming that the surface area of the polyamide resin falling along the support is S ₁ , and the area where the support and the polyamide resin are in contact is S ₂ , the conditions satisfy the relationship of S ₁ / S ₂ > 1. It is necessary to polymerize.
Here, S ₁ : The surface area of the falling polyamide resin is the average surface area of the surface of the polyamide resin falling along the surface of the support in contact with the gas phase. For example, a wire-shaped support When the polyamide resin is dropped along the surface, it is geometrically calculated from the average radius around the wire of the polyamide resin that wraps around the wire and flows down into a cylindrical shape or a truncated cone shape. The above “average radius of polyamide resin centered on the wire” is determined by a method of measuring from a peep window installed in the polymerization vessel, a method of calculating from the weight of the resin staying inside the polymerization vessel and the shape of the support, etc. You can ask.

S ₂ : The area value where the support and the polyamide resin are in contact is equal to the surface area of the support when the polyamide resin wraps the entire support. The present invention needs to have a relationship of S ₁ / S ₂ > 1. In the case of S ₁ / S ₂ ≦ 1, for example, in the case of a conventionally known wet wall polymerization reactor, S ₁ / S ₂ <1, but if the value of S ₁ is increased for the purpose of promoting the polycondensation reaction, it is inevitable. the value of S ₂ is also increased, polyamide resin drop becomes difficult as a high polymerization degree. As a result, surface renewal due to dropping is not performed sufficiently, and foaming at the time of dropping is difficult to occur, so that the polymerization reaction is stalled, and when the polymerization intermediate falls along the support, single flow tends to occur and uniform It is difficult to obtain a high quality polyamide resin. Further, since gel is formed on the support and adheres to it, it is difficult to operate continuously for a long time. This tendency becomes more conspicuous as the polyamide resin having a higher degree of polymerization is obtained. To try to improve the surface renewability falling reversed to facilitate the inevitable to increase the thickness, resulting in the value of S ₁ is becomes small, also a high polymerization degree of the polyamide resin It is difficult to manufacture.

In contrast, the present invention is characterized in that the value of S ₁ / S ₂ is made larger than ₁ by using a support such as a wire. The value of S ₁ / S ₂ can be arbitrarily adjusted depending on the shape of the support and the supply amount of the polymerization intermediate, but is more preferably 1.5 or more, further preferably 2 or more, and particularly preferably 3 or more. And most preferably 4 or more, and most preferably 5 or more. Unlike the case of the wet wall polymerization apparatus, the effect of increasing the surface area by increasing the value of S ₁ and the effect of increasing the surface renewability by decreasing the value of S ₂ to facilitate the fall of the polymerization intermediate. Since both can be achieved, the polymerization rate can be dramatically improved. Of course, the single flow at the time of dropping can also be prevented and the gel does not adhere, so a high-quality polyamide resin can be produced continuously for a long period of time.

  The specific structure of the support is “wire”, “chain” or “lattice (wire mesh)” combining wire-like materials, and wire-like materials connected like a jungle gym. Examples thereof include “three-dimensional lattice shape”, “thin plate shape” having flatness or curvature, and “perforated plate shape”. In addition, in order to efficiently extract reaction by-products and impurities generated by thermal decomposition during polymerization, the surface area of the resin to be dropped is increased, and the support having an unevenness in the dropping direction of the polymerization intermediate It is preferable to cause agitation and renewal of the surface positively by dropping along, and a support having a structure that prevents the resin from dropping, such as “wire shape with unevenness in the resin dropping direction” is also preferable. . A combination of these supports can also be used.

“Wire-like” refers to a material in which the ratio of the length in the direction perpendicular to the cross section to the average length of the outer circumference of the cross section is very large. It is not particularly limited to the area of the cross section, usually in the range of ¹⁰ -3 ^{~10 2} cm 2, preferably in the range of ¹⁰ -3 ^~10 1 cm ^2, particularly preferably from ¹⁰ -3 1 cm ² It is. The shape of the cross section is not particularly limited, and is usually selected from shapes such as a circle, an ellipse, a triangle, a quadrangle, a polygon, and a star. The cross-sectional shape includes both the same and different shapes in the length direction. The wire includes a hollow wire. The wire includes a single wire such as a wire or a combination of a plurality of wires by a method such as twisting. Examples of the surface of the wire include a smooth surface, a surface with unevenness, and a surface partially having protrusions.

“Chain” refers to a material in which rings made of the wire-like material described above are connected. Examples of the shape of the ring include a circle, an ellipse, a rectangle, and a square. The method of connection includes any one of one dimension, two dimensions, and three dimensions.
“Lattice (wire mesh)” represents a material obtained by combining the wire-like materials described above into a lattice. The wire to be combined includes straight and curved wires, and the angle to be combined can be arbitrarily selected. There is no particular limitation on the area ratio between the material and the space when a grid-like (wire mesh) material is projected from the direction perpendicular to the surface, but it is usually in the range of 1: 0.5 to 1: 5000, Preferably it is the range of 1: 1-1: 3000, Most preferably, it is the range of 1: 5-1: 1000. The area ratio is preferably equal in the horizontal direction, and is preferably equal in the vertical direction, or the space ratio is increased toward the lower part.

The “three-dimensional lattice shape” represents a material in which a wire-like material is three-dimensionally combined into a three-dimensional lattice shape like a so-called jungle gym. The wire to be combined may be linear or curved, and the angle to be combined can be arbitrarily selected.
“Wire shape with irregularities in the falling direction of the polymer” means that a wire with a round or polygonal cross section attached to the wire at a right angle, or a wire or a disk or cylindrical object attached to the wire. is there. The uneven step is preferably 5 mm or more. As a specific example, a wire with a disk whose diameter is 5 mm or more and 100 mm or less than a wire diameter, the wire penetrates the center of a disk having a thickness of 1 to 50 mm, and the distance between the disks is 1 to 500 mm. It is done.

The ratio between the volume of the support installed in the reactor and the internal volume of the reactor is not particularly limited, but is usually in the range of 1: 0.5 to 10 ⁷ , preferably 1:10 to 10. It is in the range of 1:10 ⁶ , particularly preferably in the range of 1:50 to 1:10 ⁵ . The ratio of the volume of the support to the internal volume of the reactor is preferably equal in the horizontal direction, and is preferably equal in the vertical direction, or the ratio of the internal volume of the reactor is increased in the lower part.
Depending on the shape, a single support or a plurality of supports can be appropriately selected. If "shaped wire" or "chain-like" is generally 1 to 10 ^5, preferably 3 to 10 ^4. "Grid pattern", "two-dimensionally continuous chain-like", "thin plate", in the case of "perforated plate" is generally 1 to 10 ^4, preferably 2 to 10 ^3. In the case of “three-dimensional chain shape” and “three-dimensional lattice shape”, whether to use a single or divided into a plurality can be appropriately selected in consideration of the size of the apparatus, installation space, and the like.

When there are a plurality of supports, it is also preferable to prevent the indicators from coming into contact with each other using a spacer or the like as appropriate.
The material of the support is not particularly limited, but is usually selected from stainless steel, carbon steel, hastelloy, titanium and the like. Further, the wire includes cases where various surface treatments such as plating, lining, passive state treatment, and acid cleaning are performed as necessary.
In the present invention, the polymerization intermediate is usually supplied from one or more holes of the perforated plate to one support, but the number of holes can be appropriately selected according to the shape of the support. It is also possible to drop the polymerization intermediate that has passed through one hole along a plurality of supports.
The position of the support is not particularly limited as long as the polymerization intermediate can fall along the support, and the method of attaching the support to the porous plate is the same as when it is installed through the hole of the porous plate. The case where it installs in the lower part of the hole of a perforated panel without selecting can be selected suitably.
The height at which the polymerization intermediate that has passed through the holes is dropped along the support is preferably in the range of 0.5 to 50 m, more preferably in the range of 1 to 20 m, and more preferably in the range of 2 to 10 m. It is a range.

(C-3) Discharge port:
The discharge port is provided at the bottom of the polymerization vessel, and a device for discharging the polymerized polyamide resin such as a gear pump and / or a screw type pump to the outside of the polymerization vessel is installed. In order to remove the resin that has fallen to the bottom of the polymerization vessel while replacing it with the resin that flows down without being retained for a long period of time, it is preferable that the bottom of the polymerization vessel has a slope, and the slope of the bottom of the polymerization vessel and the vertical line It is more preferable that the angle formed between and is in the range of 0 to 85 °.
Further, the bottom of the polymerization vessel is preferably smooth in order to suppress the formation of foreign matters, and more preferably the ten-point average surface roughness defined in JIS B0601 is 500 μm or less.
The number of the discharge ports and the discharge devices installed in the discharge ports may be one or two or more. In the case of a large polymerization vessel with high productivity, it is more preferable to install two or more. There are no particular limitations on the number of discharge ports and the number of discharge devices installed in the discharge port.

(C-4) Heating device:
The polymerization temperature is appropriate by controlling the temperature of the heater or heat medium jacket placed on the wall of the polymerizer covering the support, or by controlling the temperature of the heater or heat medium placed inside the support. Can be set.
(C-5) Pressure reducing device:
The degree of vacuum of the polymerization vessel can be appropriately set by connecting a vent port installed at an arbitrary position of the polymerization vessel to a vacuum line and controlling the degree of pressure reduction. From the vent port, polymerization by-products, impurities generated by thermal decomposition during polymerization, and an inert gas introduced in a small amount into the polymerization vessel as necessary for the purpose of increasing the polymerization rate are discharged.
(C-6) Inert gas supply device:
When an inert gas is directly introduced into the polymerization vessel for the purpose of increasing the polymerization rate, it can be supplied from an introduction port installed at an arbitrary position of the polymerization vessel. The position of the inert gas inlet is preferably far from the perforated plate and near the outlet of the polyamide resin. It is also desirable to be away from the vent port.

  Alternatively, a method in which an inert gas is absorbed and / or contained in the polymerization intermediate in advance is also possible. In this case, an inert gas supply device is added upstream of the polymerization reactor of the present invention. The inert gas supply device is, for example, a chemical device design / operation series No. 2. Revised gas absorption, pages 49 to 54 (published on March 15, 1981, published by Chemical Industry Co., Ltd.), known absorption devices such as packed tower type absorption devices, shelf type absorption devices, spray tower type absorption devices, etc. Examples thereof include a method used and a method in which an inert gas is injected into a pipe for transferring a polymerization intermediate. The most preferable method is to use an apparatus that absorbs the inert gas while dropping the polymerization intermediate along the support in an inert gas atmosphere. In this method, an inert gas having a higher pressure than that inside the polymerization vessel is introduced into the apparatus for absorbing the inert gas. The pressure at this time is preferably 0.01 to 1 MPa, more preferably 0.05 to 0.5 MPa, and still more preferably 0.1 to 0.2 MPa.

(D) Description of polymerization method:
The present inventors have surprisingly surprised the polyamide resin that falls along the support by polymerizing the above-described polymerization intermediate within the range of the polymerization temperature and the degree of vacuum described later using the above-described polymerization vessel. In the state of containing a large amount of bubbles, the phenomenon that “the surface area of the polymer is increased” and “the polymer rolls down on the support in the form of bubble balls” was found. Along with this, it was confirmed that the polymerization rate was dramatically increased and the hue of the polymerized polyamide resin was improved. In the present invention, even if the degree of polymerization of the polyamide resin is increased, the polymer is polymerized in a state containing a large amount of bubbles, so that the fluidity is good on the support and the bottom of the polymerization vessel, and it does not stay for a long time at these locations. It is considered that the hue has been improved. It is considered that the gel formation hardly occurs during the polymerization because of the same reason. Moreover, when a highly polymerized polyamide resin is extracted from the polymerization vessel, high shearing force is hardly generated and there is little deterioration in product quality due to increase in liquid temperature or molecular chain breakage.

(D-1) Polymerization temperature:
The polymerization temperature is preferably a melting point of the polyamide resin polymerization intermediate of −10 ° C. or higher and a melting point of + 60 ° C. or lower. By setting the melting point to −10 ° C. or more, solidification of the reaction product and an increase in reaction time can be prevented, and by setting the melting point to 60 ° C. or less, a polyamide resin having an excellent color tone can be manufactured while suppressing thermal decomposition. The melting point is preferably −5 ° C. or higher, melting point + 40 ° C. or lower, more preferably melting point −3 ° C. or higher, melting point + 30 ° C. or lower, particularly preferably melting point −2 ° C. or higher, melting point + 20 ° C. or lower, melting point −1 ° C. or higher, The melting point + 10 ° C. or lower is most preferable.
The reason why such a relatively low polymerization temperature is preferable in the present invention is that the polyamide resin tends to contain a large amount of bubbles during the polymerization, and the polymerization rate can be dramatically increased.
Here, the melting point is a peak temperature of an endothermic peak derived from the melting of a crystal when measured under the following conditions using a Pyris 1 DSC (input compensation differential calorimeter) manufactured by Perkin Elmer. The peak temperature was determined using the attached analysis software.
Measurement temperature: 0 to 320 ° C
Temperature increase rate: 10 ° C / min

(D-2) Polymerization pressure:
The melt polymerization reaction of the present invention must be performed under reduced pressure in order to bring the polyamide resin during polymerization into a state containing a large amount of bubbles. The degree of vacuum is appropriately adjusted according to the sublimation state and reaction rate of polyamide resin, by-products, oligomers, and the like. The degree of vacuum is preferably 100000 Pa or less, more preferably 80000 Pa or less, further preferably 50000 Pa or less, and particularly preferably 20000 Pa or less. The lower limit is not particularly limited, but is preferably 0.1 Pa or more in view of the scale of equipment for reducing the pressure in the polymerization vessel.
In addition, a small amount of inert gas that does not adversely affect the polymerization reaction is introduced into the polymerization vessel under reduced pressure, and polymerization by-products and impurities generated by thermal decomposition during polymerization are accompanied with these gases and removed. This is also a preferred method.

  The introduction of the inert gas into the polymerization vessel is conventionally understood to be because the reaction is advantageously advanced by lowering the partial pressure of polymerization by-products and shifting the equilibrium. However, the amount of the inert gas introduced in the present invention may be very small, and the effect of increasing the polymerization rate due to the partial pressure lowering effect is so small that the effect of the inert gas cannot be explained by the conventional understanding. According to the study by the present inventors, surprisingly, by introducing an inert gas into the polymerization vessel, the foaming phenomenon of the polymerization intermediate falling in a molten state along the support becomes intense, and the polymerization intermediate It was observed that the surface area of the body increased dramatically, and the surface renewal state became extremely good. Although the principle is not clear, it is presumed that the change in the internal and surface states of this polymerization intermediate causes the polymerization rate to increase dramatically.

The inert gas to be introduced is preferably a gas that does not adversely affect the polyamide resin such as coloring, transformation, decomposition, etc., and includes nitrogen, argon, helium, carbon dioxide, lower hydrocarbon gas, and mixed gas thereof. As the inert gas, nitrogen, argon, helium and carbon dioxide are more preferable, and nitrogen is particularly preferable because of its availability.
The amount of the inert gas introduced in the present invention may be very small, and is preferably 0.05 to 100 mg per 1 g of polyamide resin withdrawn from the polymerization reactor. By setting the amount of the inert gas to 0.05 mg or more per 1 g of the polyamide resin to be extracted, the foaming of the resin is sufficient and the effect of increasing the degree of polymerization is increased. On the other hand, when the amount is 100 mg or less, it is easy to increase the degree of vacuum. The amount of the inert gas is more preferably 0.1 to 50 mg per 1 g of the polyamide resin to be extracted, and particularly preferably 0.2 to 10 mg.

  As a method for introducing the inert gas, a method of directly introducing into the polymerization vessel, an inert gas is absorbed and / or contained in the polymerization intermediate in advance, and the absorbed and / or contained gas is polymerized under reduced pressure. Examples thereof include a method of releasing from an intermediate and introducing it into the polymerization vessel, and a method of using these in combination. Here, absorption refers to the case where an inert gas is dissolved in the polymerization intermediate and does not exist as bubbles, and inclusion refers to the presence as bubbles. When present as bubbles, the smaller the bubble size, the better. The average bubble diameter is preferably 5 mm or less, and more preferably 2 mm or less.

(D-3) Polymerization time:
The total time required for dropping the polyamide resin along the support during polymerization and the residence time at the bottom of the polymerization vessel is the polymerization time, preferably in the range of 30 seconds to 100 hours, and preferably 1 minute to 10 hours. The range of 5 minutes to 5 hours is more preferable, and the range of 20 minutes to 3 hours is particularly preferable.
In particular, in the present invention, it is possible to produce a polyamide resin having a high degree of polymerization without retaining the polymer in the liquid retention part for a long time, and dispersion in the degree of polymerization of the product due to the long time residence at the bottom of the polymerization vessel. In order to suppress the generation of gelled products, quality deterioration such as deterioration of hue, and the generation of high shearing force when extracting a highly polymerized polyamide resin from the polymerization vessel, The residence time at the bottom of the polymerization vessel is preferably in the range of 10 seconds to 1 hour. The residence time at the bottom of the polymerization vessel is more preferably in the range of 20 seconds to 40 minutes, more preferably in the range of 30 seconds to 20 minutes, and particularly preferably in the range of 40 seconds to 10 minutes. Most preferably, it is in the range of 1 minute to 5 minutes.
In the present invention, there are a method of extracting all the polyamide resin polymerized from the polymerization intermediate from the polymerization vessel in one pass, a method of circulating a part of the polymerized polyamide resin and introducing it again into the polymerization device, etc. The method is more preferred. In the case of circulation, in order to suppress thermal decomposition at the bottom of the polymerization vessel, the circulation line, etc., it is preferable to shorten the residence time in these places and lower the temperature.

(D-4) Polymerization rate:
In the case of a wire-like support, the polymerization capacity of the polymerization vessel of the present invention has a feature that increases in proportion to the number of wires installed in the polymerization vessel, and has a feature that a scale-up design is easy.
In the case of a wire-like support, the polymerization intermediate flow rate per support is preferably 10 ⁻² to 10 ² liter / hr, and by setting this range, sufficient production capacity can be secured and polymerization can be performed. Speed can also be increased dramatically. More preferably, it is the range of 0.1-50 liter / hr.
Such as lattice-like (wire mesh-like), in the case of a support that combines wire, per one vertical wire structure constituting the support, preferably 10 ^-2 to 10 ² liters / hr, more preferably In the range of 0.1 to 50 liters / hr.
Lamellar such, when the support is not a structure combining wire, per hole of the perforated plate supplies polymer intermediate to the support, preferably 10 ^-2 to 10 ² liters / hr, More preferably, it is the range of 0.1-50 liter / hr.

(D-5) Discharge method of polyamide resin:
As described above, in the present invention, the polymerization is performed for the purpose of suppressing the deterioration of the product quality due to the residence at the bottom of the polymerization vessel for a long time and the generation of high shear force when the polyamide resin having a high polymerization degree is withdrawn from the polymerization vessel. The residence time of the polyamide resin at the bottom of the polymerization vessel is preferably in the range of 10 seconds to 1 hour, but the polyamide resin falling and staying at the bottom of the polymerization vessel is The ratio of the volume (V / U) where the line at the upper end in contact with the inner wall surface is L, the volume of the polymerization vessel below the line L is U, and the volume of the polymer staying at the bottom is V Is preferably discharged in a range of 0.00001 to 0.95, since the polyamide resin flow at the bottom of the polymerization vessel becomes a piston flow, and the above object can be further achieved. About the value of V and U, it can obtain | require by the method of measuring from the observation window installed in the superposition | polymerization device, the method of calculating from the resin weight which retains in the bottom part of a superposition | polymerization device, The value of (V / U) is The discharge rate of the polyamide resin and the shape of the bottom of the polymerization vessel can be adjusted.

By setting (V / U) to 0.00001 or more, it becomes easy to keep the discharge amount of the polyamide resin constant. By setting (V / U) to 0.95 or less, the effect of piston flow is exhibited. (V / U) is more preferably in the range of 0.00002 to 0.90, further preferably in the range of 0.00005 to 0.80, and particularly preferably in the range of 0.0001 to 0.70. is there.
The discharged polyamide resin can be once pelletized and then re-melted and used for molding, or it can be transferred to a molding machine or spinning machine in the molten state and molded into a higher quality molded product. Can be manufactured at low cost.

  In the case of pellets, it is desired that there is little loss and that the pellets can be uniformly extruded by an extruder. In order to obtain such pellets, it is preferable to extrude the molten resin into a strand shape or a sheet shape, quickly put it in a coolant such as water, cool it, and then cut it. The temperature of the refrigerant is preferably 60 ° C. or lower, more preferably 50 ° C. or lower, and further preferably 40 ° C. or lower. As the refrigerant, water is preferable in view of economic efficiency and handleability. For this reason, the refrigerant temperature is preferably 0 ° C. or higher. The cutting to form a pellet is preferably performed after cooling to 100 ° C. or less within 180 seconds after extruding the resin.

(D-6) Others:
In addition to the above-described method of supplying from the perforated plate of the polymerizer, the present invention may be equipped with a uniaxial or biaxial kneader or static mixer between the polymerizer and the molding machine, and if necessary, a stabilizer. This includes the case where additives such as nucleating agents and pigments are added to the resin.
From the viewpoint of productivity and quality, the relative viscosity of the polyamide resin obtained by the production method of the present invention is preferably 2.5 to 6.0, more preferably 2.7 to 5.7, and still more preferably. Is 2.8 to 5.5. When it is out of the above range, when the polyamide resin is molded and used for the intended purpose, there is a tendency that problems such as difficulty in molding and deterioration of the quality of the obtained product tend to occur.
In the present invention, various additives as required, for example, polymerization catalyst, polymerization inhibitor, heat stabilizer, lubricant, flame retardant, antistatic agent, antifoaming agent, color adjuster, antioxidant, ultraviolet absorber, This includes the case where a crystal nucleating agent, a brightening agent, an impurity scavenger, and a matte are copolymerized or mixed. These additives can be added at any stage.

  The polyamide resin produced according to the present invention has a high degree of polymerization, excellent hue, and low impurity content, so that it can be used in various applications such as fibers, films, sheets, plates, containers, food containers, toys. , Stationery such as pen shafts, caps, clips and boards, office supplies parts such as desks, chairs and bags, clothing parts such as fasteners, buttons and clips, mechanical parts such as gears, cams and springs, sockets and connectors, etc. Electronic equipment parts, composite parts formed by insert molding or outsert molding with casings and metal parts such as electrical appliances, building material parts such as boards, artificial marble and handles, automobile parts such as bumpers, panels, handles and safety belts, etc. It can be preferably used in a wide range of fields.

Next, as a preferred example of the present invention, polymerization of polyamide resin will be described with reference to the drawings.
FIG. 1 and the following figures show preferred combinations for achieving the method of the present invention, but the present invention is not limited thereto.
In FIG. 1, the polyamide resin polymerization intermediate is supplied to the polymerization vessel from the raw material supply port 2 via the transfer pump 1, introduced into the polymerization vessel through the perforated plate 3, and falls along the support 5. The inside of the polymerization vessel is controlled to a predetermined pressure reduction degree, and by-product water and the like, and inert gas such as nitrogen introduced from the inert gas supply port 6 as needed are discharged from the pressure reduction exhaust port 7. . The polymerized polyamide resin is discharged by the discharge pump 8 and extracted from the discharge port 9, and then quickly brought into contact with a coolant such as water and cooled, and then cut into pellets.

The polyamide resin polymerized while dropping along the support falls to the lower part of the polymerization vessel, and is then extracted from the discharge port by the discharge pump. At this time, the polymerized polyamide resin is removed from the bottom of the polymerization vessel. It is preferable to control the residence time to be within a range of 10 seconds to 1 hour and to be as constant as possible. The amount of stay can be controlled by monitoring the amount of stay from the observation window or by monitoring the amount of stay using a capacitance type level meter, etc. To implement.
The transfer pump, the polymerization vessel main body, the discharge pump, the resin transfer pipe, and the like are heated and kept warm by a heater or a jacket.

The polymerization vessel used in the present invention can be equipped with a stirrer or the like at the bottom of the polymerization vessel, but is not particularly necessary. Therefore, it is possible to eliminate the rotation drive unit in the polymerization vessel body, and polymerization can be performed under well-sealed conditions even under high vacuum. Since the rotation drive part of the discharge pump is covered with the discharged polyamide resin, the sealing performance is much better than when the polymerization apparatus body has the rotation drive part.
The method of the present invention can be carried out with one polymerization vessel, but may be carried out with two or more. Further, it is possible to partition one polymerization group into a vertical type or a horizontal type to form a multistage polymerization vessel.

In the present invention, the process of increasing the molecular weight from the polyamide resin polymerization intermediate to the desired high-polymerization polyamide resin may be carried out by a method of polymerizing while dropping all the way from the hole of the perforated plate along the support. Although it is possible, it can also be carried out in combination with other polymerization methods such as a stirred tank type polymerizer, a horizontal type stirred polymerizer and the like.
Examples of the horizontal agitation polymerizer include screw type, independent blade type, uniaxial type, biaxial type, etc., for example, “Reaction Engineering Research Group Research Report: Reactive Processing Part 2” (Polymer Society of Japan; 1992), Chapter 4 Etc.
As the stirring tank type polymerization apparatus, for example, any of the stirring tanks described in Chapter 11 of Chemical Equipment Handbook (Edited by Chemical Engineering Association; 1989) can be used. There is no restriction | limiting in particular in the shape of a tank, Usually, a vertical type or a horizontal cylindrical type is used. The shape of the stirring blade is not particularly limited, and a paddle type, an anchor type, a turbine type, a screw type, a ribbon type, a double blade type, and the like are used.

  The process from the raw material to the production of the polymerization intermediate can be performed batchwise or continuously. In the case of carrying out in a batch system, the entire amount of reactants can be transferred to the next reactor after the raw materials and reactants are supplied to the reactor and reacted for a predetermined time. On the other hand, when performing continuously, it can carry out by supplying a raw material and a reaction material continuously to each reactor, and discharging | emitting a reaction material continuously. When producing a large quantity of polyamide resin of uniform quality, it is preferable to carry out continuously.

FIG. 2 is a specific example of a polymerization vessel for producing a polyamide resin when an inert gas absorption device is used. The polymerization intermediate is supplied to the inert gas absorption device N10 from the raw material supply port N2 via the transfer pump N1, introduced into the inert gas absorption device through the perforated plate N3, and falls along the support N5. The inside of the inert gas absorption device is controlled to a predetermined pressure reduction degree by the reduced pressure exhaust port N7, and the polymerization intermediate absorbs the inert gas such as nitrogen introduced from the inert gas supply port N6 while dropping, It is supplied to the polymerization vessel 10 from the raw material supply port 2 via the transfer pump N8, is introduced into the polymerization vessel through the perforated plate 3, and falls along the support 5. The inside of the polymerization vessel is controlled to a predetermined pressure reduction degree, and by-produced water or the like is discharged from the pressure reduction exhaust port 7. The manufactured polyamide resin is discharged from the discharge port 9 by the discharge pump 8, and is quickly brought into contact with a coolant such as water and cooled, and then cut into pellets.
A transfer pump, an inert gas absorber main body, a polymerization vessel main body, a discharge pump, a resin transfer pipe, and the like are heated and kept warm by a heater or a jacket.

The present invention will be described based on examples.
In addition, the main measured value in an Example was measured with the following method. (1) Relative viscosity It implemented according to JIS-K6810. Specifically, a 1% concentration solution ((polyamide resin 1 g) / (98% sulfuric acid 100 ml)) was prepared using 98% sulfuric acid and measured under a temperature condition of 25 ° C.
(2) Crystal melting point The crystal melting point was measured under the following conditions using a Pyris 1 DSC (input compensation differential calorimeter) manufactured by Perkin Elmer, and the peak value of the endothermic peak derived from the melting of the crystal was determined as the crystal melting point. did. The peak value was determined using the attached analysis software.
Measurement temperature: 0 to 320 ° C
Temperature rising rate: 10 ° C./min (3) Whiteness The whiteness of polyamide resin pellets obtained by the following formula was determined using ND-100DP manufactured by Nippon Denshoku Industries Co., Ltd.
W = 100 − [(100−L) ² + a ² + b ² ] ^1/2
(L, a, and b are hue scales proposed by R. S. Hunter, and indicate brightness, redness, and yellowness, respectively.)

[Example 1]
Using the apparatus shown in FIG. 1, a polymerization intermediate of nylon 66 resin having a relative viscosity of 2.9 and a crystal melting point of 260 ° C. is supplied from the raw material supply port 2 to the polymerization vessel 10 by the transfer pump 1, and the temperature is 270 ° C. After being discharged at a rate of 10 g / min per hole from the holes of the perforated plate 3 in the molten state, it is polymerized at a reduced pressure of 40000 Pa while dropping along the support at the same atmospheric temperature as the discharge temperature. The pellets were extracted from the discharge port 9 by the discharge pump 8 and pelletized, and were continuously operated for 48 hours to produce nylon 66 resin pellets.
A perforated plate having a thickness of 50 mm and four holes having a diameter of 1 mm arranged linearly at intervals of 30 mm was used. The support is a grid of 2 mm in diameter and 8 m in length, attached to each hole in the vicinity of each hole and hanging vertically, and 2 mm in diameter and 150 mm in length attached to the wires at intervals of 50 mm. A thing was used. The material of the support was stainless steel.

The discharge pump was operated while monitoring from the observation window so that the nylon 66 resin did not stay at the bottom of the polymerization vessel for a long time and the amount of the stay was constant. The residence time in the polymerization vessel at this time was 130 minutes. As the residence time, a value obtained by dividing the amount of resin in the polymerization vessel by the supply amount was used. At this time, the residence time at the bottom of the polymerization vessel was video-shooted from the viewing window, and the residence time at the bottom of the polymerization vessel was calculated to be 3.2 minutes from 5 still image intervals of 3 minutes. . When the (V / L) value was also evaluated using the same still image, it was 0.85.
During polymerization, there was very little foaming of the polymer intermediate discharged from the perforated plate, and contamination of the die surface and wall surface due to this. The falling resin contained a large amount of foam, and the behavior of rolling down the support in the form of foam balls was observed while wrapping the longitudinal wires of the support. The resin falling from the observation window was video-recorded, and the average radius of the resin flow centered on the longitudinal wire was calculated from five still images at 3-minute intervals, and it was 1.35 cm. From this, S ₁ = Calculated as 27130 cm ² . On the other hand, since the total surface area (S ₂ ) of the support was 5357 cm ² , the value of S ₁ / S ₂ was calculated to be 5.1.
High quality nylon 66 resin pellets having a high degree of polymerization and good whiteness were stably produced. The results are shown in Table 1.
In addition, although the bottom part of the polymerization vessel was observed after the experiment was completed, adhesion of foreign substances such as gel was not recognized.

[Comparative Example 1]
Nylon 66 resin pellets were produced by continuous operation for 48 hours in the same manner as in Example 1 except that a large amount of nylon 66 resin was retained at the bottom of the polymerization vessel. At this time, the current value of the discharge pump 8 increased by 50% or more compared to Example 1, and the fluctuation range of the current value also increased.
In addition, RV and whiteness of the manufactured pellets were lowered, and fluctuations in characteristic values were also observed. The results are shown in Table 1.
When the bottom of the polymerization vessel was observed after the experiment was completed, a small amount of gel was attached to the periphery.

[Examples 2 to 4]
Compared to the porous plate of Example 1, the number of holes is 8 times, and the array of 4 arrays arranged linearly at intervals of 30 mm is arranged in parallel at 2 intervals of 100 mm. The same polymerization vessel as in Example 1 was used except that two lattice-like supports as in Example 1 were installed in parallel at an interval of 100 mm. Nylon 66 resin pellets were produced by continuous operation for 48 hours in the same manner as in Example 1 except that the polymerization was carried out under various polymerization intermediates and various polymerization conditions shown in Table 1.
In Examples 2 to 4, the (V / L) value was 0.50 or less. At this time, the fluctuation range of the current value of the discharge pump 8 was smaller than that in Example 1. About all of Examples 2-4, the high quality nylon 66 resin pellet which has a high polymerization degree and favorable whiteness was able to be manufactured stably. The results are shown in Table 1.

[Example 5]
Using the same polymerization vessel as in Examples 2-4, nylon 6 resin pellets were continuously operated for 48 hours by the same operation as in Example 1 except that a polymerization intermediate of nylon 6 resin was polymerized under the conditions shown in Table 1. Manufactured.
High quality nylon 6 resin pellets having a high degree of polymerization and good whiteness were stably produced. The results are shown in Table 1.

[Comparative Examples 2-3]
Nylon 6 resin pellets were produced by continuous operation for 48 hours by the same operation as in Example 5 except that the conditions shown in Table 1 were used.
In Comparative Example 2, since the polymerization temperature was too high, the RV and whiteness of the pellets decreased, and fluctuations in the characteristic values were also observed. Further, when the bottom of the polymerization vessel was observed after the experiment was completed, a gel-like substance adhered to the periphery.
In Comparative Example 3, since the polymerization temperature was too low, the polymerization intermediate introduced into the polymerization vessel was solidified and could not be carried out.

  The present invention is a melt polymerization technique that can replace a solid phase polymerization technique and produce a high-quality and high-polymerization polyamide resin with a uniform quality, industrially stable, and at low cost.

It is a schematic diagram which shows an example of the superposition | polymerization device used by this invention. It is a schematic diagram which shows an example of the superposition | polymerization device used by this invention.

Explanation of symbols

1. Transfer pump 2. 2. Raw material supply port Perforated plate 4. Peep window 5. 5. Support and falling resin 6. Inert gas supply port Vacuum outlet 8 8. Discharge pump Discharge port 10. Polymerizer N1. Transfer pump N2. Raw material supply port N3. Perforated plate N5. Support and falling polymer N6. Inert gas inlet N7. Vacuum outlet N8. Discharge / transfer pump N10. Inert gas absorber

Claims (6)

The polyamide resin polymerization intermediate is supplied to the polymerization vessel from the raw material supply port in a molten state, and is discharged from the holes of the perforated plate, and then dropped along the surface of the support installed in the polymerization vessel, A method of polymerizing under a reduced pressure at a crystal melting point of −10 ° C. or higher and a crystal melting point + 60 ° C. or lower of the polymerization intermediate, which satisfies the following conditions (A) and (B): A method for producing a polyamide resin.
(A) The surface area S _{1 of the} polyamide resin falling along the support and the area S ₂ where the support and the polyamide resin are in contact satisfy the relationship of S ₁ / S ₂ > 1.
(B) The residence time of the polymerized polyamide resin at the bottom of the polymerization vessel is in the range of 10 seconds to 1 hour.   When discharging the polyamide resin remaining at the bottom of the polymerization vessel, the upper end line in contact with the inner wall surface of the polymerization vessel is defined as line L, and the volume U of the polymerization vessel below the line L is retained at the bottom. 2. The method for producing a polyamide resin according to claim 1, wherein the ratio (V / U) of the volume V of the polymer is controlled in the range of 0.00001 to 0.95.   The method for producing a polyamide resin according to claim 1 or 2, wherein the polyamide resin polymerization intermediate has a relative viscosity of 1.5 to 3.0 in terms of relative viscosity.   The polyamide resin manufactured by the manufacturing method in any one of Claims 1-3.   A polyamide resin having a relative viscosity of 2.5 to 6.0, produced by the production method according to claim 1.   The molded object manufactured from the polyamide resin of Claim 4 or 5.

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