JP2013052508A - Method of producing polyester resin, protective sheet for solar cell module, and solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of producing a polyester resin capable of preventing vacuum break during stand-by operation and suppressing vent-up.SOLUTION: The method of producing the polyester resin includes a melt extrusion process of melting and kneading polyester material resin and performing melt extrusion by increasing an extrusion amount Q [kg/h] of molten polyester resin from Qto Qby adjusting a screw rotational frequency N in a range in which a unit extrusion amount Y [kg/hr/rpm] satisfies a region indicated by the following relationships (1), (2): (1) (Y-Y)/Q≤(Y-Y)/Q; and (2) (Y-a×Y)/(Q-Q)≥(Y-Y)/Q(wherein, Y denotes the unit extrusion amount Q/N [kg/hr/rpm] per rotation of a screw, Yis 3.4×10×D[kg/hr/rpm] and Yis 6.6×10×D[kg/hr/rpm], respectively, D denotes a screw diameter [mm], Q denotes the extrusion amount [kg/h] per unit time of the molten polyester resin during operation, Qdenotes an extrusion amount during production operation, Qdenotes an extrusion amount during the stand-by operation, N denotes the rotational frequency [rpm] of the screw, and (a) denotes a numerical value defining a lower limit of Q/N of the extrusion amount during the production operation.).

Description

  The present invention relates to a polyester resin production method, a solar cell protective sheet, and a solar cell module.

  Polyester is applied to various uses such as electrical insulation and optical uses. Among these, solar cell applications such as a sheet for protecting the back surface of a solar cell (so-called back sheet) have attracted attention as electrical insulation applications in recent years.

  On the other hand, polyester usually has many carboxy groups and hydroxyl groups on its surface, and tends to undergo a hydrolysis reaction under environmental conditions where moisture exists, and tends to deteriorate over time. For example, the installation environment in which solar cell modules are generally used is an environment that is constantly exposed to wind and rain, such as outdoors, and because it is exposed to conditions where hydrolysis reaction is likely to proceed, the hydrolyzability of polyester is stable. It is desired that the state is controlled to be suppressed.

  Polyester is generally formed by melt extrusion using a vented twin screw extruder. Conventionally, the rotation speed N of the screw is set so that the unit extrusion amount Q / N of the extruded resin per rotation of the screw of the extruder is always constant, and the operation is controlled. On the other hand, except in the case of performing the desired production operation, it is switched to the standby operation mode. However, in the standby operation, the extrusion is not normally stopped completely, and a certain amount is continuously held in the extruded state. Yes.

  However, when Q / N is constant, especially when the raw material supply amount increases, for example, when switching from standby operation to production operation, the molten resin fills the vent (reverse flow), and further for suction that leads to the vent. There is a problem that a so-called vent-up is easily caused, for example, the molten resin is sucked into the vent pipe and the pipe is clogged.

  As one of the methods for preventing the above-mentioned vent-up, for example, the sign of vent-up is detected by the output of the pressure sensor arranged in the deaeration part in the cylinder, and the screw rotation speed and the supply amount are set within a range not venting up. A control technique is disclosed (for example, see Patent Document 1).

  Also, in order to reduce the amount of molten resin discharged during the so-called standby operation until the production operation, when shifting from the standby operation state to the production operation, the gear pump inlet pressure is set to a predetermined set value and the feeder discharge An extrusion method in which the amount is changed from one set value to another set value is disclosed (for example, see Patent Document 2).

  Also, a control method for increasing the raw material supply amount to the steady operation state while controlling the raw material supply amount, the extrusion rotation speed, and the take-up speed so as to satisfy the predetermined relational expression in order to shorten the startup time until the steady production operation. Is disclosed (for example, see Patent Document 3).

JP-A-6-254945 JP 2008-23847 A JP 2002-347103 A

  However, in the method of detecting a sign of vent-up as described above, monitoring is always necessary, and it is difficult to completely eliminate the vent-up. When vent-up occurs, foreign matter failure due to long-term staying occurs, the intrinsic viscosity (IV: Intrinsic Viscosity) decreases, etc., not only the quality of the resin itself decreases, but also the extruder can be stopped. There is sex. In addition, recyclability is also impaired due to quality degradation. Therefore, a method for effectively preventing vent-up is required.

  As described above, in the extrusion molding method in which the feeder discharge amount is changed from one set value to another set value, the Q / N is set to a predetermined value in advance, and the inlet pressure of the gear pump is set to a predetermined value. , Switched to production operation. Therefore, although it is not impossible to prevent vent-up in advance, pressure control in the cylinder is not effective in order to keep the Q / N and the tip pressure of the cylinder constant, and therefore the pressure tends to fluctuate constantly in the cylinder. Therefore, it is still necessary to constantly monitor the vent-up.

  Further, in the conventional control method in which the raw material supply amount is increased to the steady manufacturing operation state by controlling the raw material supply amount, the extrusion rotation speed, and the take-off speed, the Q / N is kept constant and the steady operation state is maintained. Therefore, it is difficult to prevent vent-up when the raw material supply amount is increased only by the control here.

  As described above, conventionally, even in a production process in which the supply amount of raw materials increases, such as switching from standby operation to production operation, the operation is normally performed without changing Q / N. However, if the Q / N is kept constant when the raw material supply amount is increased, vent-up is likely to occur, and in order to reduce raw material loss during standby operation, the amount of extrusion during standby is kept lower than before. If it tries to do so, vent-up when starting up production operation cannot be ignored. Therefore, it is still indispensable to monitor vent-up and the present situation is that the problem of vent-up has not been completely solved.

  On the other hand, in order to reduce the raw material loss during standby, when the amount pushed out during standby is further reduced, the melt sealing effect due to the molten resin is lost and the vacuum in the cylinder cannot be maintained, so-called vacuum break. There are also challenges. When a vacuum break occurs, the quality of the resin decreases, for example, the IV of the resin decreases.

  The present invention has been made in view of the above, and in the case of producing a polyester resin using a vented twin-screw extruder, while preventing a vacuum break during a low discharge standby operation and suppressing a vent-up, the standby operation A polyester resin production method for producing a polyester resin in which the startup speed is high and the quality suitable for recycling is stably maintained, the solar cell protective sheet having a stable quality, and stable for a long time An object of the present invention is to provide a solar cell module capable of obtaining a typical power generation performance, and to achieve the object.

  The present invention shifts from standby operation to production operation in the manufacturing process by the vented twin-screw extruder, that is, when increasing the supply amount of the raw material resin to the extruder, while controlling the pressure of the gear pump from a lower discharge state. Acquired knowledge that if the Q / N value is controlled, vent-up can be prevented, vacuum breaks at the vent can be suppressed at low discharge, and the vacuum can be discharged while drawing a certain degree of vacuum. This has been achieved based on such findings.

Specific means for achieving the above object are as follows.
<1> The polyester raw material resin charged in the twin screw extruder is melt-kneaded in a cylinder, and the extrusion amount Q per unit time of the melted polyester resin is expressed as unit extrusion amount Y [kg / hr / rpm]. From the relationship with the extrusion amount Q [kg / h], at least the number of rotations of the screw in the cylinder is adjusted so that the unit extrusion amount Y satisfies the region represented by the following relational expressions (1) to (2). This is a method for producing a polyester resin having a melt extrusion step of performing melt extrusion by increasing from Q _min to Q ₀ .
(1) (Y−Y _under ) / Q ≦ (Y _over −Y _under ) / Q ₀
(2) (Y−a × Y _under ) / (Q−Q ₀ ) ≧ (Y _over −Y _under ) / Q ₀

In each of the above formulas, Y represents the unit extrusion amount Q / N [kg / hr / rpm] per one revolution of the screw, and Y _under and Y _over are Y _under [kg / hr / rpm] = 3.4. × 10 ⁻⁶ × D ³ , Y _over [kg / hr / rpm] = 6.6 × 10 ⁻⁶ × D ³ . D represents a screw diameter [mm]. Q represents the extruded amount [kg / h] per unit time of the molten polyester resin during operation, Q ₀ represents the extruded amount during production operation, and Q _min represents the extruded amount during standby operation. N represents the number of rotations [rpm] of the screw. However, a represents the numerical value which determines the minimum of Q / N in the amount of extrusion at the time of production operation.

<2> unit extrusion amount Y _is for _{Y min} at _{Q min,} the ratio of _{Y 0} in _{Q 0} is a method for producing a polyester resin according to <1> which satisfies the following relationship (3). In the following relational expression (3), Y _min represents Q _min / N _min during standby operation. N _min represents the minimum number of rotations at Q _min .
1.3 ≦ Y ₀ / Y _min ≦ 6.0 (3)
<3> The method for producing a polyester resin according to <1> or <2>, wherein a ratio of Q _{0 to} Q _min satisfies the following relational expression (4).
3.3 ≦ Q ₀ / Q _min ≦ 12.0 (4)
<4> The method for producing a polyester resin according to any one of <1> to <3>, wherein the melt extrusion is performed while continuously changing Y.

<5> for _{Y min} of the unit extrusion amount Y of _{Q min,} the ratio of _{Y 0} in _{Q 0} is any one of the satisfying the following relationship (5) <1> to <4> It is a manufacturing method of the polyester resin of description.
1.3 ≦ Y ₀ / Y _min ≦ 4.6 (5)
<6> The method for producing a polyester resin according to any one of <1> to <5>, wherein a ratio of Q _{0 to} Q _min satisfies the following relational expression (6).
3.3 ≦ Q ₀ / Q _min ≦ 7.5 (6)
<7> A solar cell protective sheet having a polyester film obtained by stretching a polyester resin produced by the method for producing a polyester resin according to any one of <1> to <6>.
<8> A transparent substrate on which sunlight is incident, a solar cell element disposed on one side of the substrate, and a surface of the solar cell element disposed on the opposite side to the side on which the substrate is disposed. 7>. The solar cell module provided with the protective sheet for solar cells as described in 7>.

According to the present invention, when a polyester resin is produced using a vented twin-screw extruder, the vacuum break during the low discharge standby operation is prevented, and the startup when starting from the standby operation while suppressing the vent-up is performed. Provided is a method for producing a polyester resin, which produces a polyester resin having a high speed and stably maintaining a quality suitable for recycling. Also,
According to the present invention, a solar cell protective sheet having stable quality and a solar cell module capable of obtaining stable power generation performance over a long period of time are provided.

It is sectional drawing which shows the example of a schematic structure of the twin-screw extruder with a vent. It is a figure which shows the range enclosed by relationship lines (1)-(2) in the two-dimensional coordinate axis | shaft where the vertical axis | shaft is unit extrusion amount Y (= Q / N) and the horizontal axis is the extrusion amount Q of molten resin. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in Example 1, (B) is a figure which shows the relationship of Y with respect to Q of Example 1. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt-extrusion in Example 2, (B) is a figure which shows the relationship of Y with respect to Q of Example 2. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in Example 3, (B) is a figure which shows the relationship of Y with respect to Q of Example 3. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in Example 4, (B) is a figure which shows the relationship of Y with respect to Q of Example 4. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in Example 5, (B) is a figure which shows the relationship of Y with respect to Q of Example 5. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in the comparative example 1, (B) is a figure which shows the relationship of Y with respect to Q of the comparative example 1. (A) is a graph which shows the change of Q, N, and Q / N at the time of melt-extrusion in the comparative example 2, (B) is a figure which shows the relationship of Y with respect to Q of the comparative example 2. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in the comparative example 3, (B) is a figure which shows the relationship of Y with respect to Q of the comparative example 3. FIG. (A) is a graph which shows the change of Q, N, and Q / N at the time of the melt extrusion in the comparative example 4, (B) is a figure which shows the relationship of Y with respect to Q of the comparative example 4.

  Hereinafter, the manufacturing method of the polyester resin of the present invention will be described in detail, and a solar cell protective sheet and a solar cell module using the polyester resin produced by the polyester resin manufacturing method will be described in detail.

In the polyester resin production method of the present invention, the polyester raw material resin charged in the twin-screw extruder is melt-kneaded in a cylinder, and the extrusion amount Q per unit time of the melted polyester resin is determined as the unit extrusion amount Y [ From the relationship between kg / hr / rpm] and extrusion amount Q [kg / h], at least the screw in the cylinder is within the range where the unit extrusion amount Y satisfies the region represented by the following relational expressions (1) to (2). A melt-extrusion process is performed in which melt-extrusion is performed by adjusting the number of rotations and increasing Q _min to Q ₀ .

  Here, the relationship between the unit extrusion amount Y and the extrusion amount Q is such that the unit extrusion amount Y [kg / hr / rpm] is set on one axis (for example, the vertical axis) on the two-dimensional coordinate axis, and the other axis (for example, the horizontal axis). ) Based on the relationship line drawn by taking the extrusion rate Q [kg / h]. For example, the following relational expressions (1) to (2) are obtained when a relational line is drawn on a two-dimensional coordinate axis with the unit extrusion amount Y on the vertical axis and the extrusion amount Q [kg / h] on the horizontal axis. It may indicate a relationship.

  The method for producing a polyester resin of the present invention includes a melt extrusion step, a sheet forming step of forming the extruded polyester resin into a sheet shape, for example, cooling on a casting drum, and a drawing step of stretching the sheet-like polyester resin. Other processes such as may be provided.

Melt extruders are generally in standby operation except during the desired production, but since the molten resin is being extruded without being completely stopped even during standby operation, it is possible to reduce raw material loss during standby operation. It is necessary to suppress the amount of extrusion of as much as possible. However, if the amount of extrusion during standby operation is kept too low, the vacuum inside the cylinder cannot be maintained (vacuum break), and if the raw material supply amount is increased by switching to production operation, venting tends to occur. is there. If a vacuum break or vent up is caused, not only will the quality deteriorate, but also the recyclability will be impaired.
Conventionally, when the raw material supply amount to the extruder is increased when extruding the molten resin from the twin screw extruder, the gear pump control is started after changing the Q / N in advance, and the Q / N remains constant. There were operations such as increasing the supply of raw materials. However, in such an operation, a vacuum break is likely to occur during standby, but if a certain amount of extrusion is ensured in order to avoid vacuum break, a material loss during the standby operation is large. In addition, since the Q / N is constant, vent-up is likely to occur. Under these circumstances,
In the present invention, when extruding a molten polyester resin (hereinafter, also simply referred to as a molten resin), the extruded amount Q of the molten resin per unit time is increased from Q _min to Q ₀ to be extruded. The extrusion amount Q of the resin is not controlled so that Y (= Q / N) is constant, but the unit extrusion amount Y per one rotation of the screw is expressed by the following relational expressions (1) to (2). Control within the range that fills the area. At this time, in addition to the number of rotations of the screw in the cylinder, the supply amount of the raw material and the pressure control of the gear pump attached to the cylinder are controlled so as to satisfy the relational expressions (1) to (2). As a result, when switching the vented twin-screw extruder from the standby operation to the production operation, the vacuum break is prevented at the time of low discharge during the standby operation, and after the switching, the supply amount of the raw material resin to the extruder increases. Polyester resin vent-up is prevented. In addition, there is an ester resin that suppresses vent-up but has a shorter start-up time (i.e., higher start-up speed) when starting up from standby operation than before, and stably maintaining quality appropriate for recycling. Manufactured. Expected to improve productivity.

-Melt extrusion process-
In the melt extrusion step of the present invention, the polyester raw material resin charged in the twin screw extruder is melt-kneaded in a cylinder, and the extrusion amount Q per unit time of the melted polyester resin is determined as a unit extrusion amount Y [kg / hr / rpm] and the extrusion amount Q [kg / h], the rotation of the screw in the cylinder is within a range where the unit extrusion amount Y satisfies the region represented by the following relational expressions (1) to (2). The extrusion is performed by adjusting the number and increasing the extrusion amount from Q _min to Q ₀ .
(1) (Y−Y _under ) / Q ≦ (Y _over −Y _under ) / Q ₀
(2) (Y−a × Y _under ) / (Q−Q ₀ ) ≧ (Y _over −Y _under ) / Q ₀

Details of Y, D, Q ₀ , Q, etc. in the above formulas are shown below.
Y: Unit extrusion amount per screw rotation Q / N [kg / hr / rpm]
_Yunder : 3.4 × 10 ⁻⁶ × D ³ [kg / hr / rpm]
Y _over : 6.6 × 10 ⁻⁶ × D ³ [kg / hr / rpm]
D: Screw diameter [mm]
Q: Extruded amount per unit time of the molten polyester resin during operation [kg / h]
Q ₀ : Extrusion amount during production operation Q _min : Extrusion amount during standby operation N: Screw rotation speed [rpm]
a = Numerical value that defines the lower limit of Q / N in the amount of extrusion during production operation

  The melt kneading by the twin screw extruder to be used is basically necessary to obtain a desired polyester resin by using a conventionally known twin screw extruder equipped with a twin screw and a vent for extruding the molten resin. You can set various conditions. The twin-screw extruder may use either a small or large apparatus.

  A configuration example of a twin screw extruder suitable for the present invention is shown in FIG. FIG. 1 is a schematic cross-sectional view schematically showing a configuration example of a twin-screw extruder that can be used in carrying out the method for producing a polyester film according to the present invention.

  When a polyester film is produced by a melt extrusion method, generally used extruders are roughly classified into a single screw and a multi screw. As the multi-shaft, a twin screw extruder (a twin screw extruder) is widely used. As a twin-screw extruder, for example, as shown in FIG. 1, a cylinder 10 (barrel) having a supply port 12 for supplying a raw material resin and an extruder outlet 14 for extruding a molten resin has an outer diameter of 140 mm or more. The twin screw extruder 100 may include two screws 20 </ b> A and 20 </ b> B that rotate in the cylinder 10 and a temperature control unit 30 that is disposed around the cylinder 10 and controls the temperature in the cylinder 10. . A raw material supply device can be provided in front of the supply port 12, and a filter 42 and a die 40 are provided at the tip of the extruder outlet 14. Further, although not shown, a gear pump may be further provided at the tip of the extruder outlet 14.

<Cylinder>
The cylinder 10 has a supply port 12 for supplying the raw material resin and an extruder outlet 14 through which the heated and melted resin is extruded.
The inner wall surface of the cylinder 10 is made of a material that is excellent in heat resistance, wear resistance, and corrosion resistance and that can ensure friction with the resin. Generally, nitrided steel whose inner surface is nitrided is used, but chromium molybdenum steel, nickel chromium molybdenum steel, and stainless steel can also be nitrided and used. For applications that require wear resistance and corrosion resistance in particular, a bimetallic cylinder in which a corrosion-resistant and wear-resistant material alloy such as nickel, cobalt, chromium, and tungsten is lined on the inner wall surface of the cylinder 10 by centrifugal casting. It is effective to use or form a ceramic sprayed coating.

The cylinder 10 is provided with vents 16A and 16B for drawing a vacuum. By evacuating through the vents 16A and 16B, volatile components such as moisture in the resin in the cylinder 10 can be efficiently removed. By appropriately arranging the vents 16A and 16B, raw materials (pellets, powders, flakes, etc.) in an undried state, crushed waste (fluffs) of the film produced during film formation, etc. can be used as raw material resins as they are. .
The vents 16A and 16B are required to have an appropriate opening area and number of vents in relation to the deaeration efficiency. The twin-screw extruder 100 desirably has one or more vents (for example, 16A and 16B). In addition, when there are too many vents 16A and 16B, there exists a possibility that a vent up may become large and there exists a possibility of a residence deterioration foreign material increase. Therefore, it is preferable to provide the vent at one place or two places.
In addition, if the resin staying on the wall surface near the vent or the deposited volatile component falls into the extruder 100 (cylinder 10), it may be manifested as a foreign substance in the product, so care must be taken. For retention, optimization of the shape of the vent lid and appropriate selection of the upper vent and the side vent are effective, and precipitation of volatile components is generally performed by a method of preventing precipitation by heating the piping or the like.

For example, when extruding PET, the suppression of hydrolysis, thermal decomposition, and oxidative decomposition has a great influence on the quality of the product (film). For example, oxidative decomposition can be suppressed by evacuating the resin supply port 12 or performing a nitrogen purge.
Further, by providing the vents 16A and 16B at a plurality of locations, even when the raw material moisture content is about 2000 ppm, the same extrusion as when the resin dried to 50 ppm or less is extruded on a single axis is possible.
Further, in order to suppress resin decomposition due to shearing heat generation, it is preferable that segments such as kneading are not provided as much as possible within a range in which both extrusion and degassing can be achieved.
Further, since the shear heat generation increases as the pressure at the screw outlet (extruder outlet) 14 increases, the pressure at the extruder outlet 14 is as much as possible within a range in which the degassing efficiency and the stability of the extrusion by the vents 16A and 16B can be secured. It is preferable to make it low.

<Biaxial screw>
In the cylinder 10, two screws 20A and 20B having a screw diameter (outer diameter) D of φ140 mm or more and rotated by a driving means 21 including a motor and a gear are provided. A large twin-screw extruder having a screw diameter D of φ140 mm or more can be mass-produced. On the other hand, vent-up is likely to occur, melting unevenness is likely to occur, and quality is likely to deteriorate. However, in the present invention, even when a large twin-screw extruder having a screw with an outer diameter of 140 mm or more is used, vent-up is prevented, melting unevenness is suppressed, and generation of foreign substances or heating of terminal COOH due to heating is suppressed. Increase can be suppressed.

The twin screw extruder is roughly divided into a meshing type and a non-meshing type of the two screws 20A and 20B, and the meshing type has a larger kneading effect than the non-meshing type. In the present invention, any of a meshing type and a non-meshing type may be used, but it is preferable to use a meshing type from the viewpoint of sufficiently kneading the raw material resin and suppressing melting unevenness.
The rotation directions of the two screws 20A and 20B are also divided into the same direction and different directions, respectively. The different-direction rotating screws 20A and 20B have a higher kneading effect than the same-direction rotating type, and the same-direction rotating type has a self-cleaning effect, which is effective for preventing retention in the extruder.
Furthermore, the axial direction is also parallel and oblique, and there is also a conical type shape used when applying strong shear.

In the twin screw extruder used in the present invention, screw segments having various shapes are used. As the shape of the screws 20 </ b> A and 20 </ b> B, for example, a full flight screw provided with a single spiral flight 22 having an equal pitch is used.
By using a segment that imparts shear, such as a kneading disk or a rotor, in the heating and melting part, the raw material resin can be more reliably melted. Further, by using a reverse screw or a seal ring, it is possible to dam the resin and form a melt seal when pulling the vents 16A and 16B. For example, as shown in FIG. 1, kneading parts (kneading disks) 24A and 24B for promoting melting of the raw material resin as described above can be provided in the vicinity of the vents 16A and 16B.

  On the downstream side in the resin extrusion direction of the extruder 100, it is effective to provide a temperature control zone (cooling section) for cooling the molten resin. When the heat transfer efficiency of the cylinder 10 is higher than the shear heat generation, by providing the screw 28 with a short pitch in the temperature control zone (cooling portion), the resin moving speed of the wall surface of the cylinder 10 is increased, and the temperature control efficiency can be increased. . From the viewpoint of enhancing the cooling effect, the pitch of the screws 28 located in the cooling section is preferably 0.5D to 0.8D with respect to the screw diameter D.

<Temperature control means>
A temperature control means 30 is provided around the cylinder 10. In the extruder 100 shown in FIG. 1, heating / cooling devices C <b> 1 to C <b> 9 divided into nine in the longitudinal direction from the raw material supply port 12 toward the extruder outlet 14 constitute the temperature control means 30. Thus, by the heating / cooling devices C1 to C9 arranged separately around the cylinder 10, for example, the heating / melting parts C1 to C7 and the cooling parts C8 and C9 are divided into areas (zones), and the inside of the cylinder 10 is divided. Each region can be controlled to a desired temperature.

  For heating, a band heater or a sheathed wire aluminum cast heater is usually used, but is not limited thereto, and for example, a heating medium circulating heating method can also be used. On the other hand, air cooling by a blower is generally used for cooling, but there is also a method of flowing water or oil through a pipe wound around the cylinder 10.

<Die>
A die 40 is provided at the extruder outlet 14 of the cylinder 10 for discharging the molten resin extruded from the extruder outlet 14 into a film (strip shape). Also, a filter 42 is provided between the extruder outlet 14 of the cylinder 10 and the die 40 to prevent unmelted resin and foreign matter from entering the film.

<Gear pump>
In order to improve the thickness accuracy, it is important to reduce the fluctuation of the extrusion amount as much as possible. A gear pump may be provided between the extruder 100 and the die 40 in order to reduce the fluctuation of the extrusion amount as much as possible. By supplying a certain amount of resin from the gear pump, the thickness accuracy can be improved. In particular, when a twin screw extruder is used, it is preferable to stabilize the extrusion with a gear pump because the pressure raising capability of the extruder itself is low.

  In the present invention, when performing melt extrusion so as to satisfy the relational expressions (1) to (2), it is preferable to adjust the rotational speed of the screw and control the pressure with a gear pump.

  By using the gear pump, the pressure fluctuation on the secondary side of the gear pump can be reduced to 1/5 or less of the primary side, and the resin pressure fluctuation range can be within ± 1%. As other merits, it is possible to perform filtration with a filter without increasing the pressure at the tip of the screw, so that prevention of an increase in the resin temperature, improvement in transport efficiency, and shortening of the residence time in the extruder can be expected. It is also possible to prevent the amount of resin supplied from the screw from fluctuating with time due to the increase in the filtration pressure of the filter. However, when a gear pump is installed, the length of the equipment becomes longer depending on the equipment selection method, and the residence time of the resin becomes longer, and the shearing stress of the gear pump section may cause the molecular chain to be broken. is there.

  When the difference between the primary pressure (input pressure) and the secondary pressure (output pressure) is too large in the gear pump, the load on the gear pump increases and shear heat generation increases. Therefore, the differential pressure during operation is set to 20 MPa or less, preferably 15 MPa, and more preferably 10 MPa or less. In order to make the film thickness uniform, it is also effective to control the screw rotation of the extruder or to use a pressure control valve in order to keep the primary pressure of the gear pump constant.

In the melt extrusion process of the present invention, for example, a twin screw extruder and a polyester raw material resin configured as shown in FIG. 1 are prepared, the cylinder 10 is heated by the temperature control means 30, and the screws 20A and 20B are rotated and supplied. Raw material resin is supplied from the port 12. The supply port 12 is preferably cooled to prevent heat transfer of the raw material resin pellets and the like, and to protect the screw drive equipment such as the motor.
The raw material resin supplied into the cylinder is not only heated by the temperature control means 30, but also due to friction between the resins accompanying rotation of the screws 20A and 20B, friction between the resin and the screws 20A and 20B and the cylinder 10, and the like. It is melted by heat generation and gradually moves toward the extruder outlet 14 as the screw rotates.
The raw material resin supplied into the cylinder is heated to a temperature equal to or higher than the melting point Tm (° C.). However, if the resin temperature is too low, the melting at the time of melt extrusion is insufficient, and there is a possibility that the discharge from the die 40 becomes difficult. is there. On the other hand, if the resin temperature is too high, the terminal COOH is remarkably increased by thermal decomposition, which may lead to a decrease in hydrolysis resistance. From these viewpoints, the maximum resin temperature (Tmax; [° C.]) in the longitudinal direction (resin extrusion direction) in the twin-screw extruder is adjusted by adjusting the heating temperature by the temperature control means 30 and the rotational speed of the screws 20A and 20B. (Tm + 40) ° C. to (Tm + 60) ° C., preferably (Tm + 40) ° C. to (Tm + 55) ° C., more preferably (Tm + 45) ° C. to (Tm + 50) ° C.

  The maximum resin temperature Tmax in the longitudinal direction (resin extrusion direction) in the twin-screw extruder is the temperature of the raw material resin heated in the cylinder 10 in which the screws 20A and 20B of the twin-screw extruder 100 are disposed. When heat is generated, the temperature includes a local high temperature portion due to the heat generation. Tmax is obtained by measuring the resin temperature in the cylinder. The Tmax is preferably 290 ° C. or less, and more preferably 280 ° C. or less, from the viewpoint of suppressing increase in terminal COOH. Further, the lower limit temperature of Tmax is preferably 260 ° C. from the viewpoint of preventing insufficient melting of the resin.

−Vent pressure−
By evacuating through the vents 16A and 16B, volatile components such as moisture in the resin in the cylinder can be efficiently removed. If the vent pressure is too low, the molten resin may overflow from the cylinder 10, and if the vent pressure is too high, removal of volatile components may be insufficient, and hydrolysis of the resulting film may easily occur. The vent pressure is preferably 1.333 Pa to 666.5 Pa (0.01 Torr to 5 Torr) from the viewpoint of preventing the molten resin from overflowing from the vents 16A and 16B and selectively removing volatile components. More preferably, the pressure is 333 Pa to 533.2 Pa (0.01 Torr to 4 Torr).

-Average residence time-
It is preferable that the average residence time from when the raw material resin is heated and melted in the cylinder to exit the extruder outlet 14 to be extruded into a film from the die 40 is 10 minutes to 20 minutes. When the average residence time from when the raw material resin is melted by heating until it exits the extruder outlet 14 of the extruder 100 and is extruded from the die 40 is 10 minutes or more, the residual unmelted resin can be suppressed to a low level. Further, when the average residence time is 20 minutes or less, an increase in the amount of terminal COOH due to thermal decomposition can be prevented, and more excellent hydrolysis resistance can be obtained. From such a viewpoint, the average residence time after the raw material resin is heated and melted and extruded from the extruder outlet 14 is more preferably 10 minutes to 15 minutes.
The average residence time is defined by the following formula.
Average residence time (seconds) = {Pipe volume on the downstream side of the extruder [cm ³ ] × Melt density [g / cm ³ ] × 3600/1000} / Extrusion amount [kg / h]

-Cooling-
While the raw material resin is heated and melted in the cylinder as described above, the temperature control means 30 causes the inner wall on the side of the extruder outlet 14 of the cylinder 10 to be a cooling portion having a melting point Tm (° C.) or less of the polyester resin (raw material resin). To control. If the inner wall of the cylinder 10 on the side of the extruder outlet 14 is used as a cooling part and controlled to be equal to or lower than the melting point Tm (° C.) of the raw resin, it is possible to suppress the resin from being heated excessively and increasing the amount of terminal COOH. From the viewpoint of reliably suppressing the increase in the amount of terminal COOH, the temperature in the cooling section is preferably in the range of (Tm-100) ° C to Tm ° C, and in the range of (Tm-50) ° C to (Tm-10) ° C. The inside is more preferable.

The length of the cooling part is preferably 4D to 11D with respect to the screw diameter D. If the length of the cooling section is 4D or more, the molten and heated resin is effectively cooled to suppress the increase in terminal COOH. On the other hand, if the length of the cooling section is 11D or less, it is possible to prevent the resin from being overcooled and solidified, and to smoothly perform melt extrusion.
The resin temperature Tout at the extruder outlet 14 is preferably Tm + 30 ° C. or lower. However, if the resin temperature Tout at the extruder outlet 14 is too low, part of the molten resin may be solidified. Therefore, the resin temperature Tout at the extruder outlet 14 is more preferably Tm to (Tm + 25) ° C. or less. More preferably, it is set to (Tm + 10) ° C. to (Tm + 20) ° C.

The polyester resin extruded from the extruder outlet 14 of the cylinder 10 passes through the filter 42 and is extruded from the die 40 (for example, to a cooling roll such as a casting drum) to be molded into a sheet and cooled.
After extruding the melt (molten resin) from the die 40, for example, until it is brought into contact with the cooling roll (air gap), the humidity is preferably adjusted to 5% RH to 60% RH, and 15% RH to 50%. It is more preferable to adjust to RH. By adjusting the humidity in the air gap to the above range, it is possible to adjust the COOH amount and OH amount on the film surface. Moreover, the amount of carboxylic acid on the film surface can be reduced by adjusting to low humidity.

Moreover, by raising the resin temperature once and then cooling, it is possible to suppress an increase in the amount of terminal COOH and to suppress the occurrence of unmelted foreign matter. Furthermore, the effect which suppresses the haze rise of the polyester resin shape | molded in the sheet form is acquired. In particular, when forming into a thick sheet, the haze is likely to increase due to insufficient cooling rate, but the increase in that case can be suppressed.
In addition, 2 mm-8 mm are preferable, as for the thickness of a film, More preferably, they are 2.5 mm-7 mm, More preferably, they are 3 mm-6 mm. By increasing the thickness, the time required for the extruded melt to cool below the glass transition temperature (Tg) can be increased. During this time, COOH groups on the film surface are diffused into the polyester, and the amount of surface COOH can be reduced.

In the present invention, the difference (ΔAV) between the terminal COOH amount of the polyester raw material and the terminal COOH amount of the melt-extruded sheet-like polyester resin is preferably 3 eq / t or less. For example, a polyester sheet having a terminal COOH amount of 25 eq / t (tons) or less is obtained. When the terminal COOH amount is 25 eq / ton or less, the hydrolysis resistance is excellent and long-term durability is obtained. From the viewpoint of hydrolysis resistance, it is desirable that the amount of terminal COOH is low, but from the viewpoint of enhancing the adhesion when the molded sheet is adhered to an adherend, the AV of the polyester resin molded into a sheet after extrusion is used. Is preferably 2 eq / ton, and a preferable AV range is 10 to 20 eq / ton.
The terminal COOH amount can be measured in the same manner as described above.
“Eq / t” represents the molar equivalent per ton.

Next, a melt extrusion process for performing melt extrusion by increasing the extrusion amount Q from Q _min to Q ₀ will be described.

  When melt extrusion is performed with a vented twin-screw extruder, when switching from standby operation and standby operation to the desired production operation, it is important to reduce discharge against material loss and prevent vacuum breaks during low discharge during standby. Yes, it is important to prevent vent-up when switching to production operation and increasing the feed rate. In the present invention, by controlling Y (= Q / N) within a predetermined range from a state of lower discharge than usual, the vacuum break is prevented at the time of low discharge during standby, and the vent-up is suppressed. However, the start-up speed at the time of start-up from the standby operation is increased, and an ester resin in which a quality suitable for recycling is stably maintained is manufactured.

Specifically, at least the number of rotations of the screw in the cylinder is adjusted so that the unit extrusion amount Y per one rotation of the screw satisfies a region represented by the following relational expressions (1) to (2). Is done by.
(1) (Y−Y _under ) / Q ≦ (Y _over −Y _under ) / Q ₀
(2) (Y−a × Y _under ) / (Q−Q ₀ ) ≧ (Y _over −Y _under ) / Q ₀

Q represents an extrusion amount per unit time of the molten polyester resin during operation [kg / h], Q ₀ represents the extrusion rate at the time of performing the production run of the desired.

N represents the number of rotations [rpm] of the screw. Here, N is the case representing the minimum rotational speed _{N min, N min} represents the minimum rotation speed at _{Q min.} The minimum rotation speed N _min indicates the rotation speed during standby operation, and Q _min indicates the amount of extrusion during standby operation.

The relational expressions (1) to (2) will be described with reference to FIG.
In FIG. 2, the vertical axis represents unit extrusion rate Y (= Q / N; unit: [kg / hr / rpm]), and the horizontal axis represents molten resin extrusion rate Q (unit: [kg / h]). It is a figure which shows the area | region enclosed with relationship lines (1)-(2) in the two-dimensional coordinate axis.

The extrusion amount Q of the polyester resin is the unit extrusion amount Y (= Q / N) after switching from the standby operation to the production operation when the extrusion amount during the standby operation is raised to the extrusion amount during the production operation. Perform within the range that satisfies (1). That is,
Relational expression (1) represents that the unit extrusion amount Y is set to a range equal to or less than the Y value on the line segment (a) in FIG. If Y is in the range exceeding the Y value on the line segment (a), the amount of extrusion per one rotation of the screw becomes too large, so that vent-up is likely to occur.

In the present invention, by adjusting the rotational speed N in consideration of the resin viscosity, the supply amount of the raw material resin, etc., the range can be adjusted to satisfy the relational expression (1).
In relational expression (1), the method for increasing Y (= Q / N) with respect to Q is not particularly limited, and may include a process of decreasing in the middle. However, from the viewpoint of venting up, it is preferable to increase Y (= Q / N) monotonously. Further, the method of increasing Q is not particularly limited, and a process of decreasing in the middle may be included. However, from the viewpoint of raw material loss, it is preferable to increase Q monotonously.

Further, the unit extrusion amount Y (= Q / N) after switching from the standby operation to the production operation is performed in a range satisfying the relational expression (2). That is,
Relational expression (2) represents that the unit extrusion amount Y is set to a range equal to or greater than the Y value on the line (b) in FIG. When Y is in a range lower than the Y value on the line segment (b), since the screw rotation speed N is too large, the melt sealing effect by the molten resin is reduced, and the vacuum in the cylinder cannot be maintained (vacuum) In addition, the resin is deteriorated and residual foreign matters are easily generated. When a vacuum break occurs, the quality of the resin is lowered and the recyclability is deteriorated. Moreover, when a residual foreign material increases, it will lead to the fall of the weather resistance of a polyester resin, and the fall of a film characteristic.

In the relational expression (2), a represents a numerical value that defines the lower limit of the Q / N in the extrusion amount during the production operation, and is a value determined by the presence or absence of the possibility of vacuum break during the standby operation. Since the rotational speed N is large when Q / N is small, the resin is easily deteriorated by shear heat generation, and the IV value is likely to decrease, resulting in poor recyclability. Therefore, it is advantageous to keep Q / N high to some extent, and it is desirable to increase the a value from this point. The larger the a value, the higher the unit extrusion amount Y increases as the extrusion amount Q increases. For this reason, the large a value makes it possible to continuously increase the amount of extrusion while preventing vent-up, suppressing resin deterioration due to vent-up and more quickly starting from standby operation to production operation. It can be done. In addition, a vacuum break during standby operation is prevented, and the recyclability is improved.
As a, a = 1.3 is preferable and a = 1.5 is more preferable for the above reason.
In FIG. 2, a line segment (c) represented by a one-dot chain line indicates a relational line when a = 1.5, and a range surrounded by the line segment (a) and the line segment (c) is preferable.

Therefore, in the present invention, when the amount of extrusion when shifting from standby operation to production operation is increased from the amount of extrusion Q _min during standby operation to the amount of extrusion Q ₀ during production operation, the unit extrusion amount Y (= The amount of extrusion Q is increased or decreased so that Q / N) falls within the relational expressions (1) to (2), that is, the region sandwiched between the line segment (a) and the line segment (b) in FIG. To control. Thereby, vent-up at the time of melt-kneading is effectively prevented, and the startup speed at startup is increased while suppressing vent-up. That is, the startup time from standby operation can be shortened. In addition, the amount of extrusion during the standby operation can be reduced as compared with the prior art, and a vacuum break during the standby operation with a reduced amount of extrusion can be prevented. Therefore, in the manufactured polyester resin, a quality suitable for recycling is stably maintained.

When the extrusion amount is increased from Q _min to Q ₀ when the twin-screw extruder is switched from the standby operation to the production operation, it is preferable to continuously change Q / N represented by Y. By continuously changing the Q / N, it is possible to increase the more extrusion amount Q ₀ to the extrusion amount during rapid production operation can be further shortened switching time to production run from the standby operation.
At this time, the time during which Q / N is constant is preferably within 5 seconds.

In the present invention, in the unit extrusion amount Y, the ratio of Y ₀ at Q ₀ during production operation to Y _min at Q _min during standby operation is a range that satisfies the following relational expression (3): It is preferable to do.
1.3 ≦ Y ₀ / Y _min ≦ 6.0 (3)
In the relational expression (3), Y _min represents Q _min / N _min during standby operation. N _min represents the minimum rotation speed at the extrusion amount Q _min during standby operation.

That is, the unit extrusion amount Q ₀ / N ₀ during production operation is preferably in the range of 1.3 times to 6.0 times the unit extrusion amount Q _min / N _min during standby operation.
When the Y ₀ / Y _min ratio is 1.3 or more, vent-up during standby operation can be prevented. Further, if the Y ₀ / Y _min ratio is 6.0 or less, excessive heat generation during standby operation can be suppressed, and deterioration of the resin can be prevented. Moreover, the melt seal by the molten resin during the standby operation can be maintained, and the vacuum break during the standby operation can be prevented.
Therefore, by setting Y ₀ / Y _min within the above range, the quality of the resin can be maintained even during standby operation, and a polyester resin excellent in recyclability can be obtained.

The ratio of the _Y 0 _{/ Y min,} for the same reason as above, more preferably in the range of _{1.3 ≦ Y 0 / Y min ≦} 4.6, 1.3 ≦ Y 0 / Y min ≦ 2.5 The range of is more preferable.

Further, for the extrusion rate Q _min during standby operation, as the ratio of the unit extrusion amount Q ₀ during production operation, it is preferably in a range satisfying the following relational expression (4).
3.3 ≦ Q ₀ / Q _min ≦ 12.0 (4)

That is, the extrusion rate _{Q 0} during production operation, to the extrusion amount _{Q min} during standby operation, is preferably in the range of 3.3 times to 12.0 times.
When the Q ₀ / Q _min ratio is 3.3 or more, the amount of extrusion during standby operation can be suppressed to a low level, and raw material loss can be reduced. Further, when the Q ₀ / Q _min ratio is 12.0 or less, a vacuum break during standby operation can be prevented.
Therefore, by setting Q ₀ / Q _min in the above range, a raw material loss can be suppressed and a polyester resin excellent in recyclability can be obtained.

The ratio of the _Q 0 _{/ Q min,} for the same reason as above, more preferably _{3.3 ≦ Q 0 / Q min ≦} 7.5, the range of _{3.3 ≦ Q 0 / Q min ≦} 5.0 Is more preferable.

  The region represented by the above relational expressions (1) to (2) is, for example, the amount of raw material supplied from a raw material supply unit such as a hopper or a feeder attached to the cylinder, and the rotational speed of the screw disposed in the cylinder This is achieved by adjusting the pressure control of a gear pump attached to the extrusion tip of the cylinder and realizing an increase in the extrusion amount while keeping the pressure at the cylinder tip constant. Specifically, as shown in FIG. 1, this can be done by adjusting the number of rotations of the screws 20 </ b> A and 20 </ b> B in the cylinder 10. For example, as shown in FIG. 1, the rotational speed can be adjusted by a driving means 21 including a motor and a gear connected to a screw. The drive means 21 is electrically connected to a control means (not shown) for outputting a signal to the drive means 21 for control.

-Polyester raw resin-
Next, a polyester raw material resin (hereinafter, also simply referred to as a raw material resin) used for manufacturing a polyester resin will be described.

(Polyester raw resin)
The polyester raw material resin is not particularly limited as long as it is a raw material for the polyester film and contains polyester, and may contain a slurry of inorganic particles or organic particles in addition to the polyester. The polyester raw resin may contain a titanium element derived from the catalyst.
The kind of polyester contained in the polyester raw material resin is not particularly limited, and for example, a polyester synthesized using a dicarboxylic acid component and a diol component may be used, or a commercially available polyester may be used.

As the raw material resin, a polyester resin having an intrinsic viscosity (IV) of 0.7 to 0.9 is preferable.
When the IV of the raw material resin is 0.7 or more, the terminal COOH of the raw material can be suppressed to be small, and the film quality can be maintained well. Moreover, when IV is 0.9 or less, the increase in terminal COOH is small and the film quality is good. IV of raw material resin becomes like this. Preferably it is 0.70-0.85, More preferably, it is 0.70-0.80.

  IV of raw material resin can be adjusted with a polymerization system and polymerization conditions. For example, the intrinsic viscosity can be adjusted to the above range by performing solid phase polymerization after liquid phase polymerization.

The terminal COOH amount (AV) of the raw material resin is preferably 25 eq / t (equivalent / ton) or less, and more preferably 15 eq / t or less. For example, from the viewpoint of obtaining adhesion between the adherend and the adherend, the amount of terminal COOH of the raw material resin is desirably 2 eq / t or more.
The amount of terminal COOH is a value measured by the following method. That is,
After 0.1 g of the raw material resin is dissolved in 10 ml of benzyl alcohol, chloroform is further added to obtain a mixed solution, and a phenol red indicator is added dropwise thereto. This solution is titrated with a standard solution (0.01N KOH-benzyl alcohol mixed solution), and the amount of terminal carboxyl groups is determined from the amount added.
“Eq / t” represents the molar equivalent per ton.
When a plurality of types of resins are mixed and used, the terminal COOH amount of the raw material resin represents the amount in a mixed state. For example, when polyethylene terephthalate (PET) is mixed with one or more kinds of pellets or chip material that is crushed waste of PET film, the total amount of terminal COOH of pellets, or the amount of terminal COOH of pellets and chips And the total amount of terminal COOH.

  The melting point (Tm) of the raw material resin is preferably in the range of 250 ° C to 260 ° C. Tm is a value obtained by differential scanning calorimetry. When mixing several resin, it is preferable that the average value of melting | fusing point exists in the said range.

The bulk specific gravity of the raw material resin is preferably in the range of 0.6 to 0.8. When the bulk specific gravity is 0.6 or more, extrusion can be performed more stably, and when the specific gravity is 0.8 or less, local heat generation can be effectively suppressed.
The bulk specific gravity of the raw material resin refers to the specific gravity (per unit volume) obtained by dividing the mass of the powder into a predetermined shape by dividing the powder into a predetermined volume in a constant volume container. Mass), the smaller the bulk specific gravity, the larger the bulk.
Among the above, the bulk specific gravity of the raw material resin is particularly preferably in the range of 0.7 to 0.75 in that the increase in terminal COOH is further suppressed by suppressing heat generation during extrusion.

The polyester resin constituting the raw material resin can be obtained by subjecting dicarboxylic acid or an ester derivative thereof and a diol compound to an esterification reaction and / or an ester exchange reaction by a known method.
Examples of the dicarboxylic acid or ester derivative thereof include malonic acid, succinic acid, glutaric acid, adipic acid, suberic acid, sebacic acid, dodecanedioic acid, dimer acid, eicosandioic acid, pimelic acid, azelaic acid, methylmalon. Aliphatic dicarboxylic acids such as acid, ethyl malonic acid, adamantane dicarboxylic acid, norbornene dicarboxylic acid, isosorbide, cyclohexanedicarboxylic acid, decalin dicarboxylic acid, terephthalic acid, isophthalic acid, phthalic acid, 1,4 -Naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 1,8-naphthalenedicarboxylic acid, 4,4'-diphenyldicarboxylic acid, 4,4'-diphenylether dicarboxylic acid, 5-sodium Sulfoisophthalate Acid, phenyl ene boys carboxylic acid, anthracene dicarboxylic acid, phenanthrene carboxylic, 9,9'-bis (4-carboxyphenyl) a dicarboxylic acid or an ester derivative such as an aromatic dicarboxylic acid such as fluorene acid.

  Examples of the diol compound include aliphatic diols such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,2-butanediol, and 1,3-butanediol. , Cycloaliphatic dimethanol, spiroglycol, isosorbide and other alicyclic diols, bisphenol A, 1,3-benzenedimethanol, 1,4-benzendimethanol, 9,9'-bis (4-hydroxyphenyl) fluorene And aromatic diols such as.

  Conventionally known reaction catalysts can be used for the esterification reaction and / or the transesterification reaction. Examples of the reaction catalyst include alkali metal compounds, alkaline earth metal compounds, zinc compounds, lead compounds, manganese compounds, cobalt compounds, aluminum compounds, antimony compounds, titanium compounds, and phosphorus compounds. Usually, it is preferable to add an antimony compound, a germanium compound, or a titanium compound as a polymerization catalyst at an arbitrary stage before the polyester production method is completed. As such a method, for example, when a germanium compound is taken as an example, it is preferable to add a powder of the germanium compound as it is.

  Preferred polyesters are polyethylene terephthalate (PET) and polyethylene-2,6-naphthalate (PEN), more preferably PET. PET is preferably polymerized using one or more selected from a germanium (Ge) -based catalyst, an antimony (Sb) -based catalyst, an aluminum (Al) -based catalyst, and a titanium (Ti) -based catalyst. More preferred is a Ti-based catalyst.

  The Ti-based catalyst has high reaction activity and can lower the polymerization temperature. Therefore, it is possible to suppress the thermal decomposition of PET and the generation of COOH particularly during the polymerization reaction. In the present invention, it is suitable for adjusting the terminal COOH amount of the polyester film to a range of 30 eq / ton or less.

  For production of a Ti catalyst PET obtained by polymerization using a Ti catalyst, for example, JP 2005-340616 A, JP 2005-239940 A, JP 2004-319444 A, Patent 3436268, The polymerization methods described in Japanese Patent No. 3978666, Japanese Patent No. 3780137, Japanese Patent Application Laid-Open No. 2007-204538, and the like can be used.

When a titanium-based compound is used as the Ti-based catalyst, the amount of titanium-based compound used is 1 ppm to 30 ppm, more preferably 2 ppm to 20 ppm, more preferably 3 ppm to 15 ppm in terms of titanium element, It is preferred to carry out the polymerization. In this case, the polyester film preferably contains 1 ppm or more and 30 ppm or less of titanium.
When the amount of the titanium-based compound is 1 ppm or more, preferable IV is obtained, and when it is 30 ppm or less, the terminal COOH can be kept low, which is advantageous in improving hydrolysis resistance.

The raw material resin is preferably prepared by mixing pulverized pieces of a resin film.
As the resin film, a polyester film is preferable, and a polyester film of the same type as the polyester resin in the raw resin is preferable. The pulverized piece of the resin film is a pulverized product obtained by pulverizing an unnecessary film into small pieces (so-called chips), scrap pieces, etc., giving a bulkiness and lowering the bulk specific gravity, for example, compared to the case of only a pellet. be able to.

  The size of the crushed pieces is not limited as long as the bulk change is given, but those having a thickness of 20 to 5000 μm are preferable. Among these, from the viewpoint of preventing the filling ratio from excessively decreasing due to excessive bulk specific gravity and avoiding insufficient melting, the range of 100 to 1000 μm, more preferably the range of 100 to 500 μm is more preferable.

  Further, in terms of further reducing the terminal COOH amount of the polyester film to be formed, it is preferable that the variation in the size of the crushed pieces is smaller, for example, in the thickness of the crushed pieces, the variation is preferably within ± 100%, More preferably, it is within ± 50%, and further within ± 10%. When the pulverized pieces are used, variation in the terminal COOH amount of the obtained polyester film can be suppressed to a low level by suppressing variation in size such as thickness.

  The mass ratio of the crushed pieces in the raw material resin is preferably 50% by mass or less with respect to the total mass of the raw material resin, and the lower limit of the mass ratio is preferably 10% by mass. By setting the proportion of the crushed pieces to 50% by mass or less, the fluctuation range of the terminal COOH amount of the obtained polyester film can be further reduced. Among these, for the same reason, the mass ratio of the crushed pieces is more preferably 10 to 30% by mass, and particularly preferably 20 to 30% by mass.

  The bulk specific gravity of the crushed pieces is preferably in the range of 0.3 to 0.7 in the range where the bulk specific gravity of the raw material resin satisfies the above range. The bulk specific gravity is synonymous with the bulk specific gravity of the raw material resin described above, and is measured in the same manner as described above.

  The polyester resin in the present invention can further contain additives such as a light stabilizer and an antioxidant.

  When a light stabilizer is contained, UV degradation can be prevented. Examples of the light stabilizer include a compound that absorbs light such as ultraviolet rays and converts it into heat energy, and a material that captures radicals generated by light absorption and decomposition of the resin and suppresses the decomposition chain reaction. The light stabilizer is preferably a compound that absorbs light such as ultraviolet rays and converts it into heat energy. By containing such a light stabilizer, the effect of improving the partial discharge voltage can be kept high for a long period of time even if it is irradiated with ultraviolet rays continuously for a long period of time. Change, strength deterioration, etc. are prevented.

  For example, if an ultraviolet absorber is a range in which other properties of the polyester are not impaired, any of organic ultraviolet absorbers, inorganic ultraviolet absorbers, and combinations thereof are preferably used without particular limitation. Can do. On the other hand, it is desired that the ultraviolet absorber is excellent in moisture and heat resistance and can be uniformly dispersed in the resin.

Examples of ultraviolet absorbers include, for example, salicylic acid-based, benzophenone-based, benzotriazole-based, cyanoacrylate-based ultraviolet absorbers, hindered amine-based ultraviolet stabilizers, and the like as organic ultraviolet absorbers. Specifically, for example, salicylic acid-based pt-butylphenyl salicylate, p-octylphenyl salicylate, benzophenone-based 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy -5-sulfobenzophenone, 2,2 ', 4,4'-tetrahydroxybenzophenone, bis (2-methoxy-4-hydroxy-5-benzoylphenyl) methane, benzotriazole 2- (2'-hydroxy-5) '-Methylphenyl) benzotriazole, 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, 2,2'-methylenebis [4- (1,1,3,3-tetramethylbutyl) -6 (2H benzotriazol-2-yl) phenol], a cyanoacrylate Ethyl-2-cyano-3,3′-diphenylacrylate), 2- (4,6-diphenyl-1,3,5-triazin-2-yl) -5-[(hexyl) oxy] -phenol as triazine system Hindered amine-based bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, dimethyl succinate 1- (2-hydroxyethyl) -4-hydroxy-2,2,6,6-tetramethyl Piperidine polycondensate, in addition, nickel bis (octylphenyl) sulfide, 2,4-di-t-butylphenyl-3 ′, 5′-di-t-butyl-4′-hydroxybenzoate, and the like .
Of these ultraviolet absorbers, triazine-based ultraviolet absorbers are more preferable in that they have high resistance to repeated ultraviolet absorption. In addition, these ultraviolet absorbers may be added to the above-mentioned ultraviolet absorber alone, or a form in which an organic conductive material or a water-insoluble resin is copolymerized with a monomer having an ultraviolet absorber ability. May be introduced.

  The content of the light stabilizer in the polyester film is preferably 0.1% by mass or more and 10% by mass or less, and more preferably 0.3% by mass or more and 7% by mass or less with respect to the total mass of the polyester film. More preferably, it is 0.7 mass% or more and 4 mass% or less. Thereby, the molecular weight fall of the polyester by the photodegradation over a long time can be suppressed, and the adhesive force fall resulting from the cohesive failure in the film which arises as a result can be suppressed.

  In addition to the light stabilizer, the polyester film of the present invention contains, for example, a lubricant (fine particles), an ultraviolet absorber, a colorant, a nucleating agent (crystallization agent), a flame retardant, and the like. It can contain as.

<Protective sheet for solar cell>
The protective sheet for a solar cell of the present invention is a polyester resin produced by the above-described method for producing a polyester resin of the present invention, and further, an unstretched polyester sheet obtained by molding the polyester resin into a sheet shape, and / or stretched in the longitudinal direction. The polyester film obtained as described above is provided.

  Since the polyester resin produced by the method for producing a polyester resin of the present invention is used, the polyester film (protective sheet for solar cell) obtained through stretching has a stable and good quality and is therefore desirable. It has excellent hydrolysis resistance and, as a result, excellent weather resistance.

  In longitudinal stretching, for example, a film is passed through a pair of nip rolls sandwiching an unstretched polyester sheet, and the film is transported in the longitudinal direction (MD direction) of the film, while being tensioned between two or more pairs of nip rolls arranged in the film transport direction. This can be done by giving In the longitudinal stretching step, the longitudinal stretching ratio is preferably 2 to 5 times, more preferably 2.5 to 4.5 times, and even more preferably 2.8 to 4 times.

  The transverse stretching can be performed by applying tension to the preheated polyester in the width direction (TD direction) perpendicular to the longitudinal direction (MD direction).

  For the stretched polyester film, heat-fixing process by heating and crystallizing the polyester after longitudinal stretching and lateral stretching, and heating the polyester film fixed in the heat-fixing process In addition, a thermal relaxation process may be provided that relaxes the tension of the polyester film and removes residual strain.

The polyester sheet of the present invention, after having been subjected to a desired stretching treatment, an easily adhesive layer that enhances adhesion to the battery side substrate, an ultraviolet absorbing layer, a reflective layer configured to be light reflective, including a white pigment, etc. By providing at least one functional layer such as a white layer (colored layer), a solar cell protective sheet can be formed. For example, a functional layer may be formed by coating on a polyester film after uniaxial stretching and / or biaxial stretching. For the coating formation, a known coating technique such as a roll coating method, a knife edge coating method, a gravure coating method, or a curtain coating method can be used.
Further, surface treatment (flame treatment, corona treatment, plasma treatment, ultraviolet treatment, etc.) may be performed before the coating. Furthermore, it is also preferable to bond together using an adhesive.

<Solar cell module>
A solar cell module generally includes a solar cell element that converts light energy of sunlight into electric energy, a transparent substrate on which sunlight is incident, and the polyester film of the present invention described above (back sheet for solar cell). It is arranged between them. As a specific embodiment, a power generating element (solar cell element) connected by a lead wiring (not shown) for extracting electricity is sealed with a sealing agent such as ethylene / vinyl acetate copolymer system (EVA system) resin, The aspect comprised by sticking together this between the transparent substrates, such as glass, and the polyester film (back sheet | seat) of this invention may be sufficient.

  Examples of solar cell elements include silicon-based materials such as single crystal silicon, polycrystalline silicon, and amorphous silicon, and group III-V such as copper-indium-gallium-selenium, copper-indium-selenium, cadmium-tellurium, and gallium-arsenic. Various known solar cell elements such as II-VI group compound semiconductor systems can be applied. A space between the substrate and the polyester film can be configured by sealing with a resin (so-called sealing material) such as an ethylene-vinyl acetate copolymer.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the following examples unless it exceeds the gist thereof. Unless otherwise specified, “part” is based on mass.

(Examples 1-5, Comparative Examples 1-4)
-Twin screw extruder-
As shown in FIG. 1, a melt extruder is provided with a screw having the following configuration in a cylinder provided with vents at two locations, and is divided into nine zones (C1 to C9) around the cylinder in the resin extrusion direction. A vented twin-screw extruder 100 equipped with a heater 30 capable of controlling the temperature was prepared. Details of this twin screw extruder are shown below.
<Twin screw extruder>
・ Double vent type same direction rotation meshing type twin screw extruder ・ Length L [mm] / screw diameter D [mm]: 31.5 (Cylinder 1 zone is 3.5D)
・ Size: 180mm
・ Discharge rate: 3000kg / h
・ Screw rotation speed: 60rpm
Barrel temperature-C1: 70 ° C, C2: 270 ° C, C3: 270 ° C, C4: 270 ° C, C5: 270 ° C, C6: 270 ° C, C7: 270 ° C, C8: 270 ° C, C9: 250 ° C
・ Screw shape: neutral kneading 2D, reverse screw 1D just before the first vent
Neutral kneading 2D just before the second vent

As shown in FIG. 1, a metal fiber filter 42 and a die 40 are connected in the resin extrusion direction of the vented twin-screw extruder 100, and a gear pump (not shown) is interposed between the screw and the metal fiber filter. Is provided. The set temperature of the heater for heating the die was 280 ° C., and the average residence time was 10 minutes.
・ Gear pump: 2-gear type ・ Filter: Sintered metal fiber filter (pore size 20μm)
・ Die: Lip spacing 4mm

-Raw material-
As the raw material resin, pellets of polyethylene terephthalate (melting point Tm: 257 ° C., intrinsic viscosity IV: 0.78, terminal COOH amount: 10 equivalent / t, crystallized at 160 ° C. with a Henschel mixer) (hereinafter referred to as PET pellets). ) Was used.
PET pellets having an average major axis: 4.5 mm, an average minor axis: 1.8 mm, and an average length: 4.0 mm were used.

-Melt extrusion-
Using the prepared twin screw extruder with a vent, the raw material resin was supplied from the supply port 12 and heated and melted for melt kneading, and melt extrusion was performed under the conditions shown in Table 1 below (melt extrusion step). Here, the values of Q, N, and Q / N and the relationship between the extrusion amount Q and the unit extrusion amount Y (= Q / N) in each of the examples and comparative examples shown in Table 1 below are shown in FIG. To FIG.

The melt (melted resin) extruded from the exit of the extruder passes through a gear pump and a metal fiber filter (pore diameter 20 μm), and then is extruded from a die onto a cooling roll (casting drum), and is applied to the cooling roll using an electrostatic application method. Adhered. By closely contacting the cooling roll, the melt was formed into a sheet and cooled. A hollow chill roll was used as the cooling roll. The chill roll can be adjusted in temperature through water as a heat medium.
The conveyance area (air gap) from the die exit to the cooling roll surrounds this conveyance area, and humidity is adjusted to 30% RH by introducing humidity-conditioned air therein. The melt thickness was set to 3000 μm by adjusting the extrusion amount of the twin screw extruder and the slit width of the die.
As described above, an unstretched PET sheet was obtained.

-Evaluation-
(1) Vent-up The presence or absence of vent-up during the melt-extrusion process in the melt-extrusion process was visually observed and evaluated according to the following evaluation criteria. The evaluation results are shown in Table 1 below.
<Evaluation criteria>
○: No vent-up was observed.
Δ: Vent up was observed.
X: Vent up significantly occurred.

(2) Recyclability The IV value of the polyester resin extruded from the twin screw extruder was measured and evaluated according to the following evaluation criteria. The evaluation results are shown in Table 1 below. In addition, IV value was calculated | required from the solution viscosity at 30 degreeC in a 1,1,2,2-tetrachloroethane / phenol (= 2/3 [mass ratio]) mixed solvent. In addition, IV drop shows the difference ((DELTA) IV) which subtracted IV value of the polyester resin extruded from IV of raw material resin.
<Evaluation criteria>
(Double-circle): The value of IV drop was 0.07 or less, and recyclability was favorable.
A: The value of IV drop is larger than 0.07 and in the range of 1.50 or less, and a recyclable quality was obtained.
X: The value of IV drop was in a range larger than 1.50, the quality was poor, and the recycling suitability was not met.

(3) Vacuum break The degree of vacuum was measured at the vent of a twin screw extruder, the presence or absence of a vacuum break was confirmed, and evaluation was performed according to the following evaluation criteria. The evaluation results are shown in Table 1 below.
<Evaluation criteria>
○: The degree of vacuum was 0.8 kPa or less, and the vacuum state was maintained.
X: The degree of vacuum was larger than 0.8 kPa, and the vacuum state was not maintained.

  As shown in Table 1, in the examples, vent-up was prevented, and the produced polyester resin was stable in quality. On the other hand, in the comparative example, even if vent-up could not be prevented or even if vent-up was suppressed, a polyester resin with stable quality could not be obtained due to the influence of vacuum break or the like.

DESCRIPTION OF SYMBOLS 10 ... Cylinder 12 ... Supply port 14 ... Extruder outlet 16A, 16B ... Vent 20A, 20B ... Screw 22 ... Flight 30 ... Temperature control means 40 ... Die 42 ... Filter 100 ... Twin screw extruders C1 to C9 ... Heating / cooling device

Claims (8)

The polyester raw resin charged in the twin-screw extruder is melt-kneaded in the cylinder, and the extrusion amount Q per unit time of the melted polyester resin is determined by the unit extrusion amount Y [kg / hr / rpm] and the extrusion amount Q. the relationship between [kg / h], the unit extrusion amount Y is adjusting the rotation speed of the screw of at least the cylinder in the range satisfying the region represented by the following equation (1) to (2), from Q _min method for producing a polyester resin having a melt extrusion step of performing melt-extruded by increasing the Q _0.
(1) (Y−Y _under ) / Q ≦ (Y _over −Y _under ) / Q ₀
(2) (Y−a × Y _under ) / (Q−Q ₀ ) ≧ (Y _over −Y _under ) / Q ₀
[In the formula, Y represents the unit extrusion amount Q / N [kg / hr / rpm] per one rotation of the screw, and Y _under and Y _over are Y _under [kg / hr / rpm] = 3.4 ×. 10 ⁻⁶ × D ³ , Y _over [kg / hr / rpm] = 6.6 × 10 ⁻⁶ × D ³ . D represents a screw diameter [mm]. Q represents the extruded amount [kg / h] per unit time of the molten polyester resin during operation, Q ₀ represents the extruded amount during production operation, and Q _min represents the extruded amount during standby operation. N represents the number of rotations [rpm] of the screw. However, a represents the numerical value which determines the minimum of Q / N in the amount of extrusion at the time of production operation. ] Unit extrusion rate Y _is for _{Y min} at _{Q min,} method for producing a polyester resin according to claim 1, the ratio of _{Y 0} in _{Q 0} satisfy the following relationship (3).
1.3 ≦ Y ₀ / Y _min ≦ 6.0 (3)
[Y _min represents Q _min / N _min during standby operation. N _min represents the minimum number of rotations at Q _min . ] The method for producing a polyester resin according to claim 1 or 2, wherein a ratio of Q _{0 to} Q _min satisfies the following relational expression (4).
3.3 ≦ Q ₀ / Q _min ≦ 12.0 (4)   The method for producing a polyester resin according to claim 1, wherein the melt extrusion is performed while Y is continuously changed. For _{Y min} at _{Q min} of the unit extrusion amount Y, the ratio of _{Y 0} in _{Q 0,} the polyester resin according to any one of claims 1 to 4 satisfying the following relationship (5) Production method.
1.3 ≦ Y ₀ / Y _min ≦ 4.6 (5) The ratio of Q ₀ for Q _min The method for producing a polyester resin according to any one of claims 1 to 5 satisfying the relational expression (6) below.
3.3 ≦ Q ₀ / Q _min ≦ 7.5 (6)   The protective sheet for solar cells which has the polyester film obtained by extending | stretching the polyester resin produced by the manufacturing method of the polyester resin of any one of Claims 1-6.   The transparent board | substrate which sunlight injects, the solar cell element distribute | arranged to the one side of the said board | substrate, and it distribute | arranged to the opposite side to the side by which the said board | substrate of this solar cell element was distribute | arranged. A solar cell module comprising: a solar cell protective sheet.