JP2015178613A - Manufacturing method of polyarylene sulfide and polyarylene sulfide resin composition - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing polyarylene sulfide with higher purity and less weight reduction during heating at low temperature in short time by using a more stable catalyst compound with resolving problem that there is much conversion which needs high temperature and long time, has not enough high polymerization degree and not enough promotion effect and stability of a catalyst during conversion of cyclic polyarylene sulfide to polyarylene sulfide.SOLUTION: There is provided a method for manufacturing polyarylene sulfide including heating cyclic polyarylene sulfide in a presence of a support type transition metal catalyst where a supporter is a powdery material.

Description

  The present invention relates to a method for producing polyarylene sulfide and a polyarylene sulfide resin composition. More specifically, a method for producing a polyarylene sulfide, comprising heating a cyclic polyarylene sulfide in the presence of a supported transition catalyst whose support is a powdery substance, and a polyarylene sulfide resin containing the supported transition metal catalyst It relates to a composition.

  Polyarylene sulfides typified by polyphenylene sulfide (hereinafter sometimes abbreviated as PPS) have excellent heat resistance, barrier properties, chemical resistance, electrical insulation, moist heat resistance, flame resistance, and other suitable properties as engineering plastics. It is resin which has. Furthermore, it can be molded into various molded parts, films, sheets, fibers, etc. by injection molding and extrusion molding, and widely used in fields requiring heat resistance and chemical resistance, such as various electrical / electronic parts, mechanical parts, and automotive parts. It has been.

  As a specific method for producing this polyarylene sulfide, a method of reacting an alkali metal sulfide such as sodium sulfide with a polyhaloaromatic compound such as p-dichlorobenzene in an organic amide solvent such as N-methyl-2-pyrrolidone. Has been proposed. This method is widely used as an industrial production method of polyarylene sulfide (for example, Patent Document 1). However, this production method requires the reaction to be carried out under high temperature, high pressure, and strong alkaline conditions, and further requires an expensive high boiling polar solvent such as N-methyl-2-pyrrolidone. The energy consuming type requires a great deal of cost, and has a problem that a great deal of process cost is required.

  As another method for producing a polyarylene sulfide that solves the problems of the method for producing a polyarylene sulfide as described above, a method for producing a polyarylene sulfide by heating a cyclic polyarylene sulfide is disclosed. In this method, it can be expected to obtain a polyarylene sulfide having a high molecular weight, a narrow molecular weight distribution, and a small weight loss when heated. However, since the reaction requires a high temperature and a long time to complete the reaction of the cyclic polyarylene sulfide, a method for producing a polyarylene sulfide at a lower temperature and in a shorter time has been desired (for example, Patent Document 2).

  In the conversion of cyclic polyarylene sulfide to polyarylene sulfide, there is known a method using various catalyst components (a compound having a radical generating ability, an ionic compound, an organic carboxylic acid, etc.) that promote the conversion (for example, patents) Documents 3 to 7 and Non-Patent Document 1). However, in any method, there is a problem that high temperature and long time are required to complete the reaction of cyclic polyarylene sulfide, and a method for producing polyarylene sulfide at further low temperature and short time is desired. It was.

  Furthermore, a method of using a transition metal compound (zero-valent transition metal compound or low-valent iron compound) as a catalyst for promoting the conversion in the conversion of cyclic polyarylene sulfide to polyarylene sulfide has also been reported (for example, patents). Literature 8-10). Patent Document 8 discloses a method using, for example, tetrakis (triphenylphosphine) palladium as a zero-valent transition metal compound. When this method is used, polyarylene sulfide can be obtained at low temperature in a short time. Therefore, there has been a demand for a production method using a catalyst having low catalyst stability, high catalyst cost, and high stability and low cost. Patent Document 9 discloses a method using iron chloride or the like as a low-valent iron compound, and even when this method is used, polyarylene sulfide can be obtained at a low temperature in a short time. Furthermore, a method for producing a polyarylene sulfide having a high degree of polymerization has been desired. Patent Document 10 discloses a method using, for example, bis (1,5-cyclooctadiene) nickel, tetrakis (triphenylphosphite) nickel, etc. as a zero-valent transition metal compound under devolatilization conditions, When this method is used, polyarylene sulfide can be obtained at a low temperature and in a short time. However, there has been a demand for a production method using a catalyst that has low catalyst stability, is expensive, and is more stable and inexpensive. In recent years, there has been a demand for higher purity of polyarylene sulfide, and further, there has been a demand for polyarylene sulfide with less weight loss when heated.

Japanese Patent Laid-Open No. 52-12240 International Publication No. 2007/034800 US Pat. No. 5,869,599 JP-A-5-163349 Japanese Patent Laid-Open No. 5-301962 JP-A-5-105757 JP 2011-173953 A International Publication No. 2011-013686 JP 2012-92315 A JP 2014-159544 A

Macromolecules, Volume 30, 1997 (pages 4502-4503)

  The present invention has a problem that in the conversion of cyclic polyarylene sulfides into polyarylene sulfides in the prior art, the degree of polymerization of polyarylene sulfides is not sufficient, and there are many cases where the catalyst promoting effect and stability are not sufficient. It is an object of the present invention to provide a method for producing polyarylene sulfide using a more stable catalyst compound at a low temperature and in a short time, with a higher purity and less weight loss when heated.

  The present invention relates to a method for producing polyarylene sulfide, which comprises heating cyclic polyarylene sulfide in the presence of a supported transition metal catalyst, and a polyarylene sulfide resin composition containing the supported transition metal catalyst.

That is, the present invention is as follows.
1. A method for producing a polyarylene sulfide, comprising heating a cyclic polyarylene sulfide in the presence of a supported transition metal catalyst whose support is a powdery substance.
2. 2. The method for producing polyarylene sulfide according to 1, wherein the carrier of the supported transition metal catalyst is an inorganic compound.
3. 3. The production of polyarylene sulfide according to either 1 or 2, wherein the supported transition metal catalyst support is at least one support selected from diatomaceous earth, silica, alumina, zeolite, and activated carbon. Method.
4). 4. The method for producing polyarylene sulfide according to any one of 1 to 3, wherein the supported transition metal catalyst is a transition metal catalyst having no organic ligand.
5. 5. The metal species of the supported transition metal catalyst is at least one metal selected from Group 8 to Group 11 and Period 4 metal in the periodic table, according to any one of 1 to 4, A method for producing polyarylene sulfide.
6). 6. The method for producing polyarylene sulfide according to 5, wherein the metal species of the supported transition metal catalyst is nickel or palladium.
7). 7. The method for producing polyarylene sulfide according to 6, wherein the metal species of the supported transition metal catalyst is nickel.
8). 8. The method for producing polyarylene sulfide according to 7, wherein the supported transition metal catalyst is a stabilized nickel catalyst.
9. The method for producing polyarylene sulfide according to any one of 1 to 8, wherein the supported transition metal catalyst has a specific surface area of 100 m ² / g or more and 1000 m ² / g or less.
10. A polyarylene sulfide resin composition comprising at least a polyarylene sulfide resin and a supported transition metal catalyst whose carrier is a powdery substance.
11. 11. The polyarylene sulfide resin composition according to 10, wherein the polyarylene sulfide resin is obtained by heating cyclic polyarylene sulfide.

  ADVANTAGE OF THE INVENTION According to this invention, when manufacturing a polyarylene sulfide by heating cyclic polyarylene sulfide, the manufacturing method which can obtain a polyarylene sulfide at low temperature and a short time compared with the conventional method can be provided. . The supported transition metal catalyst is stable and easy to handle, and by using a compound having no organic ligand as the catalyst, the amount of gas generated during heat processing can be further reduced.

  Further, when a necessary amount of a supported transition metal catalyst whose carrier is a powdery substance is used, a resin composition reinforced with a powdery carrier can be easily obtained.

  Embodiments of the present invention will be described below.

<Polyarylene sulfide>
The polyarylene sulfide in the present invention is a homopolymer or copolymer having a repeating unit of the formula:-(Ar-S)-as a main constituent unit, preferably containing 80 mol% or more of the repeating unit. Ar includes units represented by the following formulas (A) to (K), among which the formula (A) is particularly preferable.

  As long as this repeating unit is a main structural unit, it can contain a small amount of branching units or crosslinking units represented by the following formulas (L) to (N). The amount of copolymerization of these branched units or cross-linked units is preferably in the range of 0 to 1 mol% with respect to 1 mol of-(Ar-S)-units.

  In addition, the polyarylene sulfide in the present invention may be any of a random copolymer, a block copolymer and a mixture thereof containing the above repeating unit.

  Typical examples of these include polyphenylene sulfide, polyphenylene sulfide sulfone, polyphenylene sulfide ketone, random copolymers thereof, block copolymers, and mixtures thereof. Particularly preferred polyarylene sulfides include polyphenylene sulfide containing 80 mol% or more, particularly 90 mol% or more of p-phenylene sulfide units as the main structural unit of the polymer.

  The preferred molecular weight of the polyarylene sulfide of the present invention is 10,000 or more in terms of weight average molecular weight, preferably 20,000 or more, more preferably 40,000 or more, still more preferably 50,000 or more, and even more preferably 60,000. More preferably, it is 80,000 or more. When the weight average molecular weight is 10,000 or more, the moldability at the time of processing is good, and the properties such as mechanical strength and chemical resistance of the molded product are high. Although there is no restriction | limiting in particular in the upper limit of a weight average molecular weight, Less than 1,000,000 can be illustrated as a preferable range, More preferably, it is less than 500,000, More preferably, it is less than 200,000. Sex can be obtained.

  The polyarylene sulfide obtained by the production method of the present invention tends to have a feature that the molecular weight distribution is broad, that is, the degree of dispersion expressed by the ratio of the weight average molecular weight to the number average molecular weight (weight average molecular weight / number average molecular weight) is narrow. is there. The degree of dispersion of the polyarylene sulfide obtained by the production method of the present invention is preferably 2.5 or less, more preferably 2.3 or less, and even more preferably 2.1 or less. If the degree of dispersion is 2.5 or less, the amount of low-molecular components contained in polyarylene sulfide tends to decrease, which is an improvement in mechanical properties when polyarylene sulfide is used for molding processing, and gas when heated There are effects such as a reduction in the amount generated and a reduction in the amount of eluted components when in contact with the solvent. The weight average molecular weight and number average molecular weight can be determined using, for example, SEC (size exclusion chromatography) equipped with a differential refractive index detector.

  Unlike the conventional method, the polyarylene sulfide obtained by the production method of the present invention does not require a solvent such as N-methyl-2-pyrrolidone at the time of production, and has a known radical-generating compound or ionicity. Since it does not use a catalyst such as a compound, it has the advantage of producing less gas during heat processing. Furthermore, by using a compound having no organic ligand as a catalyst, it is possible to further reduce the amount of gas generated during heat processing.

This gas generation amount can be evaluated from the weight reduction rate ΔWr when heated, which is obtained by a general thermogravimetric analysis and is represented by the following formula.
ΔWr = (W1-W2) / W1 × 100

  ΔWr is the weight of the sample (W1 when reaching 100 ° C. when thermogravimetric analysis is performed at a rate of temperature increase of 20 ° C./min from 50 ° C. to 330 ° C. or higher in a non-oxidizing atmosphere at normal pressure. ) Based on the sample weight (W2) when reaching 330 ° C.

  The atmosphere in the thermogravimetric analysis is a normal pressure non-oxidizing atmosphere. A non-oxidizing atmosphere is an atmosphere in which the oxygen concentration in the gas phase in contact with the sample is 5% by volume or less, preferably 2% by volume or less, and more preferably an oxygen-free atmosphere, that is, an inert gas such as nitrogen, helium, or argon. A nitrogen atmosphere is particularly preferred from the standpoints of economy and ease of handling. The normal pressure is a pressure in the vicinity of the standard state of the atmosphere, and is an atmospheric pressure condition in which the temperature is about 25 ° C. and the absolute pressure is about 101.3 kPa. If the measurement atmosphere is other than the above, oxidation of polyarylene sulfide during measurement may occur, and the measurement may be in line with the actual use of polyarylene sulfide, for example, greatly different from the atmosphere used for molding polyarylene sulfide. There is no possibility.

  In the measurement of ΔWr, thermogravimetric analysis is performed by raising the temperature from 50 ° C. to an arbitrary temperature of 330 ° C. or higher at a rate of temperature increase of 20 ° C./min. Preferably, after holding at 50 ° C. for 1 minute, the temperature is increased at a rate of temperature increase of 20 ° C./min to perform thermogravimetric analysis. This temperature range is a temperature range frequently used when polyarylene sulfide typified by polyphenylene sulfide is actually used. Also, it is frequently used when a solid polyarylene sulfide is melted and then molded into an arbitrary shape. It is also a temperature range. The weight reduction rate in the actual use temperature range is related to the amount of gas generated from the polyarylene sulfide during actual use, the amount of components attached to the die, the mold, and the like during the molding process. Therefore, it can be said that the polyarylene sulfide having a lower weight loss rate in such a temperature range is an excellent polyarylene sulfide having higher quality. ΔWr is desirably measured with a sample amount of about 10 mg, and the shape of the sample is desirably a fine particle having a size of about 2 mm or less.

  In the polyarylene sulfide obtained by the production method of the present invention, the weight reduction rate ΔWr when heated as described above varies depending on the concentration of the polymerization catalyst used and the type of the polymerization catalyst, but is preferably 0.25% or less. .16% or less is more preferable, 0.13% or less is more preferable, and 0.10% or less is even more preferable.

  When ΔWr is within the above range, for example, the amount of gas generated tends to decrease when molding polyarylene sulfide, and the amount of deposits on the die or die during extrusion molding and the mold during injection molding is reduced. This is desirable because it tends to increase molding processability.

  In the production method of the present invention, the conversion rate of cyclic polyarylene sulfide to polyarylene sulfide is preferably 70% or more, more preferably 80% or more, and further preferably 90% or more. If the conversion is 70% or more, a polyarylene sulfide having the above-described characteristics can be obtained.

The conversion ratio of cyclic polyarylene sulfide to polyarylene sulfide is determined by the amount of cyclic polyarylene sulfide contained in the raw material before heating and the amount of unreacted cyclic polyarylene sulfide contained in the product obtained by heating. Quantitatively using high performance liquid chromatography (HPLC), and can be calculated from the value. In particular,
Conversion rate = (Amount of cyclic polyarylene sulfide contained in raw material before heating−Amount of unreacted cyclic polyarylene sulfide) / Amount of cyclic polyarylene sulfide contained in the raw material before heating .

<Cyclic polyarylene sulfide>
The cyclic polyarylene sulfide in the method for producing a polyarylene sulfide of the present invention is a compound represented by the formula: — (Ar—S) — having a repeating unit as a main constituent unit, preferably the following general formula containing 80 mol% or more of the repeating unit. The cyclic compound such as (O) contains at least 50% by weight, preferably 70% by weight or more, more preferably 80% by weight or more, and still more preferably 90% by weight or more. Ar includes units represented by the above formulas (A) to (K), among which the formula (A) is particularly preferable.

  In the cyclic compound of the formula (O) in the cyclic polyarylene sulfide, repeating units such as the formulas (A) to (K) may be included randomly or in blocks. Any of the mixtures may be used. Typical examples of these include cyclic polyphenylene sulfide, cyclic polyphenylene sulfide sulfone, cyclic polyphenylene sulfide ketone, cyclic random copolymers containing these, cyclic block copolymers, and mixtures thereof. . Particularly preferred cyclic compounds of the formula (O) include cyclic compounds containing 80 mol% or more, particularly 90 mol% or more of p-phenylene sulfide units as main structural units.

  Although there is no restriction | limiting in particular in the repeating number m in the said (O) formula contained in cyclic polyarylene sulfide, 4-50 are preferable. Here, the lower limit is preferably 4 or more, more preferably 5 or more, still more preferably 6 or more, still more preferably 7 or more, and still more preferably 8 or more. Since cyclic compounds having a small m tend to have low reactivity, it is preferable to set m in the above range from the viewpoint that polyarylene sulfide can be obtained in a short time. On the other hand, the upper limit is preferably 50 or less, more preferably 25 or less, and even more preferably 15 or less. As will be described later, the conversion of the cyclic polyarylene sulfide to the polyarylene sulfide by heating is preferably performed at a temperature equal to or higher than the temperature at which the cyclic polyarylene sulfide is melted. However, when m is increased, the temperature at which the cyclic polyarylene sulfide is melted is increased. It tends to be higher. Therefore, in order to convert the cyclic polyarylene sulfide to the polyarylene sulfide at a lower temperature, it is preferable to set m to the above range.

  The cyclic compound of the formula (O) contained in the cyclic polyarylene sulfide may be either a single compound having a single repeating number or a mixture of cyclic compounds having different repeating numbers, but different repeating numbers. A mixture of cyclic compounds having a tendency to melt at a lower temperature than a single compound having a single number of repetitions, and the use of a mixture of cyclic compounds having different numbers of repetitions may result in conversion to polyarylene sulfide. Since the heating temperature at the time of performing can be made lower, it is preferable.

  It is particularly preferable that the components other than the cyclic compound of the formula (O) in the cyclic polyarylene sulfide are polyarylene sulfide oligomers. Here, the polyarylene sulfide oligomer is a linear homo-oligomer or co-oligomer having a repeating unit of the formula, — (Ar—S) —, as a main constituent unit, preferably containing 80 mol% or more of the repeating unit. . Ar includes units represented by the above formulas (A) to (K), among which the formula (A) is particularly preferable. The polyarylene sulfide oligomer can contain a small amount of branching units or crosslinking units represented by the above formulas (L) to (N) as long as these repeating units are the main structural units. The amount of copolymerization of these branched units or cross-linked units is preferably in the range of 0 to 1 mol% with respect to 1 mol of-(Ar-S)-units. Further, the polyarylene sulfide oligomer may be any of a random copolymer, a block copolymer and a mixture thereof containing the above repeating unit.

  Typical examples of these include polyphenylene sulfide oligomers, polyphenylene sulfide sulfone oligomers, polyphenylene sulfide ketone oligomers, random copolymers, block copolymers, and mixtures thereof. Particularly preferred polyarylene sulfide oligomers include polyphenylene sulfide oligomers containing 80 mol% or more, particularly 90 mol% or more of p-phenylene sulfide units as the main structural unit of the polymer.

  Examples of the molecular weight of the polyarylene sulfide oligomer include those having a molecular weight lower than that of the polyarylene sulfide, and specifically, the weight average molecular weight is preferably less than 10,000. When the weight average molecular weight of the polyarylene sulfide oligomer contained in the cyclic polyarylene sulfide is less than 10,000, the melting temperature of the cyclic polyarylene sulfide tends to decrease, and the polyarylene sulfide of the cyclic polyarylene sulfide In order to carry out the conversion to a lower temperature, the above range is preferred.

  The amount of the polyarylene sulfide oligomer contained in the cyclic polyarylene sulfide is particularly preferably smaller than the cyclic compound of the above formula (O) contained in the cyclic polyarylene sulfide. That is, the weight ratio of the cyclic compound (O) to the polyarylene sulfide oligomer in the cyclic polyarylene sulfide (cyclic compound of the formula (O) / polyarylene sulfide oligomer) is preferably more than 1. More preferably 3 or more, more preferably 4 or more, and even more preferably 9 or more. By using such a cyclic polyarylene sulfide, it is possible to easily obtain a polyarylene sulfide having a weight average molecular weight of 10,000 or more. It is. Accordingly, the larger the weight ratio of the cyclic compound of formula (O) to the polyarylene sulfide oligomer in the cyclic polyarylene sulfide, the higher the weight average molecular weight of the polyarylene sulfide obtained by the method for producing polyarylene sulfide of the present invention. Tend to grow. Although there is no particular upper limit to this weight ratio, in order to obtain a cyclic polyarylene sulfide having a weight ratio exceeding 100, it is necessary to significantly reduce the polyarylene sulfide oligomer content in the cyclic polyarylene sulfide. Takes a lot of effort. According to the polyarylene sulfide production method of the present invention, it is possible to easily obtain a polyarylene sulfide having a weight average molecular weight of 10,000 or more even when a cyclic polyarylene sulfide having a weight ratio of 100 or less is used.

The weight ratio of the cyclic compound of the formula (O) and the polyarylene sulfide oligomer in the cyclic polyarylene sulfide is determined from the amount of the cyclic compound of the formula (O) in the cyclic polyarylene sulfide determined by HPLC. Can be calculated. For example, when the component other than the cyclic compound of the formula (O) in the cyclic polyarylene sulfide is a polyarylene sulfide oligomer,
Weight ratio = Amount of cyclic compound of formula (O) (%) / (100−Amount of cyclic compound of formula (O) (%))
It can be calculated as follows.

<Supported transition metal catalyst>
In the present invention, various supported transition metal catalysts are used as the polymerization catalyst. The reason why the supported transition metal catalyst effectively acts as a polymerization catalyst for cyclic polyarylene sulfide is not clear at present, but the following possibilities are considered. The effect of the metal species itself is that these transition metal atoms, which can take many valence states, tend to interact with the cyclic polyarylene sulfide structure and tend to generate active transition metal compounds during the decomposition reaction by heating. It is speculated that these transition metal atoms are strong or can form a transition metal compound that is easily dispersed in the cyclic polyarylene sulfide. Further, it is presumed that the effect of the supported catalyst is that the surface area of the catalyst is increased because the transition metal catalyst is supported on the carrier.

  Examples of the transition metal catalyst include a transition metal simple substance, a complex having an organic ligand, a carboxylate, and a halide. Among these, a transition metal having no organic ligand is preferable. From the viewpoint of reducing the amount of generated gas of polyarylene sulfide obtained, a single transition metal is more preferable.

  As the transition metal species, transition metals selected from Group 8 to Group 11 and Period 4 to 6 metals in the periodic table tend to have a high effect of promoting the conversion of cyclic polyarylene sulfide, which is preferable. . Specific examples include iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, silver, and gold. The reason for this is not clear at the moment, but the following possibilities are considered. The effect of the metal species itself is that these transition metal atoms, which can take many valence states, tend to interact with the cyclic polyarylene sulfide structure and tend to generate active transition metal compounds during the decomposition reaction by heating. It is speculated that these transition metal atoms are strong or can form a transition metal compound that is easily dispersed in the cyclic polyarylene sulfide. Further, it is presumed that the effect of the supported catalyst is that the surface area of the catalyst is increased because the transition metal catalyst is supported on the carrier.

  Among these transition metal species, nickel or palladium is preferable, and in particular, it tends to have a high effect of promoting the conversion of cyclic polyarylene sulfide. Although the reason for this is not clear at present, these metal species are used in many carbon-sulfur bond formation reactions as described in Chemical Reviews, 111, 2011 (1596-4503). It is considered that the carbon-sulfur interaction is likely to occur, the active transition metal compound is easily generated, or the compound that is easily dispersed in the cyclic polyarylene sulfide can be formed. ing. Furthermore, nickel which is excellent in terms of catalyst cost and availability is more preferable.

  As nickel of the supported nickel catalyst, any of the carrier supported catalysts such as nickel metal powder, alloys with other metals, oxides, hydroxides, inorganic salts, organic salts, Raney catalysts, organometallic complexes, etc. Can be used in the present invention. For example, metallic nickel, reduced nickel, stabilized nickel, nickel-diatomaceous earth, Raney-type nickel, modified Raney-type nickel, nickel formate, lacquer raw nickel, nickel complex, nickel-copper, nickel-zirconia, nickel-cobalt, nickel-copper- Examples thereof include supported catalysts such as cobalt, nickel-iron, nickel-iron-cobalt, and nickel-iron-phosphorus.

  Among these supported nickel catalysts, it is more preferable to use stabilized nickel. Stabilized nickel catalyst is a compound that can be handled stably in air, after reducing nickel oxide, etc., then oxidizing part of the surface of the reduced nickel and protecting the reduced nickel with its oxidized surface film. . For this reason, it is more preferable to use stabilized nickel which has high catalyst stability and is easy to handle.

  Examples of such stabilized nickel catalysts include 5 to 80 wt% nickel as nickel or nickel oxide in the catalyst on diatomaceous earth (mainly silica), or in addition, copper, chromium, manganese as co-catalysts It is preferable to contain 0.1 to 10% by weight of a single or plural kinds of substances appropriately selected from iron, cobalt, zinc, aluminum, molybdenum, tungsten or oxides thereof.

Among the stabilized nickel catalysts, nickel is contained in the catalyst in an amount of 40 to 60% by weight as nickel or nickel oxide, and in addition, as a co-catalyst, copper, chromium, manganese, iron, cobalt, zinc, aluminum, molybdenum, tungsten or oxidation thereof It is more preferable to contain 1 to 5% by weight of a single or plural kinds of substances appropriately selected from those. Specific examples of commercially available products include stabilized nickel catalysts N111, N112, N113, N113B, N103, N103B, N103K (JGC), SN-110, SN-150, SN-250, SN-300, SN-750 (Sakai Chemical Industry Co., Ltd.), Ni-5123P, Ni-5136P, Ni-5256P, Ni-0104T, Ni-3266E, Ni-3288E, Ni-3737T, Ni-5256E (N-Echemcat Corporation) Is mentioned. Among them, stabilized nickel catalyst SN-250 (a catalyst in which 55 wt% of nickel or nickel oxide (II) is supported on diatomaceous earth), stabilized nickel catalyst SN-750 (47 wt% of nickel or nickel oxide (II) is supported in diatomaceous earth) Catalyst) (Sakai Chemical Industry Co., Ltd.). The larger the specific surface area of these stabilized nickel catalysts, the stronger the catalytic effect tends to be. Specifically, a specific surface area of 100 m ² / g or more can be exemplified as a preferable specific surface area. The larger the specific surface area, the more easily nickel and the cyclic polyarylene sulfide come into contact with each other, and the reaction tends to proceed faster. Therefore, among the above commercially available products, the stabilized nickel catalyst SN-750 (specific surface area having a particularly large specific surface area). : 150-200 m ² / g), SN-250 (specific surface area: 120-170 m ² / g) is more preferable.

  As the supported palladium catalyst, any of supported catalysts such as metal palladium, alloys with other metals, oxides, hydroxides, inorganic salts, organic salts, and organometallic complexes can be used in the present invention. For example, palladium-activated carbon, palladium-alumina, palladium black, Lindlar catalyst and the like can be mentioned as supported catalysts of metallic palladium.

The specific surface area of the carrier of the supported transition metal catalyst of the present invention is not particularly limited because the transition metal catalyst can be more efficiently supported as it is larger. A range of ² / g can be exemplified, and a range of 100 to 1000 m ² / g is preferable. When the specific surface area is within the above range, the transition metal catalyst can be efficiently supported, and the transition metal catalyst particles tend to be small and the catalytic activity tends to be high. The shape and size of the catalyst itself are not limited, and may be set appropriately according to the purpose.

  The amount of the metal catalyst relative to the carrier in the present invention varies depending on the type of supported catalyst used, but is usually 1 to 80 wt%, preferably 5 to 60 wt%, more preferably 10 to 60 wt%. If the amount of the metal catalyst relative to the support is 80 wt% or less, the catalyst activity tends to be maintained without coarsening the particle diameter of the supported metal catalyst. Therefore, as an upper limit, it is preferable that the amount of the metal catalyst with respect to the support is 80 wt% or less. If the amount of the metal catalyst relative to the support is 1 wt% or more, the amount of the metal catalyst support does not become excessive in the polyarylene sulfide obtained by polymerization, and the characteristics of the polyarylene sulfide obtained in the present invention are less likely to be affected. It is in. Therefore, as a lower limit, it is preferable that the amount of the metal catalyst with respect to the support is 1 wt% or more.

  The support for the supported transition metal catalyst of the present invention is not particularly limited as long as it is a powdery substance, and a commercially available support or the like can be used. For example, metal oxides (silica, alumina, titania, zirconia, magnesia, etc.), composite oxides (silica / alumina, titania / silica, silica / magnesia, etc.), zeolite, mesoporous silica, natural minerals (clay, diatomaceous earth, pumice, etc.) ), Activated carbon, carbon black, fullerene, graphite, molecular sieves and the like. Among these, inorganic compounds are preferable, and diatomaceous earth, silica, alumina, zeolite, and activated carbon are more preferable. These carriers are preferable because they are stable in the polymerization temperature region of cyclic polyarylene sulfide described later and have a large surface area and are suitable as a catalyst carrier.

  The average particle size of the powdery carrier is preferably in the range of 0.1 to 400 μm, more preferably in the range of 0.5 to 200 μm, and still more preferably in the range of 1 to 150 μm. When the average particle size of the support carrier of the powdery substance is in the above preferred range, the transition metal catalyst is efficiently supported and a highly active catalyst is easily obtained. When the average particle size of the support carrier of the powdery substance is smaller than 0.1 μm, the metal catalyst tends to aggregate when the transition metal catalyst is supported, and the catalytic activity tends to decrease. Depending on the size of the average particle diameter, unless otherwise specified, the average particle diameter of the carrier is 100-200 times or scanning type using an optical microscope (apparatus: OPTIHOT-POL manufactured by Nikon Corporation). Observe the carrier of the powdery substance with an electron microscope (SEM) (JSM-6360LV manufactured by JEOL Ltd.) at a magnification of 1000 to 2000 times, and confirm the dispersion state of the carrier of the powdery substance. Is the average particle size obtained. 100 particles were randomly extracted from the optical microscope image or scanning electron microscope image observed by this method, and the value obtained by averaging the sum of the major axis and the minor axis was taken as the representative particle diameter, and the number average of the representative particle diameters This is a value obtained as an average particle diameter. In addition, since local information is obtained by observation with a scanning electron microscope, in order to accurately evaluate the particle size, it is necessary to confirm the presence or absence of coarse particles that can be observed visually or with an optical microscope. . When coarse particles that can be observed visually or with an optical microscope are present, the average particle diameter is determined by combining the observation results and the observation results of the scanning electron microscope. The average particle diameter is calculated from the observation result of the scanning electron microscope.

  The average aspect ratio of the powdery substance-supported carrier is preferably in the range of 1 to less than 200, more preferably in the range of 1 to 80, and still more preferably in the range of 1 to 30. When the average aspect ratio of the support for the powdery substance is in the above preferred range, the metal catalyst is supported efficiently and a highly active catalyst is easily obtained. The measuring method of the aspect ratio is 100-200 times using an optical microscope (apparatus: Nikon Corporation OPTIHOT-POL) or a scanning electron microscope (SEM) (JSM-6360LV manufactured by JEOL Ltd.) 1000- It is an average aspect ratio obtained by observing a powdery substance-supported carrier at a magnification of 2000 times and confirming the dispersion state of the powdery substance-supported carrier. Randomly extract 100 particles from the optical microscope image or scanning electron microscope image observed by this method, measure each major axis and minor axis, and calculate each aspect ratio (major axis / minor axis). Furthermore, it calculated | required by calculating the number average value. In the case of a powdery substance close to a plate shape, the volume average particle diameter and the number average thickness may be obtained and calculated by “volume average particle diameter (μm) / number average thickness (μm)”. The “volume average particle size” is determined by using a laser diffraction / scattering particle size distribution measuring device (LA-300 manufactured by HORIBA) after weighing 100 mg of a powdery substance and dispersing it in water. “Thickness” is a measurement of 100 randomly selected thicknesses from an image of a powdery substance observed at a magnification of 2000 using a scanning electron microscope (SEM) (JSM-6360LV manufactured by JEOL Ltd.) The number average value.

  Examples of the transition metal complex having an organic ligand include complexes having ligands such as carbene, carbonyl, alkene, alkyne, diene, arene, phosphine, phosphite and amine. For example, as a ligand, triphenylphosphine, tri-t-butylphosphine, tricyclohexylphosphine, 1,2-bis (diphenylphosphino) ethane, 1,1′-bis (diphenylphosphino) ferrocene, dibenzylideneacetone, Examples include dimethoxydibenzylideneacetone, cyclooctadiene, and carbonyl complexes. These supported catalysts may be used singly or in combination of two or more.

  The concentration of the supported transition metal catalyst to be used varies depending on the molecular weight of the target polyarylene sulfide and the type of the catalyst, but usually the transition in the supported transition metal catalyst is relative to the sulfur atom in the cyclic polyarylene sulfide. The amount of the metal is 0.001 to 20 mol%, preferably 0.005 to 15 mol%, more preferably 0.01 to 10 mol%. If it is 0.001 mol% or more, the cyclic polyarylene sulfide is sufficiently converted to polyarylene sulfide, and if it is 20 mol% or less, a polyarylene sulfide having the above-described properties can be obtained.

  What is necessary is just to add to the said polymerization catalyst as it is, However, After adding a polymerization catalyst to cyclic polyarylene sulfide, it is preferable to disperse | distribute a polymerization catalyst and cyclic polyarylene sulfide uniformly. Examples of the uniform dispersion method include a mechanical dispersion method and a dispersion method using a solvent. Specific examples of the mechanical dispersion method include a pulverizer, a stirrer, a mixer, a shaker, and a method using a mortar. Specific examples of the method of dispersing using a solvent include a method of dissolving or dispersing cyclic polyarylene sulfide in an appropriate solvent, adding a predetermined amount of a polymerization catalyst thereto, and then removing the solvent. In addition, when the polymerization catalyst is dispersed, when the polymerization catalyst is a solid, it is preferable that the average particle size of the polymerization catalyst is 1 mm or less because more uniform dispersion is possible.

  In addition, the supported transition metal catalyst used in the present invention is preferably added in a non-oxidizing atmosphere, but depending on the type of catalyst, it tends to be highly stable, so it can also be added in the atmosphere. is there. The non-oxidizing atmosphere is an atmosphere in which the oxygen concentration in the gas phase in contact with the cyclic polyarylene sulfide and the supported transition metal catalyst is 5% by volume or less, preferably 2% by volume or less, more preferably substantially free of oxygen, It indicates an inert gas atmosphere such as nitrogen, helium, and argon, and a nitrogen atmosphere is preferable from the viewpoint of economy and ease of handling. The term “in the atmosphere” means that the atmosphere has a general composition with an oxygen concentration of about 21% by volume.

<Production conditions for polyarylene sulfide>
The heating temperature for producing the polyarylene sulfide in the present invention is preferably a temperature at which the cyclic polyarylene sulfide is melted. However, if the heating temperature is lower than the melting temperature of the cyclic polyarylene sulfide, a long time tends to be required to obtain the polyarylene sulfide. The temperature at which the cyclic polyarylene sulfide melts varies depending on the composition and molecular weight of the cyclic polyarylene sulfide and the environment during heating. It is possible to grasp by analyzing with a differential scanning calorimeter. However, in general, the melting temperature has a range, and the endotherm accompanying melting tends to continue even when the melting point is exceeded, so that the heating temperature may be equal to or higher than the melting point of the cyclic polyarylene sulfide. Preferably, the temperature is 10 ° C. or more higher than the melting point of the cyclic polyarylene sulfide, and more preferably 20 ° C. or more. The melting point can be measured with a differential scanning calorimeter.

  As a minimum of heating temperature, 180 ° C or more can be illustrated, preferably 200 ° C or more, more preferably 220 ° C or more, still more preferably 240 ° C or more. In this temperature range, the cyclic polyarylene sulfide is melted, and a polyarylene sulfide having a high degree of polymerization can be obtained in a short time. On the other hand, if the temperature is too high, undesirable side reactions represented by crosslinking and decomposition reactions between cyclic polyarylene sulfides, between polyarylene sulfides produced by heating, and between polyarylene sulfides and cyclic polyarylene sulfides, etc. Therefore, it is desirable to avoid a temperature at which such undesirable side reactions are remarkably caused, since the characteristics of the resulting polyarylene sulfide may be deteriorated. As an upper limit of heating temperature, 400 degrees C or less can be illustrated. Below this temperature, adverse effects on the properties of the resulting polyarylene sulfide due to undesirable side reactions tend to be suppressed, and a polyarylene sulfide having the above-described properties can be obtained. Further, the heating temperature is preferably lower because the energy required for heating or cooling can be reduced and the time can be shortened to improve productivity. From this, a preferable heating temperature is 400 ° C. or lower, more preferably 360 ° C. or lower, more preferably 320 ° C. or lower, and still more preferably 300 ° C. or lower.

  The atmosphere in heating the cyclic polyarylene sulfide is preferably a non-oxidizing atmosphere. The non-oxidizing atmosphere is an atmosphere in which the oxygen concentration in the gas phase in contact with the cyclic polyarylene sulfide is 5% by volume or less, preferably 2% by volume or less, and more preferably contains substantially no oxygen, that is, nitrogen, helium, argon, etc. In particular, a nitrogen atmosphere is preferable from the viewpoint of economy and ease of handling. This tends to suppress the occurrence of undesirable side reactions such as cross-linking reactions and decomposition reactions between cyclic polyarylene sulfides, between polyarylene sulfides generated by heating, and between polyarylene sulfides and cyclic polyarylene sulfides. .

  The heating of the cyclic polyarylene sulfide is not limited to atmospheric pressure as long as it is in a non-oxidizing atmosphere, and can be performed under pressure conditions higher than atmospheric pressure. It is also preferable to carry out under conditions.

  The pressurization condition higher than the atmospheric pressure is preferable from the viewpoint that the polymerization catalyst is hardly volatilized during heating, and the upper limit of the pressurization condition is not particularly limited, but is 0.2 MPa from the viewpoint of easy handling of the reactor. The following is preferred. Moreover, when heating is performed under conditions of 50 kPa or more, it is preferable that the atmosphere in the reaction system is once changed to a non-oxidizing atmosphere and then set to a target pressure condition. This tends to suppress the occurrence of undesirable side reactions such as cross-linking reactions and decomposition reactions between cyclic polyarylene sulfides, between polyarylene sulfides generated by heating, and between polyarylene sulfides and cyclic polyarylene sulfides. .

  The reduced pressure condition means that the reaction system is lower than atmospheric pressure, and the upper limit is preferably 50 kPa or less, more preferably 20 kPa or less, and even more preferably 10 kPa or less. An example of the lower limit is 0.1 kPa or more, and 0.2 kPa or more is more preferable. When the decompression condition is not less than the preferred lower limit, the cyclic compound of the formula (O) having a low molecular weight contained in the cyclic polyarylene sulfide tends to hardly evaporate. On the other hand, below the preferred upper limit, it is easy to remove the components and ligands decomposed from the supported transition metal catalyst from the heating system, the concentration of the above decomposition products in the melted raw material decreases, and the decomposition by heating more efficiently Polyarylene sulfide with a high degree of polymerization can be obtained at a lower temperature and in a shorter time by enabling the reaction, the generation of an active transition metal compound, and the removal of the polyarylene sulfide oligomer contained in the cyclic polyarylene sulfide from the heating system. Is preferable because it tends to be obtained.

  The devolatilization condition is a condition for removing a gaseous component generated when the cyclic polyarylene sulfide is heated in the presence of the supported transition metal catalyst from the heating system. The components in the gaseous state vary depending on the characteristics of each compound and the details of the devolatilization conditions, and whether or not they occur vary. For example, hydrated water contained in a supported transition metal catalyst is generated during a decomposition reaction by heating. Examples thereof include polyarylene sulfide oligomers contained in components, ligands and cyclic polyarylene sulfides.

  The above conditions are not particularly limited as long as the generated gaseous component can be removed from the heating system. For example, devolatilization under continuous decompression conditions, or gas continuously flows into the system. In addition to the inflowing gas, conditions for causing the generated gaseous component to flow out of the heating system, conditions for cooling the generated gaseous state component to be collected outside the system, and the like can be given. By heating under devolatilization conditions, it is easier to remove components decomposed from the supported transition metal catalyst from within the heating system, the concentration of the decomposition products in the melted raw material is reduced, and the decomposition reaction by heating, Accordingly, the active transition metal compound can be generated more efficiently, so that polyarylene sulfide tends to be obtained at a lower temperature and in a shorter time. In addition, the polyarylene sulfide oligomer is less likely to remain in the heating system, and the weight ratio of the (O) cyclic compound to the polyarylene sulfide oligomer in the cyclic polyarylene sulfide in the heating system tends to be larger. The polyarylene sulfide obtained by the method for producing a polyarylene sulfide of the invention is also preferred in that the weight average molecular weight tends to increase.

  In the devolatilization under continuous decompression conditions, the continuous decompression condition is not limited as long as the generated gaseous components can be removed from the heating system. For example, the entire system in which the reaction is performed is continuously decompressed. In the case of heating using a mold for manufacturing a molded article, an extruder, a melt kneader, or the like, from inside a mold under an ordinary pressure or pressurized condition, in an extruder, in a melt kneader, etc. A part may be connected to a decompression device and continuously decompressed. However, for example, rather than sealing and heating the inside of the polymerization system under reduced pressure conditions, the concentration of the decomposition product component in the melted raw material is reduced by continuously reducing pressure and devolatilization, and the decomposition reaction by heating, As a result, the production of active transition metal compounds and the removal of the polyarylene sulfide oligomer contained in the cyclic polyarylene sulfide from the heating system can be made more efficient, resulting in a polyarylene having a high degree of polymerization at a lower temperature and in a shorter time. There is a tendency that a sulfide resin composition can be obtained.

  Further, when the pressure is continuously reduced, it is preferable that the atmosphere in the reaction system is once reduced to a non-oxidizing atmosphere. As a result, undesirable side reactions such as cross-linking reactions and decomposition reactions occur between cyclic polyarylene sulfides, between polyarylene sulfides produced by heating, and between polyarylene sulfides and cyclic polyarylene sulfides, and zero valences produced There is a tendency to suppress the deactivation of nickel.

  Under conditions where the gas is continuously flowed into the system and the generated gaseous components are flown out of the heating system together with the gas that has flowed in, the atmosphere in the reaction system is preferably a non-oxidizing atmosphere. As a result, it was possible to suppress the occurrence of undesirable side reactions such as cross-linking reactions and decomposition reactions between cyclic polyarylene sulfides, between polyarylene sulfides generated by heating, and between polyarylene sulfides and cyclic polyarylene sulfides. It exists in the tendency which can suppress the deactivation of an active transition metal compound. The gas to be used is preferably an inert gas such as nitrogen, helium or argon, and among these, nitrogen gas is particularly preferred from the viewpoint of economy and ease of handling.

  Although the temperature of the gas flowing into the system depends on the flow rate of the flowing gas, the heating temperature in the system, and the structure of the reaction system, there is no particular limitation as long as the heating temperature in the system can be stably controlled. However, from the viewpoint of stable gas temperature control, it is preferably 0 ° C. or higher, more preferably 20 ° C. or higher, further preferably 50 ° C. or higher, from the viewpoint of stable heating temperature control in the system. Is more preferably 100 ° C. or higher, more preferably 150 ° C. or higher, further preferably 180 ° C. or higher, and an even more preferable range is the same temperature as the heating temperature in the system. it can.

  The flow rate of the gas flowing into the system depends on the temperature of the flowing gas, the heating temperature in the system, and the structure of the reaction system, but when the cyclic polyarylene sulfide is heated in the presence of the supported transition metal catalyst. There is no particular limitation as long as the gaseous component generated in the system can be removed from the heating system and the heating temperature in the system can be stably controlled. However, in terms of the effect of removing the gaseous component generated when the cyclic polyarylene sulfide is heated in the presence of the supported transition metal catalyst from the heating system, the gas flowing into the system in one minute The flow rate is preferably 1% or more of the volume in the system, more preferably 5% or more, still more preferably 10% or more, and even more preferably 20% or more. it can.

  The removal amount of the gaseous component generated by devolatilization from the heating system is a method of collecting and weighing the component removed outside the heating system, a method of calculating from the weight difference before and after heating, and the obtained polyarylene sulfide. It can be grasped by a method of calculating and subtracting the amount of the remaining component by reducing the weight during heating.

  The reaction time depends on conditions such as the content of the cyclic compound of formula (O) in the cyclic polyarylene sulfide used, the number of repetitions m, and the molecular weight, the type of polymerization catalyst used, the heating temperature, etc. Although it is different and cannot be defined uniformly, it is preferable to set so that the above-mentioned undesirable side reaction does not occur as much as possible. The lower limit of the heating time can be exemplified by 0.01 hours or more, preferably 0.05 hours or more. In 0.01 hours or more, the cyclic polyarylene sulfide is sufficiently converted to polyarylene sulfide. On the other hand, as an upper limit, 100 hours or less can be illustrated, Preferably it is 20 hours or less, More preferably, 10 hours or less can be illustrated. According to the preferred production method of the present invention, the cyclic polyarylene sulfide can be heated in 2 hours or less. Examples of the heating time include 2 hours or less, 1 hour or less, 0.5 hours or less, 0.3 hours or less, and 0.2 hours or less. When the time is less than 100 hours, adverse effects on the properties of the polyarylene sulfide obtained due to undesirable side reactions tend to be suppressed.

  The heating of the cyclic polyarylene sulfide can also be performed under conditions substantially free of a solvent. When carried out under such conditions, the temperature can be raised in a short time, the reaction rate is high, and polyarylene sulfide tends to be easily obtained in a short time. Here, the substantially solvent-free condition means that the solvent in the cyclic polyarylene sulfide is 10% by weight or less, and more preferably 3% by weight or less.

  The heating may be performed in a mold for producing a molded product, as well as by a method using a normal polymerization reaction apparatus, or may be performed using an extruder or a melt kneader. Any apparatus can be used without particular limitation, and a known method such as a batch system or a continuous system can be adopted, and an apparatus equipped with a devolatilization mechanism is more preferable.

  The above-mentioned cyclic polyarylene sulfide can be heated in the presence of a fibrous substance. Here, the fibrous substance is a thin thread-like substance, and an arbitrary substance having a structure elongated like a natural fiber is preferable. By converting the cyclic polyarylene sulfide to the polyarylene sulfide in the presence of the fibrous substance, a composite material structure composed of the polyarylene sulfide and the fibrous substance can be easily prepared. Since such a structure is reinforced by a fibrous substance, it tends to be superior in mechanical properties, for example, as compared to the case of polyarylene sulfide alone.

  Here, among the various fibrous materials, it is preferable to use reinforcing fibers composed of long fibers, which makes it possible to highly reinforce polyarylene sulfide. In general, when creating a composite material structure composed of a resin and a fibrous substance, the resin and the fibrous substance tend to become poorer due to the high viscosity when the resin is melted. In many cases, the mechanical properties do not appear as expected, such as the inability to make composite materials. Here, wetting is the physical state of the fluid material and the solid substrate so that substantially no air or other gas is trapped between the fluid material such as a molten resin and the solid substrate such as a fibrous compound. It means that there is good and maintained contact. Here, the lower the viscosity of the fluid substance, the better the wetting with the fibrous substance. The cyclic polyarylene sulfide of the present invention has a remarkably low viscosity when melted as compared with a general thermoplastic resin, for example, polyarylene sulfide, so that the wetting with the fibrous material tends to be good. After the cyclic polyarylene sulfide and the fibrous material form good wetting, the cyclic polyarylene sulfide is converted into the polyarylene sulfide according to the method for producing the polyarylene sulfide of the present invention. It is possible to easily obtain a composite material structure in which sulfide is formed with good wetting.

As described above, it is preferable that the fibrous material is a reinforcing fiber composed of long fibers. The reinforcing fiber used in the present invention is not particularly limited. And fibers having good heat resistance and tensile strength. For example, the reinforcing fiber includes glass fiber, carbon fiber, graphite fiber, aramid fiber, silicon carbide fiber, alumina fiber, and boron fiber. Among these, carbon fiber and graphite fiber, which have good specific strength and specific elastic modulus and have a great contribution to weight reduction, can be exemplified as the best. Any type of carbon fiber or graphite fiber can be used as the carbon fiber or graphite fiber depending on the application, but high strength and high elongation carbon having a tensile strength of 450 kgf / mm ² and a tensile elongation of 1.6% or more. Fiber is most suitable. In the case of using long fiber-like reinforcing fibers, the length is preferably 5 cm or more. In the range of this length, it becomes easy to sufficiently develop the strength of the reinforcing fiber as a composite material. Carbon fibers and graphite fibers may be used in combination with other reinforcing fibers. Moreover, the shape and arrangement | sequence of a reinforced fiber are not limited, For example, even if it is a single direction, a random direction, a sheet form, a mat form, a textile form, and a braid form, it can be used. In particular, for applications that require high specific strength and specific elastic modulus, an array in which reinforcing fibers are aligned in a single direction is most suitable. Arrangements are also suitable for the present invention.

  Further, the conversion of the cyclic polyarylene sulfide to the polyarylene sulfide can be performed in the presence of a filler. Examples of the filler include non-fibrous glass, non-fibrous carbon, and inorganic fillers such as calcium carbonate, titanium oxide, and alumina.

  The present invention will be specifically described below with reference to examples. These examples are illustrative and not limiting.

<1> Evaluation of properties of cyclic polyphenylene sulfide and polyphenylene sulfide <Measurement of molecular weight>
The molecular weights of polyphenylene sulfide and cyclic polyphenylene sulfide were calculated as number average molecular weight (Mn) and weight average molecular weight (Mw) in terms of polystyrene by gel permeation chromatography (GPC), which is a type of size exclusion chromatography (SEC). . The measurement conditions for GPC are shown below.
Equipment: Senshu Science SSC-7110
Column name: Shodex UT806M × 2
Eluent: 1-chloronaphthalene detector: differential refractive index detector Column temperature: 210 ° C
Pre-constant temperature: 250 ° C
Pump bath temperature: 50 ° C
Detector temperature: 210 ° C
Flow rate: 1.0 mL / min
Sample injection amount: 300 μL (slurry: about 0.2% by weight)

<Measurement of weight loss rate during heating of polyphenylene sulfide>
The weight loss rate during heating of polyphenylene sulfide was measured under the following conditions using a thermogravimetric analyzer. In addition, the sample used the fine granule of 2 mm or less.
Apparatus: Perkin Elmer TGA7
Measurement atmosphere: Sample preparation weight under nitrogen stream: Approximately 10 mg
Measurement conditions (a) Hold for 1 minute at a program temperature of 50 ° C. In this case, the weight reduction rate ΔWr when heated at a rate of temperature increase of 20 ° C./min can be obtained from the following equation.
ΔWr = (W1-W2) / W1 × 100

  ΔWr is the weight of the sample (W1 when reaching 100 ° C. when thermogravimetric analysis is performed at a rate of temperature increase of 20 ° C./min from 50 ° C. to 330 ° C. or higher in a non-oxidizing atmosphere at normal pressure. ) Based on the sample weight (W2) when reaching 330 ° C.

<Measurement of conversion>
Calculation of the conversion rate of cyclic polyphenylene sulfide to polyphenylene sulfide was performed by high performance liquid chromatography (HPLC) by the following method.

About 10 mg of a product obtained by heating cyclic polyphenylene sulfide was dissolved in about 5 g of 1-chloronaphthalene at 250 ° C. A precipitate formed upon cooling to room temperature. The 1-chloronaphthalene insoluble component was filtered using a membrane filter having a pore size of 0.45 μm to obtain a 1-chloronaphthalene soluble component. The amount of unreacted cyclic polyphenylene sulfide was quantified by HPLC measurement of the obtained soluble component, and the conversion rate of cyclic polyphenylene sulfide to polyphenylene sulfide was calculated. The measurement conditions for HPLC are shown below.
Apparatus: Shimadzu Corporation LC-10Avp series Column: Mightysil RP-18 GP150-4.6 (5 μm)
Detector: Photodiode array detector (UV = 270 nm).

<Infrared spectroscopic analysis>
Apparatus: Perkin Elmer System 2000 FT-IR
Sample preparation: KBr method.

Reference Example 1 Preparation of cyclic polyphenylene sulfide In a stainless steel autoclave equipped with a stirrer, 48 wt% of a 48 wt% aqueous solution of sodium hydrosulfide was prepared using 28.06 g (0.240 mol), 96% sodium hydroxide. 21.88 g (0.252 mol) of aqueous solution, 615.0 g (6.20 mol) of N-methyl-2-pyrrolidone (NMP), and 36.16 g (0.246 mol) of p-dichlorobenzene (p-DCB) Was charged. The reaction vessel was sufficiently purged with nitrogen, and then sealed under nitrogen gas.

  While stirring at 400 rpm, the temperature was raised from room temperature to 200 ° C. over about 1 hour. Next, the temperature was raised from 200 ° C. to 250 ° C. over about 30 minutes. After maintaining at 250 ° C. for 2 hours, the contents were recovered after quenching to near room temperature.

  500 g of the obtained contents were diluted with about 1500 g of ion-exchanged water, and then filtered through a glass filter having an average opening of 10 to 16 μm. The filter-on component was dispersed in about 300 g of ion-exchanged water, stirred at 70 ° C. for 30 minutes, and filtered again in the same manner three times to obtain a white solid. This was vacuum dried at 80 ° C. overnight to obtain a dry solid.

  The obtained solid was charged into a cylindrical filter paper, and Soxhlet extraction was performed for about 5 hours using chloroform as a solvent to separate low molecular weight components contained in the solid.

  After removing the solvent from the extract obtained by the chloroform extraction operation, about 5 g of chloroform was added to prepare a slurry, which was added dropwise to about 600 g of methanol while stirring. The precipitate thus obtained was collected by filtration and vacuum dried at 70 ° C. for 5 hours to obtain a white powder. This white powder was confirmed to be a compound composed of phenylene sulfide units from an absorption spectrum in infrared spectroscopic analysis. Furthermore, this white powder has a p-phenylene sulfide unit as the main structural unit, based on mass spectral analysis of the components separated by high performance liquid chromatography (apparatus; Hitachi M-1200H) and molecular weight information by MALDI-TOF-MS. It was found to be a cyclic polyphenylene sulfide containing about 96% by weight of a cyclic compound having 4 to 13 units and suitably used for producing the polyarylene sulfide of the present invention. As a result of GPC measurement, the cyclic polyphenylene sulfide was completely dissolved in 1-chloronaphthalene at room temperature, and the weight average molecular weight was 900.

Example 1
The cyclic polyphenylene sulfide obtained in Reference Example 1 has a stabilized nickel catalyst SN-750 (manufactured by Sakai Chemical Industry Co., Ltd., nickel or nickel oxide (II) 55 wt% supported on diatomaceous earth, nickel and nickel oxide. (II) and a catalyst consisting only of diatomaceous earth, specific surface area of 150 to ²⁰⁰ m ² / g, average particle diameter of 6.2 μm, aspect ratio of 2.0) is 5 mol as nickel amount relative to sulfur atom in cyclic polyphenylene sulfide % Was added and mixed in the air using a mortar, and 300 mg of the mixed powder was charged into a glass ampule, and the inside of the ampule was replaced with nitrogen. The ampule was placed in an electric furnace adjusted to 300 ° C. and heated for 10 minutes while keeping the inside of the ampule in a nitrogen atmosphere, and then the ampule was taken out and cooled to room temperature to obtain a black solid. From the absorption spectrum in the solid infrared spectroscopic analysis, it was confirmed that the solid was a compound (PPS) composed of phenylene sulfide units. The solid was partially insoluble in 1-chloronaphthalene at 250 ° C., but it was found that the insoluble part was not a compound having a phenylene sulfide structure but a nickel compound or a catalyst carrier, and the produced PPS component was soluble. . As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 26%. The results are shown in Table 1.

Example 2
Stabilized nickel catalyst SN-250 (manufactured by Sakai Chemical Industry Co., Ltd., nickel or nickel oxide (II) 47 wt% supported on diatomaceous earth, specific surface area 120-170 m ² / g, average particle size 5.0 μm A black solid was obtained in the same manner as in Example 1, except that the aspect ratio was changed from 1.7) to 5 mol% of nickel added to the sulfur atom in the cyclic polyphenylene sulfide. As a result of HPLC measurement, it was found that the conversion ratio of cyclic polyphenylene sulfide to PPS was 64%. The results are shown in Table 1.

Comparative Example 1
300 mg of the cyclic polyphenylene sulfide obtained in Reference Example 1 was charged into a glass ampule, and the inside of the ampule was replaced with nitrogen. The ampule was placed in an electric furnace adjusted to 300 ° C. and heated for 10 minutes while keeping the inside of the ampule in a nitrogen atmosphere, and then the ampule was taken out and cooled to room temperature to obtain a brown solid. From the absorption spectrum in the solid infrared spectroscopic analysis, it was confirmed that the solid was a compound (PPS) composed of phenylene sulfide units. The solid was completely dissolved in 1-chloronaphthalene at 250 ° C. As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 12%. The results are shown in Table 1.

  From the comparison between Examples 1 and 2 and Comparative Example 1, the cyclic polyphenylene sulfide was heated in the presence of the stabilized nickel catalyst SN-750 or SN-250 which is a supported transition metal catalyst. It was found that the conversion of the formula polyphenylene sulfide to polyphenylene sulfide proceeds.

Example 3
To the cyclic polyphenylene sulfide obtained in Reference Example 1, 5 mol% of the stabilized nickel catalyst SN-750 (manufactured by Sakai Chemical Industry Co., Ltd.) was added as the amount of nickel with respect to the sulfur atom in the cyclic polyphenylene sulfide. After mixing, 300 mg of the mixed powder was charged into a glass ampule and the inside of the ampule was replaced with nitrogen, and then the pressure was reduced to about 0.4 kPa using a vacuum pump. About 10 seconds after the pressure was reduced to about 0.4 kPa, the ampule was placed in an electric furnace adjusted to 300 ° C. and heated for 10 minutes while maintaining the inside of the ampule at about 0.4 kPa with a vacuum pump. The product was taken out and cooled to room temperature to obtain a black solid. From the absorption spectrum in the solid infrared spectroscopic analysis, it was confirmed that the solid was a compound (PPS) composed of phenylene sulfide units. The solid was partially insoluble in 1-chloronaphthalene at 250 ° C., but it was found that the insoluble part was not a compound having a phenylene sulfide structure but a nickel compound or a catalyst carrier, and the produced PPS component was soluble. . As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 21%. The results are shown in Table 1.

Comparative Example 2
300 mg of the cyclic polyphenylene sulfide obtained in Reference Example 1 was charged into a glass ampule, the inside of the ampule was replaced with nitrogen, and then the pressure was reduced to about 0.4 kPa using a vacuum pump. About 10 seconds after the pressure was reduced to about 0.4 kPa, the ampule was placed in an electric furnace adjusted to 300 ° C. and heated for 10 minutes while maintaining the inside of the ampule at about 0.4 kPa with a vacuum pump. Removal and cooling to room temperature gave a brown solid. From the absorption spectrum in the solid infrared spectroscopic analysis, it was confirmed that the solid was a compound (PPS) composed of phenylene sulfide units. The solid was completely dissolved in 1-chloronaphthalene at 250 ° C. As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 11%.

  From the comparison of Example 1, Example 3, and Comparative Example 2, the cyclic polyphenylene sulfide was heated in the presence of SN-750, a stabilized nickel catalyst that is a supported transition metal catalyst. It was found that the conversion of cyclic polyphenylene sulfide to polyphenylene sulfide proceeds in a shorter time regardless of the conditions.

Example 4
Powdered palladium-activated carbon (manufactured by Wako Pure Chemical Industries, Ltd., weight percentage of palladium being 10 wt%, manufacturer code 161-15273, described as Pd / C in the table) with respect to sulfur atoms in cyclic polyphenylene sulfide A black solid was obtained in the same manner as in Example 1 except that 5 mol% of palladium was added and mixed. As a result of HPLC measurement, it was found that the conversion ratio of cyclic polyphenylene sulfide to PPS was 60%. The evaluation results of the obtained black solid are summarized in Table 1. The results are shown in Table 1.

  From the comparison between Example 4 and Comparative Example 1, the cyclic polyphenylene sulfide can be converted to polyphenylene sulfide in a shorter time by heating the cyclic polyphenylene sulfide in the presence of Pd / C, which is a supported gold transition group catalyst. I found it going.

Comparative Example 3
Example 1 except that 5 mol% of nickel metal powder (manufactured by Sigma-Aldrich, product number 203904-25G, described as Ni in the table) was added and mixed as a nickel amount with respect to sulfur atoms in cyclic polyphenylene sulfide. The same operation was performed to obtain a black solid. As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 10%. The results are shown in Table 1.

Comparative Example 4
Changed to adding 5 mol% of silica gel (Kanto Chemical Co., Ltd., trade name: silica gel 60N, product number 37556-96, described as SiO _{2 in} the table) as the amount of silicon relative to sulfur atoms in cyclic polyphenylene sulfide. Except that, the same operation as in Example 1 was performed to obtain a black solid. As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 11%. The results are shown in Table 1.

  From the comparison of Example 1 and Comparative Examples 3 and 4, the conversion of cyclic polyphenylene sulfide to polyphenylene sulfide in a shorter time in the presence of only nickel and silica, which are constituent components of the stabilized nickel catalyst, which is a supported metal catalyst, It was found that there was an effect of promoting the conversion of cyclic polyphenylene sulfide to polyphenylene sulfide by being a supported metal catalyst.

Example 5
A black solid was obtained in the same manner as in Example 1 except that the reaction time was changed to 60 minutes. As a result of HPLC measurement, it was found that the conversion of cyclic polyphenylene sulfide to PPS was 93%. As a result of measuring the weight loss rate during heating of the obtained product, ΔWr was 0.18%. The results are shown in Table 2.

Example 6
A black solid was obtained in the same manner as in Example 4 except that the reaction time was changed to 60 minutes. As a result of HPLC measurement, it was found that the conversion ratio of cyclic polyphenylene sulfide to PPS was 73%. As a result of measuring the weight loss rate during heating of the obtained product, ΔWr was 0.25%. The results are shown in Table 2.

Comparative Example 5
Tetrakis (triphenylphosphine) nickel (0) (product number 22398-1A manufactured by Kanto Chemical Co., Inc., described as Ni (tpp) ₄ in the table) is added in an amount of 5 mol% as the amount of nickel relative to sulfur atoms in the cyclic polyphenylene sulfide. A black solid was obtained in the same manner as in Example 1 except that the reaction time was changed to 60 minutes. As a result of HPLC measurement, it was found that the conversion rate of cyclic polyphenylene sulfide to PPS was 90%. As a result of measuring the weight loss rate during heating of the obtained product, ΔWr was 0.80%. The results are shown in Table 2.

  From the comparison between Examples 5 to 6 and Comparative Example 5, the weight loss amount of polyphenylene sulfide obtained by heating cyclic polyphenylene sulfide in the presence of a supported metal catalyst having no organic ligand is as follows. It was found that the weight loss was less than that obtained using a conventional transition metal catalyst.

Claims (11)

A method for producing a polyarylene sulfide, comprising heating a cyclic polyarylene sulfide in the presence of a supported transition metal catalyst whose support is a powdery substance. The method for producing a polyarylene sulfide according to claim 1, wherein the carrier of the supported transition metal catalyst is an inorganic compound. 3. The production of polyarylene sulfide according to claim 1, wherein the carrier of the supported transition metal catalyst is at least one carrier selected from diatomaceous earth, silica, alumina, zeolite, and activated carbon. Method. The method for producing a polyarylene sulfide according to any one of claims 1 to 3, wherein the supported transition metal catalyst is a transition metal catalyst having no organic ligand. The polytype according to any one of claims 1 to 4, wherein the metal species of the supported transition metal catalyst is at least one metal selected from metals of Groups 8 to 11 and Period 4 of the periodic table. A process for producing arylene sulfide. 6. The method for producing polyarylene sulfide according to claim 5, wherein the metal species of the supported transition metal catalyst is nickel or palladium. The method for producing a polyarylene sulfide according to claim 6, wherein the metal species of the supported transition metal catalyst is nickel. The method for producing polyarylene sulfide according to claim 7, wherein the supported metal catalyst is a stabilized nickel catalyst. The method for producing a polyarylene sulfide according to claim 1, wherein the supported transition metal catalyst has a specific surface area of 100 m ² / g or more and 1000 m ² / g or less. A polyarylene sulfide resin composition comprising at least a polyarylene sulfide resin and a supported transition metal catalyst whose carrier is a powdery substance. The polyarylene sulfide resin composition according to claim 10, wherein the polyarylene sulfide resin is obtained by heating cyclic polyarylene sulfide.