JP6871426B2 - プロピレン−ブテン共重合体樹脂組成物およびその製造方法 - Google Patents
プロピレン−ブテン共重合体樹脂組成物およびその製造方法 Download PDFInfo
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- JP6871426B2 JP6871426B2 JP2019563583A JP2019563583A JP6871426B2 JP 6871426 B2 JP6871426 B2 JP 6871426B2 JP 2019563583 A JP2019563583 A JP 2019563583A JP 2019563583 A JP2019563583 A JP 2019563583A JP 6871426 B2 JP6871426 B2 JP 6871426B2
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- butene copolymer
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- 125000006606 n-butoxy group Chemical group 0.000 description 1
- UWHRNIXHZAWBMF-UHFFFAOYSA-N n-dodecyl-n-methyldodecan-1-amine Chemical compound CCCCCCCCCCCCN(C)CCCCCCCCCCCC UWHRNIXHZAWBMF-UHFFFAOYSA-N 0.000 description 1
- 125000003136 n-heptyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 125000001298 n-hexoxy group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])O* 0.000 description 1
- 125000001280 n-hexyl group Chemical group C(CCCCC)* 0.000 description 1
- 125000003935 n-pentoxy group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])O* 0.000 description 1
- 125000003506 n-propoxy group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])O* 0.000 description 1
- 125000001971 neopentyl group Chemical group [H]C([*])([H])C(C([H])([H])[H])(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 125000002255 pentenyl group Chemical group C(=CCCC)* 0.000 description 1
- 125000000951 phenoxy group Chemical group [H]C1=C([H])C([H])=C(O*)C([H])=C1[H] 0.000 description 1
- 125000004344 phenylpropyl group Chemical group 0.000 description 1
- 238000010094 polymer processing Methods 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 229960001860 salicylate Drugs 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- 238000001308 synthesis method Methods 0.000 description 1
- 125000004213 tert-butoxy group Chemical group [H]C([H])([H])C(O*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 125000003944 tolyl group Chemical group 0.000 description 1
- ZMANZCXQSJIPKH-UHFFFAOYSA-O triethylammonium ion Chemical compound CC[NH+](CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-O 0.000 description 1
- 125000000026 trimethylsilyl group Chemical group [H]C([H])([H])[Si]([*])(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
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- C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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- C08F210/06—Propene
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- C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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- C08F210/08—Butenes
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- C08F4/00—Polymerisation catalysts
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- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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- C08F4/00—Polymerisation catalysts
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- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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- C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
- C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
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- C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
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- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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- C08F4/62—Refractory metals or compounds thereof
- C08F4/64—Titanium, zirconium, hafnium or compounds thereof
- C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
- C08F4/6592—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
- C08F4/65922—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not
- C08F4/65927—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not two cyclopentadienyl rings being mutually bridged
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- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C08L23/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
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Description
本出願は、2017年7月11日付韓国特許出願第10−2017−0087999号に基づいた優先権の利益を主張し、当該韓国特許出願の文献に開示された全ての内容は本明細書の一部として組み含まれる。
R7、R8およびR9は、それぞれ独立に水素、ハロゲン、炭素数1乃至20のヒドロカルビル基およびハロゲンで置換された炭素数1乃至20のヒドロカルビル基のうちのいずれか一つであり、
mは2以上の整数であり、
Lは中性または陽イオン性ルイス塩基であり、
Wは13族元素であり、Jは、それぞれ独立に炭素数1乃至20のヒドロカルビル基;炭素数1乃至20のヒドロカルビルオキシ基;およびこれら置換基の1以上の水素原子がハロゲン、炭素数1乃至20のヒドロカルビルオキシ基および炭素数1乃至20のヒドロカルビル(オキシ)シリル基のうちの1以上の置換基で置換された置換基のうちのいずれか一つである。
(製造例1:遷移金属化合物および担持触媒の製造)
2−メチル−4−tert−ブチルフェニルインデン(20.0g、76mmol)をトルエン/THF=10/1溶液(230mL)に溶解した後、ここにn−ブチルリチウム溶液(2.5M、ヘキサン溶媒、22g)を約0℃で徐々に滴加した。そして、得られる混合溶液を常温で一日間攪拌した。その後、約−78℃で前記混合溶液に(6−t−ブトキシヘキシル)ジクロロメチルシラン(1.27g)を徐々に滴加し、約10分間攪拌した後、常温で一日間攪拌した。その後、水を加えて有機層を分離した後、溶媒を減圧蒸留してビス(2−メチル−4−(4−tert−ブチルフェニル)インデニル)(6−t−ブトキシヘキシル)(メチル)シランを得た。
前記1段階で製造した(6−t−ブトキシヘキシル)(メチル)−ビス(2−メチル−4−(4−tert−ブチルフェニル)インデニル)シランをトルエン/THF=5/1溶液(95mL)に溶解した後、n−ブチルリチウム溶液(2.5M、ヘキサン溶媒、22g)を約−78℃で徐々に滴加した後、常温で一日間攪拌した。ビス(N,N’−ジフェニル−1,3−プロパンジアミド)ジクロロジルコニウムビス(テトラヒドロフラン[Zr(C5H6NCH2CH2CH2NC5H6)2Cl2(C4H8O)2]をトルエン(229mL)に溶解した後、前記反応液に約−78℃で徐々に滴加し、常温で一日間攪拌した。反応液を約−78℃に冷却させた後、HClエーテル溶液(1M、183mL)を徐々に滴加した後、約0℃で約1時間攪拌した。以降、濾過して真空乾燥した後、ヘキサンを入れて攪拌して結晶を析出させた。析出された結晶を濾過および減圧乾燥して[(6−t−ブトキシヘキシルメチルシラン−ジイル)−ビス(2−メチル−4−(4−tert−ブチルフェニル)インデニル)]ジルコニウムジクロライド(20.5g、yield61%)を得た。
シリカ3gが入っているシュレンクフラスコにメチルアルミノキサン(MAO)52mmolを入れて約90℃で約24時間反応させた。反応終了後、反応生成物が沈むと、上層部溶液を除去して残った沈殿物をトルエンで2回にわたって洗浄した。そして、前記フラスコに前記で製造した[(6−t−ブトキシヘキシルメチルシランジイル)−ビス(2−メチル−4−(4−tert−ブチルフェニル)インデニル)]ジルコニウムジクロライド240umolをトルエンに溶解して注入し、約70℃で約5時間反応させた。以降、前記フラスコにN,N−ジメチルアニリウムテトラキス(ペンタフルオロフェニル)ボレート48umolを入れ、約70℃で約5時間反応させた。反応終了後、反応生成物が沈むと、上層部溶液を除去した後、残った沈殿物をトルエンで洗浄し、ヘキサンで再び洗浄した後、真空乾燥して固体粒子形態のシリカ担持メタロセン触媒を得た。
まず、100mLのトリクロロメチルシラン溶液(約0.21mol、ヘキサン)に100mLのt−ブトキシヘキシルマグネシウムクロライド溶液(約0.14mol、エーテル)を約−100℃下で約3時間にわたって徐々に滴加した後、常温で約3時間攪拌した。前記混合溶液から透明な有機層を分離した後、分離された透明有機層を真空乾燥して過量のトリクロロメチルシランを除去して、透明な液状の(6−t−ブトキシヘキシル)ジクロロメチルシランを得た。
以前に製造した(6−tert−ブトキシヘキシル)(メチル)ビス(2−メチル−4−フェニル)インデニルシランエーテル/ヘキサン=1/1溶液(3.37mmol)50mLにn−ブチルリチウム溶液(2.5Minヘキサン)3.0mLを約−78℃で徐々に滴加した後、常温で約2時間攪拌した後、真空乾燥した。ヘキサンで塩を洗浄した後、濾過および真空乾燥して黄色の固体を得た。グローブボックス(glove box)内で合成したリガンド塩(ligand salt)とビス(N,N’−ジフェニル−1,3−プロパンジアミド)ジクロロジルコニウムビス(テトラヒドロフラン[Zr(C5H6NCH2CH2NC5H6)Cl2(C4H8O)2]をシュレンクフラスコに称量した後、約−78℃でエーテルを徐々に滴加した後、常温で一日間攪拌した。以降、赤色の反応溶液を濾過分離した後、HClエーテル溶液(1M)4当量を約−78℃で徐々に滴加した後、常温で約3時間攪拌した。以降、濾過して真空乾燥してオレンジ色の固体成分のアンサ−メタロセン化合物を85%の収率で得た(racemic:meso=10:1)。
製造例1の3段階と同様な方法で、前記で合成したメタロセン化合物([(6−t−ブトキシヘキシルメチルシラン−ジイル)−ビス(2−メチル−4−フェニルインデニル)]ジルコニウムジクロライド)を用いてシリカ担持メタロセン触媒を製造した。
(実施例1:プロピレンのランダム重合)
下記表1に示したようにプロピレンの含有量、1−ブテンの含有量、重合工程条件などを調節して、プロピレン−ブテン共重合体樹脂組成物(C4−ランダム共重合体)を得た。
下記表1に示したように、水素をそれぞれ400ppmおよび550ppmで投入したことを除いては、実施例1と同様な方法でプロピレン−ブテン共重合体樹脂組成物(C4−ランダム共重合体)を得た。
下記表1に示したように、製造例1の触媒の代わりに比較製造例1の触媒を用い、触媒が変わることによって実施例1乃至3と類似するMI水準の樹脂を製造するためにそれぞれ水素を350ppm、450ppm、および550ppm投入したことを除いては、実施例1乃至3と同様な方法で比較例1乃至3のプロピレン−ブテン共重合体樹脂組成物(C4−ランダム共重合体)を得た。
下記表1に示したように、1−ブテンの含有量をそれぞれ2gおよび20g投入したことを除いては、実施例1と同様な方法でプロピレン−ブテン共重合体樹脂組成物(C4−ランダム共重合体)を得た。
2Lのステンレス反応器を約65℃で真空乾燥した後に冷却し、室温でトリエチルアルミニウム1.5mmol、水素500ppm、およびプロピレン770gを順次に投入した。この後、約10分間攪拌した後、製造例1によるシリカ担持メタロセン触媒0.048gをTMA処方されたヘキサン20mLに溶かして窒素圧力で反応器に投入した。以降、反応器温度を約70℃まで徐々に昇温した後、約1時間重合した。反応終了後、未反応のプロピレンはベントした。
2Lのステンレス反応器を65℃で真空乾燥した後に冷却し、室温でトリエチルアルミニウム1.5mmolおよびプロピレン770gを順次に投入した。以降、10分間攪拌した後、前記製造例1で製造したメタロセン触媒0.048gをTMA処方されたヘキサン20mLに溶かして窒素圧力で反応器に投入した。以降、エチレンを総5g投入しながら反応器温度を70℃まで徐々に昇温した後、1時間重合した。反応終了後、未反応のプロピレンおよびエチレンはベントした。
チーグラ−ナッタ触媒でプロピレンのホモ重合を行って製造したプロピレンホモ重合体樹脂組成物(Z/NホモPP、プロピレンホモ重合体)として、現在市販中の製品(製造会社:LG化学、製品名H7700)を準備した。
(試験例1:樹脂組成物の物性評価)
前記実施例1乃至3および比較例1乃至8による樹脂組成物に対して、以下のような方法で物性評価を行い、その結果を下記表2に示した。
米国材料試験協会の規格ASTM D 1238により230℃で2.16kg荷重で測定し、10分間溶融して出た重合体の重量(g)で示した。
米国材料試験協会の規格ASTM D 5576により実施例1乃至3および比較例1乃至7による樹脂組成物のフィルムあるいはフィルム形態の試験片をFT−IR装備のMagnetic holderに固定させた後、IR吸収スペクトルで試験片の厚さを反映する4800〜3500cm-1ピークの高さと1−ブテン成分が現れる790〜660cm-1ピークの面積を測定して計算した。米国材料試験協会の規格ASTM D 5576の方法により、測定した値はStandardサンプルの790〜660cm-1ピークの面積を4800〜3500cm-1ピークの高さで割った値をプロット(Plot)して求めたカリブレーション(Calibration)式に代入した。
温度を200℃まで増加させた後、約5分間その温度で維持し、その後、30℃まで温度を下げ、再び温度を増加させてDSC(Differential Scanning Calorimeter、TA社製造)曲線の頂点を溶融点とした。この時、温度の上昇と下降の速度は10℃/minであり、溶融点は第2の温度が上昇する区間で測定した結果を用いた。
実施例1乃至3および比較例1乃至8による樹脂組成物に対して、それぞれ試料を取って235℃下で200%の変形(strain)を加えた後、10分間残留応力の変化を測定した。
前述のような方法で測定した溶融指数(X)と残留応力比率(Y)の測定値に基き、下記計算式4による具体的な数値範囲を下記表2に示した。
実施例1乃至3および比較例1乃至8による樹脂組成物に対して、ゲル透過クロマトグラフィー(GPC)を利用して重量平均分子量(Mw)および数平均分子量(Mn)を測定した後、これに基づいて分子量分布(MWD、つまり、Mw/Mn)を算測した。
実施例1乃至3および比較例1乃至8による樹脂組成物を原料にメルトスパン工程を行ってスパンボンド不織布を製造した。
Claims (15)
- 1−ブテンの含有量が0.5乃至5.0重量%であり、溶融指数が12g/10min乃至37g/10minであり、溶融指数(MI、X)および残留応力比率(Y)は下記計算式1を満たすものである、プロピレン−ブテン共重合体樹脂組成物。
- 溶融指数が13g/10min乃至35g/10minである、請求項1に記載のプロピレン−ブテン共重合体樹脂組成物。
- 残留応力比率が0.005%乃至0.085%である、請求項1または2に記載のプロピレン−ブテン共重合体樹脂組成物。
- 分子量分布が2.6以下である、請求項1乃至3のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物。
- 溶融点が148℃以下である、請求項1乃至4のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物。
- 下記化学式1で表される遷移金属化合物を含む触媒存在下で、プロピレンおよび1−ブテンを99:1乃至90:10の重量比に重合させてプロピレン−ブテン共重合体を製造する段階を含む請求項1乃至5のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 前記化学式1のR3およびR4がそれぞれ独立に炭素数1乃至3の直鎖アルキルのうちのいずれか一つである遷移金属化合物が含まれている触媒が用いられる、請求項6に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 前記化学式1のR5およびR6がそれぞれ独立に炭素数3乃至6の分枝鎖アルキルのうちのいずれか一つである遷移金属化合物が含まれている触媒が用いられる、請求項6または7に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 前記化学式1のR1が炭素数3乃至6の分枝鎖アルキルのうちのいずれか一つであり、nが3乃至9の間の整数である遷移金属化合物が含まれている触媒が用いられる、請求項6乃至8のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 前記化学式1のR2が炭素数1乃至3の直鎖アルキルのうちのいずれか一つである遷移金属化合物が含まれている触媒が用いられる、請求項6乃至9のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 前記化学式1のMがTi、ZrおよびHfのうちのいずれか一つである遷移金属化合物が含まれている触媒が用いられる、請求項6乃至10のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物の製造方法。
- 請求項1乃至5のいずれか1項に記載のプロピレン−ブテン共重合体樹脂組成物を用いたスパンボンド不織布。
- 不織布の坪量が13乃至17.5g/m2である条件下で、不織布の縦方向(MD、machine direction)に対するハンドルオメーター(Handle−O−meter)測定値が7.5g以下であり、不織布の横方向(CD、cross direction)に対するハンドルオメーター(Handle−O−meter)測定値は4.0g以下である、請求項13に記載のプロピレン−ブテン共重合体スパンボンド不織布。
- 不織布の坪量が13乃至17.5g/m2である条件下で、不織布の縦方向(MD、machine direction)に対してASTM D−5035の方法により測定した引張強度が1600gf以上であり、不織布の横方向(CD、cross direction)に対してASTM D−5035の方法により測定した引張強度が730gf以上である、請求項13または14に記載のプロピレン−ブテン共重合体スパンボンド不織布。
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