JP6913210B2 - Polymer particles and their uses - Google Patents

Description

The present invention relates to polymer particles preferably used as raw materials for optical members such as a light diffusing film and an antiglare film, uses of the polymer particles (optical film and resin molded product), and a method for producing the polymer particles. Regarding.

Polymer particles having a volume average particle diameter of 1 to 100 μm are, for example, additives for coating agents such as paints (matting agents, etc.), additives for inks (matting agents, etc.), main components of adhesives, or Additives, additives for artificial marble (low shrinkage agents, etc.), paper treatment agents, fillers for external preparations such as cosmetics (fillers for improving slipperiness), column fillers used for chromatography, static charge Used as an additive for toner used for image development, an anti-blocking agent for film, a light diffuser for optical members (optical film such as light diffusing film, antiglare film, light diffusing body, etc.), etc. ing.

Such polymer particles can be produced by polymerizing a polymerizable monomer. Suspension polymerization, seed polymerization, emulsion polymerization and the like are known as polymerization methods for polymerizing polymerizable monomers. In these polymerization methods, a surfactant is usually used so that the polymerization reaction can be stably carried out and the generation of coarse particles can be suppressed.

For example, in Patent Document 1, it is obtained by polymerizing a vinyl-based monomer in a medium containing a surfactant as resin fine particles (polymer particles) used as a light diffusing agent, and remains in the resin fine particles. The amount of surfactant to be applied is 0.05 parts by weight or less with respect to 100 parts by weight of the resin fine particles (
Specifically, 0.005 to 0.36 parts by weight) are disclosed.

Further, Patent Document 2 describes organic particles (polymer particles) in which a surfactant obtained by emulsion polymerization or suspension polymerization is attached to the surface as organic particles to be blended in an epoxy resin composition.
Is disclosed after cleaning.

Japanese Unexamined Patent Publication No. 2006-233055 JP-A-2007-016183

By the way, as an optical film such as a light diffusing film or an antiglare film, there is one in which a resin composition containing polymer particles and a binder is coated on a film base material.

When producing such an optical film, before coating the resin composition on the film substrate so that stable optical characteristics can be obtained by the coating film composed of the above resin composition on the film substrate. In addition, it is necessary to uniformly disperse the polymer particles in the resin composition (specifically, in the binder).

However, even if the polymer particles produced by using the surfactants disclosed in Patent Documents 1 and 2 are uniformly dispersed in the binder to obtain a resin composition, the resin composition can be obtained on the film substrate. In the process of coating on the resin to form a coating film, the dispersed state of the polymer particles in the resin composition becomes unstable. For example, when the optical film is produced using the polymer particles disclosed in Patent Documents 1 and 2, the polymer particles in the resin composition are used in the process of forming a coating film by the coating. The dispersed state was not stable, and the polymer particles sometimes agglomerated excessively. As a result, the polymer particles did not spread over the entire coating film formed on the base film, and the desired optical characteristics could not be stably obtained.

Therefore, in the process of applying the resin composition obtained by dispersing the polymer particles in a binder onto the film substrate to form a coating film, a stable dispersed state is obtained, and the optical film is stably optically charged. It has been desired to develop polymer particles having excellent dispersion stability that can impart characteristics.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide polymer particles having excellent dispersion stability, a method for producing the same, and an optical film and a resin molded product using the polymer particles. do.

As a result of diligent studies in view of the above problems, the inventors of the present application have affected the dispersion stability of the surface of the polymer particles, and in order to improve the dispersion stability, the manufacturing process in the polymer particles It was found that it is necessary to suppress the content (residual amount) of the surfactant used in the above (specifically, less than 50 ppm) very slightly.

The polymer particles of the present invention are characterized by having a surfactant content of more than 0 ppm and less than 50 ppm.

Since the polymer particles of the present invention have a surfactant content of less than 50 ppm, they are excellent in dispersion stability in the binder when used in combination with a binder. Further, when the resin composition obtained by dispersing the polymer particles of the present invention in a binder is coated on a film substrate, the dispersed state of the polymer particles in the resin composition is the coating. It is maintained substantially stable in the process of forming the coating film, and excessive aggregation of the polymer particles during the coating is suppressed. As a result, the polymer particles spread evenly on the film substrate, and it is possible to impart uniform and stable optical properties such as light diffusivity and antiglare to the entire coating film formed by the coating.

The optical film of the present invention is characterized in that a coating resin composition containing the polymer particles of the present invention and a binder is applied onto a film substrate.

Since the optical film of the present invention is formed by coating a base material with a coating resin composition containing the polymer particles of the present invention having excellent dispersion stability, the entire coating film formed by the coating is applied. In the above, even optical characteristics such as light diffusivity and antiglare can be stably obtained. Therefore, according to the optical film of the present invention, high quality stability can be obtained.

The resin molded product of the present invention is characterized by molding a molding resin composition containing the polymer particles of the present invention and a transparent resin.

Since the resin molded product of the present invention is formed by molding a molding resin composition containing the polymer particles of the present invention having excellent dispersion stability, the resin molded product has uniform light diffusivity and light diffusivity. Stable optical characteristics such as antiglare can be obtained. Therefore, according to the resin molded product of the present invention, high quality stability can be obtained.

In the method for producing polymer particles of the present invention, a vinyl-based monomer is polymerized in a liquid medium in the presence of a surfactant, and the polymer particles containing the surfactant and the medium are crudely contained. In the polymerization step of obtaining a product, the crude product is charged into a filter, and the medium contained in the charged crude product is passed through the filter medium of the filter, while the polymer particles contained in the crude product are passed. In the solid-liquid separation step of holding the polymer particles on the filter medium, the cleaning liquid was put into the filter holding the polymer particles on the filter medium, and the cleaning liquid was brought into contact with the polymer particles to obtain the polymer particles. A unit of the medium that has passed through the filter medium in the solid-liquid separation step, including a cleaning step of obtaining polymer particles washed with the cleaning liquid on the filter medium by passing the contacted cleaning liquid through the filter medium. The amount per hour is the following conditional formula (1);
X ≦ 5.50 × A ・ ・ ・ (1)
(In the formula (1), X is the amount (kg / mi) per unit time of the medium that has passed through the filter medium.
^{n) means, A means the area (m 2} ) of the interface between the filter medium and the object to be filtered), and in the cleaning step, the amount of the cleaning liquid that has passed through the filter medium per unit time is determined. The following conditional expression (2);
Y ≦ 8.50 × A ・ ・ ・ (2)
(In the formula (2), Y is the amount (kg / m) of the cleaning liquid that has passed through the filter medium per unit time.
^{In), and A means the area (m 2} ) of the interface between the filter medium and the object to be filtered. ) Satisfied, and the cleaning step is characterized in that a cleaning liquid having a weight of 10 times or more the weight of the polymer particles held on the filter medium is used.

In the above manufacturing method, in the solid-liquid separation step, the amount of the medium that has passed through the filter medium per unit time satisfies the conditional formula (1), and in the cleaning step, the amount of the cleaning liquid that has passed through the filter medium per unit time is the conditional formula (1). Since a cleaning solution satisfying 2) and having a weight of 10 times or more the weight of the polymer particles held on the filter medium is used in the cleaning step, the surfactant adhering to the polymer particles in the polymerization step is used. Most can be removed with the medium and cleaning solution. As a result, polymer particles having an extremely low content (residual amount) of the surfactant and excellent dispersion stability can be obtained.

According to the present invention, it is possible to provide polymer particles having excellent dispersion stability, a method for producing the same, and an optical film and a resin molded product using the polymer particles.

FIG. 1 is a schematic view showing a schematic configuration of a pressure filter that can be used in the embodiment of the present invention, (a) is a schematic cross-sectional view of the pressure filter, and (b) is the addition. It is a schematic top view which shows the inside of the pressure-resistant container of a pressure filter.

Hereinafter, the present invention will be described in detail.

[Polymer particles]
The polymer particles of the present invention are characterized by having a surfactant content of more than 0 ppm and less than 50 ppm. In the polymer particles of the present invention, the smaller the content of the surfactant, the more preferable it is, preferably more than 0 ppm to 30 ppm, and more than 0 ppm to 20 ppm.
Is more preferable, and more than 0 ppm to 15 ppm is further preferable. The content of the surfactant in the polymer particles can be measured by using, for example, liquid chromatography-mass spectrometry (LC-MS-MS).

The surfactant contained in the polymer particles of the present invention is the one in which the surfactant used in the production of the polymer particles remains. Therefore, as the above-mentioned surfactant, any surfactant usually used for producing polymer particles, for example, an anionic surfactant as described in the section [Method for producing polymer particles] described later, and the like. Nonionic surfactants, cationic surfactants, and amphoteric surfactants can be mentioned. Further, the surfactant contained in the polymer particles of the present invention preferably contains at least one of an anionic surfactant and a nonionic surfactant.

The polymer particles contain a surfactant, that is, the content of the surfactant is 0.
Exceeding ppm means, for example, a time-of-flight secondary ion mass spectrometer (TOF-SIMS).
By detecting the peak of the fragment derived from the surfactant in the measurement by
Alternatively, it can be confirmed by detecting a peak on the chromatogram in the measurement of the content of the surfactant in the polymer particles using a liquid chromatograph mass spectrometer (LC / MS / MS apparatus) described later. Is.

Since the content (residual amount) of the surfactant used in the production of the polymer particles of the present invention is suppressed to less than 50 ppm, it can be said that the amount of the surfactant on the particle surface is small. Therefore, when the polymer particles of the present invention are used in combination with a binder, the difference in surface state between the polymer particles mixed in the binder is small, and as a result, the difference in surface state is small.
When the polymer particles of the present invention are dispersed in a dispersion medium and used, the dispersed state of the polymer particles in the dispersion medium is maintained substantially stable. That is, the polymer particles of the present invention are excellent in dispersion stability. In addition, the polymer particles of the present invention contain (residual amount) of the surfactant used in the production.
Is suppressed to less than 50 ppm, and the amount of the above-mentioned surfactant on the particle surface is small. Therefore, when the polymer particles of the present invention are used in combination with a dispersion medium, they can be used as a dispersion medium. The time required for uniform dispersion is stable. Further, as described above, the polymer particles of the present invention have a small amount of the surfactant on the particle surface and are excellent in dispersion stability. Therefore, for example, the polymer particles can be obtained by dispersing the polymer particles in a binder. When the resin composition is coated on a film substrate and used, the dispersed state of the polymer particles in the resin composition is maintained substantially stable in the process of forming the coating film by the coating. Therefore, excessive aggregation of the polymer particles during the coating is suppressed. As a result, the polymer particles spread evenly on the film substrate, and it is possible to impart uniform and stable optical properties such as light diffusivity and antiglare to the entire coating film formed by the coating. Therefore, the optical film produced by using the polymer particles of the present invention has excellent quality stability.

In the polymer particles of the present invention, the smaller the content of the surfactant on the particle surface, the more preferable. For example, the total ionic strength of positive ions and negative ions measured by a time-of-flight secondary ionic mass analyzer. The ratio of the ionic strength of the negative ions derived from the surfactant (hereinafter referred to as the ionic strength ratio) to the total ionic strength of the above is 0.01 × 10 ^-4 to 2.
It is preferably 0 × 10 ^-4. When a plurality of peaks of negative ion fragments derived from the surfactant are detected in the measurement by the flight time type secondary ion mass spectrometer, the ionic strength is the highest among the detected fragments. The ionic strength of the high fragment is used as the ionic strength of the negative ions derived from the surfactant to obtain the ionic strength ratio.

From the ionic strength ratio, it is recognized that the polymer particles having the ionic strength ratio within the above range have an extremely small amount of the surfactant on the particle surface. Therefore, when polymer particles having an ionic strength ratio within the above range are used in combination with a binder,
The surface states of the polymer particles mixed in the binder are almost the same, and as a result,
When the polymer particles are dispersed in a dispersion medium and used, the dispersed state of the polymer particles in the dispersion medium is maintained extremely stable. That is, the polymer particles having the ionic strength ratio within the above range are extremely excellent in dispersion stability. Further, since the polymer particles having an ionic strength ratio within the above range have an extremely small amount of the surfactant on the particle surface, the polymer particles of the present invention are used by mixing with a dispersion medium. In some cases, the time required for uniform dispersion in the dispersion medium is more stable. When a resin composition obtained by dispersing polymer particles having an ionic strength ratio within the above range in a binder is applied onto a film substrate and used, the polymer in the resin composition is used. The dispersed state of the particles is maintained extremely stable in the process of forming the coating film by the coating, and excessive aggregation of the polymer particles during the coating is surely suppressed. As a result, the polymer particles spread evenly on the film substrate, and the entire coating film formed by the coating can be reliably imparted with optical properties such as stable light diffusivity and antiglare. .. Therefore, the optical film produced by using the polymer particles having the ionic strength ratio within the above range is more excellent in quality stability.

The polymer constituting the polymer particles of the present invention is, for example, a polymer of a vinyl-based monomer. Examples of the vinyl-based monomer include a monofunctional vinyl-based monomer having one ethylenically unsaturated group and a polyfunctional vinyl-based monomer having two or more ethylenically unsaturated groups. ..

Examples of the monofunctional vinyl-based monomer include (meth) acrylic acid ester-based monomers;
Styrene-based monomer (aromatic vinyl-based monomer); saturated fatty acid vinyl-based monomer such as vinyl acetate, vinyl propionate, vinyl versaticate; vinyl cyanide-based monomer such as acrylonitrile and methacrylonitrile; Acrylic acid, methacrylic acid, crotonic acid, citraconic acid,
Ethylene unsaturated carboxylic acid such as itaconic acid, maleic acid, fumaric acid; ethylenically unsaturated carboxylic acid anhydride such as maleic anhydride; ethylenically unsaturated dicarboxylic acid monoalkyl ester such as monobutylmaleic acid; Ethylene unsaturated carboxylic acid salts such as ammonium salt or alkali metal salt of unsaturated carboxylic acid and ethylenically unsaturated dicarboxylic acid monoalkyl ester; ethylenically unsaturated carboxylic acid amides such as acrylamide, methacrylamide and diacetoneacrylamide; Ethylity such as N-methylol acrylamide, N-methylol methacrylate, methylolated diacetone acrylamide, and etherified products of these monomers and alcohols having 1 to 8 carbon atoms (for example, N-isobutoxymethyl acrylamide). Examples thereof include methylolates of unsaturated carboxylic acid amides and derivatives thereof.

Examples of the (meth) acrylate-based monomer include methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, 2-ethylhexyl acrylate, and the like.
Alkyl acrylate monomers such as n-octyl acrylate, isononyl acrylate, lauryl acrylate, stearyl acrylate; methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, 2-ethylhexyl methacrylate, stearyl methacrylate Alkyl methacrylate-based monomers such as; (meth) acrylic acid ester having an epoxy group (glycidyl group) such as glycidyl acrylate and glycidyl methacrylate; hydroxyalkyl (meth) such as 2-hydroxyethyl methacrylate and 2-hydroxypropyl acrylate. Acrylate; (meth) acrylic acid ester having an amino group such as dimethylaminoethyl methacrylate and diethylaminoethyl methacrylate can be mentioned. The (meth) acrylic acid ester-based monomer preferably contains at least one of an alkyl acrylate-based monomer and an alkyl methacrylate-based monomer. In the application documents, "(meth) acrylate" means acrylate or methacrylate, and "(meth) acrylic".
Shall mean acrylic or methacryl.

Examples of the styrene-based monomer include styrene, α-methylstyrene, vinyltoluene, ethylvinylbenzene and the like.

Examples of the polyfunctional vinyl-based monomer include allyl (meth) acrylate, divinylbenzene, diallyl phthalate, triallyl cyanurate, and ethylene glycol di (meth).
Examples thereof include acrylate, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and pentaeristol tetra (meth) acrylate.

The above-mentioned vinyl-based monomer may be used alone or in combination of two or more.

The polymers constituting the polymer particles are (meth) acrylic polymers, styrene-based polymers, and the like.
It is preferably any of (meth) acrylic-styrene-based polymers. Thereby, polymer particles having high light transmission can be realized. The (meth) acrylic polymer is a polymer of a (meth) acrylic acid ester-based monomer, or a (meth) acrylic acid ester-based monomer, a (meth) acrylic acid ester-based monomer, and styrene. It is a copolymer with a vinyl-based monomer other than the system-based monomer. The styrene-based polymer is a polymer of a styrene-based monomer, or a styrene-based monomer and a (meth) acrylic acid ester-based monomer and a vinyl-based monomer other than the styrene-based monomer. It is a polymer. The (meth) acrylic-styrene copolymer is a copolymer of a (meth) acrylic acid ester-based monomer and a styrene-based monomer, or a (meth) acrylic acid ester-based monomer. , A copolymer of a styrene-based monomer and a vinyl-based monomer other than the (meth) acrylic acid ester-based monomer and the styrene-based monomer.

The polymer constituting the polymer particles is preferably a copolymer (crosslinked polymer) of the monofunctional vinyl-based monomer and the polyfunctional vinyl-based monomer. For example, the amount of the structural unit derived from the polyfunctional vinyl-based monomer in the polymer is preferably in the range of 5 to 50% by weight with respect to 100% by weight of the polymer. When the amount of the structural unit derived from the polyfunctional vinyl-based monomer is less than the above range, the degree of cross-linking of the polymer is low. As a result, when the polymer particles are mixed with the binder and coated as a resin composition, the polymer particles may swell and the viscosity of the resin composition may increase, resulting in a decrease in coating workability. Further, as a result of lowering the degree of cross-linking of the polymer, when the polymer particles are mixed with a binder and molded (so-called kneading use), the polymer particles are heated during mixing or molding. Particles are more likely to dissolve or deform. When the amount of the structural unit derived from the polyfunctional vinyl monomer is larger than the above range, the effect is not improved in proportion to the amount of the polyfunctional vinyl monomer used.
Production costs may increase.

The gel fraction of the polymer particles of the present invention is preferably 90% or more, more preferably 97% or more. If the gel content is less than 90%, sufficient solvent resistance cannot be ensured. Therefore, for example, polymer particles are mixed with an organic solvent together with a binder and coated on a film substrate to provide an antiglare film or light. In the case of using an optical film such as a diffusing film, the polymer particles may be dissolved in an organic solvent, and optical characteristics such as light diffusivity and antiglare may not be sufficiently obtained. In this application document, the gel fraction refers to, for example, the gel fraction measured by the method described in the section of Examples.

The volume average particle size of the polymer particles is preferably 0.5 to 100 μm, more preferably 1 to 30 μm. Thereby, when the polymer particles are used for the optical member such as the antiglare film or the light diffusing film, the optical characteristics such as the antiglare property and the light diffusing property of the optical member can be improved. In this application document, the volume average particle size of the polymer particles refers to the arithmetic mean of the volume-based particle size distribution measured by the Coulter method, for example, the method described in the section of Examples.

The coefficient of variation (CV) of the particle size of the polymer particles is preferably 15% or less. As a result, when polymer particles are used for optical members such as antiglare films and light diffusing films,
It is possible to improve optical characteristics such as antiglare property and light diffusivity of the optical member.

The polymer particles are preferably obtained by absorbing a vinyl-based monomer into seed particles and polymerizing (that is, seed polymerization) in the presence of a surfactant. Since the polymer particles obtained by seed polymerization have little variation in particle size, when used in an optical member such as an antiglare film or a light diffusing film, the antiglare property and light diffusing property of the optical member, etc. The optical characteristics of the film can be improved.

[Method for producing polymer particles]
The polymer particles of the present invention can be produced by the production method of the present invention.

In the method for producing polymer particles of the present invention, a vinyl-based monomer is polymerized in a liquid medium in the presence of a surfactant, and the polymer particles containing the surfactant and the medium are crudely contained. In the polymerization step of obtaining the product, the crude product is charged into a filter, and the medium contained in the charged crude product is passed through the filter medium of the filter, while the polymer particles contained in the crude product are passed. In the solid-liquid separation step of holding the polymer particles on the filter medium, the cleaning liquid was put into the filter holding the polymer particles on the filter medium, and the cleaning liquid was brought into contact with the polymer particles to obtain the polymer particles. The cleaning step includes passing the contacted cleaning liquid through the filter medium to obtain polymer particles washed with the cleaning liquid on the filter medium.

Hereinafter, each step of the production method of the present invention will be described in detail.

[Polymerization process]
In the polymerization step, the vinyl-based monomer is polymerized in a liquid medium in the presence of a surfactant.
A crude product containing the polymer particles containing the surfactant and the medium is obtained.

As the liquid medium (medium contained in the crude product), an aqueous medium is preferable, and for example, water;
Lower alcohols such as methyl alcohol and ethyl alcohol (alcohols with 5 or less carbon atoms)
Examples include a mixture of water and lower alcohol.

Further, in the polymerization step, the surfactant stabilizes the dispersion of the vinyl-based monomer in the liquid medium. As the surfactant, any of an anionic surfactant, a cationic surfactant, a nonionic surfactant, and an amphoteric surfactant can be used, but in the polymerization step, a liquid medium can be used. At least one of the anionic surfactant and the nonionic surfactant can be obtained because the dispersion of the vinyl-based monomer in the mixture can be more stably secured and the polymer particles having the same particle size can be obtained. Is preferably used.

As the anionic surfactant, any known anionic surfactant such as a fatty acid salt type, a sulfate ester salt type, or a sulfonate type can be used, and examples thereof include sodium oleate, potassium castin oil soap, and the like. Fatty acid soap; alkyl sulfates such as sodium lauryl sulfate and ammonium lauryl sulfate; alkylbenzene sulfonates such as sodium dodecylbenzene sulfonate; alkylnaphthalene sulfonates, alkane sulfonates, di (2-ethylhexyl) sulfosuccinate (sodium) Dialkyl sulfosuccinates such as salt), dioctyl sulfosuccinate (sodium salt); alkenyl succinate (dipotassium salt); alkyl phosphate ester salts; naphthalene sulfonic acid formarin condensates; polyoxyethylene alkyl phenyl ether sulfates; Examples thereof include polyoxyethylene alkyl ether sulfates such as sodium polyoxyethylene lauryl ether sulfate; polyoxyethylene alkyl sulfates; and polyoxyethylene styrene phenyl ether sulfates. One of these anionic surfactants may be used alone, or two or more thereof may be used in combination.

As the nonionic surfactant, any known nonionic surfactant such as an ester type, an ether type or an ester ether type can be used, and for example, a polyoxyethylene alkyl such as a polyoxyethylene tridecyl ether can be used. Polyoxyethylene alkyl phenyl ethers such as ethers and polyoxyethylene octyl phenyl ethers, polyoxyethylene styrene phenyl ethers, polyoxyalkylene alkyl ethers such as polyoxyalkylene tridecyl ethers having 3 or more carbon atoms, and poly Examples thereof include polyoxyethylene sorbitan fatty acid esters such as oxyethylene fatty acid ester, sorbitan fatty acid ester, and monolauric acid polyoxyethylene sorbitan, polyoxyethylene alkylamine, glycerin fatty acid ester, and oxyethylene-oxypropylene block polymer. One of these nonionic surfactants may be used alone, or two or more thereof may be used in combination.

As the cationic surfactant, any known cationic surfactant such as an amine salt type or a quaternary ammonium salt type can be used, but a water-soluble cationic surfactant is used in terms of handling. It is advantageous. Specific examples of the above cationic surfactants include alkylamine salts such as laurylamine acetate and stearylamine acetate; alkyltrimethylammonium such as lauryltrimethylammonium chloride, hexadecyltrimethylammonium chloride, cocoyltrimethylammonium chloride and dodecyltrimethylammonium chloride. Chloride; Examples thereof include alkyldimethylbenzyl chloride such as hexadecyldimethylbenzylammonium chloride and lauryldimethylbenzylammonium chloride. One of these cationic surfactants may be used alone, or two or more thereof may be used in combination.

Examples of the amphoteric surfactant include lauryldimethylamine oxide, a phosphate ester-based surfactant, and a phosphite ester-based surfactant. One of these amphoteric surfactants may be used alone, or two or more thereof may be used in combination.

The above-mentioned surfactant may be used alone or in combination of two or more. As the above-mentioned surfactant, the solubility in water at a liquid temperature of 25 ° C. is 0.3 g / 100 ml or more.
5.0 g / 100 ml is preferable, and 0.5 g / 100 ml to 3.0 g / 100 ml
Is more preferable. If a surfactant having a solubility of less than 0.3 g / 100 ml is used, the vinyl-based monomer may not be stably dispersed in the aqueous medium when the liquid medium is an aqueous medium in the polymerization step. In addition, since it is difficult to elute the surfactant into water, a large amount of cleaning liquid is required in the cleaning step described later for cleaning the polymer particles, which is not preferable in terms of productivity. On the other hand, the above-mentioned surfactant having a solubility of more than 5.0 g / 100 ml has a poor effect of the hydrophobic group and a poor effect of stabilizing the dispersion of the vinyl-based monomer in the aqueous medium. When used, in the polymerization step, when the liquid medium is an aqueous medium, a large amount of surfactant is required to stabilize the dispersion of the vinyl-based monomer in the aqueous medium, and the production is carried out. It is not preferable in terms of sex.

The amount of the surfactant used in the polymerization of the vinyl-based monomer is the amount of the vinyl-based monomer used 1.
It is preferably in the range of 0.01 to 5 parts by weight with respect to 00 parts by weight. If the amount of the surfactant used is less than the above range, the polymerization stability may be lowered. Further, when the amount of the surfactant used is larger than the above range, it is uneconomical in terms of cost.

The polymerization method of the vinyl-based monomer is not particularly limited as long as it is a known polymerization method using a liquid medium and a surfactant, and for example, a method such as seed polymerization, emulsion polymerization, suspension polymerization or the like. Can be mentioned. Of these polymerization methods, seed polymerization is most preferable because the variation in the particle size of the obtained polymer particles is the smallest.

In the above emulsion polymerization, a liquid medium, a vinyl-based monomer that is difficult to dissolve in this medium, and a surfactant (emulsifier) are mixed, and a polymerization initiator that is soluble in the medium is added thereto for polymerization. It is a polymerization method to be carried out. The emulsion polymerization is characterized in that the particle size of the obtained polymer particles does not vary much. The suspension polymerization is a polymerization method in which a vinyl-based monomer and an aqueous medium such as water are mechanically stirred to suspend the vinyl-based monomer in the aqueous medium for polymerization. The suspension polymerization is characterized in that polymer particles having a small particle size and a relatively uniform particle size can be obtained.

The above-mentioned seed polymerization is a method in which when the polymerization of a vinyl-based monomer is started, seed particles made of a polymer of a vinyl-based monomer prepared separately are added to carry out the polymerization. More specifically, in the above-mentioned seed polymerization, polymer particles made of a polymer of a vinyl-based monomer are used as seed particles.
This is a method in which the seed particles absorb the vinyl-based monomer in an aqueous medium and the vinyl-based monomer is polymerized in the seed particles. In this method, by growing the seed particles, polymer particles having a particle size larger than that of the original seed particles can be obtained. As described above, seed polymerization is the most preferable method for polymerizing vinyl-based monomers. Therefore, in the production method of the present invention, the polymerization step is carried out in a liquid medium in the presence of seed particles and a surfactant. , The vinyl monomer is preferably seed-polymerized to obtain a crude product containing the polymer particles containing the surfactant and the medium.

The general method of seed polymerization will be described below, but the polymerization method in the production method of the present invention is not limited to this method.

In seed polymerization, first, seed particles are added to an emulsion (suspension) containing a vinyl-based monomer, an aqueous medium, and a surfactant. The emulsion can be prepared by a known method. For example, an emulsified solution can be obtained by adding a vinyl-based monomer and a surfactant to an aqueous medium and dispersing them with a fine emulsifier such as a homogenizer, an ultrasonic processor, or a nanomizer. As the aqueous medium, water or a mixture of water and an organic solvent (for example, a lower alcohol (alcohol having 5 or less carbon atoms)) can be used.

The amount of the surfactant used in the seed polymerization is preferably in the range of 0.01 to 5 parts by weight with respect to 100 parts by weight of the vinyl-based monomer. If the amount of the surfactant used is less than the above range, the polymerization stability may be lowered. Further, when the amount of the surfactant used is larger than the above range, it is uneconomical in terms of cost.

The seed particles may be added to the emulsion as they are, or may be added to the emulsion in the form of being dispersed in an aqueous medium. After the seed particles are added to the emulsion, the vinyl-based monomer is absorbed by the seed particles. This absorption can usually be carried out by stirring the emulsion at room temperature (about 20 ° C.) for 1-12 hours. Further, in order to promote the absorption of the vinyl-based monomer into the seed particles, the emulsion may be heated to about 30 to 50 ° C.

Seed particles swell by absorbing vinyl-based monomers. The mixing ratio of the vinyl-based monomer and the seed particles is preferably in the range of 5 to 300 parts by weight, preferably in the range of 100 to 250 parts by weight, with respect to 1 part by weight of the seed particles. It is more preferable to be inside. When the mixing ratio of the vinyl-based monomer is smaller than the above range, the increase in the particle size due to the polymerization is small, so that the production efficiency is lowered. On the other hand, when the mixing ratio of the vinyl-based monomer is larger than the above range, the vinyl-based monomer is not completely absorbed by the seed particles and is independently suspended and polymerized in an aqueous medium, resulting in an abnormally small particle size. Polymer particles may be produced. The end of absorption of the vinyl-based monomer into the seed particles can be determined by confirming the enlargement of the particle size by observing with an optical microscope.

Next, polymer particles are obtained by polymerizing the vinyl-based monomer absorbed by the seed particles. The polymer particles may be obtained by repeating the step of absorbing the vinyl-based monomer into the seed particles and polymerizing the particles a plurality of times.

A polymerization initiator may be added to the vinyl-based monomer, if necessary. The polymerization initiator may be obtained by mixing the polymerization initiator with a vinyl-based monomer and then dispersing the obtained mixture in an aqueous medium, or both the polymerization initiator and the vinyl-based monomer may be used. Those separately dispersed in an aqueous medium may be mixed. The particle size of the droplets of the vinyl-based monomer present in the obtained emulsion is
It is preferable that the particle size is smaller than the particle size of the seed particles because the vinyl-based monomer is efficiently absorbed by the seed particles.

The polymerization initiator is not particularly limited, but for example, benzoyl peroxide, lauroyl peroxide, o-chlorobenzoyl peroxide, o-methoxybenzoyl peroxide, 3
, 5,5-trimethylhexanoyl peroxide, t-butylperoxy-2-ethylhexanoate, di-tert-butyl peroxide and other organic peroxides; 2,2'-azobisisobutyronitrile, 2,2'-Azobis (2,4-dimethylvaleronitrile),
2,2'-azobis (2,3-dimethylbutyronitrile), 2,2'-azobis (2-methylbutyronitrile), 2,2'-azobis (2,3,3-trimethylbutyronitrile)
, 2,2'-azobis (2-isopropylbutyronitrile), 1,1'-azobis (cyclohexane-1-carbonitrile), 2,2'-azobis (4-methoxy-2,4-dimethylvaleronitrile) , (2-Carbamoylazo) isobutyronitrile, 4,4'-azobis (4-cyanovaleric acid), dimethyl-2,2'-azobisisobutyrate and other azo compounds and the like. The polymerization initiator is 0.
It is preferably used in the range of 1 to 1.0 parts by weight.

The polymerization temperature of the seed polymerization can be appropriately selected depending on the type of the vinyl-based monomer and the type of the polymerization initiator used as needed. Specifically, the polymerization temperature of the seed polymerization is 25.
The temperature is preferably ~ 110 ° C, more preferably 50 to 100 ° C. The polymerization time of the seed polymerization is preferably 1 to 12 hours. The polymerization reaction of the seed polymerization may be carried out in an atmosphere of an inert gas (for example, nitrogen) which is inert to the polymerization. The polymerization reaction of the seed polymerization is preferably carried out by raising the temperature after the vinyl-based monomer and the polymerization initiator used as needed are completely absorbed by the seed particles.

In the above seed polymerization, a polymer dispersion stabilizer may be added to the polymerization reaction system in order to improve the dispersion stability of the polymer particles. Examples of the polymer dispersion stabilizer include polyvinyl alcohol, polycarboxylic acid, celluloses (hydroxyethyl cellulose, carboxymethyl cellulose, etc.), polyvinylpyrrolidone, and the like. Further, the above-mentioned polymer dispersion stabilizer may be used in combination with an inorganic water-soluble polymer compound such as sodium tripolyphosphate. Of these polymer dispersion stabilizers, polyvinyl alcohol and polyvinylpyrrolidone are preferable. The amount of the polymer dispersion stabilizer added is 1 with respect to 100 parts by weight of the vinyl-based monomer.
It is preferably in the range of 10 parts by weight.

Further, in order to suppress the generation of emulsified particles (polymer particles having a particle size too small) in the aqueous medium in the above polymerization reaction, nitrites such as sodium nitrite, nitrites, hydroquinones, ascorbic acids, and water-soluble. A water-soluble polymerization inhibitor such as vitamin Bs, citrates, and polyphenols may be added to the aqueous medium. The amount of the polymerization inhibitor added is preferably in the range of 0.02 to 0.2 parts by weight with respect to 100 parts by weight of the vinyl-based monomer.

The polymerization method for polymerizing the vinyl-based monomer to obtain seed particles is not particularly limited, but is dispersion polymerization, emulsion polymerization, soap-free emulsion polymerization (emulsion polymerization without using a surfactant as an emulsifier). , Seed polymerization, suspension polymerization and the like can be used. In order to obtain polymer particles having a substantially uniform particle size by seed polymerization, it is necessary to first use seed particles having a substantially uniform particle size and to grow these seed particles substantially uniformly. Seed particles having a substantially uniform particle size as a raw material can be produced by polymerizing a vinyl-based monomer by a polymerization method such as soap-free emulsion polymerization (emulsion polymerization without using a surfactant) or dispersion polymerization. Therefore, as a polymerization method for polymerizing a vinyl-based monomer to obtain seed particles, emulsion polymerization, soap-free emulsion polymerization, etc.
Seed polymerization and dispersion polymerization are preferred.

A polymerization initiator is also used as necessary in the polymerization for obtaining seed particles. Examples of the polymerization initiator include persulfates such as potassium persulfate, ammonium persulfate, and sodium persulfate; benzoyl peroxide, lauroyl peroxide, o-chlorobenzoyl peroxide, o-.
Methoxybenzoyl peroxide, 3,5,5-trimethylhexanoyl peroxide, te
Organic peroxides such as rt-butylperoxy-2-ethylhexanoate, di-tert-butyl peroxide; 2,2'-azobisisobutyronitrile, 1,1'-azobiscyclohexanecarbonitrile, 2,2'-Azobis (2,4-dimethylvaleronitrile)
And the like, azo compounds and the like can be mentioned. The amount of the polymerization initiator used is preferably in the range of 0.1 to 3 parts by weight with respect to 100 parts by weight of the vinyl-based monomer used to obtain the seed particles. The weight average molecular weight of the obtained seed particles can be adjusted by adjusting the amount of the polymerization initiator used.

In the polymerization for obtaining seed particles, a molecular weight modifier may be used to adjust the weight average molecular weight of the obtained seed particles. Examples of the molecular weight modifier include mercaptans such as n-octyl mercaptan and tert-dodecyl mercaptan; α-methylstyrene dimer; terpenes such as γ-terpinene and dipentene; halogenated hydrocarbons such as chloroform and carbon tetrachloride. Can be used. The weight average molecular weight of the obtained seed particles can be adjusted by adjusting the amount of the molecular weight adjusting agent used.

[Solid-liquid separation process]
In the solid-liquid separation step, the crude product is charged into a filter, and the medium contained in the charged crude product is passed through the filter medium of the filter, while the polymer particles contained in the crude product are passed through the filter medium. Hold on the filter medium.

In the solid-liquid separation step, the amount of the medium that has passed through the filter medium per unit time is determined by the following conditional expression (1);
X ≦ 5.50 × A ・ ・ ・ (1)
(In the formula (1), X is the amount (kg / mi) per unit time of the medium that has passed through the filter medium.
^{n) means, and A means the area (m 2} ) of the interface between the filter medium and the object to be filtered).

In the solid-liquid separation step, by controlling the amount of the medium that has passed through the filter medium per unit time so as to satisfy the above-mentioned conditional formula (1), the surfactant contained in the crude product can be obtained together with the medium. It can be removed, and the residual amount of the surfactant in the polymer particles remaining on the filter medium (specifically, the amount of the surfactant adhering to the surface of the polymer particles) can be reduced.

In the solid-liquid separation step, the filter is not particularly limited, but for example, FIG.
A pressure-resistant container 2 having a columnar internal space as shown in the above, a filter medium 3 arranged at the inner bottom of the pressure-resistant container 2, and a compressed gas (inert gas such as nitrogen, air, etc.) are placed in the pressure-resistant container. A pressurized filter 1 provided with a compressed gas feeder (not shown) for supplying to the gas can be mentioned. In the pressure filter 1 shown in FIG. 1, the area of the bottom surface of the columnar internal space of the pressure-resistant container 2 (see FIG. 1 (b)) is the interface between the filter medium 3 and the product to be filtered (crude product P). It is almost the same as the area.

In the solid-liquid separation step using the pressure filter 1, for example, the crude product P is put into the pressure vessel 2 of the pressure filter 1 in the form of a slurry solution and placed on the filter medium 3 in the pressure vessel 2. The crude product P is filled, and the compressed gas is supplied to the upper space S of the filter medium 3 in the pressure-resistant container 2 by a compressed gas feeder to pressurize the upper space S of the filter medium 3 inside the pressure-resistant container 2. As a result, the crude product P is pressed against the filter medium 3, the liquid medium contained in the crude product P passes through the filter medium 3, and the liquid medium is discharged as a filtrate to the outside of the pressure-resistant container 2. Then, a cake of polymer particles remains on the filter medium 3.

The pressure-resistant container 2 is preferably made of stainless steel and has a pressure resistance of 0.50 MPa or more.

The filter medium 3 is not particularly limited as long as it can reliably collect polymer particles. For example, a filter cloth such as a woven cloth or a non-woven fabric made of natural fibers, synthetic fibers or the like; a wire mesh made of sintered metal; Nonwoven fabric made of sintered metal; filter plate made of natural fiber, glass fiber, etc. (porous plate); net made of synthetic resin: filter paper; glass fiber filter, etc., but filter cloth is preferable.

In the solid-liquid separation step, the pressure condition for pressurizing the upper space S of the filter medium 3 in the pressure-resistant container 2 using the pressure filter 1 is as long as the pressure satisfies the above-mentioned condition formula (1). Although not particularly limited, for example, it is preferable to pressurize the pressure vessel 2 so that the internal pressure is in the range of 0.01 MPa to 0.50 MPa. In the solid separation step, the internal pressure of the pressure-resistant container 2 is
From the start of pressurization to the end of the solid-liquid separation step, it is preferable that the internal pressure of the pressure-resistant container 2 is kept substantially constant so as to satisfy the above conditional equation (1), but the internal pressure of the pressure-resistant container 2 is the crude product P after pressurization. As the medium contained in the filter medium 3 passes through the filter medium 3, the pressure inside the pressure-resistant container 2 gradually decreases. Specifically, the filter medium 3
When the amount of the medium passing through the pressure vessel 2 is reduced or almost eliminated, the compressed air pressure in the pressure vessel 2 is released from the bottom, and it becomes difficult to maintain the internal pressure of the pressure vessel 2 at the pressure at the time of pressurization. Will be below.

Further, in the solid-liquid separation step, the amount of the medium contained in the crude product P charged into the filter (pressurized filter 1) (when all the crude products obtained in the polymerization step are charged into the filter). It is preferable to remove the medium contained in the crude product P by passing a medium in an amount of 70% by weight or more through the filter medium 3 with respect to 100% by weight of the amount of the medium used in the polymerization step. In the solid-liquid separation step, 70% by weight or more of the medium is passed through the filter medium 3 with respect to 100% by weight of the medium contained in the crude product P charged into the filter (pressurized filter 1). As a result, the residual amount of the surfactant in the polymer particles remaining on the filter medium 3 can be reduced. As a result, it is possible to reduce the amount of the cleaning liquid in the cleaning step described later.

For example, when the pressure filter 1 is used as the filter in the solid-liquid separation step,
In the solid-liquid separation step, the amount of the medium contained in the crude product P charged into the pressure filter 1 (when all the crude products P obtained in the polymerization step are charged into the pressure filter 1) The amount of medium used in the polymerization step) is 100% by weight, and 70% by weight or more of the medium passes through the filter medium 3, and the internal pressure of the pressure resistant container 2 is 100% by weight. , It is preferable to end when it becomes 80% or less. This makes it possible to surely reduce the residual amount of the surfactant in the polymer particles remaining on the filter medium 3 and reduce the amount of the cleaning liquid in the cleaning step described later.

[Washing process]
In the cleaning step, the cleaning liquid is charged into the filter in which the polymer particles are held on the filter medium.
By bringing the cleaning liquid into contact with the polymer particles and passing the cleaning liquid in contact with the polymer particles through the filter medium, the polymer particles washed with the cleaning liquid are obtained on the filter medium.

In the cleaning step, the amount of the cleaning liquid that has passed through the filter medium per unit time is determined by the following conditional expression (2);
Y ≦ 8.50 × A ・ ・ ・ (2)
(In the formula (2), Y is the amount (kg / m) of the cleaning liquid that has passed through the filter medium per unit time.
^{In), and A means the area (m 2} ) of the interface between the filter medium and the object to be filtered. ) Satisfies. When the amount of the cleaning liquid that has passed through the filter medium per unit time does not satisfy the above condition formula (2), the time that the polymer particles and the cleaning liquid are in contact with each other is short, so that the surface of the polymer particles is exposed to the surface. The attached surfactant may not be sufficiently removed, and a large amount of the surfactant may remain in the finally obtained polymer particles.

Further, the amount of the cleaning liquid that has passed through the filter medium in the cleaning step per unit time is determined.
From the start to the end of cleaning the polymer particles by passing the cleaning liquid through the filter medium, on average, the following conditional expression (3);
2.50 × A ≦ Y ≦ 8.50 × A ・ ・ ・ (3)
(In the formula (3), Y is the amount (kg / mi) of the cleaning liquid that has passed through the filter medium per unit time.
^{It means n), and A means the area (m 2} ) of the interface between the filter medium and the object to be filtered. ) Is preferably satisfied. When the amount of the cleaning liquid passing through the filter medium in the cleaning step per unit time satisfies the above-mentioned conditional formula (3) on average, the surfactant adhering to the surface of the polymer particles is sufficiently sufficiently applied. By removing it, the residual amount of the surfactant in the finally obtained polymer particles can be reduced.

For example, when the pressure filter 1 as shown in FIG. 1 is used in the solid-liquid separation step, the cleaning liquid is used while keeping the cake of the polymer particles remaining on the filter medium 3 as it is on the filter medium 3. The cake and the cleaning liquid are brought into contact with each other by supplying the cake into the pressure-resistant container 2, and the compressed gas is supplied to the upper space S of the filter medium 3 in the pressure-resistant container 2 by the compressed gas supply machine.
Pressurize the upper space S of. As a result, the cake is washed in contact with the washing liquid, and the washing liquid after washing is discharged as a filtrate to the outside of the pressure-resistant container 2. After supplying the cleaning liquid and before pressurizing, the cleaning liquid supplied into the pressure-resistant container 2 may be mixed with the cake to form a slurry. Further, the cracks in the cake may be repaired by using a stirrer before supplying the cleaning liquid for cleaning. This eliminates the short path of the cleaning solution.
Efficient cleaning can be performed.

In the above-mentioned cleaning step, the pressurizing condition when pressurizing the upper space S of the filter medium 3 in the pressure-resistant container 2 by using the pressurizing filter 1 is particularly limited as long as the pressure satisfies the above-mentioned conditional expression (2). However, for example, it is preferable to pressurize the pressure vessel 2 so that the internal pressure is in the range of 0.01 MPa to 0.50 MPa. The upper space S of the filter medium 3 is 0.01 to 0.30 MPa.
It is preferable to pressurize at a rate of / min. In the cleaning step, the internal pressure of the pressure-resistant container 2 is preferably kept substantially constant from the start of pressurization to the end of the cleaning step so as to satisfy the above conditional expression (2). After pressurization, the pressure inside the pressure-resistant container 2 gradually decreases as the cleaning liquid charged into the pressure-resistant container 2 passes through the filter medium 3. Specifically, when the amount of cleaning liquid passing through the filter medium 3 is reduced or almost eliminated, the compressed air pressure in the pressure-resistant container 2 is released from the bottom, and it becomes difficult to maintain the internal pressure of the pressure-resistant container 2 at the pressure at the time of pressurization. , The pressure at the time of pressurization will be lower.

The cleaning liquid used in the cleaning step is preferably an aqueous medium, for example, water; lower alcohols such as methyl alcohol and ethyl alcohol (alcohols having 5 or less carbon atoms);
Examples thereof include a mixture of water and a lower alcohol, but it is preferable to use the same medium as the medium used in the above polymerization step.

The weight of the cleaning liquid used in the cleaning step is the weight of the polymer particles held on the filter medium 3 (when all the crude products obtained in the polymerization step in the solid-liquid separation step are put into the filter, the polymerization step. The total amount of vinyl-based monomers used in (1) is 10 times or more. If the weight of the cleaning liquid used in the cleaning step is less than 10 times the weight of the polymer particles held on the filter medium 3, the removal of the surfactant contained in the polymer particles becomes insufficient, and the desired polymer is obtained. Particles (surfactant content 5
Polymer particles of less than 0 ppm) may not be obtained.

Further, the weight of the cleaning liquid used in the cleaning step is preferably equal to or more than the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the following calculation formula (4) for each type of surfactant used in the polymerization step. .. When the weight of the cleaning liquid used in the cleaning step is equal to or greater than the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the following calculation formula (4) for each type of surfactant used in the polymerization step.
The content of the surfactant in the polymer particles can be further reduced.

D = (E ÷ F) × 2000 ... (4)
D: Lower limit of the weight of cleaning solution required for one type of surfactant (g)
E: Amount of the above-mentioned one type of surfactant used (g)
F: Solubility of the above-mentioned one type of surfactant in a cleaning liquid having a liquid temperature of 25 ° C. (g / 100 ml)

The temperature of the cleaning liquid used for cleaning is preferably a temperature at which the surfactant is sufficiently eluted, for example, preferably 40 to 80 ° C, more preferably 50 to 80 ° C. As a method of heating the cleaning liquid to the above temperature for cleaning, a method of supplying the heated cleaning liquid to a filter (for example, the pressure-resistant container 2 of the pressure filter 1) may be used, and the cleaning liquid is supplied to the filter. The cleaning liquid may be heated by a heater jacket arranged around the filter after being supplied to the filter.

In the above cleaning step, the conductivity of the cleaning liquid that has passed through the filter medium 3 is 2.0 times or less the conductivity of the cleaning liquid before being charged into the filter (pressurized filter 1), and the internal pressure of the pressure-resistant container 2 is increased. It is preferable to end the process when the pressure becomes 80% or less with respect to 100% of the pressure at the time of pressurization. The conductivity of the cleaning liquid that has passed through the filter medium 3 is 2.0, which is the conductivity of the cleaning liquid before it is put into the filter (pressurized filter 1).
By charging the cleaning liquid into the pressure-resistant container 2 until the amount becomes double or less, the residual amount of the surfactant contained in the finally obtained polymer particles can be surely reduced. Further, by passing the cleaning liquid charged in the pressure-resistant container 2 through the filter medium 3 until the internal pressure of the pressure-resistant container 2 becomes 80% or less with respect to 100% of the pressure at the time of pressurization, the water content that can be absorbed by the polymer particles. The amount can be reduced, and the time required for drying the polymer particles after washing can be shortened.

The polymer particles obtained in the cleaning step are dried in a vacuum dryer to almost completely remove the cleaning liquid, and if necessary, are classified (preferably airflow classification), so that the weight can be used as a product. It can be a coalesced particle.

According to the above-mentioned method for producing polymer particles, the amount of the medium that has passed through the filter medium per unit time satisfies the condition formula (1) in the solid-liquid separation step, and the unit time of the cleaning liquid that has passed through the filter medium in the cleaning step. Since the amount of contact satisfies the condition formula (2) and a cleaning liquid having a weight of 10 times or more the weight of the polymer particles held on the filter medium is used in the cleaning step, the polymer particles are used in the polymerization step. Most of the surfactant adhering to the surface can be removed together with the medium and the cleaning liquid. As a result, polymer particles having an extremely low content (residual amount) of the surfactant and excellent dispersion stability can be obtained. Further, according to the above-mentioned production method, a large amount of the polymer dispersion stabilizer that can be used in the polymerization step is also removed in the solid-liquid separation step and the washing step. Therefore, the polymer particles obtained by the above production method can have a small amount of the polymer dispersion stabilizer.

[Use of polymer particles]
The polymer particles of the present invention are suitable for optical films such as antiglare films and light diffusing films, and optical members such as light diffusing materials, and are particularly suitable for antiglare members.

[Optical film]
The optical film of the present invention comprises a coating resin composition containing the polymer particles of the present invention and a binder coated on a film substrate. In the optical film of the present invention, for example, the polymer particles are dispersed in a binder to obtain a coating resin composition, and the obtained coating resin composition is coated on a film base material to obtain the coating. It is obtained by forming a coating film made of a resin composition for use on the film substrate.

The binder is not particularly limited as long as it is used in the art, depending on the required properties such as transparency, polymer particle dispersibility, light resistance, moisture resistance and heat resistance. Examples of the binder include (meth) acrylic resin; (meth) acrylic-urethane resin; urethane resin; polyvinyl chloride resin; polyvinylidene chloride resin; melamine resin; styrene resin; alkyd resin. Phenolic resin; Epoxy resin; Polyester resin; Silicone resin such as alkylpolysiloxane resin; (Meta) acrylic-silicone resin, silicone-alkyd resin, silicone-urethane resin, silicone-polyester resin, etc. Modified silicone resin; Examples thereof include binder resins such as fluororesins such as polyvinylidene fluoride and fluoroolefin vinyl ether polymers.

The binder resin is preferably a curable resin capable of forming a crosslinked structure by a crosslinking reaction from the viewpoint of improving the durability of the coating resin composition. The curable resin can be cured under various curing conditions. The above curable resin depends on the type of curing.
It is classified into an ionizing radiation curable resin such as an ultraviolet curable resin and an electron beam curable resin, a thermosetting resin, and a warm air curable resin.

Examples of the thermosetting resin include a thermosetting urethane resin composed of an acrylic polyol and an isocyanate prepolymer, a phenol resin, a urea melamine resin, an epoxy resin, an unsaturated polyester resin, and a silicone resin.

The ionizing radiation curable resin is a polyfunctional (meth) acrylate resin such as a polyhydric alcohol polyfunctional (meth) acrylate; synthesized from a diisocyanate, a polyhydric alcohol, a (meth) acrylic acid ester having a hydroxy group, or the like. Examples thereof include polyfunctional urethane acrylate resins. As the ionizing radiation curable resin, a polyfunctional (meth) acrylate resin is preferable, and a polyhydric alcohol polyfunctional (meth) acrylate having three or more (meth) acryloyl groups in one molecule is more preferable. 3 or more (meta) in one molecule
Specific examples of the polyhydric alcohol polyfunctional (meth) acrylate having an acryloyl group include trimethylolpropane tri (meth) acrylate, trimethylolethanetri (meth) acrylate, and 1,2,4-cyclohexanetetra (meth). Acrylate, pentaglycerol triacrylate, pentaerythritol tetra (meth) acrylate, pentaerythritol tri (meth) acrylate, dipentaerythritol triacrylate, dipentaerythritol pentaacrylate, dipentaerythritol tetra (meth)
Examples thereof include acrylate, dipentaerythritol hexa (meth) acrylate, tripentaerythritol triacrylate, and tripentaerythritol hexaacrylate. Two or more types of the ionizing radiation curable resin may be used in combination.

As the ionizing radiation curable resin, in addition to these, a polyether resin having an acrylate-based functional group, a polyester resin, an epoxy resin, an alkyd resin, a spiroacetal resin, a polybutadiene resin, a polythiol polyene resin and the like can also be used.

When an ultraviolet curable resin is used among the above ionizing radiation curable resins, a photopolymerization initiator is added to the ultraviolet curable resin to form a binder. Any of the above photopolymerization initiator may be used, but it is preferable to use one suitable for the ultraviolet curable resin to be used.

Examples of the photopolymerization initiator include acetophenones, benzoins, benzophenones, phosphine oxides, ketals, α-hydroxyalkylphenones, α-aminoalkylphenones, anthraquinones, thioxanthones, azo compounds, and peroxides. (Japanese Patent Laid-Open No. 2
001-139663), 2,3-dialkyldione compounds, disulfide compounds, fluoroamine compounds, aromatic sulfoniums, onium salts, borate salts, active halogen compounds, α-acyloxime esters, etc. Can be mentioned.

Examples of the acetophenones include acetophenone, 2,2-diethoxyacetophenone, p-dimethylacetophenone, 1-hydroxydimethylphenylketone, 1-.
Examples thereof include hydroxycyclohexylphenyl ketone, 2-methyl-4-methylthio-2-morpholinopropiophenone, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone and the like. Examples of the benzoins include benzoins,
Examples thereof include benzoin benzoate, benzoin benzene sulfonic acid ester, benzoin toluene sulfonic acid ester, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether and the like. Examples of the benzophenones include benzophenone, 2,4-dichlorobenzophenone, 4,4-dichlorobenzophenone, and p-.
Examples include chlorobenzophenone. Examples of the phosphine oxides include 2
, 4,6-trimethylbenzoyldiphenylphosphine oxide and the like. Examples of the ketals include benzylmethyl ketals such as 2,2-dimethoxy-1,2-diphenylethane-1-one. Examples of the α-hydroxyalkylphenones include 1-hydroxycyclohexylphenyl ketone. The above α-
Examples of aminoalkylphenones include 2-methyl-1- [4- (methylthio) phenyl] -2- (4-morpholinyl) -1-propanol.

Commercially available photoradical polymerization initiators include the trade name "Irgacure (registered trademark) 651" (2,2-dimethoxy-1,2-diphenylethane-1-one) manufactured by BASF Japan Ltd. and BASF Japan Ltd. Product name "Irgacure (registered trademark) 184", BA
Product name "Irgacure (registered trademark) 907" (2-methyl-1) manufactured by SF Japan Co., Ltd.
− [4- (Methylthio) phenyl] -2- (4-morpholinyl) -1-propanol) and the like are preferred examples.

The amount of the photopolymerization initiator used is usually in the range of 0.5 to 20% by weight, preferably in the range of 1 to 5% by weight, based on 100% by weight of the binder.

As the binder resin, a thermoplastic resin can be used in addition to the curable resin. Examples of the thermoplastic resin include cellulose derivatives such as acetyl cellulose, nitro cellulose, acetyl butyl cellulose, ethyl cellulose, and methyl cellulose; homopolymers and copolymers of vinyl acetate, homopolymers and copolymers of vinyl chloride, and vinylidene chloride. Vinyl-based resins such as homopolymers and copolymers; acetal resins such as polyvinylformal and polyvinylbutyral; homopolymers and copolymers of acrylic acid esters, homopolymers and copolymers of methacrylic acid esters, etc. (meth) ) Acrylic resin; polystyrene resin; polyamide resin; linear polyester resin; polycarbonate resin and the like.

Further, as the binder, in addition to the binder resin, a rubber-based binder such as synthetic rubber or natural rubber, an inorganic binder, or the like can also be used. Examples of the rubber-based binder resin include ethylene-propylene copolymer rubber, polybutadiene rubber, styrene-butadiene rubber, and acrylonitrile-butadiene rubber. These rubber-based binder resins may be used alone or in combination of two or more.

Examples of the inorganic binder include silica sol, alkaline silicate, silicon alkoxide, and phosphate. As the inorganic binder, an inorganic or organic-inorganic composite matrix obtained by hydrolyzing and dehydrating a metal alkoxide or a silicon alkoxide can also be used. As the inorganic-based or organic-inorganic composite-based matrix, a silicon oxide-based matrix obtained by hydrolyzing and dehydrating and condensing silicon alkoxide, for example, tetraethoxysilane, etc. can be used. These inorganic binders may be used alone or in combination of two or more.

The amount of polymer particles in the coating resin composition is 10 as the solid content of the binder.
It is preferably 2 parts by weight or more, more preferably 4 parts by weight or more, and further preferably 6 parts by weight or more with respect to 0 parts by weight. By setting the amount of the polymer particles to 2 parts by weight or more with respect to 100 parts by weight of the solid content of the binder, it becomes easy to make the matte property of the coating film formed by the coating resin composition sufficient. Therefore, it becomes easy to make the optical characteristics such as antiglare property and light diffusivity of the film obtained by coating the coating resin composition on the film base material sufficient. The amount of the polymer particles in the coating resin composition is preferably 300 parts by weight or less, more preferably 200 parts by weight or less, and 100 parts by weight, based on 100 parts by weight of the solid content of the binder. The following is more preferable. By setting the amount of the polymer particles to 300 parts by weight or less with respect to 100 parts by weight of the solid content of the binder, it becomes easy to make the linear permeability of the coating film formed by the coating resin composition sufficient.

The coating resin composition may further contain an organic solvent. When the coating resin composition is applied to a base material such as a film base material to be described later, the organic solvent is contained in the coating resin composition to form a coating resin composition on the base material. It is not particularly limited as long as it facilitates coating. Examples of the organic solvent include aromatic solvents such as toluene and xylene; alcohol solvents such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol and propylene glycol monomethyl ether;
Ester solvents such as ethyl acetate and butyl acetate; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone and cyclohexanone; 2-methoxyethanol, 2-ethoxyethanol, 2-butoxyethanol, ethylene glycol dimethyl ether, ethylene Glycol ethers such as glycol diethyl ether, diethylene glycol dimethyl ether, propylene glycol methyl ether; 2-methoxyethyl acetate, 2-ethoxyethyl acetate (cellosolve acetate), 2
-Glycol ether esters such as butoxyethyl acetate and propylene glycol methyl ether acetate; chlorine-based solvents such as chloroform, dichloromethane, trichloromethane and methylene chloride; tetrahydrofuran, diethyl ether, 1,4-dioxane,
Ether-based solvents such as 1,3-dioxolane; amide-based solvents such as N-methylpyrrolidone, dimethylformamide, dimethyl sulfoxide, and dimethylacetamide can be used. One of these organic solvents may be used alone, or two or more of them may be mixed and used.

The film substrate is preferably transparent. Examples of the transparent film substrate include polyester-based polymers such as polyethylene terephthalate (PET) and polyethylene naphthalate, cellulose-based polymers such as diacetyl cellulose and triacetyl cellulose (TAC), polycarbonate-based polymers, and polymethyl methacrylate. Examples thereof include a film made of a polymer such as a (meth) acrylic polymer. Also, as a transparent film base material,
Styrene-based polymers such as polystyrene and acrylonitrile / styrene copolymers, polyethylene, polypropylene, polyolefins having a cyclic or norbornene structure, ethylene /
Examples thereof include a film made of an olefin polymer such as a propylene copolymer, a vinyl chloride polymer, and a polymer such as an amide polymer such as nylon or aromatic polyamide. Further, as a transparent film substrate, an imide polymer, a salfone polymer, a polyether sulfone polymer, a polyether ether ketone polymer, a polyphenyl sulfide polymer, a vinyl alcohol polymer, vinylidene chloride. Examples thereof include a film composed of a polymer such as a system polymer, a vinyl butyral polymer, an allylate polymer, a polyoxymethylene polymer, an epoxy polymer, or a blend of the above polymers. As the film base material, a film having a particularly low birefringence is preferably used. Further, a film provided with an easy-adhesion layer such as (meth) acrylic resin, copolymerized polyester resin, polyurethane resin, styrene-maleic acid graft polyester resin, and acrylic graft polyester resin on these films is also used as the film base material. Can be used.

The thickness of the film base material can be appropriately determined, but is generally in the range of 10 to 500 μm in terms of strength, workability such as handling, thin layer property, etc., and within the range of 20 to 300 μm. It is preferably in the range of 30 to 200 μm, and more preferably in the range of 30 to 200 μm.

Further, an additive may be added to the film base material. Examples of the additive include an ultraviolet absorber, an infrared absorber, an antistatic agent, a refractive index adjuster, an enhancer and the like.

As a method of applying the above resin composition for coating on a film substrate, bar coating, blade coating, spin coating, reverse coating, die coating, spray coating, roll coating, gravure coating, micro gravure coating, lip coating, air Known coating methods such as knife coating and dipping method can be mentioned.

When the binder contained in the coating resin composition is an ionizing radiation curable resin, the solvent is dried as necessary after application of the coating resin composition, and then ionizing radiation curing is performed by irradiating with active energy rays. The sex resin may be cured.

Examples of the active energy beam include xenon lamps, low-pressure mercury lamps, and high-pressure mercury lamps.
Ultraviolet rays emitted from light sources such as ultra-high pressure mercury lamps, metal halide lamps, carbon arc lamps, and tungsten lamps; usually 20 to 2000 KeV Koklov Walton type, bandegraph type, resonance transformer type, insulated core transformer type, linear type, dynamitron type , High frequency type electron beam accelerator, electron beam, α ray, β ray, γ ray and the like can be used.

The thickness of the layer in which the polymer particles are dispersed in the binder, which is formed by coating (and curing) the resin composition for coating, is not particularly limited and is appropriately determined by the particle size of the polymer particles. It is preferably in the range of 10 μm, more preferably in the range of 3 to 7 μm.

Since the optical film of the present invention is formed by coating a base material with a coating resin composition containing the polymer particles of the present invention having excellent dispersion stability, the entire coating film formed by the coating is applied. In the above, even optical characteristics such as light diffusivity and antiglare can be stably obtained. Therefore, according to the optical film of the present invention, high quality stability can be obtained.

The optical film of the present invention described above can be suitably used for light diffusion or antiglare, that is, as a light diffusion film or antiglare film.

[Resin molded product]
The resin molded product of the present invention is obtained by molding a molding resin composition containing the polymer particles and a transparent resin. In the resin molded product of the present invention, the polymer particles function as light diffusing particles. Therefore, the resin molded product of the present invention functions as a light diffuser such as a light diffuser, and is L.
It can be used as an ED lighting cover, etc.

The transparent resin is a base material of the resin molded body, and is, for example, a combination of (meth) acrylic resin, polycarbonate resin, polystyrene resin, (meth) acrylic-styrene resin ((meth) acrylic) acid ester and styrene. Polymer) and the like. Among them, polystyrene resin or (meth) acrylic-styrene resin is preferable as the transparent resin.

The amount of polymer particles contained in the resin composition is 0.0 with respect to 100 parts by weight of the transparent resin.
It is preferably in the range of 1 to 5 parts by weight, and more preferably in the range of 0.1 to 5 parts by weight. Additives such as an ultraviolet absorber, an antioxidant, a heat stabilizer, a light stabilizer, and a fluorescent whitening agent may be added to the resin composition.

The thickness and shape of the resin molded product can be appropriately selected depending on the intended use of the resin molded product.

The resin molded product of the present invention can be obtained by melt-kneading the transparent resin and the polymer particles with a single-screw extruder, a twin-screw extruder or the like. Further, the resin composition obtained by melt-kneading may be molded into a plate shape via a T die and a roll unit to obtain a resin molded product. Alternatively, the resin composition obtained by melt-kneading may be pelletized, and the pellet may be molded into a plate shape by injection molding, press molding, or the like to obtain a resin molded body.

Since the resin molded product of the present invention is formed by molding a molding resin composition containing the polymer particles of the present invention having excellent dispersion stability, the resin molded product has uniform light diffusivity and light diffusivity. Stable optical characteristics such as antiglare can be obtained. Therefore, according to the resin molded product of the present invention, high quality stability can be obtained.

Hereinafter, the present invention will be described with reference to Examples and Comparative Examples, but the present invention is not limited thereto. First, in the following Examples and Comparative Examples, a method for measuring the volume average particle diameter of the polymer particles and a fluctuation coefficient of the particle diameter, a method for measuring the volume average particle diameter of the seed particles used for producing the polymer particles, and a polymer. A method for measuring the X value (amount of medium that has passed through the filter medium per unit time (kg / min)) in the solid-liquid separation step of particle production, and the Y value (cleaning liquid that has passed through the filter medium) in the cleaning process of polymer particle production. (Amount per unit time (kg / min)), method for measuring the content of surfactant in polymer particles (liquid chromatograph mass analysis method (LC-MS-MS))
)) The method for measuring the polymer particles by TOF-SIMS, the method for measuring the gel fraction of the polymer particles, and the method for measuring the dispersion stabilization time of the polymer particles will be described.

[Measurement method of volume average particle size and coefficient of variation of particle size of polymer particles]
The volume average particle size is measured by Coulter Multisizer III (measuring device manufactured by Beckman Coulter Co., Ltd.). The measurement is Mul issued by Beckman Coulter Co., Ltd.
It shall be carried out using apertures calibrated according to the ^{sizer TM 3 User's Manual.}

When selecting the aperture to be used for measurement, when the assumed volume average particle diameter of the polymer particles to be measured is 1 μm or more and 10 μm or less, an aperture having a size of 50 μm is selected, and the assumed volume average of the polymer particles to be measured is selected. 10 when the particle size is larger than 10 μm and 30 μm or less
An aperture having a size of 0 μm is selected, and the assumed volume average particle diameter of the polymer particles is 30.
If it is larger than μm and 90 μm or less, select an aperture with a size of 280 μm.
400 when the assumed volume average particle size of the polymer particles is larger than 90 μm and 150 μm or less
Perform as appropriate, such as selecting an aperture with a size of μm. If the volume average particle size after measurement is different from the assumed volume average particle size, change to an aperture with an appropriate size.
Make the measurement again.

Also, when an aperture with a size of 50 μm is selected, the Current (aperture current) is set to -800, and the Gain (gain) is set to 4, and when an aperture with a size of 100 μm is selected, the Current (aperture current) is-. 1600, Gain (
Gain) is set to 2, and when apertures with sizes of 280 μm and 400 μm are selected, Current (appearance current) is set to -3200 and Gain is set to 1.

As a sample for measurement, 0.1 g of polymer particles was placed in 10 m1 of a 0.1 wt% nonionic surfactant aqueous solution in a touch mixer (manufactured by Yamato Scientific Co., Ltd., “TOUCHMIXER MT-”.
31 ") and ultrasonic cleaner (manufactured by Vervocrea Co., Ltd.," ULTRASONIC "
CLEANER VS-150 ") is used to disperse and use a dispersion.
A beaker filled with ISOTON (registered trademark) II (manufactured by Beckman Coulter Co., Ltd .: electrolyte for measurement) is set in the measuring unit of Coulter Multisizer III, and the dispersion liquid is dropped while gently stirring the inside of the beaker. Then, after adjusting the reading of the densitometer on the screen of the Coulter Multisizer III main body to 5 to 10%, the measurement is started. During the measurement, the beaker is gently stirred so that no bubbles enter, and the measurement is completed when 100,000 polymer particles are measured. The volume average particle size of the polymer particles is an arithmetic mean in the volume-based particle size distribution of 100,000 particles.

The coefficient of variation (CV value) of the particle size of the polymer particles is calculated by the following formula.

Coefficient of variation of particle size of polymer particles = (standard deviation of particle size distribution based on volume of polymer particles)
÷ Volume average particle size of polymer particles) × 100

[Measurement method of volume average particle size of seed particles]
The volume average particle size of the seed particles is measured by a laser diffraction / scattering particle size distribution measuring device (“LS 13 320” manufactured by Beckman Coulter, Inc.) and a universal liquid sample module.

For the measurement, 0.1 g of seed particles were placed in 10 m1 of a 0.1 wt% nonionic surfactant aqueous solution in a touch mixer (manufactured by Yamato Scientific Co., Ltd., "TOUCHMIXER MT-31") and an ultrasonic cleaner (Vervok Co., Ltd.). Made by Leah, "ULTRASONIC CLEANE"
R VS-150 ") is used to disperse and use a dispersion.

Further, in the software of the above-mentioned laser diffraction / scattering type particle size distribution measuring device, the following optical parameters required for evaluation based on the Me theory are set.

<Parameter>
The real part of the refractive index BI of the liquid (nonionic surfactant aqueous solution) = 1.333 (refractive index of water)
The real part of the refractive index of the solid (seed particle to be measured) = the refractive index of the seed particle The imaginary part of the refractive index of the solid = 0
Solid Scherrer = 1
The measurement conditions and measurement procedure are as follows.

<Measurement conditions>
Measurement time: 60 seconds Number of measurements: 1
Pump speed: 50-60%
PIDS relative concentration: about 40 to 55% Ultrasonic output: 8
<Measurement procedure>
After performing offset measurement, optical axis adjustment, and background measurement, the above-mentioned dispersion liquid is injected into the universal liquid sample module of the above-mentioned laser diffraction / scattering type particle size distribution measuring device using a dropper. When the concentration in the universal liquid sample module reaches the PIDS relative concentration and the software of the laser diffraction / scattering particle size distribution measuring device displays "OK", the measurement is started. The measurement is performed in a state where the seed particles are dispersed by performing pump circulation in the universal liquid sample module, and in a state where the ultrasonic unit (ULM ULTRASONIC MODE) is activated.

In addition, the measurement was performed at room temperature, and from the obtained data, the software of the above-mentioned laser diffraction / scattering type particle size distribution measuring device was used to use the above-mentioned preset optical parameters.
Calculate the volume average particle size of the seed particles (arithmetic mean diameter in the volume-based particle size distribution).

The refractive index of the seed particles was measured by inputting the refractive index of the polymer constituting the seed particles. For example, since the polymer constituting the seed particles used in the production of Examples and Comparative Examples described later is polymethylmethacrylate or ethylpolymethacrylate, the known refractive indexes of methyl polymethacrylate and ethyl polymethacrylate are known. A rate of 1.495 was entered.

[Measurement method of X value]
_{In the solid-liquid separation step, the time T 1} (min) from the start of passing the medium contained in the crude product through the filter medium to the end of the passage of the filter medium of the medium is measured. _{In addition, the total weight G 1} (kg) of the filtrate (medium) obtained in the solid-liquid separation step is weighed. Then, the amount X (kg / min) per unit time of the medium that has passed through the filter medium is obtained by the following calculation formula.
X (kg / min) = G ₁ (kg) / T ₁ (min)

[Measurement method of Y value]
_{The weight G 2} (kg) of the cleaning liquid used in the cleaning step is measured. Further, in the cleaning step, the weight of the cleaning liquid used in the cleaning step after starting to pass the cleaning liquid through the filter medium G ₂ (g).
_{Measure the time T 2} (min) spent for the cleaning solution having a weight of 0.8 times that of the filter medium to pass through the filter medium. Then, according to the following calculation formula, the amount Y (kg) of the cleaning liquid that has passed through the filter medium per unit time.
/ Min) is calculated.
Y (kg / min) = 0.8 × G ₂ (kg) / T ₂ (min)

[Method for measuring the content of surfactant in polymer particles]
The content of the surfactant in the polymer particles is measured by extracting the polymer particles with a solvent and using a liquid chromatograph mass spectrometer (LC / MS / MS apparatus).

In addition, for the measurement of the content of the surfactant in the polymer particles of Examples and Comparative Examples described later, as an LC / MS / MS apparatus, "ULCM ACCELA" manufactured by Thermo Fisher Scientific and Thermo Fisher Scientific are used.
"Linear Ion Trap LC / MS ⁿ LXQ" manufactured by ic was used.

Further, the polymer particles in Examples and Comparative Examples described later are used as a surfactant as di (2-).
Ethylhexyl) sulfosuccinate, polyoxyethylene styrenated phenyl ether sulfate (see formula (A) below), alkenyl succinate (see formula (C) below),
And, at least one of polyoxyethylene styrenated phenyl ether (see formula (E) described later) is used, and the content of the surfactant in the polymer particles of Examples and Comparative Examples is as follows. It was measured by the method shown.

Approximately 0.10 g of polymer particles as a sample are precisely weighed in a centrifuge tube, and methanol 5 as an extract is used.
Add mL with a whole pipette to mix the polymer particles and the extract well. 15 minutes
After ultrasonic extraction, centrifugation is performed at 3500 rpm for 15 minutes, and the resulting supernatant is used as a test solution.

The concentration of the surfactant in this test solution is measured using an LC / MS / MS apparatus. Then, the concentration of the surfactant in the measured test solution (μg / ml), the weight of the polymer particles used as the sample (sample weight (g)), and the amount of the extract (extract amount (ml)). From, according to the following formula
The content (μg / g) of the surfactant in the polymer particles is determined. The amount of the extract is 5 ml.

Surfactant content (μg / g)
= {Concentration of surfactant in test solution (μg / ml) x amount of extract (ml)} ÷ sample weight (g)

The surfactant concentration is calculated from the calibration curve prepared in advance from the peak area value on the obtained chromatogram using an LC / MS / MS apparatus. When the polymer particles contain a plurality of types of surfactants, a calibration curve is prepared for each of the surfactants.
The surfactant concentration was calculated from the prepared calibration line, and the total of the calculated surfactant concentrations of each surfactant was used as the "surfactant concentration in the test solution (μg / ml)" in the above calculation formula. The content of the surfactant in the coalesced particles is determined.

The method for preparing a calibration curve is as follows, depending on the type of surfactant used in Examples and Comparative Examples.

[Method for preparing a calibration curve for di (2-ethylhexyl) sulfosuccinate]
Approximately 1000 ppm intermediate standard solution (methanol solution) of di (2-ethylhexyl) sulfosuccinate was prepared, and then diluted stepwise with methanol to 0.1 ppm, 0.2 ppm,
Prepare standard solutions for preparing calibration curves of 0.5 ppm, 1.0 ppm, and 2.0 ppm. The standard solution for preparing a calibration curve of each concentration was measured under LC measurement conditions and MS measurement conditions described later, and on a chromatogram of monitor ion m / z = 421.3 (precursor ion) → 227.2 (product ion). Obtain the peak area value. Each concentration and area value are plotted to obtain an approximate curve (quadratic curve) by the least squares method, and this is used as a calibration curve for quantification.

-Method for preparing calibration curve of polyoxyethylene styrenated phenyl ether sulfate ester-
Approximately 1000 ppm intermediate standard solution (methanol solution) of polyoxyethylene styrenated phenyl ether sulfate ester salt is prepared, and then diluted stepwise with methanol to 0.1 pp.
Prepare a standard solution for preparing a calibration curve of m, 0.5 ppm, 1.0 ppm, 2.0 ppm, and 10.0 ppm. The standard solution for preparing a calibration curve of each concentration was measured under LC measurement conditions and MS measurement conditions described later, and on a chromatogram of monitor ion m / z = 601.4 (precursor ion) → 301.2 (product ion). Obtain the peak area value. Each concentration and area value are plotted to obtain an approximate curve (quadratic curve) by the least squares method, and this is used as a calibration curve for quantification.

-How to prepare a calibration curve for alkenyl succinate-
After preparing an intermediate standard solution (methanol solution) of about 1000 ppm of alkenyl succinate, it is further diluted stepwise with methanol to 0.03 ppm, 0.15 ppm, 0.60 ppm,
Prepare a standard solution for preparing a calibration curve of 1.5 ppm and 3.0 ppm. The standard solution for preparing a calibration curve of each concentration was measured under LC measurement conditions and MS measurement conditions described later, and monitor ion m / z = 33.
Obtain the peak area value on the chromatogram of 9.3 (precursor ion) → 295.2 (product ion). Each concentration and area value are plotted to obtain an approximate curve (quadratic curve) by the least squares method, and this is used as a calibration curve for quantification.

-How to prepare a calibration curve for polyoxyethylene styrenated phenyl ether-
Approximately 1000 ppm intermediate standard solution (methanol solution) of polyoxyethylene styrenated phenyl ether is prepared, and then diluted stepwise with methanol to 0.1 ppm and 0.5 pp.
Prepare a standard solution for preparing a calibration curve at m, 2.5 ppm, 5.0 ppm, and 10.0 ppm. The standard solution for preparing a calibration curve of each concentration was measured under LC measurement conditions and MS measurement conditions described later, and monitor ion m / z = 980.5 (precursor ion) → 963.2 (product ion).
Obtain the peak area value on the chromatogram of. Each concentration and area value are plotted to obtain an approximate curve (quadratic curve) by the least squares method, and this is used as a calibration curve for quantification.

The LC measurement conditions according to the type of surfactant used in Examples and Comparative Examples are as follows.

-Di (2-ethylhexyl) sulfosuccinate, polyoxyethylene styrenated phenyl ether sulfate, and L of polyoxyethylene styrenated phenyl ether
C measurement conditions-
Measuring device: UHPLC ACCELA (Thermo Fisher Scientific)
Made by ic)
Column: Thermo Fisher Scientific Hypersil G
OLD C18 1.9 μm (inner diameter 2.1 mm, length 100 mm)
Column temperature: 40 ° C
Mobile phase: (A: 10 mM ammonium acetate / B: acetonitrile)
Mobile phase conditions: (0 min = B concentration 90%, 0 → 0.5 min = B concentration 90% → 100%,
0.5 → 1 min = B concentration 100%, 1 → 1.1 min = B concentration 100% → 90%, 1.
1 → 3min = B concentration 90%)
Flow rate: 0.3 mL / min
Pump temperature: Room temperature (25 ° C)
Injection volume: 2 μL
Measurement time: 3 min

-LC measurement conditions for alkenyl succinate-
Measuring device: UHPLC ACCELA (Thermo Fisher Scientific)
Made by ic)
Column: Thermo Fisher Scientific Hypersil G
OLD C18 1.9 μm (inner diameter 2.1 mm, length 100 mm)
Column temperature: 40 ° C
Mobile phase: (A: 10 mM ammonium acetate / B: acetonitrile = 25/75)
Flow rate: 0.3 mL / min
Pump temperature: Room temperature (25 ° C)
Injection volume: 2 μL
Measurement time: 5 min

The MS measurement conditions according to the type of surfactant used in Examples and Comparative Examples are as follows.

-MS measurement conditions for di (2-ethylhexyl) sulfosuccinate-
Measuring device: Liner Ion Trap LC / MS ⁿ LXQ (Thermo F)
(Made by isher Scientific)
Ionization: (ESI / negative)
Sheath Gas: 30 arb
Auxiliary gas (AUX Gas): 10 arb
Sweep Gas: 0 arb
Spray voltage (I Spray Voltage): 5.0 kV
Capillary Temperature: 350 ° C
Capillary voltage: -20V
Tube lens Voltage: -100V
Monitoring ion (m / Z): Di (2-ethylhexyl) sulfosuccinate (n = 421.3 / n2 = 227.2)

-MS measurement conditions for polyoxyethylene styrenated phenyl ether sulfate ester-
Measuring device: Liner Ion Trap LC / MS ⁿ LXQ (Thermo Fi)
(manufactured by she Scientific)
Ionization: (ESI / negative)
Sheath Gas: 30 arb
Auxiliary gas (AUX Gas): 10 arb
Sweep Gas: 0 arb
Spray voltage (I Spray Voltage): 5.0 kV
Capillary Temperature: 350 ° C
Capillary voltage: -20V
Tube lens Voltage: -100V
Monitoring ion (m / Z): Polyoxyethylene styrenated phenyl ether sulfate ester salt (n = 601.4 / n2 = 301.2)

-MS measurement conditions for alkenyl succinate-
Measuring device: Liner Ion Trap LC / MS ⁿ LXQ (Thermo Fi)
(manufactured by she Scientific)
Ionization: (ESI / negative)
Sheath Gas: 30 arb
Auxiliary gas (AUX Gas): 10 arb
Sweep Gas: 0 arb
Spray voltage (I Spray Voltage): 5.0 kV
Capillary Temperature: 350 ° C
Capillary voltage: -20V
Tube lens Voltage: -100V
Monitoring ion (m / Z): Alkenyl succinate (n = 339.3 / n)
2 = 295.3)

-MS measurement conditions for polyoxyethylene styrenated phenyl ether-
Measuring device: Liner Ion Trap LC / MS ⁿ LXQ (Thermo Fi)
(manufactured by she Scientific)
Ionization: (ESI / negative)
Sheath Gas: 30 arb
Auxiliary gas (AUX Gas): 10 arb
Sweep Gas: 0 arb
Spray voltage (I Spray Voltage): 5.0 kV
Capillary Temperature: 350 ° C
Capillary voltage: -20V
Tube lens Voltage: -100V
Monitoring ion (m / Z): Polyoxyethylene styrenated phenyl ether (n = 980.5 / n2 = 963.2)

[Measurement method of polymer particles by TOF-SIMS]
The polymer particles (sample) are measured by a time-of-flight secondary ion mass spectrometer (TOF-SIMS), and it is confirmed that a peak derived from the surfactant is detected.

For example, polymer particles are used in a time-of-flight secondary ion mass spectrometer (ION-TOF, "TO".
It is fixed to the sample table of F-SIMS 5 "), and measurement is performed under the following measurement conditions. For the measurement, an electron gun for charge correction is used to detect both positive and negative secondary ions, and then confirm that the peak derived from the surfactant is detected.

<Measurement conditions>
Primary ion: Bi ₃ ²⁺
Primary ion acceleration voltage: 25 kV
Measurement area: 200 μm square

In Examples and Comparative Examples, a peak derived from a surfactant (anionic surfactant and / or nonionic surfactant) is detected. Therefore, the ratio of the ionic strength of the negative ions derived from the surfactant to the total of the total ionic strength of the positive ions and the total ionic strength of the negative ions measured by the flight time type secondary ion mass analyzer is calculated as an ion. Obtained as an intensity ratio.

Specifically, in Examples 1 to 7 and Comparative Examples 1 to 2, as an anionic surfactant, sodium di (2-ethylhexyl) sulfosuccinate, which is an anionic surfactant, is used, and the time-of-flight type 2 is described above. In the measurement by the secondary ion mass spectrometer, a plurality of peaks of negative ion fragments derived from sodium di (2-ethylhexyl) sulfosuccinate are detected. Among the detected negative ion fragments derived from sodium di (2-ethylhexyl) sulfosuccinate, di (2-ethylhexyl) sulfosuccinate ion (molecular formula: C ₂₀ H ₃₇ S)
O ₇ ^-, molecular weight 421) is, because it exhibits the highest ionic strength, in Examples 1-7 and Comparative Examples 1-2, di (2-ethylhexyl) sulfosuccinate ion (molecular formula: C ₂₀ H ₃₇ SO ₇ ^-
, Molecular weight 421), and the ratio of the ionic strength of di (2-ethylhexyl) sulfosuccinate ion to the total ionic strength of positive ions and total ionic strength of negative ions is determined as the ionic strength ratio.

Further, in Example 8, as the surfactant, ammonium polyoxyethylene styrenated phenyl ether sulfate represented by the following formula (A), which is an anionic surfactant, is used, and the time-of-flight type secondary is used. In the measurement by the ion mass spectrometer, the following formula (A)
Multiple peaks of negative ion fragments derived from polyoxyethylene styrenated phenyl ether sulfate ammonium represented by are detected. Among the detected fragments of negative ions derived from polyoxyethylene styrenated phenyl ether sulfate ammonium represented by the following formula (A), the styrenated phenyloxy ion represented by the following formula (B) (molecular formula: C). ₂₂ H ₂₁ O ^-, molecular weight 301) is, because it exhibits the highest ionic strength, in example 8, styrenated phenyloxy ion (molecular formula: C ₂₂ H ₂₁ O ^-, molecular weight 3
01) is used as the evaluation ion species, and the styrated phenyloxy ion represented by the following formula (B) (molecular formula: C ₂₂ H _{21) with respect to the total ionic strength of positive ions and total ionic strength of negative ions.}
The ratio of the ionic strength of O ⁻ , molecular weight 301) is obtained as the ionic strength ratio.

(In the formula (A), n means the number of repeating units _{of the ethyleneoxy group (-CH 2} CH _{2 O-).)}

Further, in Example 9, dipotassium alkenyl succinate represented by the following formula (C), which is an anionic surfactant, is used as the surfactant, and is measured by the above-mentioned flight time type secondary ion mass spectrometer. In, a plurality of peaks of negative ion fragments derived from dipotassium alkenyl succinate represented by the following formula (C) are detected, and the following formula (D1) or formula (D2) is used as the negative ion species having the highest ionic strength. in the monovalent ion represented by alkenylsuccinic acid (molecular ^{_{formula: C 20 H 35 O 4 -}} , molecular weight 339) was detected. That is, the following equation to be detected (
Among the fragments of negative ions derived from dipotassium alkenylsuccinate represented by C), monovalent ions of alkenylsuccinic acid represented by the following formula (D1) or formula (D2) (molecular formula::
C ₂₀ H ₃₅ O ₄ ^-, molecular weight 339) is, because it exhibits the highest ionic strength, in Example 9,
Monovalent ion of alkenyl succinic acid represented by the following formula (D1) or formula (D2) (molecular formula: C)
₂₀ H ₃₅ O ₄ ^-, molecular weight 339) and the evaluation ionic species, to the sum of the total ionic strength of the total ionic strength and negative ions of positive ions, alkenylsuccinic acid represented by the following formula (D1) or Formula (D2) monovalent ion (molecular ^{_{formula: C 20 H 35 O 4 -}} , molecular weight 339) the ratio of the ionic strength, determined as the ion intensity ratio.

(In formula (C), R means an alkenyl group.)

(In the formula (D1) and the formula (D2), R'means an alkenyl group having 16 carbon atoms.)

Further, in Example 10, the above formula (A), which is an anionic surfactant as the surfactant, is used.
The polyoxyethylene styrene phenyl ether sulfate ammonium ester represented by the above and the polyoxyethylene styrene phenyl ether represented by the following formula (E), which is a nonionic surfactant, are used, and the above-mentioned flight time type is used. In the measurement by the secondary ion mass spectrometer, it is derived from the polyoxyethylene styrene phenyl ether sulfate ammonium ester represented by the above formula (A) and the polyoxyethylene styrene phenyl ether represented by the following formula (E). Multiple peaks of negative ion fragments are detected. Among the detected fragments of negative ions derived from the polyoxyethylene styrene phenyl ether sulfate ammonium represented by the above formula (A) and the polyoxyethylene styrene phenyl ether represented by the following formula (E), the above. Since the sulfated phenyloxy ion represented by the formula (B) (molecular formula: C ₂₂ H ₂₁ O ⁻ , molecular weight 301) exhibits the highest ionic strength, it is represented by the above formula (B) in Example 10. that styrenated phenyloxy ion (molecular formula: C ₂₂ H ₂₁ O ^-, molecular weight 301) and the evaluation ionic species, to the sum of the total ionic strength of the total ionic strength and negative ions of the positive ions, represented by formula (B) The ratio of the ionic strengths of the sulfated phenyloxy ions (molecular formula: C ₂₂ H ₂₁ O ⁻ , molecular weight 301) is determined as the ionic strength ratio.

(In the formula (E), n means the number of repeating units _{of the ethyleneoxy group (-CH 2} CH _{2 O-).)}

[Method for measuring gel fraction of polymer particles]
1.0 g of polymer particles as a sample and 0.03 g of boiling stone were precisely weighed and put into a 200 mL eggplant flask, and after further pouring 100 mL of toluene, a cooling tube was attached to the eggplant flask and 130 Immerse the eggplant flask in an oil bath kept at ° C and reflux for 24 hours.

After refluxing, the contents (dissolved solution) in the eggplant flask are subjected to the glass fiber filters "GB-140 (φ37 mm)" and "GA-200 (φ37 mm)" manufactured by ADVANTEC.
Filtered using a Büchner funnel type filter 3G (glass particle pore diameter 20 to 30 μm, capacity 30 mL) manufactured by TOP, which was weighed with the above-mentioned Büchner funnel type filter 3G.
Collect the solid content inside. Then, the solid content recovered in the Büchner funnel type filter 3G is dried together with the Büchner funnel type filter 3G in a vacuum oven at 130 ° C. for 1 hour, and then dried at a gauge pressure of 0.06 MPa for 2 hours to toluene. Remove and cool to room temperature.

After cooling, the total weight of the Büchner funnel type filter 3G, the glass fiber filter, and the solid content was measured with the solid content contained in the Büchner funnel type filter 3G.
Then, the weight of the Büchner funnel type filter 3G, the weight of the glass fiber filter and the weight of the boiling stone were subtracted from the measured total weight to obtain the weight (g) of the dry powder.

Then, using the weight (g) of the dry powder and the weight (g) of the sample put into the eggplant flask, the gel fraction was calculated by the following formula. Gel fraction (% by weight) = {drying Powder (g) / Sample weight (g)} x 100

[Method for measuring dispersion stabilization time of polymer particles]
The viscosity value of the dispersion liquid obtained by dispersing the polymer particles in the dispersion medium changes as the dispersion state of the polymer particles in the dispersion liquid changes. Therefore, after preparing the dispersion, the viscosity value of the dispersion is measured every hour to obtain the rate of change of the viscosity value, and the time required for the obtained rate of change to fall within a predetermined range, that is, The time required for the dispersion state of the polymer particles to stabilize in the dispersion liquid (dispersion stabilization time) was measured.

Specifically, the time required for the rate of change to fall within a predetermined range was measured by the following method.

(1) Method for preparing dispersion liquid To a 10 ml sample tube, 0.15 g of polymer particles and 0.90 g of methyl ethyl ketone as a dispersion medium were added, and an ultrasonic cleaner (“ULTRAS” manufactured by Vervocrea Co., Ltd.) was added.
The mixture is stirred for 1 minute using ONIC CLEANER VS-150 ”) to disperse the polymer particles in methyl ethyl ketone to obtain a dispersion. To this dispersion, 2.10 g of an acrylic resin (“Acrydic (registered trademark) A-811” manufactured by DIC Corporation) is further added, and the mixture is stirred with the above ultrasonic cleaner for about 2 minutes to obtain methyl ethyl ketone and Polymer particles are dispersed in an acrylic resin to prepare a dispersion.

(2) Viscosity value measurement method The viscosity value of the dispersion is measured by a viscometer (micro sample viscometer mV manufactured by Nihon Rufuto Co., Ltd.).
ROC) is used and the following method is used. Before measuring the viscosity value of the viscometer,
It shall be left in the measurement environment for 30 minutes or more in advance.

The dispersion to be measured is stirred with an ultrasonic cleaner for 30 minutes, then allowed to stand for 10 minutes, and then the viscosity (mPa · s) of the dispersion is measured using the viscometer. Then, the measured value of viscosity (m)
Using Pa · s) and the measurement temperature (K), the viscosity value V (mPa · s / K) per unit temperature (K) is obtained by the following calculation formula.
Viscosity value V (mPa · s / K) = measured value (mPa · s) ÷ measured temperature (K)

(3) Method for measuring dispersion stabilization time Every hour from the preparation of the dispersion liquid, the viscosity value V of the dispersion liquid is adjusted according to the above method for measuring the viscosity value.
mPa · s / K) is measured. The viscosity value V of the measured dispersion and _{V T (mPa · s / K} ), the viscosity value of 1 hour prior to the dispersion as _{V T-1 (mPa · s} / K), by the following calculation formula, change Find the rate W (%).
_{W = ((V T-1} -V T) / V T-1) × 100

The viscosity value is measured every hour until the rate of change W is in the range of more than -1% to less than 1%. Then, after the preparation of the dispersion liquid, the elapsed time T until the rate of change W of the viscosity value was within the range of more than -1% to less than 1% was measured, and the elapsed time T was defined as the dispersion stabilization time.

[Production Example 1 of Seed Particles]
In a separable flask equipped with a stirrer, a thermometer and a reflux condenser, 1000 g of water as an aqueous medium and ethyl methacrylate 1 as a (meth) acrylic acid ester-based monomer
80 g and 3.6 g of n-octyl mercaptan as a molecular weight adjuster were charged, and the inside of the separable flask was replaced with nitrogen while stirring the contents of the separable flask, and the internal temperature of the separable flask was raised to 55 ° C. It was warm. Further, while maintaining the internal temperature of the separable flask at 55 ° C., an aqueous solution prepared by dissolving 0.9 g of potassium persulfate as a polymerization initiator in 80 g of water was prepared.
After adding to the contents in the separable flask, the polymerization reaction was carried out for 12 hours. The reaction solution after the polymerization was filtered through a wire mesh of 400 mesh (opening 32 μm) to prepare a slurry containing 14% by weight of seed particles (referred to as seed particles (1)) made of polyethyl methacrylate as a solid content. The seed particles (1) contained in this slurry were spherical particles having a volume average particle diameter of 0.76 μm.

[Production example 2 of seed particles]
In a 5 L reactor equipped with a stirrer and a thermometer, 450 g of methyl methacrylate as a (meth) acrylic acid ester-based monomer and n-octyl mercaptan 4 as a molecular weight adjuster.
.. 5 g and 4.5 g of 2,2'-azobisisobutyronitrile as a polymerization initiator were mixed. The obtained mixture was added to 1800 g of ion-exchanged water as a surfactant, sodium di (2-ethylhexyl) sulfosuccinate (NOF CORPORATION "Lapisol® A-".
80 ”, solubility in water at a liquid temperature of 25 ° C; 1.5 g / 100 ml) as a pure content of 4.5 g
It was mixed with the added product and treated with a homomixer (“TK Homomixer MARK 2.5 type” manufactured by Primix Corporation) at 8000 rpm for 10 minutes to obtain an emulsion.

The slurry of the seed particles (1) produced in Production Example 1 of the seed particles was added to the emulsion in the reactor so as to have a solid content (seed particles) of 12.6 g, and the mixture was added to the emulsion at room temperature for 5 hours. Stirred. After that, polyvinylpyrrolidone as a polymer-based dispersion stabilizer ("P" manufactured by Kuraray Co., Ltd.
900 g of an aqueous solution in which 15 g of VP-90 ”) was dissolved was put into the above reactor, and a polymerization reaction was carried out at 55 ° C. for 12 hours with stirring.

The reaction solution after the polymerization is filtered through a wire mesh of 400 mesh (opening 32 μm), and contains 14% by weight of seed particles composed of polyethyl methacrylate and polymethyl methacrylate (hereinafter referred to as seed particles (2)) as solid content. A slurry was prepared. Seed particles contained in this slurry (2)
Was a spherical particle having a volume average particle diameter of 2.30 μm.

[Example 1: Production example of polymer particles]
(1) Polymerization step (meth) 280 g of methyl methacrylate (MMA) as an acrylic acid ester-based monomer
280 g of styrene (St) as a styrene-based monomer, 240 g of ethylene glycol dimethacrylate (EGDMA) as a polyfunctional vinyl-based monomer, and 2,2'-azobisisobutyro as a polymerization initiator. A monomer mixture obtained by dissolving 4 g of nitrile and 4 g of benzoyl peroxide as a polymerization initiator was added to 800 g of ion-exchanged water as an aqueous medium to di (2-ethylhexyl) sulfosuccinate as an anionic surfactant. Sodium acid (“Lapisol® A-80” manufactured by Nichiyu Co., Ltd., solubility in water at a liquid temperature of 25 ° C; 1
.. 5g / 100ml) was mixed with 8g as a pure content and placed in a homomixer (“TK Homomixer MARK 2.5 type” manufactured by Primix Corporation) for 10,000 rp.
It was treated with m for 10 minutes to obtain an emulsion. To this emulsion, the slurry of the seed particles (1) obtained in Production Example 1 of the seed particles was added so as to have a solid content (seed particles) of 4.2 g, and the mixture was stirred at 30 ° C. for 5 hours to obtain a dispersion liquid. Got

In this dispersion, 40 g of polyvinyl alcohol (“Gosenol® GM-14L” manufactured by Nippon Synthetic Chemical Co., Ltd.) as a polymer dispersion stabilizer and 0.64 g of sodium nitrite as a polymerization inhibitor are dissolved. 2400 g of the resulting aqueous solution was added, and then the polymerization reaction was carried out by stirring at 60 ° C. for 5 hours and then at 105 ° C. for 3 hours to obtain a slurry of polymer particles (hereinafter referred to as slurry (1)) as a crude product. ..

(2) Solid-Liquid Separation Step A slurry (1) of polymer particles is put into the pressure-resistant container 2 of the pressure filter 1 having the configuration shown in FIG. 1 as a crude product P, and the filter medium 3 in the pressure-resistant container 2 is charged. After filling the slurry (1) of the polymer particles on the filter cloth (“T713” manufactured by Shikishima Cambus Co., Ltd.), the compressed gas is filled in the upper space S of the filter medium 3 in the pressure-resistant container 2 by the compressed gas feeder. By supplying the pressure-resistant container 2, the inside of the pressure-resistant container 2 (specifically, the upper space S of the filter medium 3) was pressurized to 0.08 MPa. As a result, the slurry (1) of the polymer particles as the crude product P was pressure-filtered and dehydrated, and water as an aqueous medium was removed from the slurry (1) of the polymer particles as a filtrate. The amount of filtrate is 2.24
It is kg (70% of the weight of water used in the polymerization process) or more, and the internal pressure of the pressure-resistant container 2 is 0.0.
Pressurization was terminated when the pressure became 64 MPa (80% of the pressure at the time of pressurization) or less. As a result, a cake of polymer particles was obtained on the filter medium 3. The interface between the filter medium 3 (filter cloth) of the pressurized filter 1 used in this embodiment and the object to be filtered (that is, the crude product P) has a circular shape, and the diameter thereof is that of the pressure-resistant container 2. 0.115 m, which is the same as the diameter of the bottom surface of the internal space (diameter indicated by reference numeral R in FIG. 1).
Is. Therefore, the area A of the interface between the filter medium 3 (filter cloth) of the pressurized filter 1 used in this embodiment and the object to be filtered (that is, the crude product P) is 0.0104 m ² . _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.46 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 55.7 minutes.

(3) Cleaning Step While holding the cake of the polymer particles on the filter medium 3, water as a cleaning liquid is supplied onto the filter medium 3 in the pressure-resistant container 2, and then the filter medium in the pressure-resistant container 2 is supplied by a compressed gas feeder. By supplying the compressed gas to the upper space S of 3, the inside of the pressure-resistant container 2 (specifically, the upper space S of the filter medium 3) was pressurized to 0.08 MPa. As a result, pressure filtration and dehydration were performed to wash the cake of the polymer particles, and the washed water was removed as a filtrate to obtain the washed polymer particles on the filter medium 3. For cleaning, a cleaning solution having a weight of 10 times or more the weight of the polymer particles obtained in the polymerization step (total amount of vinyl-based monomers used in the polymerization step is 800 g) is used.
The conductivity of the filtrate is 2.0 times or less (specifically, 15 μS or less) of the conductivity of water before washing, and the internal pressure of the pressure-resistant container 2 is 0.064 MPa (80% of the pressure at the time of pressurization). I went until the following. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than kg (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 230.8 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 2: Production example of polymer particles]
In the solid-liquid separation step, the inside of the pressure-resistant container 2 is pressurized to 0.15 MPa, and the amount of the filtrate is 2.
.. It is 24 kg (70% of the weight of water used in the polymerization process) or more, and the internal pressure of the pressure-resistant container 2 is 0.
.. The target polymer particles were obtained in the same manner as in Example 1 except that the solid-liquid separation step was terminated when the pressure became 12 MPa (80% of the pressure at the time of pressurization) or less. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.48 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 46.6 minutes. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7 kg (8 (g) ÷ 1.5 (g / 100 ml) × 200) of the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
It weighed more than 0 = 10667 (g)). Further, in the cleaning process of this embodiment,
_{It takes 9.6 kg (0.8 times the weight of water G 2} as the cleaning liquid used in the cleaning process) of the cleaning liquid to pass through the filter medium 3 after the cleaning liquid is started to pass through the filter medium 3. The time T ₂ (min) was 355.6 minutes.

[Example 3: Production example of polymer particles]
(1) Polymerization Step Same as the polymerization step of Example 1 except that the amount of the slurry of the seed particles (1) obtained in Production Example 1 of the seed particles was 16.7 g as the solid content (seed particles). Then, a slurry of polymer particles (hereinafter referred to as slurry (2)) was obtained as a crude product.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (2)
The inside of the pressure-resistant container 2 was pressurized to 0.20 MPa, the amount of the filtrate became 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 was 0.16 MPa (70%). The polymer particle slurry (2) was used as an aqueous medium in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 80% or less of the pressure at the time of pressurization. The water was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.38 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 73.9 minutes.

(3) Cleaning step The inside of the pressure-resistant container 2 is pressurized to 0.20 MPa, and the conductivity of the filtrate becomes 2.0 times or less (specifically, 15 μS or less) the conductivity of water before cleaning. The internal pressure of 2 is 0.16MP
The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became a (80% of the pressure at the time of pressurization) or less, and the cake was washed on the filter medium 3. Polymer particles after washing were obtained. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than kg (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 346.6 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 4: Production example of polymer particles]
(1) Polymerization Step As seed particles, the slurry of seed particles (1) obtained in Production Example 1 of seed particles was replaced with 4.2 g as a solid content (seed particles), and was obtained in Production Example 2 of seed particles. In the same manner as in the polymerization step of Example 1, 18.7 g of the slurry of the seed particles (2) was used as the solid content (seed particles).
A slurry of polymer particles (hereinafter referred to as slurry (3)) was obtained as a crude product.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (3)
The inside of the pressure-resistant container 2 was pressurized to 0.15 MPa, the amount of the filtrate became 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 was 0.12 MPa (70%). The polymer particle slurry (3) was used as an aqueous medium in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 80% or less of the pressure at the time of pressurization. The water was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.50 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 49.7 minutes.

(3) Cleaning step The inside of the pressure-resistant container 2 is pressurized to 0.20 MPa, and the conductivity of the filtrate becomes 2.0 times or less (specifically, 15 μS or less) the conductivity of water before cleaning. The internal pressure of 2 is 0.16MP
The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became a (80% of the pressure at the time of pressurization) or less, and the cake was washed on the filter medium 3. Polymer particles after washing were obtained. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than kg (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 119.7 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 5: Production example of polymer particles]
(1) Polymerization step In the above-mentioned monomer mixture, styrene (St) as a styrene-based monomer is not blended.
The amount of methyl methacrylate (MMA) as the (meth) acrylic acid ester-based monomer was 560 g, and ethylene glycol dimethacrylate (E) as the polyfunctional vinyl-based monomer was used.
A slurry of polymer particles (hereinafter referred to as slurry (4)) was obtained as a crude product in the same manner as in the polymerization step of Example 1 except that the blending amount of GDMA) was 240 g.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (4)
The inside of the pressure-resistant container 2 was pressurized to 0.15 MPa, the amount of the filtrate became 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 was 0.12 MPa (70%). The polymer particle slurry (4) was used as an aqueous medium in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 80% or less of the pressure at the time of pressurization. The water was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.48 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 46.1 minutes.

(3) Cleaning step The inside of the pressure-resistant container is pressurized to 0.15 MPa, and the conductivity of the filtrate is 2 of the conductivity of water before cleaning.
.. It becomes 0 times or less (specifically, 15 μS or less), and the internal pressure of the pressure-resistant container 2 is 0.12 MPa.
The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became (80% of the pressure at the time of pressurization) or less, and the cake was washed on the filter medium 3. Later polymer particles were obtained. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7k, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than g (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 263.7 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 6: Production example of polymer particles]
(1) Polymerization Step In the above-mentioned monomer mixture, the amount of styrene (St) as a styrene-based monomer is not blended with methyl methacrylate (MMA) as a (meth) acrylic acid ester-based monomer. Weighing 560 g, ethylene glycol dimethacrylate (E) as a polyfunctional vinyl monomer
A slurry of polymer particles (hereinafter referred to as slurry (5)) was obtained as a crude product in the same manner as in the polymerization step of Example 1 except that the blending amount of GDMA) was 240 g.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (5)
The inside of the pressure-resistant container 2 was pressurized to 0.15 MPa, the amount of the filtrate became 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 was 0.12 MPa (70%). The polymer particle slurry (5) was used as an aqueous medium in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 80% or less of the pressure at the time of pressurization. The water was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.48 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 45.3 minutes.

(3) Cleaning step The inside of the pressure-resistant container 2 is pressurized to 0.10 MPa, and the conductivity of the filtrate becomes 2.0 times or less (specifically, 15 μS or less) the conductivity of water before cleaning. The internal pressure of 2 is 0.08MP
The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became a (80% of the pressure at the time of pressurization) or less, and the cake was washed on the filter medium 3. Polymer particles after washing were obtained. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than kg (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 183.6 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 7: Production example of polymer particles]
(1) Polymerization Step In the above-mentioned monomer mixture, the amount of styrene (St) as a styrene-based monomer is not blended with methyl methacrylate (MMA) as a (meth) acrylic acid ester-based monomer. Weighing 560 g, ethylene glycol dimethacrylate (E) as a polyfunctional vinyl monomer
A slurry of polymer particles (hereinafter referred to as slurry (6)) was prepared as a crude product in the same manner as in the polymerization step of Example 1 except that 240 g of divinylbenzene (DVB) was blended in place of 240 g of GDMA). Got as.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (6)
The inside of the pressure-resistant container 2 was pressurized to 0.10 MPa, the amount of the filtrate was 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 was 0.08 MPa (70%). The polymer particle slurry (6) was used as an aqueous medium in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 80% or less of the pressure at the time of pressurization. The water was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.50 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 77.2 minutes.

(3) Cleaning step The inside of the pressure-resistant container 2 is pressurized to 0.15 MPa, and the conductivity of the filtrate becomes 2.0 times or less (specifically, 15 μS or less) the conductivity of water before cleaning. The internal pressure of 2 is 0.12MP
The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became a (80% of the pressure at the time of pressurization) or less, and the cake was washed on the filter medium 3. Polymer particles after washing were obtained. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the surfactant used in the above polymerization step. 10.7, the total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of
The weight was heavier than kg (8 (g) ÷ 1.5 (g / 100 ml) × 2000 = 10667 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 151.9 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 8: Production example of polymer particles]
(1) Polymerization step As an anionic surfactant, di (2-ethylhexyl) sodium sulfosuccinate (
"Lapisol (registered trademark) A-80" manufactured by NOF CORPORATION, solubility in water at a liquid temperature of 25 ° C.; 1.5 g / 100 ml) is represented by the above formula (A) in place of 8 g as a pure content. Polyoxyethylene styrenated phenyl ether sulfate ammonium ester ("High Tenor (registered trademark) NF08" manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., solubility in water at a liquid temperature of 25 ° C; 1.2
A slurry of polymer particles (hereinafter referred to as slurry (7)) was obtained as a crude product in the same manner as in the polymerization step of Example 1 except that 8 g (g / 100 ml) was used as a pure content.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (7)
Slurry of polymer particles (7) in the same manner as in the solid-liquid separation step of Example 1 except that
Water as an aqueous medium was removed from the water. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.44 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium is 6
It was 0.1 minutes.

(3) Washing Step In the same manner as the washing step of Example 1, the cake of the polymer particles on the filter medium 3 was washed, and the washed polymer particles were obtained on the filter medium 3. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 15.0 kg (18.75 times the weight of the polymer particles obtained in the polymerization step), and is used in the above polymerization step. The total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of surfactant 13.3 kg (8 (g) ÷ 1.2 (g / 100 ml) × 200
It weighed more than 0 = 13333 (g)). rice field. Further, in the cleaning step of this embodiment, after starting to pass the cleaning liquid through the filter medium 3, 12.0 kg (0.8 times the weight _{G 2 of water as the cleaning liquid used in the cleaning step). The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 311.7 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 9: Production example of polymer particles]
(1) Polymerization step As an anionic surfactant, di (2-ethylhexyl) sodium sulfosuccinate (
"Lapisol (registered trademark) A-80" manufactured by Nichiyu Co., Ltd., solubility in water at a liquid temperature of 25 ° C.; 1.5 g / 100 ml) is represented by the above formula (C) in place of 8 g as a pure content. The same as the polymerization step of Example 1 except that 8 g of dipotassium alkenyl succinate (“Ramtel ASK” manufactured by Kao Corporation, solubility in water at a liquid temperature of 25 ° C.; 1.7 g / 100 ml) was used as a pure content. A slurry of polymer particles (hereinafter referred to as slurry (8)) was obtained as a crude product.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (8)
Slurry of polymer particles (8) in the same manner as in the solid-liquid separation step of Example 1 except that
Water as an aqueous medium was removed from the water. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.49 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium is 6
It was 2.0 minutes.

(3) Washing Step In the same manner as the washing step of Example 1, the cake of the polymer particles on the filter medium 3 was washed, and the washed polymer particles were obtained on the filter medium 3. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12.0 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the interface used in the above polymerization step. The total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of activator is 9.4 kg (8 (g) ÷ 1.7 (g / 100 ml) × 2000 = 94.
It weighed more than 12 (g)). Further, in the cleaning step of this example, 9.6 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after the start of passing the cleaning liquid through the filter medium 3). Time spent for the cleaning liquid to pass through the filter medium 3 T ₂ (mi)
n) was 250.7 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Example 10: Production example of polymer particles]
(1) Polymerization step As an anionic surfactant, di (2-ethylhexyl) sodium sulfosuccinate (
"Lapisol (registered trademark) A-80" manufactured by NOF CORPORATION, solubility in water at a liquid temperature of 25 ° C.; 1.5 g / 100 ml) is represented by the above formula (A) in place of 8 g as a pure content. Polyoxyethylene styrenated phenyl ether sulfate ammonium ester ("High Tenor (registered trademark) NF08" manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., solubility in water at a liquid temperature of 25 ° C; 1.2
8 g / 100 ml) as a pure content is used, and a nonionic surfactant is used instead of 40 g of polyvinyl alcohol (“Gosenol® GM-14L” manufactured by Nippon Synthetic Chemical Co., Ltd.) as a polymer dispersion stabilizer. Polyoxyethylene styrenated phenyl ether (manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., "Neugen (registered trademark) EA-16) represented by the above formula (E).
7 ”, solubility in water at a liquid temperature of 25 ° C.; 1.1 g / 100 ml) was used as a pure content of 8 g, but in the same manner as in the polymerization step of Example 1, a slurry of polymer particles (hereinafter, slurry (hereinafter, slurry (hereinafter, slurry (hereinafter, slurry)) 9)) was obtained as a crude product.

(2) Solid-liquid separation step As a crude product, instead of the polymer particle slurry (1), the polymer particle slurry (9)
Slurry of polymer particles (9) in the same manner as in the solid-liquid separation step of Example 1 except that
Water as an aqueous medium was removed from the water. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.44 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium is 6
It was 5.8 minutes.

(3) Washing Step In the same manner as the washing step of Example 1, the cake of the polymer particles on the filter medium 3 was washed, and the washed polymer particles were obtained on the filter medium 3. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 30.0 kg (37.5 times the weight of the polymer particles obtained in the polymerization step).
The total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above calculation formula (4) for each type of surfactant used in the above polymerization step is 27.9 kg ({8 (g) ÷ 1.2 (g / g / g /). 100 ml) x 2
000} + {8 (g) ÷ 1.1 (g / 100 ml) x 2000} = 13333 + 1454
It weighed more than 5 = 27878 (g)). Further, in the cleaning process of this embodiment,
_{It takes 24.0 kg (0.8 times the weight of water G 2} as the cleaning liquid used in the cleaning step) of the cleaning liquid to pass through the filter medium 3 after the cleaning liquid is started to pass through the filter medium 3. The time T ₂ (min) was 633.2 minutes.

(4) Post-treatment step The washed polymer particles obtained in the washing step are dried in a vacuum dryer, and then an air flow classifier (
Classification was performed using "Turbo Classifier (TC-15)") manufactured by Nisshin Engineering Co., Ltd. to obtain the desired polymer particles.

[Comparative Example 1: Comparative Production Example of Polymer Particles]
(1) Polymerization Step In the same manner as in the polymerization step of Example 1, a slurry of polymer particles (hereinafter referred to as slurry (1)) was obtained as a crude product.

(2) Solid-liquid separation step The inside of the pressure-resistant container 2 is pressurized to 0.10 MPa, the amount of the filtrate becomes 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 becomes high. Slurry of polymer particles (1) in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 0.08 MPa (80% of the pressure at the time of pressurization) or less. ), Water as an aqueous medium was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.49 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 82.5 minutes.

_{(3) Cleaning step The weight G 2} of water as a cleaning liquid used in the cleaning step is 4.0 kg (five times the weight of the polymer particles obtained in the polymerization step), and the inside of the pressure resistant container 2 is added to 0.10 MPa. It was not confirmed that the conductivity of the filtrate was 2.0 times or less (specifically, 15 μS or less) of the conductivity of water before washing by pressing, and the internal pressure of the pressure resistant container 2 was 0.08 MPa (added). The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the pressure became 80% or less of the pressure at the time of pressure. Polymer particles were obtained. In the cleaning step of this embodiment, 3.2 kg (0.8 times the weight _{of water G 2} as the cleaning liquid used in the cleaning step) after starting to pass the cleaning liquid through the filter medium 3). _{The time T 2} (min) spent for the cleaning liquid to pass through the filter medium 3 was 74.1 minutes.

[Comparative Example 2: Comparative Production Example of Polymer Particles]
(1) Polymerization Step In the same manner as in the polymerization step of Example 1, a slurry of polymer particles (hereinafter referred to as slurry (1)) was obtained as a crude product.

(2) Solid-liquid separation step The inside of the pressure-resistant container 2 is pressurized to 0.25 MPa, the amount of the filtrate becomes 2.24 kg (70% of the weight of water used in the polymerization step) or more, and the internal pressure of the pressure-resistant container 2 becomes high. Slurry of polymer particles (1) in the same manner as in the solid-liquid separation step of Example 1 except that the solid-liquid separation step was terminated when the pressure became 0.20 MPa (80% of the pressure at the time of pressurization) or less. ), Water as an aqueous medium was removed. _{The total weight G 1} of the filtrate (medium) obtained in the solid-liquid separation step of this example is 2.45 kg, and the medium (water) contained in the crude product P is started to pass through the filter medium 3. _{The time T 1} from the time until the completion of the passage of the filter medium 3 of the medium was 19.5 minutes.

(3) Cleaning step Water as a cleaning liquid is used in an amount of 8.0 kg (10 times the weight of the polymer particles obtained in the polymerization step) or more, and the inside of the pressure resistant container 2 is pressurized to 0.20 MPa to make the filtrate conductive. The rate is 2.0 times or less the conductivity of water before cleaning, and the internal pressure of the pressure resistant container 2 is 0.16 MPa (80 of the pressure at the time of pressurization).
%) The cake of the polymer particles on the filter medium 3 was washed in the same manner as in the washing step of Example 1 except that the washing was performed until the content was equal to or less than that, and the washed polymer particles were obtained on the filter medium 3. .. _{The weight G 2} of water as the cleaning liquid used in the cleaning step of this example is 12.0 kg (15 times the weight of the polymer particles obtained in the polymerization step), and the interface used in the above polymerization step. The total amount of the lower limit value D of the weight of the cleaning liquid calculated by the above formula (4) for each type of activator is 10.7 kg (8 (g) ÷ 1).
.. It weighed more than 5 (g / 100 ml) x 2000 = 10667 (g)). Further, in the cleaning step of this embodiment, after starting to pass the cleaning liquid through the filter medium 3, 9.
_{The time T 2} (min) _{spent for 6 kg of the cleaning liquid (0.8 times the weight of water G 2} as the cleaning liquid used in the cleaning step) to pass through the filter medium 3 was 80.2 minutes. ..

For Examples 1 to 10 and Comparative Examples 1 to 2, the number of the slurry of the polymer particles obtained in the polymerization step (slurry No.) and the composition of the monomer mixture constituting the polymer contained in this slurry (polymer). Composition), X value in the solid-liquid separation step (amount of medium passing through the filter medium per unit time (kg / min)), Y value in the washing step (amount of cleaning liquid passing through the filter medium per unit time (kg / min)) kg / min))), the amount of cleaning liquid (water) used in the cleaning process (k)
g), volume average particle size (μm) of the obtained polymer particles, and coefficient of variation of particle size (CV value (%)
)) Measurement results, the compound name of the surfactant (used in the polymerization step) contained in the obtained polymer particles, and the measurement result (ppm) of the surfactant content (ppm) in the obtained polymer particles. , Measurement result of the obtained polymer particles by TOF-SIMS (Ratio of the ion intensity of negative ions derived from the surfactant to the total ion intensity of positive ions and the total ion intensity of negative ions (ion intensity ratio) , The measurement result of the gel fraction (%) of the obtained polymer particles, and the measurement result of the dispersion stabilization time of the polymer particles (from the preparation of the dispersion liquid, the rate of change of the viscosity value is more than -1% to 1). The elapsed time T) until it becomes less than% is shown in Table 1. Details of the measurement results of the polymer particles of Examples 1 to 10 and Comparative Examples 1 and 2 by TOF-SIMS, specifically, TOF- Total ion intensities of positive ion fragments detected by Polymer (total positive ion intensities), TOF-S
The total ionic strength of the negative ion fragments detected by IMS (total ionic strength of negative ions), the negative ion showing the highest ionic strength among the negative ions derived from the surfactant detected by TOF-SIMS (evaluation) Ionic species), the ionic strength of this negative ion (evaluated ionic species), and the total of the total ionic strength of positive ions and the total ionic strength of negative ions.
The ratio of the ionic strengths of negative ions (evaluated ion species) (that is, the ionic strength ratio) is shown in Table 2.

Pressurized filter 1 used in the solid-liquid separation step and the washing step of Examples 1 to 10 and Comparative Examples 1 and 2.
The area A of the interface between the filter medium 3 (filter cloth) and the filtered product (that is, the crude product P) of (see FIG. 1) is
It is 0.0104 (m ² ). Therefore, in Examples 1 to 10 and Comparative Examples 1 to 2, the X value represented by the above conditional expression (1) (the amount of the medium passing through the filter medium per unit time (kg / mi)).
The upper limit of n)) is 0.0572 kg / min. Further, the upper limit of the Y value (the amount of the cleaning liquid that has passed through the filter medium per unit time (kg / min)) represented by the conditional expression (2) is 0.
.. It becomes 0884 kg / min.

From the results shown in Table 1, the X value in the solid-liquid separation step and the Y value in the washing step are each below the above upper limit values, and the amount of the washing liquid (water) used for washing is 8.0 kg or more (of the polymer particles). The polymer particles obtained in Examples 1 to 10 (10 times or more the weight) have a comparison in which the amount of the cleaning liquid (water) used for washing is less than 8.0 kg (less than 10 times the weight of the polymer particles). The ionic intensity ratio is smaller than that of the polymer particles obtained in Example 1 and the polymer particles obtained in Comparative Example 2 in which the X value in the solid-liquid separation step and the Y value in the washing step are larger than the above upper limit values. It was found that the amount of the surfactant on the surface of the polymer particles was small. That is, it was confirmed that according to the production method of the present invention, the amount of the surfactant used in the polymerization step adhering to the surface of the polymer particles can be reduced by the solid-liquid separation step and the washing step.

In addition, Examples 1 to 1 in which the content of the surfactant is in the range of more than 0 ppm and less than 50 ppm.
Compared with the polymer particles of Comparative Example 1 in which the content of the surfactant is 156 ppm, the polymer particles of 0 are dispersed in a dispersion medium to prepare a dispersion, until the viscosity value of the dispersion becomes stable. time of(
That is, the time until the rate of change of the viscosity value became more than -1% to less than 1%) was short. That is, the polymer particles of Examples 1 to 10 having a surfactant content in the range of more than 0 ppm to less than 50 ppm were compared with the polymer particles of Comparative Example 1 having a surfactant content of 156 ppm. It was found that the time required for uniform dispersion with respect to the dispersion medium was short.

[Example 11: Production example of optical film]
To a 10 ml sample tube, 0.15 g of the polymer particles obtained in Example 1 and 0.90 g of methyl ethyl ketone were added, and an ultrasonic cleaner (“ULTR” manufactured by Vervocreer Co., Ltd.) was added.
ASONIC CLEANER VS-150 ”) is used to stir for 1 minute to disperse the polymer particles in methyl ethyl ketone to obtain a dispersion. To this dispersion, 2.10 g of an acrylic resin (“Acrydic (registered trademark) A-811” manufactured by DIC Corporation) is further added, and the mixture is stirred with the above ultrasonic cleaner for about 2 minutes for coating. A resin composition was obtained. After allowing this coating resin composition to stand for 12 hours, 5.40 g of methyl ethyl ketone is added to the coating resin composition, and the mixture is stirred with the above ultrasonic cleaner for 1 minute to dilute the coating resin composition. Got

The obtained diluted solution of the resin composition for coating was applied onto a PET film using a coater having a 75 μm slit. After coating, the film was placed in a dryer kept at 70 ° C. and left for 1 hour to obtain an optical film.

[Example 12: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 2
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 13: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 3
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 14: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 4
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 15: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 5
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 16: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 6
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 17: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 7
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 18: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 8
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 19: Production example of optical film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Example 9
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Example 20: Production example of optical film]
An optical film was obtained in the same manner as in Example 11 except that 0.15 g of the polymer particles obtained in Example 10 was used instead of 0.15 g of the polymer particles obtained in Example 1.

[Comparative Example 3: Comparative Manufacturing Example of Optical Film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Comparative Example 1
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

[Comparative Example 4: Comparative Manufacturing Example of Optical Film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Comparative Example 1
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used and the standing time of the coating resin composition was changed from 12 hours to 24 hours.

[Comparative Example 5: Comparative Manufacturing Example of Optical Film]
Instead of 0.15 g of the polymer particles obtained in Example 1, the polymer particles 0 obtained in Comparative Example 2
.. An optical film was obtained in the same manner as in Example 11 except that 15 g was used.

The optical characteristics of the optical films of Examples 11 to 20 and Comparative Examples 3 to 5 were evaluated by the methods shown below.

[Evaluation method of optical characteristics]
An optical film cut into a 6 cm × 6 cm square shape is used as a test piece. According to JIS K 7136, the haze of each of the four edges and the center (five points in total) on the top, bottom, left, and right of the surface coated with the resin composition for coating of the test piece was set by Nippon Denshoku Industries Co., Ltd.
NDH-4000 "is used for measurement. Then, using the maximum value, the minimum value, and the average value of the haze (%) at the five measured points, the haze difference (%) is calculated by the following formula, and the haze difference (%) is calculated as follows. It was evaluated according to the evaluation criteria.

<Calculation formula for haze difference (%)>
R = {(Hz _MAX −Hz _MIN ) / Hz _AVE )} × 100
R: Haze difference (%)
Hz _MAX : Maximum value of haze (%) at _{5 points Hz MIN} : Minimum value _{of haze (%) at 5 points Hz AVE} : Average value of haze (%) at 5 points <Evaluation criteria>
⊚: Haze difference is less than 0.5% ○: Haze difference is 0.5% or more and less than 1.0% Δ: Haze difference is 1.0% or more and less than 3.0% ×: Haze difference is 3.0 or more

For the optical films of Examples 11 to 20 and Comparative Examples 3 to 5, the example number and surfactant content of the polymer particles used in the production of the optical film, the standing time of the coating resin composition, and the optics. Table 3 shows the evaluation results of the optical properties of the film.

An optical film (optical film of Examples 11 to 20) formed by coating a coating resin composition containing polymer particles having a surfactant content in the range of more than 0 ppm to less than 50 ppm is a surfactant. Compared with an optical film (Comparative Examples 3 to 5) coated with a coating resin composition containing polymer particles having a content of 50 ppm or more, the haze difference is small and the light diffusivity is less uneven. Was recognized. That is, the content of the surfactant is 0 ppm.
It was found that stable optical properties (antiglare and light diffusivity) can be obtained with an optical film containing polymer particles in the range of ultra to less than 50 ppm.

Further, from the results shown in Table 1, the polymer particles of Comparative Example 1 having a surfactant content of 50 ppm or more have a stable viscosity when the standing time is 16 hours or more, and are uniformly dispersed in the dispersion medium. do(
Since it was confirmed that the dispersed state is stabilized), in the production of the optical film of Comparative Example 4, the polymer particles were uniformly contained in the coating resin composition by setting the standing time of the coating resin composition to 24 hours. However, as shown in Table 3, the optical film of Comparative Example 4 had a large haze difference and stable optical characteristics could not be obtained.

On the other hand, the polymer particles of Examples 1 to 10 in which the surfactant content is in the range of more than 0 ppm to less than 50 ppm and Comparative Example 2 in which the surfactant content is 59 ppm are shown in Table 1.
From the results shown in (1), it was confirmed that the viscosity was stabilized and uniformly dispersed in the dispersion medium (the dispersion state was stabilized) in a short time of 11 to 13 hours. Therefore, in the production of the optical film of Examples 11 to 20 using the polymer particles of Examples 1 to 10 and the production of the optical film of Comparative Example 5 using the polymer particles of Comparative Example 2, the resin composition for coating is used. The standing time of the object was set to 12 hours so that the polymer particles were uniformly dispersed in the resin composition for coating.

As a result, as shown in Table 3, of Examples 11 to 20 produced using the polymer particles of Examples 1 to 10 in which the content of the surfactant is in the range of more than 0 ppm to less than 50 ppm. With the optical film, the haze difference was small and stable optical characteristics were obtained. On the other hand, the optical film of Comparative Example 5 produced by using Comparative Example 2 having a surfactant content of 59 ppm has a large haze difference and stable optical characteristics as compared with the optical films of Examples 11 to 20. Was not obtained.

From this, for the polymer particles in which the content of the surfactant is in the range of more than 0 ppm to less than 50 ppm, the coating resin composition obtained by dispersing the polymer particles in a binder is applied onto the film substrate. In the process of forming a coating film by processing, the dispersion state in the resin composition can be maintained almost stably, and the optical film can be imparted with stable optical characteristics and has excellent dispersion stability. I can say. In addition, the content of the surfactant is more than 0 ppm to 50 pp.
As described above, the optical film coated with the coating resin composition containing the polymer particles in the range of less than m has a small haze difference, stable optical characteristics, and excellent quality stability. It can be said that.

The present invention can be practiced in various other ways without departing from its spirit or key features. Therefore, the above examples are merely exemplary in all respects and should not be construed in a limited way. The scope of the present invention is shown by the scope of claims, and is not bound by the text of the specification. Furthermore, all modifications and modifications that fall within the equivalent scope of the claims are within the scope of the present invention.

In addition, this application was filed in Japan on September 30, 2013, Japanese Patent Application No. 2013-2045.
Claim priority based on 77. By reference to this, all its contents are incorporated into this application.

1 Pressurized filter 2 Pressure-resistant container 3 Filter medium R Diameter of the interface (drainage surface) between the filter medium and the object to be filtered P Crude product S Upper space of the filter medium

Claims (9)

The content of the surfactant determined by the following measurement method is more than 0 ppm and less than 50 ppm.
The volume average particle size is 1 to 100 μm,
The coefficient of variation of the particle size is 15% or less ,
Polymer particles having a gel fraction of 95.2% or more.
The polymer constituting the polymer particles is a copolymer of a monofunctional vinyl-based monomer and a polyfunctional vinyl-based monomer .
The ratio of the ionic strength of the negative ions derived from the surfactant to the total ionic strength of the positive ions and the total ionic strength of the negative ions measured by the flight time type secondary ion mass spectrometer is 0.01. polymer particles which is a × 10 ^-4 ~2.00 × 10 ^-4.
[Method for measuring the content of surfactant]
Approximately 0.10 g of polymer particles as a sample are precisely weighed into a centrifuge tube, and 5 mL of methanol as an extract is poured with a whole pipette to mix the polymer particles and the extract well. After ultrasonic extraction for 15 minutes, centrifugation is performed at 3500 rpm for 15 minutes, and the supernatant obtained by this is used as a test solution. The concentration of surfactant in this test solution is measured. Then, the concentration of the surfactant in the measured test solution (μg / ml), the weight of the polymer particles used as the sample (sample weight (g)), and the amount of the extract (extract amount (ml)). Therefore, the content (μg / g) of the surfactant in the polymer particles is determined by the following calculation formula. The amount of the extract is 5 ml.
Surfactant content (μg / g)
= {Concentration of surfactant in test solution (μg / ml) x amount of extract (ml)} ÷ sample weight (g) The polymer particles according to claim 1.
Polymer particles, wherein the surfactant contains at least one of an anionic surfactant and a nonionic surfactant. The polymer particles according to claim 1 or 2.
A polymer characterized in that the polymer constituting the polymer particles is any one of a (meth) acrylic polymer, a styrene polymer, and a (meth) acrylic-styrene copolymer. particle. The polymer particles according to any one of claims 1 to 3.
Polymer particles, which are used in a resin composition for coating. The polymer particles according to any one of claims 1 to 4.
Polymer particles characterized by being used for optical members. The polymer particles according to any one of claims 1 to 5.
Polymer particles characterized by being used for antiglare members. An optical film comprising a coating resin composition containing the polymer particles according to any one of claims 1 to 4 and a binder coated on a film substrate. The optical film according to claim 7.
An optical film characterized by being anti-glare. A resin molded product obtained by molding a molding resin composition containing the polymer particles according to any one of claims 1 to 3 and a transparent resin.

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