Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
  • C08G64/20—General preparatory processes
  • C08G64/30—General preparatory processes using carbonates
  • C08G64/307—General preparatory processes using carbonates and phenols

Definitions

• the present invention relates to a method for producing polycarbonate. Specifically, in producing a polycarbonate by transesterification from a dihydroxy compound and a carbonic acid diester, the hydrolysis resistance is impaired by adjusting the oxygen concentration in the atmosphere in which the transesterification reaction is performed.
• the present invention relates to a method for efficiently producing a polycarbonate having excellent quality without causing stagnation and burning, and having excellent color tone.
• PC polycarbonate
• phosgene interface method
• a method of producing bisphenol A or the like A method is known in which an aromatic dihydroxy compound is transesterified with a carbonic acid diester such as diphenyl carbonate in a molten state (melting method).
• the interface method involves the following: (1) toxic phosgene must be used; (2) the production equipment is corroded by chlorine-containing compounds such as hydrogen chloride and sodium chloride as a by-product; There are various problems such as difficulty in separating impurities that adversely affect the physical properties of the polymer such as sodium hydroxide mixed into the polymer.
• the melting method has the advantage that PCs can be manufactured at a lower cost than the interface method, but usually the reaction is carried out for a long time at a high temperature of 280 to 310. Therefore, it has a major drawback that it cannot escape the problem of resin coloring.
• Japanese Patent Publication No. Sho 61-39792 and Japanese Patent Laid-Open Publication No. Sho 63-23036 disclose methods using a specific catalyst.
• Japanese Patent Application Laid-Open Publication Nos. Sho 61-151, 336, and Sho 61-158, 719/19 disclose methods of adding an antioxidant at the latter stage of the reaction. I have.
• Japanese Unexamined Patent Publication No. HEI 2-1539395 uses a horizontal stirring polymerization tank. An improved technique has been disclosed. Furthermore, Japanese Patent Laid-Open No. 2
• No. 1,575,722 discloses a method for reducing the content of hydrolyzable chlorine in a monomer to a certain level or less.
• the oxygen concentration in the atmosphere in which the transesterification reaction is performed is 2 ppm or less. It is intended to provide a method for producing polycarbonate, which is characterized in that
• dihydroxy compounds used as the component (A).
• aromatic dihydroxy compounds aliphatic dihydroxy compounds, bisesters of aromatic dihydroxy compounds, bisesters of aliphatic dihydroxy compounds, carbonates of aromatic dihydroxy compounds, and aliphatic dihydroxy compounds.
• the aromatic dihydroxy compound used as ⁇ of the component (A) is represented by the general formula (I)
• R represents a halogen atom (eg, chlorine, bromine, fluorine, iodine) or an alkyl group having 1 to 8 carbon atoms (eg, a methyl group, an ethyl group, a propyl group, an n-butyl group). , Isobutyl group, amyl group, isoamyl group, hexyl group, etc.).
• a plurality of R's may be the same or different, and m is , 0 to 4 are integers.
• Z is a single bond, an alkylene group having 1 to 8 carbon atoms or an alkylidene group having 2 to 8 carbon atoms (for example, a methylene group, an ethylene group, a propylene group, a butylene group, a pentylene group, a hexylene group, Alkylene group having 5 to 15 carbon atoms or cycloalkylidene group having 5 to 15 carbon atoms (for example, cyclopentylene group, cyclohexylene group, cyclopentylidene group). Group, cyclohexylidene group, etc.), or —S—, one SO—,
• aromatic dihydroxy compounds include, for example, bis (4-hydroxyphenyl) methane; 1,1-bis (4-hydroxyphenyl) ethane; 2,2-bis (4-hydroxyphenyl) propane Mouth bread (commonly known as bisphenol A: BPA); 2,2-bis (4-hydroxyphenyl) butane; 2,2-bis (4-hydroxyphenyl) octane; 2,2-bis (4-hydroxy) (Droxyphenyl) phenyl methane; 2,2-bis (4-hydroxy-1-monomethylphenyl) prono. 1, 1-bis (4-hydroxy-tert-butylphenyl) prono.
• aliphatic dihydroxy compound as one of the components (A), there are various compounds.
• bisesters of aromatic dihydroxy compounds bisesters of aliphatic dihydroxy compounds, carbonates of aromatic dihydroxy compounds, or aliphatic dihydroxy compounds used as component (A)
• carbonates for example, the bisesters of the above compounds are represented by the general formula (II)
• Ar 1 represents a residue obtained by removing two hydroxyl groups from the aromatic dihydroxy compound, and R 2 is the same as described above. ]
• Ar 2 represents an aryl group; R 1 is the same as defined above; or a compound represented by the general formula (VI)
• R 1 and R 2 are the same as those in the above if. ]
• the above-mentioned compounds are appropriately selected and used as the dihydroxy compound of the component (A), and among these, bisphenol A, which is an aromatic dihydroxy compound, is preferably used. So When bisphenol A is used, an adduct of bisphenol A and phenol or a mixture of the adduct and phenol can also be used. By using such an adduct, bisphenol A having high purity can be obtained, which is effective.
• polyester carbonate used as the component (B).
• it is at least one compound selected from diaryl carbonate compounds, dialkyl carbonate compounds or alkylaryl carbonate compounds.
• the diaryl carbonate compound used as one ⁇ D of the component (B) is represented by the general formula (XI)
• the dialkyl carbonate compound has the general formula (XII)
• diaryl carbonate compounds include, for example, diphenyl carbonate, ditrinocarbonate, bis (chlorophenyl) carbonate, m-cresyl carbonate, dinaphthylcarbonate, bis ( Diphenyl) carbonate, bisphenol A bisphenyl carbonate and the like.
• dialkyl carbonate compound examples include getyl carbonate, dimethyl carbonate, dibutyl carbonate, dicyclohexyl carbonate, and bisphenol A bismethyl carbonate.
• alkyl carbonate compound for example, methyl
• alkyl carbonate compound for example, methyl
• examples include phenyl carbonate, ethyl phenyl carbonate, butyl phenyl carbonate, cyclohexyl phenyl carbonate, and bisphenol A methyl phenyl carbonate.
• the above compounds are appropriately selected and used as the carbonic acid diester of the component (B), and among these, difluorocarbonate is preferably used.
• a polycarbonate is obtained by an ester exchange reaction using the components (A) and (B).
• terminal stoppers can be used, if necessary, in addition to the components (A) and (B).
• terminal stopper examples include: 0-n-butylphenol; mn-butylphenol; pn-butylphenol; 0-isobutylphenol; m-isobutylphenol.
• phenols although not particularly specified in the present invention, P-tert-butylphenol; p-cumylphenol, p-phenylphenol and the like are preferable.
• n is an integer from 7 to 30
• phloroglucin trimellitic acid; 1,1,1—tris (4-hydroxyphenyl) ethane; 1— [ ⁇ -methyl- ⁇ — (4,1H Droxyphenyl) ethyl] 1 4 1 C ', a' —bis (4 "-hydroxyphenyl) ethyl] benzene; ⁇ , ', a" -tris (4-hydroxyphenyl) 1-1,3,5—tri- Isopropylbenzene; isatin bis (0-cresol) and the like can also be used as a branching agent.
• a catalyst is not particularly required, but a known catalyst may be used to promote the transesterification reaction.
• a catalyst include simple alkali metal or alkaline earth metal, oxides, hydroxides, amide compounds, alcoholates, phenolates, or ZnO, PbO.
• basic metal oxides such as S b 2 0 3, organotitanium compounds, soluble manganese compounds, C a, Mg, Z n , P b, S n, Mn, C d, C o acetate salt or a nitrogen-containing Basic compounds And a boron compound, a nitrogen-containing basic compound and an alkali (earth) metal compound, and a combined catalyst such as a nitrogen-containing basic compound and an alkali (earth) metal compound and a boron compound.
• the production method of the present invention is characterized in that the oxygen concentration in the atmosphere of the reaction system at the time of performing the transesterification reaction is set to 2 ppm or less.
• the transesterification reaction is performed in an atmosphere of an inert gas.
• an inert gas for example, nitrogen gas or a rare gas such as argon or helium is used.
• nitrogen gas or a rare gas such as argon or helium is used.
• Each of these inert gases may be used alone, or two or more of them may be used in combination.
• the oxygen concentration in the atmosphere composed of these inert gases is set to 2 ppm or less, preferably 1 ppm or less, and more preferably 0.2 Ppm or less.
• excellent hydrolysis resistance and retention burning are obtained.
• the oxygen concentration in the atmosphere in which the reaction is performed is reduced to 2 ppm or less, the initial stage of the reaction is set to normal pressure or a pressurized state, and the latter stage of the reaction is set to a reduced pressure state.
• the initial stage of the reaction is the reaction at the time of conducting the transesterification reaction.
• the temperature refers to a temperature in the range of 100 to 220 ° C.
• the term “late stage of the reaction” refers to a subsequent reaction.
• the reaction may be allowed to proceed under the above-described conditions according to a known ester exchange method.
• ester exchange method a known ester exchange method
• the dihydroxy compound of the component (A) and the ester carbonate of the component (B) are charged at a ratio of 1 to 1.5 times the molar ratio of the diester carbonate to the dihydroxy compound. Responds to transesterification.
• the amount of the carbonic acid diester is preferably 1.02 to 1.20 times the molar amount of the dihydroxy compound depending on the situation.
• the amount of the terminal terminator comprising the above-mentioned monohydric phenol or the like is 0.05 to 10 mol% with respect to 1 mol of the dihydroxy compound as the component (A).
• the hydroxyl group terminal of the obtained polycarbonate is sealed, so that a polycarbonate having sufficiently excellent heat resistance and water resistance can be obtained.
• Such a terminal terminating agent comprising a monovalent phenol may be added in advance to the reaction system in its entirety.
• part of the reaction may be added to the reaction system in advance, and the remainder may be added as the reaction proceeds.
• the whole amount may be added to the reaction system after the transesterification reaction between the dihydroxy compound (A) and the carbonic acid diester (B) partially proceeds.
• the oxygen concentration in the atmosphere in which the ester exchange reaction is carried out is set to 2 ppm or less, and the reaction temperature is not particularly limited, but is usually 100 ° C. to 330 ° C. ° C, preferably 18 (TC to 300 ° C, more preferably the progress of the reaction).
• a good method is to gradually raise the temperature from 180 ° C to 300 ° C according to the line.
• the transesterification reaction is performed at a temperature lower than 100 ° C., the progress of the reaction is slow.
• the transesterification temperature exceeds 330 ° C., thermal degradation of the polymer occurs, which is not preferable.
• the reaction pressure is set according to the vapor pressure of the monomer used and the reaction temperature. This is not limited, as long as it is set so that the reaction is performed efficiently. Normally, in the early stage of the reaction, the pressure is maintained at atmospheric pressure (normal pressure) up to 1 to 50 atm (760 to 38,000 torr) or in a pressurized state. In many cases, the final value is preferably 0.01 to 100 torr.
• reaction time may be set to the target molecular weight, and is usually about 0.2 to 10 hours.
• the above reaction is carried out in the absence of an inert solvent, but may be carried out, if necessary, in the presence of 1 to 150% by weight of the obtained PC.
• the inert solvent include: diphenyl ether, halogenated diphenyl ether, benzophenone, polyphenyl ether, aromatic compounds such as dichlorobenzene, methylnaphthalene, carbon dioxide, Gases such as dinitrogen monoxide and nitrogen.
• Fluorohydrocarbons alkanes such as ethane, brono, and cyclohexane, cyclohexane, tricyclo (5,2,10) —decane, cyclooctane, and cyclodecane
• alkanes such as ethane, brono, and cyclohexane
• cyclohexane tricyclo (5,2,10) —decane
• cyclooctane cycloctane
• cyclodecane Various types such as cycloalkane, althene such as ethene and propene are exemplified.
• an antioxidant can be used if necessary.
• Specific examples include tris (nonylphenyl) phosphite, trisphenyl phosphite, 2-ethylhexyl diphenyl phosphite, trimethyl phosphite, trimethyl phosphite, and triethyl phosphite.
• phosphoric acid oxidation inhibitors such as cresyl phosphite and triaryl phosphite.
• phenols, alcohols, or their esters and the inert solvent corresponding to the used carbonate ester are eliminated from the reactor. These desorbed substances can be separated, purified and recycled for use, and it is preferable to have a facility for removing them.
• the present invention can be carried out batchwise or continuously, and any device can be used.
• any device can be used.
• the reactor used in the present invention is provided with a film of the above-mentioned material on its inner wall, and its structure is not particularly limited, as long as it has a normal stirring function. However, since the viscosity increases in the latter stage of the reaction, those having a high viscosity type stirring function are preferable. Further, the shape of the reactor is not limited to a tank type, but may be an extruder type reactor or the like. The PC obtained as described above may be granulated as it is, or may be formed using an extruder or the like.
• the PC obtained by the present invention can be used by blending known additives such as plasticizers, pigments, lubricants, release agents, stabilizers, inorganic fillers and the like.
• the obtained PC can be blended with polymers such as polyolefin, polystyrene, polyester, polysulfonate, polyamide, and polyphenylene oxide.
• polymers such as polyolefin, polystyrene, polyester, polysulfonate, polyamide, and polyphenylene oxide.
• BPA Bisphenol A
• diphenyl carbonate (257 g, 1.2 mol) were placed in a 1.4 liter nickel steel autoclave (with stirrer). Preparation and nitrogen replacement were performed 5 times. The mixture was heated to 1 8 0 e C, to melt the Bisufuwenoru A and Jifue two Rukabone bets.
• the obtained viscous and transparent condensate was dissolved in methylene chloride, and the viscosity average molecular weight was measured.
• the obtained viscous and transparent condensate was pulverized, and pelletized at 270 ° C. using an extruder.
• the obtained pellets were press-formed, and the press plate (thickness: 3 mm) was subjected to YI, hydrolysis resistance, and retention burn tests.
• Example 1 instead of nitrogen having an oxygen concentration of 2 ppm, The procedure was performed in the same manner as in Example 1 except that nitrogen at a concentration of 1 ppm was used. -Example 3
• Example 1 was carried out in the same manner as in Example 1 except that nitrogen having an oxygen concentration of 0.2 ppm was used instead of nitrogen having an oxygen concentration of 2 ppm.
• Example 4
• Example 3 was carried out in the same manner as in Example 3 except that nitrogen having an oxygen concentration of 0.2 ppm was passed through a purification column filled with activated copper.
• the oxygen concentration was less than 0.1 ppm.
• Example 3 was carried out in the same manner as in Example 3, except that nitrogen having an oxygen concentration of 0.2 ppm was passed through a purification column filled with oxypurge N (trade name: manufactured by GE Science).
• the oxygen concentration was less than 0.1 pm.
• Example 1 except that as a catalyst, 0.2 mg (1 xlO 5 mol) of LiOH was used instead of 2.5 mg (1 X 10-5 mol) of (C 4 H 9 ) 4 NBH 4 The operation was performed in the same manner as in Example 1.
• Example 1 was carried out in the same manner as in Example 1 except that nitrogen having an oxygen concentration of 5 ppm was used instead of nitrogen having an oxygen concentration of 2 ppm.
• Table 1 shows the measurement results of Examples 1 to 6 and Comparative Example 1.
• the viscosity of the methylene chloride solution at 20 e C was measured with an Ubbelohde type viscosity tube, and the intrinsic viscosity [7?] was determined from this.
• the measurement was carried out using a color meter SM-3 (manufactured by Suga Test Instruments Co., Ltd.) in accordance with JIS 107-77.
• the present invention by adjusting the oxygen concentration in the atmosphere of the reaction system at the time of carrying out the transesterification reaction, the hydrolysis resistance is not impaired, the quality without stagnant burning is excellent, and the color tone is excellent.
• Polycarbonate can be manufactured. Therefore, the present invention can be effectively and widely used as a method for industrially advantageously producing polycarbonate by an ester exchange method.

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• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Polyesters Or Polycarbonates (AREA)

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• 1993
  • 1993-07-06 JP JP16694393A patent/JP3866299B2/ja not_active Expired - Lifetime
• 1994
  • 1994-07-05 US US08/569,131 patent/US5650480A/en not_active Expired - Lifetime
  • 1994-07-05 DE DE69417233T patent/DE69417233T3/de not_active Expired - Lifetime
  • 1994-07-05 ES ES94919850T patent/ES2128568T5/es not_active Expired - Lifetime
  • 1994-07-05 EP EP94919850A patent/EP0708128B2/en not_active Expired - Lifetime
  • 1994-07-05 WO PCT/JP1994/001090 patent/WO1995002006A1/ja not_active Ceased

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