WO2011155566A1 - アクリル系重合体の製造方法、この製造方法により得られるアクリル系重合体及びこれを用いたプラスチゾル組成物 - Google Patents
アクリル系重合体の製造方法、この製造方法により得られるアクリル系重合体及びこれを用いたプラスチゾル組成物 Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/16—Aqueous medium
- C08F2/22—Emulsion polymerisation
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F20/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
- C08F20/02—Monocarboxylic acids having less than ten carbon atoms, Derivatives thereof
- C08F20/10—Esters
- C08F20/12—Esters of monohydric alcohols or phenols
- C08F20/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
- C08F20/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/12—Esters of monohydric alcohols or phenols
- C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
- C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
- C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
- C08F265/06—Polymerisation of acrylate or methacrylate esters on to polymers thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/12—Esters of monohydric alcohols or phenols
- C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
- C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
- C08F220/1804—C4-(meth)acrylate, e.g. butyl (meth)acrylate, isobutyl (meth)acrylate or tert-butyl (meth)acrylate
Definitions
- the present invention relates to a method for producing a multilayered acrylic polymer composed of a plurality of layers having different functions, an acrylic polymer obtained by this production method, and a plastisol composition using the same.
- Patent Document 1 A core-shell type powder polymer (Patent Document 1) composed of a coalescence has been reported.
- (meth) acrylic As a substitute material for vinyl chloride sol, (meth) acrylic consists of a core layer that gives the film flexibility and a shell layer that prevents the polymer of the core layer from coming into contact with the plasticizer and gives storage stability.
- System polymer particles are known.
- core-shell type acrylic polymer particles having a specific solubility parameter and glass transition temperature in the core and shell Patent Document 2
- Patent Document 3 the manufacturing method (patent document 3) of the emulsion which adds a polymerization inhibitor in the middle of a polymerization process and contains the polymer from which a particle diameter differs is reported.
- Patent Document 3 The method described in Patent Document 3 is to obtain a dispersion containing two different physical property polymer particles.
- the core component polymer is uniformly coated with a small amount of shell component polymer, and the core component and It does not express the performance of the shell component.
- the problem of the present invention is that even when the mass ratio of the shell component is low, the core component can be sufficiently coated, each function of the polymer provided in multiple stages can be exhibited, and storage stability It is providing the manufacturing method of the acrylic polymer which can obtain the coating film which is excellent in the property, and is rich in a softness
- the present invention includes a step of emulsion polymerization of the acrylic monomer mixture (A), In the polymer dispersion (D) obtained by the emulsion polymerization, the acrylic monomer mixture (B) is emulsion polymerized in the presence of a polymerization initiator and a polymerization inhibitor in an amount satisfying the following formula (1). Including the steps of:
- the present invention relates to a method for producing an acrylic polymer, wherein the mass ratio (A) / (B) of the acrylic monomer mixture (A) and the acrylic monomer mixture (B) is 70/30 to 95/5.
- Q represents the molar amount of the polymerization inhibitor
- I represents the molar amount of the polymerization initiator present in the polymer dispersion (D) before the polymerization inhibitor is charged.
- the present invention also relates to an acrylic polymer obtained by the above production method and a plastisol composition containing the acrylic polymer and a plasticizer.
- an acrylic polymer of the present invention due to the presence of a specific ratio of the polymerization inhibitor relative to the polymerization initiator, the progress of the polymerization reaction of the outer layer monomer added to the reaction system is suppressed, After the outer layer monomer and the inner layer polymer are uniformly mixed, the inner layer polymer is uniformly coated with a small amount of the outer layer polymer by the polymerization reaction of the outer layer monomer. And a multilayer polymer capable of maximizing the effects of the inner layer and the outer layer can be produced.
- the plastisol composition using the acrylic polymer obtained by the production method of the present invention is excellent in storage stability, and the resulting coating film has excellent flexibility.
- the method for producing an acrylic polymer of the present invention satisfies the following formula (1) in the step of emulsion polymerization of the acrylic monomer mixture (A) and the polymer dispersion (D) obtained by emulsion polymerization. And emulsion polymerization of the acrylic monomer mixture (B) in the presence of an amount of a polymerization initiator and a polymerization inhibitor.
- Emulsion polymerization of acrylic monomer mixture (A) The acrylic monomer mixture (A) is polymerized by emulsion polymerization. Emulsion polymerization may be a single reaction or a multi-stage reaction over a plurality of times. In the emulsion polymerization, the temperature can be adjusted as appropriate. The completion of the emulsion polymerization reaction can be judged from the residual amount of monomer.
- the polymer dispersion (D) containing the polymer (A) obtained by emulsion polymerization of the acrylic monomer mixture (A) is used for polymerization of the acrylic monomer mixture (B) described later.
- the emulsion polymerization of the acrylic monomer mixture (A) may be performed in the presence of the polymer particles (S) serving as seed particles.
- the polymer particles (S) can be produced by a known method such as soap-free polymerization or fine suspension polymerization of an acrylic monomer.
- the acrylic monomer mixture (A) is not particularly limited as long as it contains an acrylic monomer.
- acrylic monomers include methyl (meth) acrylate, butyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, and (meth) acrylic.
- (Meth) acrylic acid esters such as 2-ethylhexyl acid, octyl (meth) acrylate, 2-acetoacetoxyethyl (meth) acrylate, dimethylaminoethyl (meth) acrylate, diethylaminoethyl (meth) acrylate, Mention may be made of unsaturated carboxylic esters such as vinyl acetate, unsaturated carboxylic acids such as acrylic acid and methacrylic acid, acrylonitrile and acrylamide. These can be used alone or in combination of two or more.
- aromatic monomers such as styrene, ⁇ -methylstyrene, vinyltoluene and divinylbenzene, substituted ethylene compounds such as vinyl chloride and vinylidene chloride, and the like can be used as monomers.
- the polymer (A) obtained from the acrylic monomer mixture (A) is compatible with the plasticizer, and the resulting coating film has flexibility. It is preferable from the point of improving.
- diisononyl phthalate is used as a plasticizer for plastisol
- the total mass of methyl methacrylate and butyl methacrylate is preferably 50% by mass or more. More preferably, the mass ratio of methyl methacrylate to butyl methacrylate is 20/80 to 75/25.
- t-butyl methacrylate is contained in the butyl methacrylate in an amount of 10% by mass or more from the viewpoint of improving the chipping strength and the storage stability.
- the solubility parameter (SA) of the polymer (A) obtained by polymerizing the acrylic monomer mixture (A) is 20.14 (J / cm 3 ) 1/2 from the viewpoint of compatibility with the plasticizer. 2 or less is preferable.
- the solubility parameter is obtained by substituting the Sp value (Sp (Ui)) of the monomer unit constituting the polymer into the following formula (2).
- Sp (ui) is the same as that of polymereEngineering and Science, Vol. 14, 147 (1974).
- Table 1 shows the Sp value (Sp (Ui)) of the monomer units used.
- an anionic surfactant or a nonionic surfactant can be used as an emulsifier.
- the anionic surfactant include alkylbenzene sulfonate, alkyl sulfonate, alkyl sulfate ester salt, fatty acid metal salt, polyoxyalkyl ether sulfate ester salt, polyoxyethylene carboxylate sulfate ester salt, polyoxyethylene Examples thereof include alkylphenyl ether sulfate ester salts and succinic acid dialkyl ester sulfonate salts. One of these may be used, or two or more may be used in combination.
- Nonionic surfactants include, for example, polyoxyethylene alkyl phenyl ether, polyoxyethylene alkyl ether, polyoxyethylene fatty acid ester, polyoxyethylene sorbitan fatty acid ester, polyoxyethylene alkyl ether glycerin borate ester, polyoxyethylene alkyl Compounds such as ether phosphates and polyoxyethylenes that have polyoxyethylene chains in the molecule and have surface activity, and polyoxyethylene chains of these compounds are replaced with copolymers of oxyethylene and oxypropylene Examples thereof include compounds, sorbitan fatty acid esters, fatty acid glycerin esters, glycerin fatty acid esters, and pentaerythritol fatty acid esters. These may be used alone or in combination of two or more. The amount of these surfactants used is preferably in the range of 0.1 to 5 parts by mass with respect to 100 parts by mass of the acrylic monomer mixture (A).
- polymerization initiator examples include hydrogen peroxide, a water-soluble inorganic peroxide, or a combination of a water-soluble reducing agent and an organic peroxide.
- water-soluble inorganic peroxide examples include potassium persulfate and ammonium persulfate. These may be used alone or in combination of two or more. The amount used is preferably in the range of 0.01 to 0.5 parts by mass per 100 parts by mass of all monomers to be subjected to polymerization.
- Water-soluble reducing agents include ethylenediaminetetraacetic acid and its sodium and potassium salts, complex compounds of these metals such as iron, copper and chromium, sulfinic acid and its sodium and potassium salts, L-ascorbic acid and its sodium Examples include salts, potassium salts, calcium salts, ferrous pyrophosphate, ferrous sulfate, ammonium ferrous sulfate, sodium sulfite, acidic sodium sulfite, sodium formaldehyde sulfoxylate, and reducing sugars. These may be used alone or in combination of two or more.
- organic peroxides include cumene hydroperoxide, p-cymene hydroperoxide, t-butylisopropylbenzene hydroperoxide, diisopropylbenzene hydroperoxide, p-menthane hydroperoxide, decalin hydroperoxide, t-amyl.
- hydroperoxides such as hydroperoxide, t-butyl hydroperoxide, and isopropyl hydroperoxide. These may be used alone or in combination of two or more.
- the emulsion polymerization of the acrylic monomer mixture (B) is performed by adding a polymerization inhibitor to the polymer dispersion (D) after the emulsion polymerization reaction of the acrylic monomer mixture (A) is completed.
- the polymerization inhibitor temporarily inhibits the polymerization reaction of the acrylic monomer mixture (B), and the acrylic monomer added to the polymer dispersion (D) due to the presence of the polymerization inhibitor.
- the generation of radicals by the polymerization initiator and the progress of the polymerization reaction due to the radicals are suppressed, and the progress of the polymerization reaction does not start even when contacting with the polymer (A).
- the polymer (A) in (D) is thoroughly mixed and reaches the surface of the polymer (A). Thereafter, when the polymerization reaction is started, a coating of the polymer (B) of the acrylic monomer mixture (B) is formed over the entire circumference of the polymer (A).
- the amount of the polymerization inhibitor in the polymer dispersion (D) is such that the Q / I is 0.1 to 30 as the molar amount (Q) relative to the molar amount (I) of the polymerization initiator. If Q / I is 0.1 or more, generation of radicals by the polymerization initiator can be suppressed for a certain period of time, and the coating of the polymer (B) is formed on the entire circumference of the polymer (A). Thus, when used as a plastisol, the storage stability is improved. When Q / I is 30 or less, the polymerization of the monomer mixture (B) is not stopped and the coating of the polymer (B) is formed, so that the storage stability is improved. Q / I is preferably 0.1 or more and 27.5 or less. More preferably, Q / I is 0.5 or more and 25 or less.
- the content of the polymerization initiator present in the polymer dispersion (D), which serves as a reference for the addition amount of the polymerization inhibitor, is the polymer of the polymer initiator used for the polymerization of the acrylic monomer mixture (A). It is the remaining amount in the dispersion and can be determined by the following formulas (3) and (4).
- the thermal decomposition rate constant kd at the polymerization temperature T of the acrylic monomer mixture (A) of the polymerization initiator to be used is obtained from the equation (3). Further, the residual rate of the polymerization initiator after the reaction for t (s) under the condition of the polymerization temperature T is obtained from the equation (4) using the obtained kd, and the residual amount is obtained from the used amount of the polymer initiator. be able to.
- the polymerization inhibitor examples include phenol compounds such as hydroquinone, p-methoxyphenol and pt-butylcatechol, N, N-diethylhydroxylamine, N-nitrosophenylhydroxylamine ammonium salt (cuperon) and the like.
- examples thereof include organic sulfur compounds such as hydroxylamine compounds, dithiobenzoyl disulfide, and tetraethylthiuram disulfide. These may be used alone or in combination of two or more.
- polymerization inhibitors having a solubility in water at 25 ° C. of 5 g / 100 ml or less are preferred.
- examples of such a polymerization inhibitor include p-methoxyphenol, pt-butylcatechol, diphenylamine and the like.
- the polymerization inhibitor As a method for adding the polymerization inhibitor, after the emulsion polymerization reaction of the acrylic monomer mixture (A) is completed, the polymerization inhibitor is added to the polymer dispersion (D) prior to the addition of the acrylic monomer mixture (B). Or a method of adding a polymerization inhibitor in advance to the acrylic monomer mixture (B) and adding it to the polymer dispersion (D).
- the acrylic monomer used for the acrylic monomer mixture (B) the same acrylic monomer used for the acrylic monomer mixture (A) can be used.
- the acrylic monomer mixture (B) has a storage stability in the acrylic sol that the polymer (B) obtained therefrom is incompatible with the plasticizer. It is preferable from the point which provides.
- the plasticizer for example, when diisononyl phthalate is used, the acrylic monomer used in the acrylic monomer mixture (B) is methyl (meth) acrylate, butyl (meth) acrylate, (meth) acrylic acid, And 2-hydroxyethyl methacrylate. These contents are adjusted so that a hardly soluble polymer (B) with respect to the plasticizer is obtained.
- the acrylic monomer mixture (B) preferably contains 75% by mass or more of methyl methacrylate.
- the polymer (B) obtained by polymerizing the acrylic monomer mixture (B) has a solubility parameter (SB) obtained by the above method of acrylic type. It is preferable from the viewpoint of storage stability that it is larger than the solubility parameter (SA) of the polymer (A) obtained by polymerizing the monomer mixture (A).
- the solubility parameter (SB) is preferably higher than the solubility parameter of the plasticizer from the viewpoint of storage stability, and is preferably 20.22 (J / cm 3 ) 1/2 or more.
- the amount of the acrylic monomer mixture (B) used is such that the mass ratio (A) / (B) between the acrylic monomer mixture (A) and the acrylic monomer mixture (B) is 70/30 to The amount is 95/5. More preferably, the mass ratio (A) / (B) is 80/20 to 95/5.
- the proportion of the acrylic monomer mixture (B) used is 5% by mass or more, the polymer (A) can be sufficiently coated, and when used in an acrylic sol, the storage stability is good. If the usage-amount of an acrylic monomer mixture (B) is 30 mass% or less, in molded objects, such as a coating film obtained, it has the outstanding softness
- the emulsion polymerization of the acrylic monomer mixture (B) can be performed by the same method as the emulsion polymerization of the acrylic monomer mixture (A).
- the acrylic monomer mixture (B) may be added to the polymer dispersion (D) at a time or divided into several times, but may be added dropwise with stirring. preferable.
- the weight average molecular weight of the acrylic polymer obtained by the production method of the present invention is preferably 10,000 to 4,000,000, more preferably 50,000 to 3,000,000, still more preferably 300,000 to 2,000,000. It is. If the weight average molecular weight is 4,000,000 or less, it is easily plasticized by a plasticizer and has excellent processability as a plastisol. If it is 10,000 or more, the storage stability as plastisol is reduced. Can be suppressed.
- the obtained acrylic polymer preferably has a volume average particle size of the acrylic polymer in the dispersion after the emulsion polymerization reaction of 0.05 to 2 ⁇ m.
- the volume average particle size of the acrylic polymer is more preferably 0.2 to 2 ⁇ m.
- volume average particle diameter a measurement value measured using a laser diffraction / scattering particle size distribution analyzer LA-920 (manufactured by HORIBA) can be adopted.
- the acrylic polymer produced by the above-mentioned acrylic polymer production method is prepared by spray drying (spray drying) or acid coagulation from the polymer dispersion after emulsion polymerization of the acrylic monomer mixture (B). Or, after solidifying the salt, it can be separated as a powder by drying.
- the resulting powder is a secondary particle structure in which a large number of polymers are agglomerated, or agglomerated particles that are agglomerated more than that, and the primary particles are not firmly bonded to each other, agglomerating loosely, and easily with weak shear
- a spray drying method is preferred in which a powder that can be made into primary particles is obtained.
- the acrylic polymer powder thus obtained preferably has a volume average particle diameter of 5 to 200 ⁇ m when used in plastisol. If the volume average particle diameter of the acrylic polymer powder is 5 ⁇ m or more, the handling of the polymer at the time of producing the plastisol composition is easy, and if it is 200 ⁇ m or less, the polymer in the plastisol composition is uniformly distributed.
- the coating film obtained by using the polymer can be dispersed, and there are few irregularities caused by poor dispersion of the polymer, and a molded product having a good appearance can be obtained.
- the plastisol composition of the present invention contains an acrylic polymer obtained by the above-described acrylic polymer production method and a plasticizer, and is obtained by mixing other fillers and the like as necessary. By containing the acrylic polymer, the storage stability is excellent and the sol property can be maintained for a long time.
- plasticizer examples include phthalate plastics such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, diisononyl phthalate, diisodecyl phthalate, and butyl benzyl phthalate.
- phthalate plastics such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, diisononyl phthalate, diisodecyl phthalate, and butyl benzyl phthalate.
- dimethyl adipate, dibutyl adipate, diisobutyl adipate, dihexyl adipate, di-2-ethylhexyl adipate, diisononyl adipate, dibutyl diglycol adipate and other adipate plasticizers trimethyl phosphate, triethyl phosphate, tributyl phosphate, tri-2-ethylhexyl Phosphate, tributoxyethyl phosphate, triphenyl phosphate, tricresyl phosphate Phosphate ester plasticizers such as trimethylenyl phosphate and cresyl phenyl phosphate, trimellitic ester plasticizers such as tri-2-ethylhexyl trimellitate, dimethyl sebacate, dibutyl sebacate, di-2- Sebacic acid ester plasticizers such as ethylhexyl sebac
- dioctyl phthalate diisononyl phthalate, diisodecyl phthalate, mezamol, and acetyl tributyl citrate as a main component.
- the content of the acrylic polymer particles in the plastisol composition is preferably 5% by mass or more and 70% by mass or less.
- the content is 5% by mass or more, the resulting coating film or molded article is excellent in strength, and when it is 70% by mass or less, the viscosity of the plastisol composition is lowered and the processability is excellent.
- the plastisol composition may contain a filler, an adhesive and the like as necessary within a range not impairing the functions of the above components.
- the filler include calcium carbonate, aluminum hydroxide, colloidal silica, talc, glass powder, aluminum oxide and the like, and the content thereof can be appropriately selected depending on the purpose.
- the adhesive can be appropriately selected depending on the base material.
- an adhesive such as an epoxy resin, a block urethane resin, or a polyamine can be used. These can be used alone or in combination of two or more.
- an acid anhydride, an imidazole compound, or the like can be used for an epoxy resin adhesive, and a dihydrazide compound can be used for a block urethane resin adhesive.
- the plastisol composition contains pigments such as titanium oxide and carbon black, diluents such as mineral terpenes and mineral spirits, and further antifoaming agents, antifungal agents, leveling agents and the like within a range not inhibiting the above components. Can do.
- a device for producing the plastisol composition a known device can be used.
- a pony mixer a change-can mixer, a Hobart mixer, a planetary mixer, Examples include butterfly mixers, rough machines, and kneaders.
- the plastisol composition of the present invention can be used as a coating material or a molding material, and is particularly useful as a coating material.
- the forming method may be any method, but examples of the method for forming a film include a method of forming a coating film by a dip coating method, a spray coating method, or the like, and baking it.
- the plastisol composition can be applied to any molded article, for example, automotive undercoat, automotive body sealer, automotive mastic adhesive, automotive coated damping material, tile carpet packing material, cushion floor, wallpaper And steel sheet paints.
- Example 1 [Preparation of acrylic polymer] Into a 2 liter four-necked flask equipped with a thermometer, a nitrogen gas inlet tube, a stirring rod, a dropping funnel and a cooling tube, 544 g of ion-exchanged water is introduced, and nitrogen gas is bubbled for 30 minutes to dissolve dissolved oxygen in the ion-exchanged water. Replaced. After stopping the aeration of nitrogen gas, the temperature was raised to 80 ° C. while stirring at 200 rpm. When the internal temperature reached 80 ° C., a monomer mixture (S) of 26.1 g of methyl methacrylate and 19.9 g of n-butyl methacrylate was added all at once.
- S monomer mixture
- a monomer mixture (B) of 77.6 g of methyl methacrylate, 2.4 g of 2-hydroxyethyl methacrylate, 0.8 g of Plex OT-P and 28 g of ion-exchanged water was added over 30 minutes. It was dripped. Stirring was continued at 80 ° C. for 2 hours and 30 minutes to obtain a dispersion of polymer (P-1).
- the polymerization was carried out in an environment in which 25 ml of nitrogen gas was aerated.
- the primary particle diameter in the polymer dispersion before spray drying of the polymer (P-1) and the volume average particle diameter of the secondary particles after spray drying are measured by a laser diffraction particle size distribution measuring device (trade name: HORIBA LA-920). , Manufactured by HORIBA, Ltd.).
- the thermal decomposition rate constant kd of potassium persulfate at 80 ° C. is 1.11 ⁇ 10 ⁇ 4 .
- Polymerization was started under conditions of 80 ° C. using 0.4 g of potassium persulfate (molecular weight: 270.3), and the residual rate of potassium persulfate after 390 minutes was calculated as 7.4% from the above formula (4). . Therefore, the number of remaining moles of potassium persulfate when the polymerization inhibitor is charged is 2.19 ⁇ 10 ⁇ 4 mole.
- the plastisol composition was applied to a 150 ⁇ 70 ⁇ 0.8 mm cationic electrodeposition plate (manufactured by Nippon Route Service Co., Ltd.) and heated at 130 ° C. for 30 minutes to form a film having a thickness of 1 mm.
- a test piece was made by making a cut of 2 mm in length ⁇ 4 mm in width, and installed at an angle of 60 degrees from the horizontal. Repeated the test of colliding 3kg of a true nut (M4 size) with a test piece from a height of 2m through a PVC pipe with a diameter of 20mm, and the total mass of nuts dropped until the test piece was destroyed and the base material was exposed. It was measured.
- the viscosity ( ⁇ ) (unit: Pa ⁇ s) after 1 minute at a rotational speed of 20 rpm was measured to obtain an initial viscosity.
- MMA Methyl methacrylate (Mitsubishi Rayon Co., Ltd.)
- t-BMA tert-butyl methacrylate (Mitsubishi Rayon Co., Ltd.)
- i-BMA Methacrylate-i-butyl (Mitsubishi Rayon Co., Ltd.)
- 2-HEMA 2-hydroxyethyl methacrylate (Mitsubishi Rayon Co., Ltd.)
- MEHQ p-methoxyphenol (manufactured by Kanto Chemical Co., Inc.)
- TBC t-butylcatechol (manufactured by Tokyo Chemical Industry Co., Ltd.)
- DPA Diphenylamine (manufactured by Nakarai Tasks)
- Comparative Examples 1 and 3 of the plastisol composition using an acrylic polymer prepared without adding a polymerization inhibitor were inferior in storage stability.
- Comparative Example 2 of the plastisol composition using an acrylic polymer prepared by adding an excessive polymerization inhibitor cannot control the polymerization reaction of the monomer mixture (B) and has poor storage stability. It was enough. Since the ratio of the monomer mixture (A) was small in Comparative Example 4, the tensile elongation and the chipping strength were inferior.
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Abstract
Description
その乳化重合によって得られた重合体分散液(D)中で、下記式(1)を満足する量の重合開始剤及び重合禁止剤の存在下でアクリル系単量体混合物(B)を乳化重合する工程とを含み、
アクリル系単量体混合物(A)とアクリル系単量体混合物(B)との質量比(A)/(B)が、70/30~95/5であるアクリル系重合体の製造方法に関する。
(式(1)中、Qは重合禁止剤のモル量を示し、Iは重合禁止剤の投入前に重合体分散液(D)中に存在する重合開始剤のモル量を示す。)
(式(1)中、Qは重合禁止剤のモル量を示し、Iは重合禁止剤の投入前に重合体分散液中に存在する重合開始剤のモル量を示す。)
アクリル系単量体混合物(A)は乳化重合により重合する。乳化重合は一回の反応でも、また、複数回に亘る、多段階の反応によってもよい。乳化重合は、適宜、温度調整等を行うことができる。乳化重合反応の終了は、単量体の残留量から判断することができる。アクリル系単量体混合物(A)の乳化重合により得られる重合体(A)を含む重合体分散液(D)は、後述するアクリル系単量体混合物(B)の重合に用いる。
アクリル系単量体混合物(A)は、アクリル系単量体を含むものであれば特に限定されない。アクリル系単量体としては、例えば、(メタ)アクリル酸メチル、(メタ)アクリル酸ブチル、(メタ)アクリル酸-2-ヒドロキシエチル、(メタ)アクリル酸-2-ヒドロキシプロピル、(メタ)アクリル酸-2-エチルヘキシル、(メタ)アクリル酸オクチル、(メタ)アクリル酸-2-アセトアセトキシエチル、(メタ)アクリル酸ジメチルアミノエチル、(メタ)アクリル酸ジエチルアミノエチル等の(メタ)アクリル酸エステルや酢酸ビニル等の不飽和カルボン酸エステル類、アクリル酸、メタクリル酸等の不飽和カルボン酸、アクリロニトリル、アクリルアミドを挙げることができる。これらは1種、又は2種類以上を組み合わせて用いることができる。更に、単量体としてこれらと共に、スチレン、α-メチルスチレン、ビニルトルエン、ジビニルベンゼン等の芳香族ビニル化合物、塩化ビニル、塩化ビニリデンのような置換エチレン化合物等を用いることができる。
アクリル系単量体混合物(A)の乳化重合には、乳化剤として、アニオン性界面活性剤や、ノニオン性界面活性剤を用いることができる。アニオン性界面活性剤としては、例えば、アルキルベンゼンスルホン酸塩、アルキルスルホン酸塩、アルキル硫酸エステル塩、脂肪酸金属塩、ポリオキシアルキルエーテル硫酸エステル塩、ポリオキシエチレンカルボン酸エステル硫酸エステル塩、ポリオキシエチレンアルキルフェニルエーテル硫酸エステル塩、コハク酸ジアルキルエステルスルホン酸塩等を挙げることができる。これらの1種を用いてもよく、2種以上を組み合わせて用いてもよい。
アクリル系単量体の乳化重合に用いる重合開始剤としては、過酸化水素、水溶性無機過酸化物、又は水溶性還元剤と有機過酸化物との組み合わせを挙げることができる。水溶性無機過酸化物としては、過硫酸カリウム、過硫酸アンモニウム等を挙げることができる。これらは1種を用いても又は2種以上を組み合わせて用いてもよい。その使用量は、重合に供される全単量体100質量部当り、0.01~0.5質量部の範囲内であることが好ましい。水溶性還元剤としては、エチレンジアミン四酢酸やそのナトリウム塩やカリウム塩、これらの鉄、銅、クロム等の金属との錯化合物、スルフィン酸やそのナトリウム塩やカリウム塩、L-アスコルビン酸やそのナトリウム塩、カリウム塩、カルシウム塩、ピロリン酸第一鉄、硫酸第一鉄、硫酸第一鉄アンモニウム、亜硫酸ナトリウム、酸性亜硫酸ナトリウム、ホルムアルデヒドスルホキシル酸ナトリウム、還元糖類等が挙げられる。これらは1種を用いてもよく、2種以上を組み合わせて用いてもよい。また、有機過酸化物としては、具体的には、クメンヒドロペルオキシド、p-サイメンヒドロペルオキシド、t-ブチルイソプロピルベンゼンヒドロペルオキシド、ジイソプロピルベンゼンヒドロペルオキシド、p-メンタンヒドロペルオキシド、デカリンヒドロペルオキシド、t-アミルヒドロペルオキシド、t-ブチルヒドロペルオキシド、イソプロピルヒドロペルオキシド等のヒドロペルオキシド類が挙げられる。これらは1種を用いてもよく、2種以上を組み合わせて用いてもよい。
上記アクリル系単量体混合物(A)を乳化重合して得られた重合体分散液(D)中で、下式(1)を満足する量の重合開始剤及び重合禁止剤の存在下でアクリル系単量体混合物(B)を乳化重合する。
(式(1)中、Qは重合禁止剤のモル量を示し、Iは重合禁止剤の投入前に重合体分散液中に存在する重合開始剤のモル量を示す。)
kd:重合開始剤の熱分解速度定数
A:重合開始剤の頻度因子(1/s)
△E:重合開始剤の活性化エネルギー(J/mol)
R:気体定数(8.314J/mol・K)
T:重合反応の絶対温度(K)
重合開始剤の残存率(%)=exp(-kdt)×100 (4)
t:重合反応時間(s)
A=2.87×1016(1/s)
△E=137937(J/mol)
である。
本発明の製造方法により得られるアクリル系重合体の重量平均分子量は、1万~400万であることが好ましく、より好ましくは5万~300万であり、更に好ましくは30万~200万の範囲である。重量平均分子量が400万以下であれば、可塑剤により容易に可塑化され、プラスチゾルとして優れた加工性を有するものが得られ、1万以上であれば、プラスチゾルとして貯蔵安定性が低下するのを抑制することができる。
本発明のプラスチゾル組成物は、上記アクリル系重合体の製造方法により得られるアクリル系重合体と可塑剤とを含み、必要に応じてその他フィラー等を混合して得られる。上記アクリル系重合体を含有することにより、貯蔵安定性に優れ、ゾル性状を長期に亘って保持することができる。
[アクリル系重合体の調製]
温度計、窒素ガス導入管、攪拌棒、滴下漏斗及び冷却管を装備した2リットルの4つ口フラスコに、イオン交換水544gを入れ、30分間窒素ガスを通気し、イオン交換水中の溶存酸素を置換した。窒素ガスの通気を停止した後、200rpmで攪拌しながら80℃に昇温した。内温が80℃に達した時点で、メタクリル酸メチル26.1g、メタクリル酸n-ブチル19.9gの単量体混合物(S)を一括投入した。続いて過硫酸カリウム0.40gとイオン交換水16gを投入した。続いて45分後にジアルキルスルホコハク酸ナトリウム(商品名:ペレックスOT-P、花王(株)製)0.32g及びイオン交換水16.0gを投入した。さらに15分後にメタクリル酸メチル336g、メタクリル酸t-ブチル318g、メタクリル酸2-ヒドロキシエチル17.5g、ペレックスOT-P5.8g及びイオン交換水235gの単量体混合物(A)を4時間30分間かけて滴下して重合を完了し、重合体(A)の分散液を得た。
重合開始剤投入後、重合温度は80℃で一定であり、重合禁止剤は重合開始剤投入時から390分後に投入した。
炭酸カルシウム(商品名:NS#200、日東粉化工業(株)製)100部、表面処理炭酸カルシウム(商品名:白艶華CCR、白石工業(株)製)150部と、可塑剤としてジイソノニルフタレート((株)ジェイプラス製)180部、アルキルスルフォン酸フェニル系可塑剤(商品名:Mesamoll、バイエル社製)20部、ブロックウレタン樹脂(商品名:タケネートB-7040、三井化学ポリウレタン(株)製)40部、アジピン酸ジヒドラジド(商品名:アジピン酸ジヒドラジド、大塚化学(株)製)1.76部、酸化カルシウム3部を計量し真空ミキサーARV-200((株)シンキー製)にて5秒間大気圧(0.1MPa)で混合した後、2.7kPaに減圧して175秒間混合して炭酸カルシウムと可塑剤の混練物を得た。続いて重合体(P-1)100部を添加し真空ミキサーにて5秒間大気圧下(0.1MPa)で混合した後、2.7kPaに減圧して115秒間混合しプラスチゾル組成物を得た。得られたプラスチゾル組成物について、耐チッピング強度、接着強度、引張強度、引張伸度、貯蔵安定性について以下のように評価した。結果を表2に示す。
70×25×0.8mmのカチオン電着版(日本ルートサービス(株)製)2枚を45mm重ねて、この間の中央部にプラスチゾル組成物を25×25×3mmに塗布し、130℃で30分加熱して試験片を得た。得られた試験片の2枚のカチオン電着板を23℃環境下で長軸反対方向に引張り、剪断接着強度を測定した。測定には引張測定装置(商品名:AG-IS 5KN、(株)島津製作所製)を用い、試験速度を50mm/分とした。
テフロン(登録商標)コーティングした鉄板上にプラスチゾル組成物を2mm厚で塗布し、130℃のオーブン中30分間で加熱し塗膜を得た。この塗膜をダンベル2号形状に打ち抜き、試験片を得た。これを23℃環境下で引張試験を行い、塗膜の強度を測定した。測定には引張測定装置(商品名:AG-IS 5KN、(株)島津製作所製)を用い、試験速度を200mm/分とした。
プラスチゾル組成物を、150×70×0.8mmのカチオン電着版(日本ルートサービス(株)製)に塗布し、130℃で30分加熱し、膜厚1mmの被膜を成形した。縦2mm×横4mmの切込みを入れて試験片とし、水平から60度の角度で設置した。真鋳製ナット(M4サイズ)3kgを直径20mmの塩ビパイプを通して2mの高さから試験片に衝突させる試験を繰り返し、試験片が破壊して基材が露出するまでに落したナットの合計質量を測定した。
重合体(P-1)100部、可塑剤としてジイソノニルフタレート((株)ジェイプラス製)100部を真空ミキサーにて5秒間大気圧下(0.1MPa)で混合した後、2.7kPaに減圧して115秒間混合し貯蔵安定性評価用プラスチゾル組成物を得た。得られたプラスチゾル組成物を25℃の恒温槽で2時間保温した後、BH型粘度計((株)東京計器製)NO.7ローターを用いて、回転数20rpmにおいて1分後の粘度(α)(単位:Pa・s)を測定し初期粘度とした。測定後の貯蔵安定性評価用プラスチゾル組成物を40℃雰囲気下で保管し、初期粘度と同様の方法で5日後、10日後の粘度(β)を測定し、この値と初期粘度(α)から下記式(5)により増粘率(%)を求めた。
増粘率(%)=〔(β-α)/α〕×100 (5)
単量体混合物(A)、単量体混合物(B)、重合禁止剤種類及び量、重合禁止剤投入時及び投入方法を、表2に示すように変更した以外は、実施例1と同様に重合体P-2~P-11、及びC-1~C-4を調製し、プラスチゾル組成物を調製し、評価を行った。結果を表2に示す。
MMA:メタクリル酸メチル(三菱レイヨン(株)製)
t-BMA:メタクリル酸-t-ブチル(三菱レイヨン(株)製)
i-BMA:メタクリル酸-i-ブチル(三菱レイヨン(株)製)
2-HEMA:メタクリル酸-2-ヒドロキシエチル(三菱レイヨン(株)製)
MEHQ:p-メトキシフェノール(関東化学(株)製)
TBC:t-ブチルカテコール(東京化成工業(株)製)
DPA:ジフェニルアミン(ナカライタスク(株)製)
Claims (4)
- アクリル系単量体混合物(A)を乳化重合する工程と、
その乳化重合によって得られた重合体分散液(D)中で、下記式(1)を満足する量の重合開始剤及び重合禁止剤の存在下でアクリル系単量体混合物(B)を乳化重合する工程とを含み、
アクリル系単量体混合物(A)とアクリル系単量体混合物(B)との質量比(A)/(B)が、70/30~95/5であるアクリル系重合体の製造方法。
0.1≦Q/I≦30 (1)
(式(1)中、Qは重合禁止剤のモル量を示し、Iは重合禁止剤の投入前に重合体分散液(D)中に存在する重合開始剤のモル量を示す。) - アクリル系単量体混合物(A)を重合して得られる重合体(A)の溶解パラメーター(SA)が、アクリル系単量体混合物(B)を重合して得られる重合体(B)の溶解パラメーター(SB)より小さい請求項1記載のアクリル系重合体の製造方法。
- 請求項1又は2に記載の製造方法により得られたアクリル系重合体。
- 請求項3記載のアクリル系重合体及び可塑剤を含むプラスチゾル組成物。
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Also Published As
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CN102933612B (zh) | 2014-10-01 |
EP2581392B1 (en) | 2018-05-30 |
EP2581392A1 (en) | 2013-04-17 |
JPWO2011155566A1 (ja) | 2013-08-01 |
KR101761452B1 (ko) | 2017-07-25 |
CN102933612A (zh) | 2013-02-13 |
US20130210979A1 (en) | 2013-08-15 |
US9056933B2 (en) | 2015-06-16 |
EP2581392A4 (en) | 2013-12-18 |
KR20130084653A (ko) | 2013-07-25 |
JP5942429B2 (ja) | 2016-06-29 |
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