WO2021124951A1 - アイオノマー樹脂、樹脂シートおよび合わせガラス - Google Patents
アイオノマー樹脂、樹脂シートおよび合わせガラス Download PDFInfo
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- WO2021124951A1 WO2021124951A1 PCT/JP2020/045450 JP2020045450W WO2021124951A1 WO 2021124951 A1 WO2021124951 A1 WO 2021124951A1 JP 2020045450 W JP2020045450 W JP 2020045450W WO 2021124951 A1 WO2021124951 A1 WO 2021124951A1
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- Prior art keywords
- ionomer resin
- meth
- unit
- resin
- acrylic acid
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- 239000011347 resin Substances 0.000 title claims abstract description 411
- 229920000554 ionomer Polymers 0.000 title claims abstract description 300
- 239000005340 laminated glass Substances 0.000 title claims description 50
- 239000005357 flat glass Substances 0.000 title description 5
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical group CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims abstract description 116
- 150000003839 salts Chemical class 0.000 claims abstract description 78
- 239000000178 monomer Substances 0.000 claims abstract description 38
- 239000002253 acid Substances 0.000 claims abstract description 27
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims abstract description 25
- 239000005977 Ethylene Substances 0.000 claims abstract description 25
- 239000010410 layer Substances 0.000 claims description 47
- -1 halogen ion Chemical class 0.000 claims description 36
- 239000011229 interlayer Substances 0.000 claims description 28
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- 239000002585 base Substances 0.000 claims description 22
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 11
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 6
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 229910052783 alkali metal Inorganic materials 0.000 claims description 5
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 5
- 229910052736 halogen Inorganic materials 0.000 claims description 5
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 claims description 4
- 150000001450 anions Chemical class 0.000 claims description 4
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- 229910001415 sodium ion Inorganic materials 0.000 claims description 4
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- NPYPAHLBTDXSSS-UHFFFAOYSA-N Potassium ion Chemical compound [K+] NPYPAHLBTDXSSS-UHFFFAOYSA-N 0.000 claims description 3
- 150000001340 alkali metals Chemical class 0.000 claims description 3
- 150000001342 alkaline earth metals Chemical class 0.000 claims description 3
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- 238000000034 method Methods 0.000 description 79
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 75
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 68
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- 238000007127 saponification reaction Methods 0.000 description 20
- 238000010583 slow cooling Methods 0.000 description 20
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 18
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- 238000000465 moulding Methods 0.000 description 15
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- 238000005979 thermal decomposition reaction Methods 0.000 description 9
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Natural products CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 8
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 8
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 8
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- 230000008018 melting Effects 0.000 description 7
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- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 6
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- 229910052698 phosphorus Inorganic materials 0.000 description 6
- 239000011574 phosphorus Substances 0.000 description 6
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 description 6
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- 150000001875 compounds Chemical class 0.000 description 5
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- DMBHHRLKUKUOEG-UHFFFAOYSA-N diphenylamine Chemical compound C=1C=CC=CC=1NC1=CC=CC=C1 DMBHHRLKUKUOEG-UHFFFAOYSA-N 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 238000001914 filtration Methods 0.000 description 5
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 5
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- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 4
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- 239000006057 Non-nutritive feed additive Substances 0.000 description 4
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- IYAZLDLPUNDVAG-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4-(2,4,4-trimethylpentan-2-yl)phenol Chemical compound CC(C)(C)CC(C)(C)C1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 IYAZLDLPUNDVAG-UHFFFAOYSA-N 0.000 description 3
- CFVWNXQPGQOHRJ-UHFFFAOYSA-N 2-methylpropyl prop-2-enoate Chemical compound CC(C)COC(=O)C=C CFVWNXQPGQOHRJ-UHFFFAOYSA-N 0.000 description 3
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- OLFNXLXEGXRUOI-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-bis(2-phenylpropan-2-yl)phenol Chemical compound C=1C(N2N=C3C=CC=CC3=N2)=C(O)C(C(C)(C)C=2C=CC=CC=2)=CC=1C(C)(C)C1=CC=CC=C1 OLFNXLXEGXRUOI-UHFFFAOYSA-N 0.000 description 2
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- 125000001280 n-hexyl group Chemical group C(CCCCC)* 0.000 description 1
- 125000000740 n-pentyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
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- 150000003297 rubidium Chemical class 0.000 description 1
- 150000003873 salicylate salts Chemical class 0.000 description 1
- 239000012488 sample solution Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
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- 239000002356 single layer Substances 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
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- 239000012321 sodium triacetoxyborohydride Substances 0.000 description 1
- 238000000371 solid-state nuclear magnetic resonance spectroscopy Methods 0.000 description 1
- 159000000008 strontium salts Chemical class 0.000 description 1
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- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
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- 150000003613 toluenes Chemical class 0.000 description 1
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Classifications
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- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
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Definitions
- the present invention relates to an ionomer resin, a resin sheet having one or more layers containing the ionomer resin, a laminated glass interlayer film made of the resin sheet, and a laminated glass having the laminated glass interlayer film.
- Ionomer which is a neutralized product of an ethylene-unsaturated carboxylic acid copolymer, is used as an interlayer film of laminated glass because of its excellent transparency and adhesiveness to glass (for example, Patent Document 1).
- Patent Document 1 the required performance for laminated glass has increased, and even for ionomer resins, high transparency is maintained regardless of the manufacturing conditions of laminated glass, high elastic modulus is maintained even at high temperatures, and the strength of laminated glass is reduced. There has been a demand for not allowing it to occur, and for having less coloring and an excellent appearance.
- Patent Document 2 describes a copolymerization unit of ethylene, a copolymerization unit of first ⁇ and ⁇ -unsaturated carboxylic acid having 3 to 10 carbon atoms, and a second ⁇ having 3 to 10 carbon atoms.
- Ionomer a neutralized product of an ethylenic acid copolymer containing a copolymerization unit of a ⁇ -unsaturated carboxylic acid derivative, is described.
- Patent Document 2 describes that the ionomer described in the document exhibits improved optical characteristics (haze) as compared with the conventional ionomer.
- the ionomer described in Patent Document 2 is easily thermally decomposed during the molding process, and the obtained interlayer film is likely to have defects such as black foreign matter.
- an object of the present invention is to provide an ionomer resin having high transparency and high thermostable decomposition property.
- the present inventors have arrived at the present invention as a result of diligent studies to solve the above problems. That is, the present invention provides the following suitable forms.
- (Meta) Acrylic acid unit (A), (Meta) Acrylic acid neutralized product unit (B), and ethylene unit (C) Ionomer resin including
- the total content of the unit (A) and the unit (B) is 6 to 10 mol% based on all the monomer units constituting the ionomer resin, and is composed of a strong acid and a strong base in the ionomer resin.
- Ionomer resin having a salt content of 1 to 400 mg / kg.
- the ionomer resin further contains a (meth) acrylic acid ester unit (D), and the total content of the unit (A), the unit (B) and the unit (D) constitutes the ionomer resin.
- the salt composed of the strong acid and the strong base is at least one cation selected from the group consisting of sodium ion and potassium ion, and at least one selected from the group consisting of halogen ion, nitrate ion, and sulfate ion.
- [5] A resin sheet having one or more layers containing the ionomer resin according to any one of [1] to [4].
- [6] A laminated glass interlayer film made of the resin sheet according to [5].
- [7] A laminated glass having two glass plates and a laminated glass interlayer film according to [6] arranged between the two glass plates.
- the ionomer resin of the present invention contains a (meth) acrylic acid unit (A), a (meth) acrylic acid neutralized product unit (B), and an ethylene unit (C), and the unit (A) and the unit (B).
- the total content of the ionomer resin is 6 to 10 mol% based on all the monomer units constituting the ionomer resin.
- the "unit” means a "constituent unit of origin", and for example, the (meth) acrylic acid unit indicates a structural unit derived from (meth) acrylic acid, and is (meth) acrylic.
- the acid neutralized product unit indicates a structural unit derived from a (meth) acrylic acid neutralized product
- the ethylene unit indicates a structural unit derived from ethylene.
- (meth) acrylic acid means methacrylic acid or acrylic acid.
- the total content exceeds the above upper limit value, it is difficult to suppress an increase in the melt viscosity during the molding process of the ionomer resin, and as a result, the molding processability of the ionomer resin tends to decrease. Further, when the total content is less than the above lower limit, the transparency of the ionomer resin, particularly the transparency when the ionomer resin is slowly cooled to promote the crystallization of the ionomer resin (hereinafter, also referred to as the transparency during slow cooling). ) Is likely to decrease.
- the total content is 6 mol% or more, preferably 6.5 mol% or more, from the viewpoint of easily improving the transparency of the ionomer resin (particularly the transparency during slow cooling) and the adhesiveness to a substrate such as glass. It is more preferably 7.0 mol% or more, still more preferably 7.5 mol% or more, and from the viewpoint of easily improving the molding processability, it is 10 mol% or less, preferably 9.9 mol% or less, more preferably. Is 9.5 mol% or less.
- the total content of the unit (A) and the unit (B) can be adjusted by the method for producing the ionomer resin. More specifically, when an ionomer resin is produced by using an ethylene- (meth) acrylic acid ester copolymer as a raw material and a method including a saponification reaction step of the copolymer, the ethylene- (meth) acrylic acid ester Each reaction that converts (meth) acrylic acid ester units in the copolymer into (meth) acrylic acid units (A) and (meth) acrylic acid neutralized product units (B) by the saponification reaction and demetallization reaction. It can be adjusted by the degree of reaction (conversion rate) of.
- (meth) acrylic acid unit (A) examples include acrylic acid and methacrylic acid, and methacrylic acid is preferable from the viewpoint of heat resistance and adhesiveness to a substrate. These (meth) acrylic acid units may be used alone or in combination of two.
- the content of the (meth) acrylic acid unit (A) in the ionomer resin is such that the total content of the unit (A) and the unit (B) is 6 to 6 based on all the monomer units constituting the ionomer resin. There is no particular limitation as long as it is within the range of 10 mol%. In one embodiment of the present invention, the content of the (meth) acrylic acid unit (A) in the ionomer resin is preferably 4.5 mol% or more, based on all the monomer units constituting the ionomer resin.
- It is preferably 5.0 mol% or more, more preferably 5.5 mol% or more, particularly preferably 5.8 mol% or more, and preferably 9.0 mol% or less, more preferably 8.5 mol% or more. Below, it is more preferably 8.0 mol% or less, and particularly preferably 7.5 mol% or less.
- the content of the unit (A) is at least the above lower limit value, the transparency of the ionomer resin and the adhesiveness to the substrate are likely to be improved. Further, when it is not more than the above upper limit value, the molding processability is likely to be improved.
- the (meth) acrylic acid neutralized product unit (B) is preferable.
- the (meth) acrylic acid neutralized product is obtained by replacing the hydrogen ion of (meth) acrylic acid with a metal ion.
- the metal ions include ions of monovalent metals such as lithium, sodium and potassium, and ions of polyvalent metals such as magnesium, calcium, zinc, aluminum and titanium. Such metal ions may be used alone or in combination of two or more. For example, it may be a combination of one or more kinds of monovalent metal ions and one or more kinds of divalent metal ions.
- the content of the (meth) acrylic acid neutralized substance unit (B) in the ionomer resin is such that the total content of the unit (A) and the unit (B) is the total monomer unit constituting the ionomer resin.
- the content of the (meth) acrylic acid neutralized product unit (B) is preferably 0.65 mol% or more, more preferably 0.65 mol% or more, based on all the monomer units constituting the ionomer resin.
- Each content of the unit (A) and the unit (B) is made from an ethylene- (meth) acrylic acid ester copolymer as a raw material, and is an ionomer by a method including a saponification reaction step and a metal removal reaction step of the copolymer.
- the (meth) acrylic acid ester unit in the ethylene- (meth) acrylic acid ester copolymer is subjected to the saponification reaction and the demetallization reaction to form the (meth) acrylic acid unit (A) and (meth). It can be adjusted by the degree of reaction in each reaction to be converted into the acrylic acid neutralized product unit (B).
- the content of the ethylene unit (C) is preferably 80 mol% or more, more preferably 85 mol% or more, based on all the monomer units constituting the ionomer resin, from the viewpoint of easily increasing the impact resistance of the ionomer resin. It is more preferably 88 mol% or more, and preferably 94 mol% or less, more preferably 91 mol% or less, from the viewpoint of easily increasing the transparency of the ionomer resin (particularly the transparency at the time of slow cooling).
- the content of the ethylene unit (C) is at least the above lower limit value, the mechanical strength and molding processability are likely to be improved, and when it is at least the above upper limit value, the transparency is likely to be improved.
- the ionomer resin of the present invention can easily obtain higher transparency. Further, it is preferable to contain the (meth) acrylic acid ester unit (D).
- the ionomer resin contains a (meth) acrylic acid ester unit (D)
- the total content of the unit (A), the unit (B) and the unit (D) is transparent (particularly transparency during slow cooling). ) Is easily improved, and it is preferably 6 to 10 mol% based on all the monomer units constituting the ionomer resin. That is, in a preferred embodiment of the present invention, the ionomer resin of the present invention comprises (meth) acrylic acid unit (A), (meth) acrylic acid neutralized unit (B), ethylene unit (C), and (meth).
- Acrylic acid ester unit (D) is included, and the total content of the unit (A), the unit (B), and the unit (D) is 6 to 6 based on all the monomer units constituting the ionomer resin. It is 10 mol%.
- the ionomer resin contains a (meth) acrylic acid ester unit (D)
- the ionomer resin It is easy to suppress an increase in melt viscosity during molding, and thereby it is easy to improve the molding processability of the ionomer resin.
- the total content is at least the lower limit value
- the transparency of the ionomer resin tends to be enhanced.
- the ionomer resin contains a (meth) acrylic acid ester unit (D)
- the total content of the unit (A), the unit (B) and the unit (D) is transparent (particularly during slow cooling).
- the content is 6 mol% or more, preferably 6.5 mol% or more, more preferably 7.0 mol% or more, still more preferably 7.5 mol% or more.
- it is 10 mol% or less, preferably 9.9 mol% or less, and more preferably 9.5 mol% or less.
- the total content of the unit (A), the unit (B) and the unit (D) can be adjusted by the raw material of the ionomer resin. More specifically, when an ionomer resin is produced by using an ethylene- (meth) acrylic acid ester copolymer as a raw material and a method including a saponomerization reaction step of the copolymer, ethylene-, which is a raw material of the ionomer resin, is produced. It can be adjusted by the amount of (meth) acrylic acid ester modification of the (meth) acrylic acid ester copolymer. Further, as described in US Pat. No.
- Examples of the monomer constituting the (meth) acrylic acid ester unit (D) include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, and isopropyl (meth) acrylate.
- preferable monomers from the viewpoint of transparency or heat resistance are methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, and ( N-Butyl (meth) acrylate, isobutyl (meth) acrylate, sec-butyl (meth) acrylate, t-butyl (meth) acrylate, and more preferred monomers are methyl (meth) acrylate, ( Ethyl acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, and more preferred monomers are (meth).
- Methyl acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, and a particularly preferred monomer is methyl (meth) acrylate.
- These (meth) acrylic acid esters may be used alone or in combination of two or more.
- the content of the (meth) acrylic acid ester unit (D) in the ionomer resin is not particularly limited.
- the content of the (meth) acrylic acid ester unit (D) in the ionomer resin is preferably more than 0 mol%, more preferably more than 0 mol%, based on all the monomer units constituting the ionomer resin. Is 0.01 mol% or more, more preferably 0.05 mol% or more, particularly preferably 0.08 mol% or more, and preferably 1.0 mol% or less, more preferably 0.7 mol% or less. , More preferably 0.5 mol% or less.
- the content of the unit (D) is at least the above lower limit value and at least the above upper limit value, the transparency of the ionomer resin is likely to be improved.
- the content of the unit (D) is a step of saponification reaction of the copolymer using an ethylene- (meth) acrylic acid ester copolymer as a raw material.
- the ionomer resin is produced by a method including a demetallization reaction step, the (meth) acrylic acid ester unit (D) in the ethylene- (meth) acrylic acid ester copolymer is replaced with the (meth) acrylic acid unit (A). It can be adjusted by the degree of reaction of the saponification reaction to be converted into.
- the ionomer resin of the present invention comprises a (meth) acrylic acid unit (A), a (meth) acrylic acid neutralized unit (B), and an ethylene unit (C), and optionally a (meth) acrylic acid ester unit (meth). It may contain other monomer units other than D). Examples of other monomer units include a carboxylic acid unit (A2) other than the (meth) acrylic acid unit (A) and a carboxylic acid neutralized product unit (B) other than the (meth) acrylic acid neutralized unit (B). B2) and the like can be mentioned.
- Examples of the monomer constituting the carboxylic acid unit (A2) include itaconic acid, maleic anhydride, monomethyl maleate, monoethyl maleate and the like, and monomethyl maleate and monoethyl maleate are preferable.
- Examples of the monomer constituting the carboxylic acid neutralized product unit (B2) include the neutralized product unit of the carboxylic acid unit (A2).
- the carboxylic acid neutralized product is obtained by replacing the hydrogen ion of the carboxylic acid with a metal ion.
- Examples of the metal ion include the same as the metal ion in the above-mentioned (meth) acrylic acid neutralized product unit (B), and the metal ion may be one kind alone or a combination of two or more kinds. These other monomer units may be used alone or in combination of two or more.
- the total content thereof for example, the total contents of (A2) and (B2) may be appropriately selected within a range that does not impair the effects of the present invention, for example.
- the monomer units constituting the ionomer resin it is preferably 5 mol% or less, more preferably 3 mol% or less, further preferably 1 mol% or less, and preferably 0.01 mol% or more. More preferably, it is 0.1 mol% or more.
- NMR nuclear magnetic resonance spectroscopy
- the ionomer resin of the present invention contains 1 to 400 mg / kg of a salt composed of a strong acid and a strong base (hereinafter, also simply referred to as “salt”).
- salt a salt composed of a strong acid and a strong base
- the present inventors have found that when the ionomer resin contains 1 to 400 mg / kg of salt, the thermostable decomposition property can be improved while maintaining the high transparency of the ionomer resin (particularly the transparency at the time of water absorption). Therefore, the ionomer resin of the present invention can achieve both high transparency and high thermodegradability.
- the ionomer resin of the present invention is excellent in thermostable decomposition property by containing a salt within the above range is not clear, but due to the interaction between the salt and the (meth) acrylic acid unit (A) in the ionomer resin, the ionomer It is considered that this is because the (meth) acrylic acid unit (A) in the resin can be suppressed from being desorbed by heat.
- the salt content exceeds the above upper limit value, the transparency of the ionomer resin tends to decrease, and if it is less than the above lower limit value, the thermostable decomposition property decreases, and for example, during molding processing, the ionomer tends to decrease.
- the resin is easily thermally decomposed.
- the content of the salt is 1 mg / kg or more, preferably 3 mg / kg or more, and more preferably 5 mg / kg or more from the viewpoint of easily improving the thermostable decomposition property. Further, from the viewpoint of easily improving the transparency (particularly the transparency at the time of water absorption), it is 400 mg / kg or less, preferably 300 mg / kg or less, and more preferably 200 mg / kg or less.
- the salt content in the ionomer resin can be appropriately selected depending on the method for adding the salt to the ionomer resin as described later.
- the salt content in the ionomer resin can be measured by using an ion chromatograph, for example, by the method described in Examples.
- the salt composed of a strong acid and a strong base is not particularly limited, and examples thereof include a metal salt of an alkali metal and / or an alkaline earth metal composed of a strong acid and a strong base. These salts may be used alone or in combination of two or more.
- alkali metal salts include lithium salt, sodium salt, potassium salt, rubidium salt, cesium salt and the like.
- the preferred alkali metal salt is a lithium salt, a sodium salt, a potassium salt, more preferably a sodium salt or a potassium salt, and further preferably a sodium salt.
- alkaline earth metal salts examples include beryllium salt, magnesium salt, calcium salt, strontium salt, barium salt and the like. From the viewpoint of easily enhancing the heat-resistant decomposition property of the ionomer resin, preferable alkaline earth metal salts are magnesium salts and calcium salts.
- more preferable salts are at least one cation selected from the group consisting of sodium ion, potassium ion, magnesium ion and calcium ion, and halogen ion, sulfate ion and nitrate ion.
- a salt consisting of at least one anion selected from the group consisting of nitrate ions are at least one anion selected from the group consisting of sodium ion, potassium ion, magnesium ion and calcium ion, and halogen ion, sulfate ion and nitrate ion.
- Specific preferred salt examples include sodium chloride, potassium chloride, magnesium chloride, calcium chloride, sodium sulfate, potassium sulfate, magnesium sulfate, calcium sulfate, sodium nitrate, potassium nitrate, magnesium nitrate, calcium nitrate, p-toluenesulfonic acid.
- Examples thereof include sodium, potassium p-toluenesulfonate, magnesium p-toluenesulfonate, and calcium p-toluenesulfonate.
- more preferable salts are sodium chloride, potassium chloride, sodium sulfate, potassium sulfate, sodium nitrate, potassium nitrate, and more preferably sodium chloride, sodium sulfate, and sodium nitrate.
- the method of containing the salt in the ionomer resin is not particularly limited, and for example, (I) a method of producing and containing a salt in the process of producing the ionomer resin, (II) a method of attaching a salt in the process of producing the ionomer resin, and the like. (III) A method of producing an ionomer resin containing no salt and then adding a salt to the resin can be mentioned. Among these methods, from the viewpoint that the salt can be easily dispersed uniformly in the ionomer resin, thereby improving the transparency and the thermostable decomposition property, the salt is generated and contained in the ionomer resin manufacturing process (the above method). I) is preferable.
- the method for adjusting the content of the salt consisting of a strong acid and a strong base in the ionomer resin can be appropriately selected according to the above-mentioned salt content method.
- the salt when the salt is contained by the method (I), it can be adjusted by the degree of cleaning of the obtained resin. More specifically, the salt content in the ionomer resin can be adjusted by the number of washings in the step of washing the obtained resin with the washing liquid.
- the cleaning solution include solvents that are good solvents for salts and poor solvents for resins, such as water, alcohols such as methanol, ketones such as acetone, and mixed solvents thereof.
- the content of the salt in the ionomer resin can be adjusted by the amount of the attached salt and the amount of the salt to be added later.
- the dispersed state of the salt composed of a strong acid and a strong base in the ionomer resin is not particularly limited, but it is preferable that the salt is uniformly dispersed in the ionomer resin from the viewpoint of easily improving transparency and thermostable decomposition.
- the degree of branching per 1000 carbons of the ionomer resin of the present invention is not particularly limited, and is preferably 5 to 30, more preferably 6 to 20.
- the degree of branching is adjusted by the temperature at which the ionomer resin is polymerized, for example, when the ionomer resin is synthesized by the EMMA saponification method, the polymerization temperature at the time of synthesizing ethylene- (meth) acrylic acid ester (X). it can.
- the degree of branching per 1000 carbons can be measured by the DDMAS method using solid-state NMR.
- the melting point of the ionomer resin of the present invention is preferably 50 ° C. or higher, more preferably 60 ° C. or higher, still more preferably 80 ° C. or higher, from the viewpoint of heat resistance and heat-degradability.
- the temperature is preferably 200 ° C. or lower, more preferably 180 ° C. or lower, and further preferably 150 ° C. or lower.
- the melting point can be measured based on JIS K7121: 2012.
- DSC differential scanning calorimeter
- the heat of fusion of the ionomer resin of the present invention is preferably 0 J / g or more and 25 J / g or less.
- the heat of fusion can be measured based on JIS K7122: 2012. Specifically, it is measured using a differential scanning calorimeter (DSC) under the conditions of a cooling rate of -10 ° C / min and a temperature rise rate of 10 ° C / min, and is calculated from the area of the melting peak at the time of the second temperature rise. can do.
- DSC differential scanning calorimeter
- the melt flow rate (MFR) of the ionomer resin of the present invention measured under the conditions of 190 ° C. and 2.16 kg according to JIS K7210-1: 2014 is preferably 0.1 g / g. 10 minutes or more, more preferably 0.3 g / 10 minutes or more, still more preferably 0.7 g / 10 minutes or more, even more preferably 1.0 g / 10 minutes or more, particularly preferably 1.5 g / 10 minutes or more. It is preferably 50 g / 10 minutes or less, more preferably 30 g / 10 minutes or less, and particularly preferably 10 g / 10 minutes or less.
- the MFR of the ionomer resin is not less than the above lower limit value and not more than the upper limit value, it is easy to perform molding processing suppressing deterioration due to heat, and it is easy to obtain a resin sheet having excellent penetration resistance.
- the melting point, heat of fusion and MFR of the ionomer resin are the molecular weight of the ionomer resin, and the (meth) acrylic acid unit (A), the (meth) acrylic acid neutralized unit (B), and the ethylene unit (C) of the ionomer resin. It can also be adjusted by the content of the (meth) acrylic acid ester unit (D), which is optionally included.
- the storage elastic modulus (E') at 50 ° C. measured by the dynamic viscoelasticity measurement of the ionomer resin of the present invention is good independence (that is, high elastic modulus), particularly high temperature. From the viewpoint of independence in an environment (high elastic modulus in a high temperature environment), it is preferably 20 MPa or more, more preferably 30 MPa or more, still more preferably 40 MPa or more, and particularly preferably 50 MPa or more.
- the upper limit of the storage elastic modulus (E') is not particularly limited and may be 1000 MPa.
- the storage modulus includes the molecular weight of the ionomer resin, as well as the (meth) acrylic acid unit (A), the (meth) acrylic acid neutralized unit (B), and the ethylene unit (C), and optionally (meth). It can be adjusted by the content of the acrylic acid ester unit (D).
- the ionomer resin of the present invention contains 1 to 400 mg / kg of salt as described above, it can have high heat-resistant decomposability.
- the 1% weight loss temperature (Td1) of the ionomer resin of the present invention at a temperature rise of 10 ° C./min under a nitrogen atmosphere is preferably 330 ° C. or higher, more preferably 350 ° C. or higher. More preferably, it is 360 ° C. or higher, particularly preferably 370 ° C. or higher, and usually 450 ° C. or lower.
- the 1% weight loss temperature of the ionomer resin is equal to or higher than the above lower limit value, it is easy to reduce foaming and / or thermal decomposition during melt molding of the ionomer resin, and black foreign matter and the like generated by thermal decomposition of air bubbles and / or the resin are generated. It is easy to obtain an interlayer film that has no defects.
- the 1% weight loss temperature represents the temperature at which the weight loss rate becomes 1% based on the weight at 200 ° C.
- the 1% weight loss temperature can be measured according to JIS K7120: 1987, and can be measured, for example, by the method described in Examples.
- the ionomer resin of the present invention has high transparency, and in a preferred embodiment of the present invention, the haze of the ionomer resin of the present invention at a sheet thickness of 0.8 mm is preferably 2.0% or less, more preferably 2.0% or less. Is 1.5% or less, more preferably 1.0% or less.
- the haze of the ionomer resin is measured using a haze meter in accordance with JIS K7136: 2000.
- the present inventors tend to improve the thermal degradability of the ionomer resin when the ionomer resin contains a salt composed of a strong acid and a strong base, while when the salt content is too large, the transparency of the ionomer resin, particularly the ionomer resin It was found that the transparency (transparency at the time of water absorption) in the state of water absorption is reduced. Therefore, as a result of further studies, the present inventors have found that if the salt content of the ionomer resin is 400 mg / kg or less, the transparency of the ionomer resin in a water-absorbed state can be enhanced.
- the ionomer resin of the present invention having a salt content of 1 to 400 mg / kg has high transparency even when it absorbs water.
- the haze (water absorption haze) at a sheet thickness of 0.8 mm in a state where the ionomer resin of the present invention has absorbed water is preferably 9.0% or less, more preferably 5.0% or less. More preferably, it is 3.0% or less.
- the lower limit is not particularly limited and may be, for example, 0.01%.
- the ionomer resin was kept immersed in ion-exchanged water at 23 ° C. for 300 hours, removed from the ion-exchanged water, and the ionomer resin from which the water adhering to the surface was wiped off was used as a test piece and a haze meter was used.
- JIS K7136 2000, and can be measured, for example, by the method described in Examples.
- the ionomer resin if the crystallinity of the ionomer resin is too high, the ionomer resin tends to whiten. Therefore, the ionomer resin is slowly cooled to be transparent in a state where the crystallization of the resin is promoted. The property (transparency during slow cooling) tends to decrease.
- the ionomer resin obtained by the present invention is difficult to crystallize because the total content of the (meth) acrylic acid unit (A) and the (meth) acrylic acid neutralized product unit (B) in the resin is 6 mol% or more. Therefore, it has high transparency even during slow cooling.
- the haze (slow cooling haze) in a state in which the crystallization of the ionomer resin of the present invention is promoted by slow cooling is preferably 5.0% or less, more preferably 4. It is 5% or less, more preferably 4.0% or less, even more preferably 3.0% or less, and particularly preferably 2.5% or less.
- an ionomer resin having a sheet thickness of 0.8 mm is placed between two glass plates to prepare a laminated glass, and the laminated glass is heated to 140 ° C. and then 140 ° C. to 0.1 ° C./min. It is obtained by measuring the haze after slowly cooling to 23 ° C. with a haze meter in accordance with JIS K7136: 2000.
- the ionomer resin of the present invention has a low degree of coloring and is preferably colorless.
- the yellowness (YI) of the ionomer resin of the present invention at a sheet thickness of 0.8 mm is preferably 2.0 or less, more preferably 1.8 or less, still more preferably 1.5 or less, from the viewpoint of low colorability. Particularly preferably, it is 1.0 or less.
- the yellowness (YI) can be measured in accordance with JIS Z8722: 2009 using a color difference meter.
- the method for producing the ionomer resin of the present invention is not particularly limited.
- the ionomer resin is produced by producing a salt in the production process. Even if (II) it is produced by attaching a salt in the production process of the ionomer resin, (III) it is produced by first producing an ionomer resin containing no salt and then adding a salt to the resin. You may.
- a salt composed of a strong acid and a strong base can be easily dispersed uniformly in the ionomer resin, thereby easily improving transparency and thermostable decomposition. Therefore, a salt is generated during the manufacturing process of the ionomer resin.
- the method (I) described above is preferable. Hereinafter, the method (I) will be described in detail.
- ethylene- (meth) acrylic acid ester copolymer (X) is used as a raw material, and all or a part of the (meth) acrylic acid ester unit in the copolymer is (meth) acrylic acid.
- Converted to units and (meth) acrylic acid neutralized units (meth) acrylic acid unit (A), (meth) acrylic acid neutralized product unit (B), ethylene unit (C) and optionally (meth)
- a crude ionomer resin containing an acrylic acid ester unit (D) was produced (step i), a poor solvent was added to the obtained crude ionomer resin solution to precipitate a granular resin (step ii), and then the precipitated granular resin was precipitated.
- Step iii can be mentioned.
- Step i> As a method of converting all or part of the (meth) acrylic acid ester unit in the ethylene- (meth) acrylic acid ester copolymer (X) into (meth) acrylic acid unit and (meth) acrylic acid neutralized product unit. Converts all or part of the (meth) acrylic acid ester unit to the (meth) acrylic acid neutralized product unit by saponifying the ethylene- (meth) acrylic acid ester copolymer (X) with a strong base. Then, an ethylene- (meth) acrylic acid ester- (meth) acrylic acid neutralized product copolymer was obtained, and then a part of the (meth) acrylic acid neutralized product unit in the obtained copolymer was strongly acidified.
- a method (hereinafter, also referred to as method (1)) of demetallizing and converting to (meth) acrylic acid unit can be mentioned.
- the (meth) acrylic acid neutralization in the ethylene- (meth) acrylic acid ester- (meth) acrylic acid neutralizer copolymer obtained by saponification in the above method (1) All the physical units are demetallized with a strong acid and converted into (meth) acrylic acid units to obtain an ethylene- (meth) acrylic acid copolymer, and then the (meth) acrylic acid units in the obtained copolymer.
- a method of neutralizing a part of the above with metal ions hereinafter, also referred to as method (2)) can be mentioned.
- a salt composed of a strong acid and a strong base is produced by a neutralization reaction between a strong base used for the saponification reaction and a strong acid used for demetallization, and is composed of the strong acid and the strong base.
- a crude ionomer resin containing a salt can be obtained.
- Examples of the monomers constituting the (meth) acrylic acid ester unit of the ethylene- (meth) acrylic acid ester copolymer (X) include methyl (meth) acrylic acid, ethyl (meth) acrylic acid, and (meth).
- N-propyl acrylate N-propyl acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, sec-butyl (meth) acrylate, t-butyl (meth) acrylate, (meth) ) Amyl acrylate, Isoamyl (meth) acrylate, n-hexyl (meth) acrylate, Cyclohexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, pentadecyl (meth) acrylate, dodecyl (meth) acrylate , (Meta) isobornyl acrylate, (meth) phenyl acrylate, benzyl (meth) acrylate, phenoxyethyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-meth
- preferred monomers are methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, ( Isobutyl acrylate, sec-butyl (meth) acrylate, t-butyl (meth) acrylate, more preferred monomers are methyl (meth) acrylate, ethyl (meth) acrylate, n (meth) acrylate.
- ethylene- (meth) acrylic acid ester copolymer (X) examples include an ethylene-methyl acrylate copolymer, an ethylene-methyl methacrylate copolymer, an ethylene-ethyl methacrylate copolymer, and an ethylene-methacryl copolymer.
- Ethyl acetate copolymer n-propyl copolymer of ethylene-acrylate, n-propyl copolymer of ethylene-methacrylate, isopropyl copolymer of ethylene-isopropylate, isopropyl copolymer of ethylene-isopropylacrylate, ethylene-acrylic acid
- examples thereof include an n-butyl copolymer, an ethylene-n-butyl methacrylate copolymer, a sec-butyl copolymer of ethylene-acrylate, a sec-butyl copolymer of ethylene-methacrylate and the like.
- copolymers As these copolymers, commercially available products may be used, or those synthesized by the high-temperature and high-pressure radical polymerization method described in US2013 / 0274424, JP-A-2006-23309 or JP-A-2007-84743 may be used.
- Examples of the commercially available product include "Aklift” (registered trademark) WD301F manufactured by Sumitomo Chemical Co., Ltd., "Lexpearl” (registered trademark) A4250 manufactured by Japan Polyethylene Corporation, and the like.
- the content of the (meth) acrylic acid ester unit in the ethylene- (meth) acrylic acid ester copolymer (X) is preferably 6 mol% or more, more preferably 6.5 mol% or more, still more preferably 7 mol. % Or more, particularly preferably 7.5 mol% or more, preferably 10 mol% or less, more preferably 9.9 mol% or less, still more preferably 9.5 mol% or less.
- the content of the (meth) acrylic acid ester unit in the copolymer (X) is the (meth) acrylic acid unit (A) and the (meth) acrylic acid neutralized product unit in the obtained crude ionomer resin and ionomer resin.
- the content of the (meth) acrylic acid ester unit in the copolymer (X) is the above lower limit.
- the transparency of the obtained ionomer resin particularly the transparency at the time of slow cooling, can be easily increased, and when the content is not more than the above upper limit value, the molding processability of the obtained ionomer resin is improved.
- the content of the (meth) acrylic acid ester unit in the copolymer (X) can be adjusted by the copolymerization ratio of ethylene and the (meth) acrylic acid ester.
- the content includes the (meth) acrylic acid unit (A), the (meth) acrylic acid neutralized product unit (B), and the ethylene unit (C) in the above-mentioned ionomer resin, and when contained (meth).
- the melt flow rate (MFR) of an ethylene- (meth) acrylic acid ester copolymer (X) measured at 190 ° C. and 2.16 kg in accordance with JIS K7210-1: 2014. ) Is preferably 5 g / 10 minutes or more, more preferably 10 g / 10 minutes or more, further preferably 50 g / 10 minutes or more, still more preferably 100 g / 10 minutes or more, preferably 400 g / 10 minutes or less, and more. It is preferably 350 g / 10 minutes or less, more preferably 300 g / 10 minutes or less, and even more preferably 250 g / 10 minutes or less.
- the MFR of the ethylene- (meth) acrylic acid ester copolymer (X) is not less than the above lower limit value and not more than the above upper limit value, the moldability and strength of the obtained ionomer resin can be easily improved.
- the MFR of the ethylene- (meth) acrylic acid ester copolymer (X) can be adjusted by the degree of polymerization and the content of the (meth) acrylic acid ester unit.
- the MFR can be measured, for example, by the method described in Examples.
- the weight average molecular weight of the ethylene- (meth) acrylic acid ester copolymer (X) is preferably 15,000 g / mol or more, more preferably 20 from the viewpoint of easily improving the moldability and strength of the obtained ionomer resin. It is 000 g / mol or more, more preferably 30,000 g / mol or more, preferably 200,000 g / mol or less, and more preferably 100,000 g / mol or less. From the same viewpoint, the number average molecular weight of the ethylene- (meth) acrylic acid ester copolymer (X) is preferably 5,000 g / mol or more, more preferably 10,000 g / mol or more, still more preferably 15.
- the weight average molecular weight and the number average molecular weight can be adjusted by the amount of the polymerization initiator and / or the chain transfer agent at the time of polymerization.
- the molecular weights (weight average molecular weight and number average molecular weight) of these ethylene- (meth) acrylic acid ester copolymers (X) are column ( three series of TSKgel GMH HR- H (20) HT) and 1,2, It can be measured in terms of polystyrene using a 4-trichlorobenzene solvent at a column temperature of 140 ° C.
- the degree of branching of the ethylene- (meth) acrylic acid ester copolymer (X) per 1000 carbons is not particularly limited, and is preferably 5 to 30, more preferably 6 to 20.
- the degree of bifurcation can be adjusted by the polymerization temperature when the copolymer (X) is polymerized.
- the degree of branching can be measured by the inverse gate decoupling method of 13 C-NMR in which the ethylene- (meth) acrylic acid ester copolymer (X) is dissolved in deuterated orthodichlorobenzene.
- Examples of the alkali used for the saponification reaction in the above methods (1) and (2) include strong bases such as sodium hydroxide, potassium hydroxide and calcium hydroxide, and the solubility in the solvent used for the saponification reaction and From the viewpoint of economy, sodium hydroxide and potassium hydroxide are preferable.
- Examples of the solvent used in the saponification reaction include ethers such as tetrahydrofuran and dioxane; halogen-containing solvents such as chloroform and dichlorobenzene; ketones having 6 or more carbon atoms such as methylbutyl ketone; hydrocarbon compounds and methanol, ethanol, etc.
- Examples thereof include a mixed solvent with alcohols such as 1-propanol, 2-propanol and 1-butanol; an aromatic compound such as benzene, toluene, xylene and ethylbenzene; and a mixed solvent between an aromatic compound and alcohols. These solvents may be used alone or in combination of two or more.
- preferable solvents are mixed solvents of hydrocarbon compounds and alcohols, mixed solvents of aromatic compounds and alcohols, and more preferable solvents are toluene and the like. It is a mixed solvent of an aromatic compound and alcohols such as methanol.
- the ratio of the hydrocarbon compound or aromatic compound to the alcohol in the mixed solvent may be appropriately selected according to the type of each solvent used. For example, the mass ratio of the hydrocarbon compound or aromatic compound to the alcohol (carbonation). Hydrocarbon compounds or aromatic compounds / alcohols) may be 50/50 to 90/10.
- the temperature at which the saponification reaction is carried out is preferably 50 ° C. or higher, more preferably 60 ° C. or higher, and further, from the viewpoint of its reactivity and solubility of the ethylene- (meth) acrylic acid ester copolymer (X). It is preferably 70 ° C. or higher, particularly preferably 80 ° C. or higher.
- the upper limit of the temperature is not particularly limited as long as it is lower than the temperature at which the ethylene- (meth) acrylic acid ester copolymer (X) is decomposed, and is, for example, 300 ° C. or lower.
- the saponification reaction may be carried out in air or in an inert gas such as nitrogen gas or argon gas. Further, the saponification reaction may be carried out under normal pressure, pressure, or reduced pressure, and is preferably carried out under pressure.
- Examples of the acid used for demetallization in the above methods (1) and (2) include strong acids such as hydrochloric acid, nitric acid, sulfuric acid, and toluenesulfonic acid. From the viewpoint of easily removing salts from the ionomer resin after demetallization, inorganic acids such as hydrochloric acid, nitric acid, and sulfuric acid are preferable.
- the solvent used for the demetallization the same solvent as the solvent used for the saponification reaction can be selected.
- the temperature at the time of demetallizing is preferably 20 ° C. or higher, more preferably 30 ° C. or higher, further preferably 40 ° C. or higher, and preferably 100 ° C. or lower, from the viewpoint of easily lowering the viscosity of the reaction solution. It is more preferably 80 ° C. or lower, still more preferably 60 ° C. or lower.
- the demetallization may be performed in air or in an inert gas such as nitrogen gas or argon gas. Further, the saponification reaction may be carried out under normal pressure, pressure, or reduced pressure, and is preferably carried out under pressure.
- the neutralizing agent used when a part of the (meth) acrylic acid unit is neutralized and converted into the (meth) acrylic acid neutralized product unit is an ionic compound containing a metal ion.
- the metal ions include alkali metal ions such as lithium, potassium and sodium, alkaline earth metal ions such as magnesium and calcium, transition metal ions such as zinc, nickel, iron and titanium, and aluminum ions.
- the neutralizing agent include sodium hydroxide and the like.
- the crude ionomer resin obtained in step i contains (meth) acrylic acid unit (A), (meth) acrylic acid neutralized product unit (B) and ethylene unit (C), and the unit (A) and the unit ( The total content of B) is 6 to 10 mol% based on all the monomer units constituting the crude ionomer resin.
- the crude ionomer resin preferably contains a (meth) acrylic acid ester unit (D) in addition to the unit (A), the unit (B) and the unit (C), and the crude ionomer resin preferably contains the crude ionomer resin.
- the total content of the unit (A), the unit (B) and the unit (D) is the total monomer unit constituting the crude ionomer resin. As a reference, it is preferably 6 to 10 mol%.
- the crude ionomer resin further comprises a carboxylic acid other than the (meth) acrylic acid unit. It may contain other monomer units such as a carboxylic acid neutralized product unit (B2) other than the acid unit (A2) and the (meth) acrylic acid neutralized product unit.
- Examples of the unit (A) and the unit (B) in the crude ionomer resin, and the unit (D) which may be contained in some cases, and other monomer units (A2) and (B2) are as follows.
- the unit (A), unit (B), unit (D), unit (A2) and unit (B2) contained in the ionomer resin of the present invention include the same units as those described above, and preferred forms are also the above-mentioned ionomer. Similar to resin.
- the total content of the unit (D) is the same as for the ionomer resin of the present invention, including the above-mentioned content and the preferable form.
- the crude ionomer resin solution can be prepared by dissolving the crude ionomer resin obtained in step i in a solvent, and the reaction solution of the crude ionomer resin obtained in step i may be used as the crude ionomer resin solution.
- the solvent in the solution of the crude ionomer resin is not particularly limited as long as it is a solvent capable of dissolving the crude ionomer resin, and examples thereof include the same solvent as the solvent used in the saponification reaction. Among them, a mixed solvent of an aromatic compound such as toluene and an alcohol such as methanol is preferable from the viewpoint of solubility of the crude ionomer resin.
- the ratio of the aromatic compound to the alcohols in the mixed solvent may be appropriately selected according to the type of each solvent used. For example, the mass ratio of the aromatic compound to the alcohols (aromatic compound / alcohols) may be selected. , 50/50 to 90/10, preferably 65/35 to 85/15.
- the concentration of the solution of the crude ionomer resin it is easy to obtain a granular resin having a small particle size, and as a result, it is easy to adjust the salt content in the ionomer resin within the range of 1 to 400 mg / kg, and the heat-resistant decomposition of the ionomer resin is easy. From the viewpoint of easily improving the properties, it is preferably 30% by mass or less, more preferably 15% by mass or less, and preferably 1% by mass or more, more preferably 5% by mass or more.
- the temperature of the solution of the crude ionomer resin makes it easy to suppress the aggregation or sticking of the precipitated granular resin, the salt content in the ionomer resin can be easily adjusted within the range of 1 to 400 mg / kg, and the thermal degradability of the ionomer resin.
- the temperature is preferably equal to or lower than the melting point of the ionomer resin, more preferably 60 ° C. or lower, still more preferably 50 ° C. or lower.
- the temperature is more preferably 25 ° C. or higher, still more preferably 30 ° C. or higher.
- the poor solvent to be added to the crude ionomer resin solution is not particularly limited as long as it is a solvent that is mixed with the crude ionomer resin solution and does not dissolve the ionomer resin.
- methanol, ethanol, 1-propanol, 2-propanol, etc. Alcohols such as 1-butanol; water; ketones such as acetone and methyl ethyl ketone; esters such as methyl acetate and ethyl acetate; ethers such as dimethyl ether, diethyl ether and tetrahydrofuran; hydrocarbons such as n-hexane, cyclohexane and heptane. Examples include compounds.
- the poor solvent is preferably methanol, 2-propanol or the like from the viewpoint that the ionomer resin is easily dried because of its low boiling point and the salt in the granular resin is easily removed because the salt can be dissolved.
- the amount of the poor solvent added may be appropriately selected according to the concentration of the crude ionomer resin solution.
- the amount of the poor solvent added is preferably 30 parts by mass or more, more preferably 60 parts by mass or more, and particularly preferably 100 parts by mass or more, based on 100 parts by mass of the solution of the crude ionomer resin.
- the upper limit of the amount of the poor solvent added is not particularly limited, and is usually 1000 parts by mass or less with respect to 100 parts by mass of the solution of the crude ionomer resin.
- the method of adding the poor solvent to the solution of the crude ionomer resin is not particularly limited.
- the poor solvent may be added to the solution of the crude ionomer resin at one time, or may be added in a plurality of times by dropping or the like.
- Good From the viewpoint that the particle size of the granular resin tends to be small, thereby improving the removability of salts in the granular resin, and as a result, the transparency of the ionomer resin tends to be improved, the addition of the poor solvent is relatively short. It is preferable to carry out with, and it is more preferable to add at once. When the poor solvent is added in a plurality of times, it is preferable to complete the addition of the poor solvent within 1 hour, more preferably within 30 minutes, and even more preferably within 10 minutes.
- the stirring speed is not particularly limited, but the faster the stirring speed, the easier it is to obtain a granular resin having a small particle size.
- the stirring time is not particularly limited, and for example, the mixture may be stirred until the granular resin is precipitated and the mixed solution of the crude ionomer resin solution and the poor solvent becomes a slurry. Specifically, it is preferably 1 second or longer. It is 3 hours or less, more preferably 10 seconds or more and 1 hour or less, and further preferably 1 minute or more and 30 minutes or less.
- the peak top particle size of the granular resin deposited by adding a poor solvent to the solution of the crude ionomer resin makes it easier to reduce the salt content in the granular resin by increasing the specific surface area of the granular resin, and as a result.
- the salt content can be easily adjusted within the range of 1 to 400 mg / kg and the thermal decomposition property of the ionomer resin can be easily improved, 700 ⁇ m or less, preferably 650 ⁇ m or less, more preferably 600 ⁇ m or less, still more preferably. It is 550 ⁇ m or less.
- it is preferably 50 ⁇ m or more, more preferably 70 ⁇ m or more, and preferably 80 ⁇ m or more.
- the peak top particle size of the granular resin precipitated by adding a poor solvent to the crude ionomer resin solution can be adjusted by adjusting the concentration and temperature of the crude ionomer resin solution. Specifically, lowering the concentration and / or temperature of the crude ionomer resin solution can reduce the peak top particle size of the precipitated granular resin, and increasing the concentration and / or temperature of the crude ionomer resin solution causes precipitation.
- the peak top particle size of the granular resin can be increased.
- the peak top particle size of the granular resin can also be adjusted by the method of adding the poor solvent and the stirring speed of the mixed solution of the crude ionomer resin solution and the poor solvent.
- the cleaning liquid in step iii is not particularly limited as long as it is a solvent in which the ionomer resin is insoluble and the salt can be dissolved.
- Examples of preferable cleaning solutions include alcohols such as methanol, ethanol, 1-propanol and 2-isopropanol; water; ketones such as acetone and methyl ethyl ketone; esters such as methyl acetate and ethyl acetate; dimethyl ether, diethyl ether, tetrahydrofuran and the like. Ethers can be mentioned. These may be used alone or in combination of two or more.
- alcohols, water, and a mixed solution thereof are preferable from the viewpoint of high salt solubility and easy removal of salts contained in the granular resin.
- a more preferable cleaning solution is a mixed solution of water and alcohols.
- Preferred alcohols are methanol, ethanol, and more preferably methanol because they are easy to dry and have high compatibility with water.
- the ratio of water to alcohols (water / alcohols (mass%)) in the mixed solution of water and alcohols is preferably 20/80 to 8/20, more preferably 30/70 to 70/30. ..
- a method of filtering the granular resin from the granular resin dispersion liquid in which the granular resin is precipitated in step ii, mixing the collected granular resin with the cleaning liquid, and then removing the liquid can be mentioned. More specifically, after mixing the granular resin collected from the granular resin dispersion and the cleaning liquid, the granular resin is collected from the cleaning liquid (hereinafter, also referred to as cleaning step (a)), and then the collected granules.
- a method of cleaning by mixing the resin with a new cleaning liquid and then filtering out the granular resin from the cleaning liquid (hereinafter, also referred to as a cleaning step (b)) can be mentioned.
- the cleaning of the granular resin is performed from the viewpoint that the content of the salt contained in the granular resin can be easily adjusted within the range of 1 to 400 mg / kg, the heat-resistant decomposition property of the ionomer resin can be easily improved, and the production efficiency of the ionomer resin is improved.
- the amount of the cleaning liquid used per cleaning step may be appropriately selected according to the amount of granular resin to be cleaned.
- the amount of the cleaning liquid used per cleaning step is preferably 100 parts by mass to 2000 parts by mass, more preferably 200 parts by mass to 1000 parts by mass, still more preferably, with respect to 100 parts by mass of the granular resin at the time of drying. Is 300 parts by mass to 700 parts by mass.
- the ionomer resin obtained in step iii may be dried if necessary.
- the drying temperature may be preferably lower than the melting point of the ionomer resin, more preferably 80 ° C or lower.
- an additive may be added to the ionomer resin of the present invention to obtain a resin composition.
- the resin composition of the present invention comprises the ionomer resin of the present invention and an additive.
- additives that may be optionally added include UV absorbers, anti-aging agents, antioxidants, thermal deterioration inhibitors, light stabilizers, anti-sticking agents, lubricants, mold release agents, polymer processing aids, etc.
- examples thereof include antistatic agents, flame retardant agents, dyes and pigments, organic pigments, matting agents, phosphors and the like.
- ultraviolet absorbers ultraviolet absorbers, antioxidants, antioxidants, thermal deterioration inhibitors, light stabilizers, anti-sticking agents, lubricants, mold release agents, polymer processing aids, and organic dyes are preferable.
- the additive When added, the additive may be used alone or in combination of two or more.
- the ultraviolet absorber is a compound that has the ability to absorb ultraviolet rays, and is said to have the function of mainly converting light energy into heat energy.
- Examples of the ultraviolet absorber include benzophenones, benzotriazoles, triazines, benzoates, salicylates, cyanoacrylates, oxalic acid anilides, malonic acid esters, formamidines and the like. These may be one kind alone or a combination of two or more kinds.
- Benzotriazoles are preferable as UV absorbers because they have a high effect of suppressing deterioration of optical properties such as coloring due to UV exposure.
- Examples of preferred benzotriazoles include 2- (2H-benzotriazole-2-yl) -4- (1,1,3,3-tetramethylbutyl) phenol (manufactured by BASF; trade name: TINUVIN329), 2 -(2H-benzotriazole-2-yl) -4,6-bis (1-methyl-1-phenylethyl) phenol (manufactured by BASF; trade name: TINUVIN234), 2,2'-methylenebis [6- (2H) -Benzotriazole-2-yl) -4-t-octylphenol] (manufactured by ADEKA Co., Ltd .; trade name: Adecastab LA-31), 2- (5-octylthio-2H-benzotriazole-2-yl) -6- Examples thereof include
- triazine UV absorbers examples include 2,4,6-tris (2-hydroxy-4-hexyloxy-3-methylphenyl) -1,3,5-triazine (manufactured by ADEKA Co., Ltd .; trade name). : Adecastab LA-F70) and its relatives, hydroxyphenyltriazine-based ultraviolet absorbers (manufactured by BASF; trade names: TINUVIN477 and TINUVIN460), 2,4-diphenyl-6- (2-hydroxy-4-hexyloxy) Phenyl) -1,3,5-triazine and the like can be mentioned. These may be one kind alone or a combination of two or more kinds.
- anti-aging agents examples include known materials. Specific examples of anti-aging agents include hydroquinone, hydroquinone monomethyl ether, 2,5-di-t-butylphenol, 2,6-di (t-butyl) -4-methylphenol, mono (or di, or tri).
- Phenolic compounds such as ( ⁇ -methylbenzyl) phenol; 2,2'-methylenebis (4-ethyl-6-t-butylphenol), 4,4'-butylidenebis (3-methyl-6-t-butylphenol), Bisphenol compounds such as 4,4'-thiobis (3-methyl-6-t-butylphenol); benzimidazole compounds such as 2-mercaptobenzimidazole and 2-mercaptomethylbenzimidazole; 6-ethoxy-1,2- Dihydro-2,2,4-trimethylquinolin, a reaction product of diphenylamine and acetone, amine-ketone compounds such as 2,2,4-trimethyl-1,2-dihydroquinolin polymer; N-phenyl-1-naphthylamine, Fragrances such as alkylated diphenylamine, octylated diphenylamine, 4,4'-bis ( ⁇ , ⁇ -dimethylbenzyl) diphenylamine, p- (p- (
- the antioxidant is effective in preventing oxidative deterioration of the resin by itself in the presence of oxygen.
- phosphorus-based antioxidants, hindered phenol-based antioxidants, thioether-based antioxidants and the like can be mentioned. These antioxidants may be used alone or in combination of two or more. Among them, phosphorus-based antioxidants and hindered phenol-based antioxidants are preferable, and a combination of phosphorus-based antioxidants and hindered phenol-based antioxidants is more preferable, from the viewpoint of the effect of preventing deterioration of optical properties due to coloring. ..
- the amount of the phosphorus-based antioxidant used is preferably 1: 5 to 2 in terms of mass ratio. 1, more preferably 1: 2 to 1: 1.
- Examples of preferable phosphorus-based antioxidants include 2,2-methylenebis (4,6-di-t-butylphenyl) octylphosphite (manufactured by ADEKA Corporation; trade name: ADEKA STAB HP-10), Tris (2).
- antioxidants examples include pentaerythrityl-tetrax [3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate] (manufactured by BASF; trade name: IRGANOX1010). Examples thereof include octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate (manufactured by BASF; trade name: IRGANOX1076). These may be one kind alone or a combination of two or more kinds.
- the heat deterioration inhibitor can prevent the heat deterioration of the resin by capturing the polymer radicals generated when exposed to high heat under a substantially oxygen-free state.
- a preferable heat deterioration inhibitor 2-t-butyl-6- (3'-t-butyl-5'-methyl-hydroxybenzyl) -4-methylphenylacrylate (manufactured by Sumitomo Chemical Co., Ltd .; trade name) : Smilizer GM), 2,4-di-t-amyl-6- (3', 5'-di-t-amyl-2'-hydroxy- ⁇ -methylbenzyl) phenylacrylate (manufactured by Sumitomo Chemical Co., Ltd .; Product name: Sumilyzer GS) and the like. These may be one kind alone or a combination of two or more kinds.
- the light stabilizer is a compound that is said to have a function of capturing radicals mainly generated by oxidation by light.
- preferred light stabilizers include hindered amines such as compounds having a 2,2,6,6-tetraalkylpiperidine skeleton. These may be one kind alone or a combination of two or more kinds.
- anti-sticking agents include fatty acid salts or esters, polyhydric alcohol esters, inorganic salts, inorganic oxides, and particulate resins.
- preferable anti-adhesion agents include calcium stearate, calcium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, silicon dioxide (manufactured by Evonik; trade name: Aerosil), particulate acrylic resin and the like. These may be one kind alone or a combination of two or more kinds.
- lubricants include stearic acid, behenic acid, stearoamic acid, methylene bisstearoamide, hydroxystearic triglyceride, paraffin wax, ketone wax, octyl alcohol, hydrogenated oil and the like. These may be one kind alone or a combination of two or more kinds.
- the release agent examples include higher alcohols such as cetyl alcohol and stearyl alcohol; and glycerin higher fatty acid esters such as stearic acid monoglyceride and stearic acid diglyceride. These may be one kind alone or a combination of two or more kinds.
- polymer particles having a particle size of 0.05 to 0.5 ⁇ m which can be produced by an emulsion polymerization method, are usually used.
- the polymer particles may be single-layer particles composed of polymers having a single composition ratio and a single extreme viscosity, or may be multilayer particles composed of two or more kinds of polymers having different composition ratios or ultimate viscosities. Good. These may be one kind alone or a combination of two or more kinds. Among these, particles having a two-layer structure having a polymer layer having a low ultimate viscosity in the inner layer and a polymer layer having a high ultimate viscosity of 5 dl / g or more in the outer layer are preferable.
- the ultimate viscosity of the polymer processing aid is preferably 3 to 6 dl / g. If the ultimate viscosity is too small, the effect of improving moldability tends to be low, and if the ultimate viscosity is too large, the moldability of the copolymer tends to be deteriorated.
- an organic dye a compound having a function of converting ultraviolet rays into visible light is preferably used.
- the organic dye may be used alone or in combination of two or more.
- fluorescent materials include fluorescent pigments, fluorescent dyes, fluorescent white dyes, fluorescent whitening agents, fluorescent bleaching agents, and the like. These may be one kind alone or a combination of two or more kinds.
- the contents of the various additives can be appropriately selected as long as the effects of the present invention are not impaired, and the total content of the various additives is preferable with respect to the total mass of the resin composition. Is 7% by mass or less, more preferably 5% by mass or less, still more preferably 4% by mass or less.
- additives may be added at the time of producing the ionomer resin, may be added after the production of the ionomer resin, or may be added at the time of producing the resin sheet described later.
- the ionomer resin of the present invention and the resin composition of the present invention may be in the form of pellets or the like in order to enhance convenience during storage, transportation, or molding.
- the ionomer resin and the resin composition are pelletized, they can be obtained, for example, by cutting the strands obtained by the melt extrusion method.
- the temperature of the resin or the resin composition at the time of melt extrusion in the case of pelleting by the melt extrusion method is preferably 150 ° C. or higher, more preferably 170 ° C. or higher from the viewpoint of easily stabilizing the discharge from the extruder. Further, the temperature is preferably 250 ° C. or lower, more preferably 230 ° C.
- the ionomer resin of the present invention and the resin composition of the present invention have high heat-resistant decomposition properties, problems such as thermal decomposition of the ionomer resin to generate black foreign matter are unlikely to occur when pelletizing by the melt extrusion method in this way. ..
- the present invention also includes a resin sheet having one or more layers containing the ionomer resin of the present invention.
- the resin sheet of the present invention has one or more layers containing the ionomer resin of the present invention (hereinafter, also referred to as layer (x)).
- the layer (x) is a layer containing the ionomer resin of the present invention and optionally additives.
- the resin sheet of the present invention may be composed of only the layer (x), or may be a laminate containing at least one layer (x).
- the laminate is not particularly limited, and examples thereof include a laminate containing two or more layers (x), a laminate including one or more layers (x), and one or more other layers. Be done.
- the layer (x) or the other layer is a plurality of layers, the resin or the resin composition constituting each layer may be the same or different.
- Examples of the other layer include a layer containing a known resin.
- the resin include polyethylene terephthalate, polybutylene terephthalate, cyclic polyolefin, and polyphenylensulfide among polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyurethane, polytetrafluoroethylene, acrylic resin, polyamide, polyacetal, polycarbonate, and polyester.
- Polytetrafluoroethylene, polysulfone, polyethersulfone, polyarylate, liquid crystal polymer, polyimide, thermoplastic elastomer and the like can be used.
- additives may also contain the above-mentioned additives, as well as plasticizers, anti-blocking agents, pigments, dyes, and heat-shielding materials (for example, inorganic heat-shielding fine particles or organic heat-shielding materials having infrared absorbing ability).
- plasticizers for example, acrylic wax, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate, polymethyl methacrylate,
- the resin sheet of the present invention has a concavo-convex structure on the surface by a conventionally known method such as melt fracture or embossing. It is preferable to have.
- a conventionally known method such as melt fracture or embossing.
- melt fracture or embossing it is preferable to have.
- shape of the melt fracture and the embossing conventionally known shapes may be appropriately selected.
- the thickness of the layer (x) 1 layer in the resin sheet of the present invention is preferably 0.1 mm or more, more preferably 0.2 mm or more, still more preferably 0.3 mm or more, and particularly preferably 0.4 mm or more. Further, it is preferably 5 mm or less, more preferably 4 mm or less, still more preferably 2 mm or less, and particularly preferably 1 mm or less.
- the layers (x) in the resin sheet are a plurality of layers, the thicknesses of the plurality of layers (x) in the resin sheet may be the same or different.
- the thickness of the resin sheet of the present invention is preferably 0.1 mm or more, more preferably 0.2 mm or more, still more preferably 0.3 mm or more, still more preferably 0.4 mm or more, and particularly preferably 0.5 mm or more. Especially more preferably 0.6 mm or more, particularly more preferably 0.7 mm or more, particularly preferably 0.75 mm or more, and preferably 20 mm or less, more preferably 15 mm or less, still more preferably 10 mm or less, still more preferably. Is 5 mm or less, particularly preferably 4 mm or less, particularly more preferably 2 mm or less, and particularly preferably 1 mm or less.
- the thickness of the resin sheet is measured using a conventionally known method, for example, a contact type or non-contact type thickness gauge.
- the resin sheet may be rolled up in a roll shape or may be in a single-wafered state one by one.
- the resin sheet of the present invention may have the same haze, water absorption haze, slow cooling haze, storage modulus and yellowness as the ionomer resin of the present invention.
- the resin sheet of the present invention preferably has a low water content from the viewpoint of being difficult to foam when manufacturing laminated glass.
- the water content of the resin sheet is preferably 1% by mass or less, more preferably 0.5% by mass or less, still more preferably 0.02% by mass or less, and particularly preferably 0.01% by mass or less.
- the content can be measured by a coulometric titration method.
- the method for producing the resin sheet of the present invention is not particularly limited.
- the layer (x) is formed by a known film forming method such as an extrusion method, a calendar method, a press method, a solution casting method, a melt casting method, or an inflation method. Can be manufactured.
- the layer (x) may be used alone as a resin sheet. Further, if necessary, two or more layers (x) or one or more layers (x) and one or more other layers may be laminated by press molding or the like to form a laminated resin sheet.
- Two or more layers (x), or one or more layers (x) and one or more other layers may be molded by a coextrusion method to form a laminated resin sheet.
- the layer (x) or the other layer is a plurality of layers, the resin or the resin composition constituting each layer may be the same or different.
- the resin temperature at the time of extrusion is preferably 150 ° C. or higher, more preferably 170 ° C. or higher, from the viewpoint of easily stabilizing the discharge of the resin from the extruder and easily reducing mechanical troubles.
- the resin temperature at the time of extrusion is preferably 250 ° C. or lower, more preferably 230 ° C. or lower, from the viewpoint of easily reducing the decomposition of the resin and the deterioration of the resin due to the decomposition.
- the resin sheet of the present invention can be suitably used as a laminated glass interlayer film (also simply referred to as an interlayer film). Therefore, the present invention includes a laminated glass interlayer film made of the resin sheet of the present invention.
- the present invention also includes a laminated glass having two glass plates and a laminated glass interlayer film of the present invention arranged between the two glass plates. Since the laminated glass of the present invention has a laminated glass interlayer film made of the resin sheet, it can have excellent transparency.
- Examples of the glass plate to be laminated with the interlayer film of the present invention include inorganic glass such as float plate glass, polished plate glass, template glass, meshed plate glass, and heat ray absorbing plate glass, as well as conventionally known organic materials such as polymethyl methacrylate and polycarbonate. Glass or the like can be used. These may be either colorless or colored. One of these may be used, or two or more thereof may be used in combination. Further, the thickness of one glass plate is preferably 100 mm or less, and the thickness of the two glass plates may be the same or different.
- the laminated glass formed by sandwiching the resin sheet of the present invention between two sheets of glass can be produced by a conventionally known method.
- a method using a vacuum laminator device, a method using a vacuum bag, a method using a vacuum ring, a method using a nip roll, and the like can be mentioned.
- Laminated glass can be manufactured by laminating (layers, etc.).
- a method using a vacuum bag or a vacuum ring is described in, for example, European Patent No. 1235683, which is a glass plate at 100 to 160 ° C. under a pressure of about 2 ⁇ 10 ⁇ 2 to 3 ⁇ 10 ⁇ 2 MPa.
- Laminated glass can be produced by laminating an interlayer film and any layer.
- a glass plate, an interlayer film and an arbitrary layer are laminated, degassed by a roll at a temperature equal to or lower than the flow start temperature of the interlayer film, and then pressure-bonded at a temperature closer to the flow start temperature.
- a method of heating to 30 to 70 ° C. with an infrared heater or the like, degassing with a roll, further heating to 50 to 120 ° C., and then crimping with a roll can be mentioned.
- the operating conditions of the autoclave process are appropriately selected depending on the thickness and composition of the laminated glass, and the pressure is, for example, 0.5 to 1.5 MPa. Underneath, it is preferable to treat at 100 to 160 ° C. for 0.5 to 3 hours.
- the laminated glass of the present invention has excellent transparency.
- the haze of the laminated glass when the sheet thickness of the interlayer film is 0.8 mm is preferably 1.0% or less, more preferably 0.8% or less, still more preferably 0.5. % Or less.
- the haze of the laminated glass is measured using a haze meter in accordance with JIS K7136: 2000.
- the laminated glass of the present invention is excellent in transparency even after being heated to 140 ° C. and then slowly cooled from 140 ° C. to 23 ° C. at a rate of 0.1 ° C./min.
- a haze (slow cooling haze) after heating a laminated glass having a sheet thickness of 0.8 mm as an interlayer film to 140 ° C. and then slowly cooling from 140 ° C. to 23 ° C. at a rate of 0.1 ° C./min is preferable. Is 5.0% or less, more preferably 4.5% or less, still more preferably 4.0% or less, and particularly preferably 3.0% or less.
- the smaller the haze the higher the transparency of the laminated glass. Therefore, the lower limit is not particularly limited and may be, for example, 0.01%.
- the slow cooling haze is also measured using a haze meter in accordance with JIS K7136: 2000.
- the laminated glass of the present invention is less colored and is preferably colorless as much as possible.
- the yellowness (YI) of the laminated glass of the present invention is preferably 2.0 or less, more preferably 1.8 or less, still more preferably 1.5 or less, when the sheet thickness of the interlayer film is 0.8 mm. Particularly preferably, it is 1.0 or less.
- the yellowness (YI) is measured according to JIS Z8722: 2009 using a color difference meter.
- the adhesive strength between the laminated glass and the interlayer film of the present invention is measured by, for example, the compression shear strength test described in WO1999-058334.
- the compressive shear strength is preferably 15 MPa or more, more preferably 20 MPa or more, and particularly preferably 25 MPa or more, from the viewpoint of easily increasing the adhesive force. Further, the compressive shear strength may be 50 MPa or less from the viewpoint of easily increasing the penetration resistance of the laminated glass.
- the resin sheet having one or more layers containing the ionomer resin of the present invention is useful as a laminated glass interlayer film.
- the laminated glass interlayer film is particularly preferable as an interlayer film for laminated glass for structural materials (for façade) because it is excellent in adhesiveness, transparency, and self-supporting property to a base material such as glass.
- the laminated glass of the present invention is not limited to the interlayer film of the laminated glass for structural materials, and the laminated glass of the present invention is used for automobile front glass, automobile side glass, automobile sun roof, automobile rear glass, head-up display glass, outer wall and roof. It can be suitably used for laminated glass, panels, doors, windows, walls, roofs, sun roofs, sound insulation walls, display windows, balconies, handrail walls and other building materials, conference room partition glass members, solar panels and the like.
- the ionomer resins obtained in Examples and Comparative Examples are each dissolved in a mixed solvent of dehydrated toluene / dehydrated acrylic acid (75/25% by mass), reacted at 100 ° C. for 2 hours, and then acetone / water (80/20).
- the (meth) acrylic acid neutralized product unit (B) was converted to the (meth) acrylic acid unit (A) by reprecipitation in a mixed solvent of (% by mass).
- the obtained resin was sufficiently washed with water, dried, and the following (1) to (3) were performed on the dried resin.
- the components of the monomer units constituting the resin were analyzed by thermal decomposition GC-MS.
- the acid value of the resin was measured according to JIS K0070: 1992.
- Chloride ion or sulfate ion was quantified based on the peak area obtained by the measurement, and the amount of the chloride ion or sulfate ion was converted into the amount of sodium salt to determine the amount of residual inorganic salt.
- Eluent A mixed solution of an aqueous sodium carbonate solution (0.6 mmol / L) and an aqueous sodium hydrogen carbonate solution (12 mmol / L); Flow velocity: 1.0 mL / min; Column temperature: 40 ° C; Column: IC-SA2 (250L x 4.0)
- melt flow rates of the raw material resins used in Examples and Comparative Examples and the ionomer resins obtained in Examples and Comparative Examples were measured. Specifically, each resin is melted in a cylinder and extruded from a die having a nominal hole diameter of 2.095 mm installed at the bottom of the cylinder under a load condition of 190 ° C. and 2.16 kg, and the amount of resin extruded per 10 minutes. (G / 10 minutes) was measured.
- thermostable decomposability of the ionomer resins obtained in Examples and Comparative Examples was evaluated according to JIS K7120: 1987. Specifically, using a differential thermogravimetric simultaneous measuring device TG-DTA7200 (manufactured by Hitachi High-Tech Science Co., Ltd.), each resin was heated at 20 ° C. under a nitrogen atmosphere with a heating rate of 10 ° C./min and a flow rate of 50 mL / min. The weight loss rate when heated to ⁇ 550 ° C. was measured. The 1% weight loss temperature (Td1), which is the temperature at which the weight loss rate becomes 1% based on the weight at 200 ° C., was used as an index of thermodegradability.
- Td1 The 1% weight loss temperature
- the haze of the water-absorbing sample is measured using a haze meter HZ-1 (manufactured by Suga Test Instruments Co., Ltd.) in accordance with JIS K7136: 2000. did.
- the laminated glass obtained by the above method was heated to 140 ° C. and then slowly cooled to 23 ° C. at a rate of 0.1 ° C./min.
- the haze of the laminated glass after the slow cooling operation was measured using a haze meter HZ-1 (manufactured by Suga Test Instruments Co., Ltd.) in accordance with JIS K7136: 2000.
- Example 1 100 parts by mass of EMMA2 in Table 1 was introduced into a pressure-resistant container made of SUS, 233 parts by mass of toluene was added thereto, and the mixture was stirred at 60 ° C. under 0.02 MPa pressurization to dissolve EMMA2.
- 96 parts by mass of a methanol solution of sodium hydroxide (20% by mass) was added, and the mixture was stirred at 100 ° C. for 4 hours to saponify EMMA2 to convert a part of methyl methacrylate into sodium methacrylate units. Converted. Then, after cooling this solution to 50 ° C., 83 parts by mass of hydrochloric acid (20% by mass) was added, and the mixture was stirred at 50 ° C.
- a resin solution was obtained.
- a mixed solvent of toluene / methanol (75/25% by mass) was added to the obtained crude ionomer resin solution so that the crude ionomer resin concentration was 10% by mass to dilute the solution.
- the diluted solution of the obtained crude ionomer resin was adjusted to 34 ° C., and then 430 parts by mass of methanol at 34 ° C. was added to the diluted solution to 100 parts by mass of the crude ionomer resin solution to precipitate the granular resin. It was.
- Example 2 Ionomer resin 2 was obtained in the same manner as in Example 1 except that EMMA3 was used instead of EMMA2 and the temperature of the diluted solution of crude ionomer resin and methanol was changed from 34 ° C. to 37 ° C. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 2.
- Example 3 Ionomer resin 3 was obtained in the same manner as in Example 1 except that EMMA3 was used instead of EMMA2 and the temperature of the diluted solution of crude ionomer resin and methanol was changed from 34 ° C. to 40 ° C. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 3.
- Example 4 The ionomer resin 4 was obtained in the same manner as in Example 3 except that 220 parts by mass of sulfuric acid (30% by mass) was added instead of hydrochloric acid. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 4.
- Example 5 Example 1 except that EEA1 was used instead of EMMA2, the concentration of the diluted solution of crude ionomer resin was changed from 10% by mass to 6% by mass, and the temperature of the diluted solution of crude ionomer resin and methanol was changed from 34 ° C to 41 ° C.
- the ionomer resin 5 was obtained in the same manner as in the above.
- Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 5.
- Example 6 Using EMMA1 instead of EMMA2, the amount of sodium hydroxide solution added in methanol (20% by mass) was changed from 96 parts by mass to 73 parts by mass, and the amount of hydrochloric acid (20% by mass) was changed from 83 parts by mass to 63 parts by mass.
- the ionomer resin 6 was obtained in the same manner as in Example 1 except that the temperature of the diluted solution of the crude ionomer resin and the methanol was changed from 34 ° C. to 37 ° C. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 6.
- Example 7 After obtaining the ionomer resin 3 in the same manner as in Example 3, 2- (2H-benzotriazole-2-yl) -4- (1,1,3,3-tetramethyl) with respect to 100 mass of the ionomer resin 3 Ionomer resin 7 was obtained by adding 0.1 parts by mass of butyl) phenol (manufactured by BASF; trade name: TINUVIN329) and melt-kneading. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 7.
- Example 1 The ionomer resin 8 was obtained in the same manner as in Example 1 except that the temperature of the diluted solution of the crude ionomer resin and the methanol was changed from 34 ° C. to 43 ° C. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 8.
- Example 2 The ionomer resin 9 was obtained in the same manner as in Example 1 except that the temperature of the diluted solution of the crude ionomer resin and the methanol was changed from 34 ° C. to 46 ° C. Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 9.
- Example 3 The ionomer resin 10 was prepared in the same manner as in Example 1 except that 220 parts by mass of sulfuric acid (30% by mass) was added instead of hydrochloric acid to change the temperature of the diluted solution of the crude ionomer resin and methanol from 34 ° C to 50 ° C. Obtained.
- Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 10.
- Granular resin is obtained by using EMMA3 instead of EMMA2 and reprecipitating the crude ionomer resin solution in a mixed solvent of 500 parts by mass of acetone / water (80/20% by mass) with respect to 100 parts by mass of the crude ionomer resin. Further, the ionomer resin 11 was obtained in the same manner as in Example 1 except that the obtained granular resin was washed three times with a mixed solvent of acetone / water (20/80 mass%). Table 2 shows the analysis results and evaluation results of the obtained ionomer resin 11.
- the ionomer resins obtained in Examples 1 to 7 have a high 1% weight loss temperature (Td1), low water absorption haze and slow cooling haze, and high transparency. confirmed.
- Td1 1% weight loss temperature
- Comparative Examples 1 to 5 at least one of the 1% weight loss temperature, the water absorption haze and the slow cooling haze gave a poor result.
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Abstract
Description
本発明は、アイオノマー樹脂、該アイオノマー樹脂を含む層を1層以上有する樹脂シート、該樹脂シートからなる合わせガラス中間膜、および該合わせガラス中間膜を有する合わせガラスに関する。
(メタ)アクリル酸中和物単位(B)、および
エチレン単位(C)
を含む、アイオノマー樹脂であって、
前記単位(A)および前記単位(B)の合計含有量は、前記アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%であり、前記アイオノマー樹脂中の強酸および強塩基からなる塩の含有量は1~400mg/kgである、アイオノマー樹脂。
[2]前記アイオノマー樹脂はさらに(メタ)アクリル酸エステル単位(D)を含み、前記単位(A)、前記単位(B)および前記単位(D)の合計含有量は、前記アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%である、[1]に記載のアイオノマー樹脂。
[3]前記強酸および強塩基からなる塩は、アルカリ金属および/またはアルカリ土類金属の金属塩である、[1]または[2]に記載のアイオノマー樹脂。
[4]前記強酸および強塩基からなる塩は、ナトリウムイオンおよびカリウムイオンからなる群から選択される少なくとも1種のカチオンと、ハロゲンイオン、硝酸イオン、および硫酸イオンからなる群から選択される少なくとも1種のアニオンとからなる塩である、[1]~[3]のいずれかに記載のアイオノマー樹脂。
[5][1]~[4]のいずれかに記載のアイオノマー樹脂を含む層を1層以上有する、樹脂シート。
[6][5]に記載の樹脂シートからなる合わせガラス中間膜。
[7]2つのガラス板と、該2つのガラス板の間に配置された[6]に記載の合わせガラス中間膜とを有する、合わせガラス。
本発明のアイオノマー樹脂は、(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)、およびエチレン単位(C)を含み、前記単位(A)および前記単位(B)の合計含有量が、前記アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%である。
本明細書において、「単位」とは、「由来の構成単位」を意味するものであり、例えば(メタ)アクリル酸単位とは、(メタ)アクリル酸由来の構成単位を示し、(メタ)アクリル酸中和物単位とは、(メタ)アクリル酸中和物由来の構成単位を示し、エチレン単位とはエチレン由来の構成単位を示す。また、本明細書において、「(メタ)アクリル酸」とは、メタクリル酸またはアクリル酸を示す。
(メタ)アクリル酸単位(A)を構成する単量体の例としては、アクリル酸、メタクリル酸が挙げられ、耐熱性および基材に対する接着性の観点から、好ましくはメタクリル酸である。これら(メタ)アクリル酸単位は1種単独でも2種の組み合わせでもよい。
(メタ)アクリル酸中和物単位(B)としては、前記(メタ)アクリル酸単位(A)の中和物単位が好ましい。なお、(メタ)アクリル酸中和物は、(メタ)アクリル酸の水素イオンを金属イオンで置き換えたものである。前記金属イオンの例としては、リチウム、ナトリウム、カリウム等の1価金属、マグネシウム、カルシウム、亜鉛、アルミニウム、チタン等の多価金属のイオンが挙げられる。このような金属イオンは1種単独でも2種以上の組み合わせでもよい。例えば、1種以上の1価金属イオンと1種以上の2価金属イオンとの組み合わせであってもよい。
エチレン単位(C)の含有量は、アイオノマー樹脂を構成する全単量体単位を基準として、アイオノマー樹脂の耐衝撃性を高めやすい観点から、好ましくは80モル%以上、より好ましくは85モル%以上、さらに好ましくは88モル%以上であり、また、アイオノマー樹脂の透明性(特に徐冷時の透明性)を高めやすい観点から、好ましくは94モル%以下、より好ましくは91モル%以下である。エチレン単位(C)の含有量が上記下限値以上であると、機械的強度および成形加工性を向上しやすく、また、上記上限値以下であると、透明性を向上しやすい。
本発明のアイオノマー樹脂は、(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)、およびエチレン単位(C)に加えて、より高い透明性を得やすい観点から、さらに(メタ)アクリル酸エステル単位(D)を含むことが好ましい。
アイオノマー樹脂が(メタ)アクリル酸エステル単位(D)を含む場合において、前記単位(A)、前記単位(B)および前記単位(D)の前記合計含有量は、透明性(特に徐冷時の透明性)および基材に対する接着性を向上しやすい観点から、6モル%以上、好ましくは6.5モル%以上、より好ましくは7.0モル%以上、さらに好ましくは7.5モル%以上であり、また、成形加工性の観点から、10モル%以下、好ましくは9.9モル%以下、より好ましくは9.5モル%以下である。
これらのうち、透明性または耐熱性の観点から、好ましい単量体は、(メタ)アクリル酸メチル、(メタ)アクリル酸エチル、(メタ)アクリル酸n-プロピル、(メタ)アクリル酸イソプロピル、(メタ)アクリル酸n-ブチル、(メタ)アクリル酸イソブチル、(メタ)アクリル酸sec-ブチル、(メタ)アクリル酸t-ブチルであり、より好ましい単量体は、(メタ)アクリル酸メチル、(メタ)アクリル酸エチル、(メタ)アクリル酸n-プロピル、(メタ)アクリル酸イソプロピル、(メタ)アクリル酸n-ブチル、(メタ)アクリル酸イソブチルであり、さらに好ましい単量体は、(メタ)アクリル酸メチル、(メタ)アクリル酸n-ブチル、(メタ)アクリル酸イソブチルであり、特に好ましい単量体は、(メタ)アクリル酸メチルである。これら(メタ)アクリル酸エステルは1種単独でも2種以上の組み合わせでもよい。
本発明のアイオノマー樹脂は、(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)、およびエチレン単位(C)、ならびに場合により含まれる(メタ)アクリル酸エステル単位(D)以外の他の単量体単位を含んでいてもよい。他の単量体単位の例としては、(メタ)アクリル酸単位(A)以外のカルボン酸単位(A2)、(メタ)アクリル酸中和物単位(B)以外のカルボン酸中和物単位(B2)等が挙げられる。
前記カルボン酸単位(A2)を構成する単量体の例としては、イタコン酸、無水マレイン酸、マレイン酸モノメチル、マレイン酸モノエチル等が挙げられ、好ましくはマレイン酸モノメチル、マレイン酸モノエチルである。前記カルボン酸中和物単位(B2)を構成する単量体の例としては、前記カルボン酸単位(A2)の中和物単位等が挙げられる。なお、カルボン酸中和物は、カルボン酸の水素イオンを金属イオンで置き換えたものである。前記金属イオンとしては、上述の(メタ)アクリル酸中和物単位(B)における金属イオンと同様のものが挙げられ、該金属イオンは、1種単独でも2種以上の組み合わせでもよい。
これらの他の単量体単位は1種単独でも2種以上の組み合わせでもよい。
本発明のアイオノマー樹脂は、強酸および強塩基からなる塩(以下、単に「塩」ともいう)を1~400mg/kg含有する。本発明者らは、アイオノマー樹脂が塩を1~400mg/kg含有する場合、アイオノマー樹脂の高い透明性(特に吸水時の透明性)を維持しつつ、耐熱分解性を向上できることを見出した。そのため、本発明のアイオノマー樹脂は、高い透明性および高い耐熱分解性を両立できる。上記範囲内の塩を含有することにより、本発明のアイオノマー樹脂が耐熱分解性に優れる理由は明らかでないが、塩とアイオノマー樹脂中の(メタ)アクリル酸単位(A)との相互作用により、アイオノマー樹脂中の(メタ)アクリル酸単位(A)が熱によって脱離することを抑制できるためだと考えられる。
本発明の一実施形態において、本発明のアイオノマー樹脂の炭素1000個当たりの分岐度は、特に制限されず、好ましくは5~30、より好ましくは6~20である。前記分岐度は、アイオノマー樹脂を重合する際の温度、例えば、アイオノマー樹脂をEMMAけん化法にて合成する場合には、エチレン-(メタ)アクリル酸エステル(X)を合成する際の重合温度により調整できる。炭素1000個当たりの分岐度は、固体NMRを用いてDDMAS法にて測定できる。
本発明の好適な実施形態において、本発明のアイオノマー樹脂が吸水した状態のシート厚さ0.8mmにおけるヘイズ(吸水ヘイズ)は、好ましくは9.0%以下、より好ましくは5.0%以下、さらに好ましくは3.0%以下である。吸水ヘイズが小さいほどアイオノマー樹脂の吸水した状態における透明性が高まるため、下限値は特に制限されず、例えば、0.01%であってもよい。なお、吸水ヘイズはアイオノマー樹脂を23℃のイオン交換水に浸漬させた状態で300時間保持し、イオン交換水から取出し、表面に付着した水分をふき取ったアイオノマー樹脂を試験片として、ヘイズメーターを用い、JIS K7136:2000に準拠して測定でき、例えば、実施例に記載の方法で測定できる。
本発明の好適な実施形態において、本発明のアイオノマー樹脂の徐冷により該樹脂の結晶化を促進させた状態のヘイズ(徐冷ヘイズ)は、好ましくは5.0%以下、より好ましくは4.5%以下、さらに好ましくは4.0%以下、さらにより好ましくは3.0%以下、特に好ましくは2.5%以下である。ヘイズが小さいほどアイオノマー樹脂の透明性が高まるため、下限値は特に制限されず、例えば、0.01%であってもよい。徐冷ヘイズは、シート厚さ0.8mmのアイオノマー樹脂を2つのガラス板の間に配置して合わせガラスを作製し、該合わせガラスを140℃まで加熱した後、140℃から0.1℃/分の速度で23℃まで徐冷した後のヘイズを、ヘイズメーターでJIS K7136:2000に準拠して測定することによって得られる。
本発明のアイオノマー樹脂の製造方法は特に制限されず、例えば、上述のアイオノマー樹脂に塩を含有させる方法として記載したように、(I)アイオノマー樹脂の製造工程において塩を生成させることにより製造しても、(II)アイオノマー樹脂の製造工程において塩を別添することにより製造しても、(III)まず塩を含まないアイオノマー樹脂を製造して、該樹脂に塩を後添加することにより製造してもよい。これらの方法のうち、強酸および強塩基からなる塩をアイオノマー樹脂中に均一に分散しやすく、これにより透明性および耐熱分解性を向上しやすい観点から、アイオノマー樹脂の製造工程中に塩を生成させて含有させる前記方法(I)が好ましい。以下、前記方法(I)について詳述する。
エチレン-(メタ)アクリル酸エステル共重合体(X)中の(メタ)アクリル酸エステル単位の全部または一部を(メタ)アクリル酸単位および(メタ)アクリル酸中和物単位に変換する方法としては、エチレン-(メタ)アクリル酸エステル共重合体(X)を、強塩基によってけん化することにより、(メタ)アクリル酸エステル単位の全部または一部を(メタ)アクリル酸中和物単位に変換して、エチレン-(メタ)アクリル酸エステル-(メタ)アクリル酸中和物共重合体を得、次いで、得られた共重合体中の(メタ)アクリル酸中和物単位の一部を強酸によって脱金属して、(メタ)アクリル酸単位に変換する方法(以下、方法(1)ともいう)が挙げられる。
前記方法(1)以外の方法としては、上記方法(1)におけるけん化によって得られるエチレン-(メタ)アクリル酸エステル-(メタ)アクリル酸中和物共重合体中の(メタ)アクリル酸中和物単位を全て強酸によって脱金属して、(メタ)アクリル酸単位に変換し、エチレン-(メタ)アクリル酸共重合体を得、次いで、得られた共重合体中の(メタ)アクリル酸単位の一部を金属イオンによって中和する方法(以下、方法(2)ともいう)が挙げられる。
なお、前記方法(1)および(2)において、けん化反応に用いる強塩基と脱金属に用いる強酸との中和反応により、強酸および強塩基からなる塩が生成して、強酸および強塩基からなる塩を含有する粗アイオノマー樹脂が得られる。
これらの共重合体として、市販品を用いてもよく、US2013/0274424、特開2006-233059または特開2007-84743に記載の高温高圧ラジカル重合法によって合成したものを用いてもよい。前記市販品としては、例えば、住友化学(株)製「アクリフト」(登録商標)WD301F、日本ポリエチレン(株)製「レクスパール」(登録商標)A4250等が挙げられる。
共重合体(X)中の(メタ)アクリル酸エステル単位の含有量は、エチレンと(メタ)アクリル酸エステルとの共重合比によって調整できる。なお、前記含有量は、上述のアイオノマー樹脂中の(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)、およびエチレン単位(C)、ならびに含まれる場合(メタ)アクリル酸エステル単位(D)、および他の単量体単位(例えば単位(A2)および単位(B2))の各含有量と同様に、熱分解ガスクロマトグラフィー、核磁気共鳴分光法(NMR)および元素分析によって求めることができる。
これらのうち、けん化反応前後の樹脂の溶解性の観点から、好ましい溶媒は炭化水素化合物とアルコール類との混合溶媒、芳香族化合物とアルコール類との混合溶媒であり、より好ましい溶媒はトルエン等の芳香族化合物とメタノール等のアルコール類との混合溶媒である。前記混合溶媒における炭化水素化合物または芳香族化合物とアルコール類と割合は、用いる各溶媒の種類に応じて適宜選択すればよく、例えば、炭化水素化合物または芳香族化合物とアルコール類との質量割合(炭化水素化合物または芳香族化合物/アルコール類)は、50/50~90/10であってよい。
(粗アイオノマー樹脂の溶液)
工程iにおいて得られる粗アイオノマー樹脂は、(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)およびエチレン単位(C)を含み、前記単位(A)および前記単位(B)の合計含有量は、前記粗アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%である。また、前記粗アイオノマー樹脂は、前記単位(A)、前記単位(B)および前記単位(C)に加えて、(メタ)アクリル酸エステル単位(D)を含むことが好ましく、前記粗アイオノマー樹脂が(メタ)アクリル酸エステル単位(D)を含む場合、前記単位(A)、前記単位(B)および前記単位(D)の合計含有量は、前記粗アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%であることが好ましい。さらに、前記粗アイオノマー樹脂は、前記単位(A)、前記単位(B)、および前記単位(C)、ならびに場合により前記単位(D)に加えて、さらに、(メタ)アクリル酸単位以外のカルボン酸単位(A2)、(メタ)アクリル酸中和物単位以外のカルボン酸中和物単位(B2)等の他の単量体単位を含んでいてもよい。
粗アイオノマー樹脂の溶液に添加する貧溶媒としては、粗アイオノマー樹脂の溶液と混合し、アイオノマー樹脂が溶解しない溶媒であれば特に制限されず、例えば、メタノール、エタノール、1-プロパノール、2-プロパノール、1-ブタノール等のアルコール類;水;アセトン、メチルエチルケトン等のケトン類;酢酸メチル、酢酸エチル等のエステル類;ジメチルエーテル、ジエチルエーテル、テトラヒドロフラン等のエーテル類;n-ヘキサン、シクロヘキサン、ヘプタン等の炭化水素化合物等が挙げられる。これらは1種単独で使用しても、2種以上を組合せて使用してもよい。これらのなかでも、沸点が低いためアイオノマー樹脂を乾燥しやすく、また、塩を溶解可能であるため粒状樹脂中の塩を除去しやすい観点から、前記貧溶媒は好ましくはメタノール、2-プロパノール等のアルコール類、水、およびこれらの混合溶媒、より好ましくはメタノール等のアルコール類である。
粗アイオノマー樹脂の溶液に貧溶媒を添加して析出させる粒状樹脂のピークトップ粒子径は、粒状樹脂の比表面積を大きくすることにより粒状樹脂中の塩の含有量を低減しやすくして、その結果、塩の含有量が1~400mg/kgの範囲内に調整しやすくなり、アイオノマー樹脂の耐熱分解性を向上しやすい観点から、700μm以下、好ましくは650μm以下、より好ましくは600μm以下、さらに好ましくは550μm以下である。また、粒状樹脂の濾過性を向上しやすく、アイオノマー樹脂の製造効率を向上しやすい観点から、好ましくは50μm以上、より好ましくは70μm以上、好ましくは80μm以上である。
(洗浄液)
工程iiiにおける洗浄液としては、アイオノマー樹脂が溶解せず、かつ、塩を溶解可能な溶媒であれば特に制限されない。好ましい洗浄液の例としては、メタノール、エタノール、1-プロパノール、2-イソプロパノール等のアルコール類;水;アセトン、メチルエチルケトン等のケトン類;酢酸メチル、酢酸エチル等のエステル類;ジメチルエーテル、ジエチルエーテル、テトラヒドロフラン等のエーテル類が挙げられる。これらは1種単独で使用しても、2種以上を組合せて使用してもよい。
水とアルコール類との混合液における水とアルコール類との割合(水/アルコール類(質量%))は、好ましくは20/80~8/20、より好ましくは30/70~70/30である。
本発明のアイオノマー樹脂に、必要に応じて添加剤を添加して樹脂組成物としてもよい。本発明における樹脂組成物は、本発明のアイオノマー樹脂と添加剤とを含んでなる。
任意に添加してよい添加剤の例としては、紫外線吸収剤、老化防止剤、酸化防止剤、熱劣化防止剤、光安定剤、膠着防止剤、滑剤、離型剤、高分子加工助剤、帯電防止剤、難燃剤、染顔料、有機色素、艶消し剤、蛍光体等が挙げられる。これらの添加剤のなかでも、紫外線吸収剤、老化防止剤、酸化防止剤、熱劣化防止剤、光安定剤、膠着防止剤、滑剤、離型剤、高分子加工助剤、有機色素が好ましい。添加する場合、添加剤は1種単独でも2種以上の組み合わせでもよい。
本発明は本発明のアイオノマー樹脂を含む層を1層以上有する樹脂シートも包含する。本発明の樹脂シートは、本発明のアイオノマー樹脂を含む層(以下、層(x)ともいう)を1層以上有する。層(x)は本発明のアイオノマー樹脂および任意に添加剤を含んでなる層である。
本発明の樹脂シートは、層(x)のみから構成されていてもよく、層(x)を少なくとも1層含む積層体であってもよい。前記積層体としては、特に限定されないが、例えば、2層以上の層(x)を含む積層体、1層以上の層(x)と1層以上の他の層とを含む積層体等が挙げられる。層(x)または他の層が複数の層である場合、各層を構成する樹脂または樹脂組成物は、同じでも異なっていてもよい。
本発明の樹脂シートの製造方法は特に限定されない。例えば、本発明のアイオノマー樹脂および任意の添加剤を均一に混練した後、押出法、カレンダー法、プレス法、溶液キャスト法、溶融キャスト法、インフレーション法等の公知の製膜方法により層(x)を製造できる。層(x)は単独で樹脂シートとして使用してもよい。また、必要に応じて、2層以上の層(x)、または1層以上の層(x)と1層以上の他の層とをプレス成形等で積層させて積層樹脂シートにしてもよく、2層以上の層(x)、または1層以上の層(x)と1層以上の他の層とを共押出法により成形して積層樹脂シートとしてもよい。層(x)または他の層が複数の層である場合、各層を構成する樹脂または樹脂組成物は、同じでも異なっていてもよい。
本発明の樹脂シートは、合わせガラス中間膜(単に中間膜ともいう)として好適に使用できる。したがって、本発明は、本発明の樹脂シートからなる合わせガラス中間膜を包含する。また、本発明は、2つのガラス板と、該2つのガラス板の間に配置された本発明の合わせガラス中間膜とを有する、合わせガラスも包含する。本発明の合わせガラスは、前記樹脂シートからなる合わせガラス中間膜を有するため、優れた透明性を有することができる。
実施例および比較例で得られたアイオノマー樹脂について、該アイオノマー樹脂における(メタ)アクリル酸単位(A)、(メタ)アクリル酸中和物単位(B)、エチレン単位(C)、および(メタ)アクリル酸エステル単位(D)の含有量の分析を、以下のようにして行った。
(1)熱分解GC-MSにより、樹脂を構成する単量体単位の成分を分析した。
(2)JIS K0070:1992に準じて、樹脂の酸価を測定した。
(3)重水素化トルエンと重水素化メタノールとの混合溶媒を用いて、樹脂の1H-NMR(400MHz、日本電子(株)製)測定を行った。
(4)また、実施例および比較例で得られたアイオノマー樹脂を、それぞれ、硝酸によるマイクロ波分解前処理に付した後、ICP発光分析(Thermo Fisher Scientific iCAP6500Duo)によって、(メタ)アクリル酸中和物単位(B)の金属イオンの種類と量を同定した。
上記(1)から、(メタ)アクリル酸エステル単位(D)および(メタ)アクリル酸単位(A)の種類と構造を同定した。その情報、ならびに上記(2)および(3)の情報から、エチレン単位(C)/(メタ)アクリル酸エステル単位(D)/((メタ)アクリル酸単位(A)と(メタ)アクリル酸中和物単位(B)の合計)の比率を算出した。さらに、上記(4)の情報からエチレン単位(C)/(メタ)アクリル酸エステル単位(D)/(メタ)アクリル酸単位(A)/(メタ)アクリル酸中和物単位(B)の比率を算出した。
また、原料であるエチレン-(メタ)アクリル酸エステル共重合体(X)の各単量体単位の含有量については、重トルエンまたは重THFに溶解させ、1H-NMR(400MHz、日本電子(株)製)にて測定し、算出した。
実施例および比較例で得られたアイオノマー樹脂を0.1g秤取し、該樹脂に超純水10mLを加え、90℃で1時間加温した。その後放冷し、目開き0.45μmのフィルターで濾過した。濾過して得た濾液をサンプル液とし、イオンクロマトグラフ((株)島津製作所製)を用いて、下記の条件にて測定した。測定で得られたピーク面積により、塩素イオンまたは硫酸イオンを定量し、該塩素イオンまたは硫酸イオンの量をナトリウム塩の量に換算し、残存無機塩量を求めた。
(測定条件)
溶離液:炭酸ナトリウム水溶液(0.6mmol/L)と炭酸水素ナトリウム水溶液(12mmol/L)との混合溶液;
流速:1.0mL/分;
カラム温度:40℃;
カラム:IC-SA2(250L×4.0)
JIS K7210-1:2014に準拠して、実施例および比較例で用いた原料樹脂、および実施例および比較例で得られたアイオノマー樹脂のメルトフローレートを測定した。具体的には、各樹脂をシリンダ内で溶融し、190℃、2.16kg荷重条件の下で、シリンダ底部に設置された公称孔径2.095mmのダイから押し出し、10分間あたりに押し出される樹脂量(g/10分)を測定した。
JIS K7120:1987に準拠して、実施例および比較例で得られたアイオノマー樹脂の耐熱分解性を評価した。具体的には、示差熱熱重量同時測定装置TG-DTA7200((株)日立ハイテクサイエンス製)を用い、昇温速度10℃/分、流量50mL/分の窒素雰囲気下で、各樹脂を20℃~550℃まで加熱した際の重量減少率を測定した。200℃時点の重量を基準に重量減少率が1%となる際の温度である1%重量減少温度(Td1)を耐熱分解性の指標とした。
実施例および比較例で得られたアイオノマー樹脂をそれぞれ210℃で溶融混練し、その溶融混練物を210℃での加熱下、4.9MPa(50kgf/cm2)の圧力にて5分間圧縮成形し、厚さ0.8mmの樹脂シートを得た。得られた樹脂シートを50mm四方に切り出し、切り出したサンプルを23℃のイオン交換水に浸漬させた状態で300時間保持し、吸水サンプルを得た。イオン交換水から取出した吸水サンプルの表面に付着した水分を拭き取った後、吸水サンプルのヘイズをヘイズメーターHZ-1(スガ試験機(株)製)を用いてJIS K7136:2000に準拠して測定した。
上述の方法と同様にして得られた樹脂シートを厚さ2.7mmのフロートガラス2枚に挟み、真空ラミネーター(日清紡メカトロニクス(株)製 1522N)を使用し、100℃で真空ラミネーター内を1分間減圧し、減圧度および温度を保持したまま30kPaで5分間プレスして、仮接着体を得た。得られた仮接着体をオートクレーブに投入し、140℃、1.2MPaで30分間処理して、合わせガラスを得た。
上述の方法にて得られた合わせガラスを140℃まで加熱したのち、0.1℃/分の速度で23℃まで徐冷した。徐冷操作後の合わせガラスのヘイズをヘイズメーターHZ-1(スガ試験機(株)製)を用いてJIS K7136:2000に準拠して測定した。
実施例および比較例において、アイオノマー樹脂の原料として用いた各エチレン-(メタ)アクリル酸エステル共重合体(X)のメタクリル酸メチル(MMA)変性量またはアクリル酸エチル(EA)変性量、およびMFRを表1に示す。
EMMA1としては住友化学(株)製「アクリフト」(登録商標)WH401F、EEA1としては日本ポリエチレン(株)製「レクスパール」(登録商標)A4250を用いた。
SUS製の耐圧容器に、表1中のEMMA2、100質量部を導入し、そこにトルエン233質量部を加えて、0.02MPa加圧下、60℃で撹拌し、EMMA2を溶解させた。得られた溶液に水酸化ナトリウムのメタノール溶液(20質量%)96質量部を添加し、100℃で4時間撹拌し、EMMA2をけん化して、メタクリル酸メチル単位の一部をメタクリル酸ナトリウム単位に変換した。次いで、この溶液を50℃まで冷却した後に、塩酸(20質量%)83質量部を添加し、50℃で1時間撹拌して、メタクリル酸ナトリウム単位の一部をメタクリル酸に変換し、粗アイオノマー樹脂溶液を得た。
得られた粗アイオノマー樹脂溶液にトルエン/メタノール(75/25質量%)の混合溶媒を粗アイオノマー樹脂濃度が10質量%となるように添加して、該溶液を希釈した。次いで、得られた粗アイオノマー樹脂の希釈溶液を34℃に調整した後、前記希釈溶液に34℃のメタノールを粗アイオノマー樹脂溶液100質量部に対して430質量部添加して、粒状樹脂を析出させた。次いで、得られた粒状樹脂を濾取した後、濾取した粒状樹脂100質量部と水/メタノール(50/50質量%)の混合溶媒600質量部とを混合した。前記混合により得られたスラリーを40℃で1時間撹拌し、その後、粒状樹脂を室温にて濾取した。水/メタノール(50/50質量%)の混合溶媒による粒状樹脂の洗浄をさらに3回行い、洗浄されたアイオノマー樹脂1を得た。
得られたアイオノマー樹脂1を8時間以上真空乾燥した後、分析し、特性を評価した。アイオノマー樹脂1の分析結果および評価結果を表2に示す。
EMMA2に代えてEMMA3を用い、粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から37℃にした以外は、実施例1と同様にして、アイオノマー樹脂2を得た。得られたアイオノマー樹脂2の分析結果および評価結果を表2に示す。
EMMA2に代えてEMMA3を用い、粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から40℃にした以外は、実施例1と同様にして、アイオノマー樹脂3を得た。得られたアイオノマー樹脂3の分析結果および評価結果を表2に示す。
塩酸に代えて硫酸(30質量%)220質量部を添加した以外は、実施例3と同様にして、アイオノマー樹脂4を得た。得られたアイオノマー樹脂4の分析結果および評価結果を表2に示す。
EMMA2に代えてEEA1を用い、粗アイオノマー樹脂の希釈溶液の濃度を10質量%から6質量%にし、粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から41℃にした以外は、実施例1と同様にして、アイオノマー樹脂5を得た。得られたアイオノマー樹脂5の分析結果および評価結果を表2に示す。
EMMA2に代えてEMMA1を用い、水酸化ナトリウムのメタノール溶液(20質量%)の添加量を96質量部から73質量部にし、塩酸(20質量%)の添加量を83質量部から63質量部にし、粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から37℃にした以外は、実施例1と同様にして、アイオノマー樹脂6を得た。得られたアイオノマー樹脂6の分析結果および評価結果を表2に示す。
実施例3と同様にしてアイオノマー樹脂3を得た後、該アイオノマー樹脂3の100質量に対し2-(2H-ベンゾトリアゾール-2-イル)-4-(1,1,3,3-テトラメチルブチル)フェノール(BASF社製;商品名:TINUVIN329)を0.1質量部加え、溶融混錬することにより、アイオノマー樹脂7を得た。得られたアイオノマー樹脂7の分析結果および評価結果を表2に示す。
粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から43℃にした以外は、実施例1と同様にして、アイオノマー樹脂8を得た。得られたアイオノマー樹脂8の分析結果および評価結果を表2に示す。
粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から46℃にした以外は、実施例1と同様にして、アイオノマー樹脂9を得た。得られたアイオノマー樹脂9の分析結果および評価結果を表2に示す。
塩酸に代えて硫酸(30質量%)220質量部を添加し、粗アイオノマー樹脂の希釈溶液ならびにメタノールの温度を34℃から50℃にした以外は、実施例1と同様にして、アイオノマー樹脂10を得た。得られたアイオノマー樹脂10の分析結果および評価結果を表2に示す。
EMMA2に代えてEMMA3を用い、粗アイオノマー樹脂溶液を該粗アイオノマー樹脂100質量部に対して500質量部のアセトン/水(80/20質量%)の混合溶媒に再沈殿させることで粒状樹脂を得、さらに得られた粒状樹脂をアセトン/水(20/80質量%)の混合溶媒で3回洗浄したこと以外は実施例1と同様にして、アイオノマー樹脂11を得た。得られたアイオノマー樹脂11の分析結果および評価結果を表2に示す。
EMMA2に代えてEMMA4を用い、水酸化ナトリウムのメタノール溶液(20質量%)の添加量を96質量部から66質量部にし、塩酸(20質量%)の添加量を83質量部から57質量部にした以外は、実施例1と同様にして、アイオノマー樹脂12を得た。得られたアイオノマー樹脂12の分析結果および評価結果を表2に示す。
Claims (7)
- (メタ)アクリル酸単位(A)、
(メタ)アクリル酸中和物単位(B)、および
エチレン単位(C)
を含む、アイオノマー樹脂であって、
前記単位(A)および前記単位(B)の合計含有量は、前記アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%であり、前記アイオノマー樹脂中の強酸および強塩基からなる塩の含有量は1~400mg/kgである、アイオノマー樹脂。 - 前記アイオノマー樹脂はさらに(メタ)アクリル酸エステル単位(D)を含み、前記単位(A)、前記単位(B)および前記単位(D)の合計含有量は、前記アイオノマー樹脂を構成する全単量体単位を基準として6~10モル%である、請求項1に記載のアイオノマー樹脂。
- 前記強酸および強塩基からなる塩は、アルカリ金属および/またはアルカリ土類金属の金属塩である、請求項1または2に記載のアイオノマー樹脂。
- 前記強酸および強塩基からなる塩は、ナトリウムイオンおよびカリウムイオンからなる群から選択される少なくとも1種のカチオンと、ハロゲンイオン、硝酸イオンおよび硫酸イオンからなる群から選択される少なくとも1種のアニオンとからなる塩である、請求項1~3のいずれかに記載のアイオノマー樹脂。
- 請求項1~4のいずれかに記載のアイオノマー樹脂を含む層を1層以上有する、樹脂シート。
- 請求項5に記載の樹脂シートからなる合わせガラス中間膜。
- 2つのガラス板と、該2つのガラス板の間に配置された請求項6に記載の合わせガラス中間膜とを有する、合わせガラス。
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WO2023008485A1 (ja) * | 2021-07-28 | 2023-02-02 | 株式会社クラレ | アイオノマー樹脂粒状物の製造方法 |
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