WO2022270336A1 - シリコーン重合体の製造方法 - Google Patents
シリコーン重合体の製造方法 Download PDFInfo
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- WO2022270336A1 WO2022270336A1 PCT/JP2022/023582 JP2022023582W WO2022270336A1 WO 2022270336 A1 WO2022270336 A1 WO 2022270336A1 JP 2022023582 W JP2022023582 W JP 2022023582W WO 2022270336 A1 WO2022270336 A1 WO 2022270336A1
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- WO
- WIPO (PCT)
- Prior art keywords
- solution
- silicone polymer
- catalyst
- producing
- acid
- Prior art date
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- 229920005573 silicon-containing polymer Polymers 0.000 title claims abstract description 86
- 238000004519 manufacturing process Methods 0.000 title claims description 39
- 239000003054 catalyst Substances 0.000 claims abstract description 61
- -1 silane compound Chemical group 0.000 claims abstract description 46
- 229910000077 silane Inorganic materials 0.000 claims abstract description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 33
- 125000000962 organic group Chemical group 0.000 claims abstract description 27
- 150000001875 compounds Chemical class 0.000 claims abstract description 20
- 238000000034 method Methods 0.000 claims abstract description 16
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims abstract description 5
- 239000000243 solution Substances 0.000 claims description 128
- NWUYHJFMYQTDRP-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;1-ethenyl-2-ethylbenzene;styrene Chemical compound C=CC1=CC=CC=C1.CCC1=CC=CC=C1C=C.C=CC1=CC=CC=C1C=C NWUYHJFMYQTDRP-UHFFFAOYSA-N 0.000 claims description 31
- 239000003456 ion exchange resin Substances 0.000 claims description 19
- 229920003303 ion-exchange polymer Polymers 0.000 claims description 19
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 18
- MUBZPKHOEPUJKR-UHFFFAOYSA-N oxalic acid group Chemical group C(C(=O)O)(=O)O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 18
- 239000012295 chemical reaction liquid Substances 0.000 claims description 16
- 150000003856 quaternary ammonium compounds Chemical group 0.000 claims description 11
- KIZQNNOULOCVDM-UHFFFAOYSA-M 2-hydroxyethyl(trimethyl)azanium;hydroxide Chemical compound [OH-].C[N+](C)(C)CCO KIZQNNOULOCVDM-UHFFFAOYSA-M 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 9
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 8
- AFVFQIVMOAPDHO-UHFFFAOYSA-N Methanesulfonic acid Chemical compound CS(O)(=O)=O AFVFQIVMOAPDHO-UHFFFAOYSA-N 0.000 claims description 8
- 239000003377 acid catalyst Substances 0.000 claims description 7
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 claims description 6
- 235000006408 oxalic acid Nutrition 0.000 claims description 6
- IJGSGCGKAAXRSC-UHFFFAOYSA-M tris(2-hydroxyethyl)-methylazanium;hydroxide Chemical compound [OH-].OCC[N+](C)(CCO)CCO IJGSGCGKAAXRSC-UHFFFAOYSA-M 0.000 claims description 6
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 claims description 5
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 4
- RKTGAWJWCNLSFX-UHFFFAOYSA-M bis(2-hydroxyethyl)-dimethylazanium;hydroxide Chemical compound [OH-].OCC[N+](C)(C)CCO RKTGAWJWCNLSFX-UHFFFAOYSA-M 0.000 claims description 4
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 claims description 4
- 239000011976 maleic acid Substances 0.000 claims description 4
- 229940098779 methanesulfonic acid Drugs 0.000 claims description 4
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 3
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims description 2
- 238000002156 mixing Methods 0.000 abstract description 14
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- 101100237844 Mus musculus Mmp19 gene Proteins 0.000 abstract 1
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- 239000010408 film Substances 0.000 description 18
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- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 14
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- 230000003068 static effect Effects 0.000 description 13
- WGTYBPLFGIVFAS-UHFFFAOYSA-M tetramethylammonium hydroxide Chemical compound [OH-].C[N+](C)(C)C WGTYBPLFGIVFAS-UHFFFAOYSA-M 0.000 description 12
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- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 9
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 8
- 238000000576 coating method Methods 0.000 description 8
- LZCLXQDLBQLTDK-UHFFFAOYSA-N ethyl 2-hydroxypropanoate Chemical compound CCOC(=O)C(C)O LZCLXQDLBQLTDK-UHFFFAOYSA-N 0.000 description 8
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- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 5
- 125000000217 alkyl group Chemical group 0.000 description 5
- 238000003756 stirring Methods 0.000 description 5
- FERIUCNNQQJTOY-UHFFFAOYSA-N Butyric acid Chemical compound CCCC(O)=O FERIUCNNQQJTOY-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 150000001298 alcohols Chemical class 0.000 description 4
- 238000009835 boiling Methods 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 229940116333 ethyl lactate Drugs 0.000 description 4
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- 150000007524 organic acids Chemical class 0.000 description 4
- 239000004065 semiconductor Substances 0.000 description 4
- VDZOOKBUILJEDG-UHFFFAOYSA-M tetrabutylammonium hydroxide Chemical compound [OH-].CCCC[N+](CCCC)(CCCC)CCCC VDZOOKBUILJEDG-UHFFFAOYSA-M 0.000 description 4
- 229910021642 ultra pure water Inorganic materials 0.000 description 4
- 239000012498 ultrapure water Substances 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- WWZKQHOCKIZLMA-UHFFFAOYSA-N Caprylic acid Natural products CCCCCCCC(O)=O WWZKQHOCKIZLMA-UHFFFAOYSA-N 0.000 description 3
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
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- NTIZESTWPVYFNL-UHFFFAOYSA-N Methyl isobutyl ketone Chemical compound CC(C)CC(C)=O NTIZESTWPVYFNL-UHFFFAOYSA-N 0.000 description 3
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- 230000002378 acidificating effect Effects 0.000 description 3
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- 125000003118 aryl group Chemical group 0.000 description 3
- OEYIOHPDSNJKLS-UHFFFAOYSA-N choline Chemical compound C[N+](C)(C)CCO OEYIOHPDSNJKLS-UHFFFAOYSA-N 0.000 description 3
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- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
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- OYHQOLUKZRVURQ-NTGFUMLPSA-N (9Z,12Z)-9,10,12,13-tetratritiooctadeca-9,12-dienoic acid Chemical compound C(CCCCCCC\C(=C(/C\C(=C(/CCCCC)\[3H])\[3H])\[3H])\[3H])(=O)O OYHQOLUKZRVURQ-NTGFUMLPSA-N 0.000 description 2
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- OKIZCWYLBDKLSU-UHFFFAOYSA-M N,N,N-Trimethylmethanaminium chloride Chemical compound [Cl-].C[N+](C)(C)C OKIZCWYLBDKLSU-UHFFFAOYSA-M 0.000 description 2
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- VJGNLOIQCWLBJR-UHFFFAOYSA-M benzyl(tributyl)azanium;chloride Chemical compound [Cl-].CCCC[N+](CCCC)(CCCC)CC1=CC=CC=C1 VJGNLOIQCWLBJR-UHFFFAOYSA-M 0.000 description 2
- HTZCNXWZYVXIMZ-UHFFFAOYSA-M benzyl(triethyl)azanium;chloride Chemical compound [Cl-].CC[N+](CC)(CC)CC1=CC=CC=C1 HTZCNXWZYVXIMZ-UHFFFAOYSA-M 0.000 description 2
- UUZYBYIOAZTMGC-UHFFFAOYSA-M benzyl(trimethyl)azanium;bromide Chemical compound [Br-].C[N+](C)(C)CC1=CC=CC=C1 UUZYBYIOAZTMGC-UHFFFAOYSA-M 0.000 description 2
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- NBXZNTLFQLUFES-UHFFFAOYSA-N triethoxy(propyl)silane Chemical compound CCC[Si](OCC)(OCC)OCC NBXZNTLFQLUFES-UHFFFAOYSA-N 0.000 description 1
- JXUKBNICSRJFAP-UHFFFAOYSA-N triethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CCO[Si](OCC)(OCC)CCCOCC1CO1 JXUKBNICSRJFAP-UHFFFAOYSA-N 0.000 description 1
- QYBKVVRRGQSGDC-UHFFFAOYSA-N triethyl methyl silicate Chemical compound CCO[Si](OC)(OCC)OCC QYBKVVRRGQSGDC-UHFFFAOYSA-N 0.000 description 1
- SEFGHEUKKXNENM-UHFFFAOYSA-M triethyl(1-hydroxyethyl)azanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)C(C)O SEFGHEUKKXNENM-UHFFFAOYSA-M 0.000 description 1
- ZGKZQHAYPIDZLW-UHFFFAOYSA-M triethyl(1-hydroxypropyl)azanium;hydroxide Chemical compound [OH-].CCC(O)[N+](CC)(CC)CC ZGKZQHAYPIDZLW-UHFFFAOYSA-M 0.000 description 1
- RBUVMOSJYGXQEK-UHFFFAOYSA-M triethyl(2-hydroxypropyl)azanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CC(C)O RBUVMOSJYGXQEK-UHFFFAOYSA-M 0.000 description 1
- DWBDUFAECGEQOS-UHFFFAOYSA-M triethyl(3-hydroxypropyl)azanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CCCO DWBDUFAECGEQOS-UHFFFAOYSA-M 0.000 description 1
- RPMOERPGTQLCAT-UHFFFAOYSA-M triethyl(hydroxymethyl)azanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CO RPMOERPGTQLCAT-UHFFFAOYSA-M 0.000 description 1
- HQYALQRYBUJWDH-UHFFFAOYSA-N trimethoxy(propyl)silane Chemical compound CCC[Si](OC)(OC)OC HQYALQRYBUJWDH-UHFFFAOYSA-N 0.000 description 1
- KKLAORVGAKUOPZ-UHFFFAOYSA-M trimethyl(phenyl)azanium;iodide Chemical compound [I-].C[N+](C)(C)C1=CC=CC=C1 KKLAORVGAKUOPZ-UHFFFAOYSA-M 0.000 description 1
- IXJNGXCZSCHDFE-UHFFFAOYSA-N triphenoxy(phenyl)silane Chemical compound C=1C=CC=CC=1O[Si](C=1C=CC=CC=1)(OC=1C=CC=CC=1)OC1=CC=CC=C1 IXJNGXCZSCHDFE-UHFFFAOYSA-N 0.000 description 1
- AMUIJRKZTXWCEA-UHFFFAOYSA-N triphenoxy(propyl)silane Chemical compound C=1C=CC=CC=1O[Si](OC=1C=CC=CC=1)(CCC)OC1=CC=CC=C1 AMUIJRKZTXWCEA-UHFFFAOYSA-N 0.000 description 1
- VUWVDNLZJXLQPT-UHFFFAOYSA-N tripropoxy(propyl)silane Chemical compound CCCO[Si](CCC)(OCCC)OCCC VUWVDNLZJXLQPT-UHFFFAOYSA-N 0.000 description 1
- KGOOITCIBGXHJO-UHFFFAOYSA-N tris[(2-methylpropan-2-yl)oxy]-phenylsilane Chemical compound CC(C)(C)O[Si](OC(C)(C)C)(OC(C)(C)C)C1=CC=CC=C1 KGOOITCIBGXHJO-UHFFFAOYSA-N 0.000 description 1
- DIZPPYBTFPZSGK-UHFFFAOYSA-N tris[(2-methylpropan-2-yl)oxy]-propylsilane Chemical compound CCC[Si](OC(C)(C)C)(OC(C)(C)C)OC(C)(C)C DIZPPYBTFPZSGK-UHFFFAOYSA-N 0.000 description 1
- 235000012431 wafers Nutrition 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 239000002349 well water Substances 0.000 description 1
- 235000020681 well water Nutrition 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/04—Polysiloxanes
- C08G77/06—Preparatory processes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/04—Polysiloxanes
- C08G77/06—Preparatory processes
- C08G77/08—Preparatory processes characterised by the catalysts used
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
- C09D183/04—Polysiloxanes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/002—Processes for applying liquids or other fluent materials the substrate being rotated
- B05D1/005—Spin coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2201/00—Polymeric substrate or laminate
- B05D2201/02—Polymeric substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2203/00—Other substrates
- B05D2203/30—Other inorganic substrates, e.g. ceramics, silicon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2203/00—Other substrates
- B05D2203/30—Other inorganic substrates, e.g. ceramics, silicon
- B05D2203/35—Glass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2518/00—Other type of polymers
- B05D2518/10—Silicon-containing polymers
Definitions
- the present invention relates to a production method that is easily automated, continuous, and obtains a silicone polymer with good reproducibility.
- Silicone polymers are organic-inorganic hybrid materials that combine organic and inorganic compounds at the molecular level. In recent years, it has been actively researched because it is a material that has the characteristics of other materials.
- silicone polymer in pattern molding when manufacturing semiconductor elements, etc., it has been proposed to use a silicone polymer as a resist underlayer film when forming a reverse pattern using lithography technology, etching technology, or the like.
- silicone polymers in particular, when a structure derived from tetramethoxysilane or tetraethoxysilane is contained in a large amount, embedding properties in fine resist underlayer film patterns and removal of resist underlayer film patterns by oxygen-based gas etching etc. It was known to have excellent etching resistance.
- the flow-microsynthesis method is generally a method in which raw materials are continuously supplied by a pump or the like and reacted in a tubular reactor or a continuous stirring tank reactor. Especially when the inner diameter of the tubular reactor is as small as several hundred ⁇ m, the diffusion distance is shortened, and the apparent reaction rate may be faster than when reacting in a conventional batch reactor (for example, See Non-Patent Document 1).
- the flow-microsynthesis method is expected to be a next-generation manufacturing method because it is easy to automate, allows continuous reactions, uses small equipment, consumes little energy, and reduces waste. .
- An object of the present invention is to provide a method for obtaining a silicone polymer that is easy to automate, continuous and reproducible.
- the method for producing a silicone polymer of the present invention comprises a compound represented by the following general formula (1), R a Si(OR 1 ) 4-a (1) (Wherein, R is a hydrogen atom or a monovalent organic group, R 1 is a monovalent organic group, and a is an integer of 1 to 2.) and a compound represented by the following general formula (2), Si(OR 2 ) 4 (2) (In the formula, R2 represents a monovalent organic group.)
- a solution A containing at least one silane compound selected from, a solution B containing a catalyst, the solution A or solution B containing water these are continuously supplied to a mixer and mixed, after which the inner diameter is 1 to It is characterized by supplying and reacting in a 20 mm tubular reactor.
- raw materials consisting of a solution A containing a silane compound and a solution B containing a catalyst are continuously supplied by a pump or the like and mixed and reacted.
- a pump or the like less than or not to supply raw materials
- a solution A containing a silane compound and a solution B containing a catalyst are continuously supplied by a pump or the like and mixed and reacted.
- automatic operation is possible by controlling the operation of pumps and the like and the temperature control of the mixer and tubular reactor by means of a program using a personal computer or the like.
- the operation of equipment can be controlled remotely without exposing workers to dangerous chemicals. Work near high-risk equipment can also be reduced.
- Autonomous operation eliminates variations due to manual operation, enabling highly reproducible production.
- a method for producing a silicone polymer mixes a specific silane compound, water and a catalyst in a mixer, preferably a static mixer. Since the static mixer has a larger specific surface area than a general reactor, it is easy to control the temperature. The smaller the inner diameter of the static mixer, the greater the specific surface area, which is preferable. Since static mixers have no driving parts, there is no risk of dust generation from sliding parts or contamination with oil, making them suitable for manufacturing materials for pharmaceuticals and electronic information materials that require strict control.
- the inner diameter of the tubular reactor is 1 to 20 mm, there is little pressure loss, and even if a long tubular reactor is designed or the supply amount is increased to increase the production amount, excessive pressure will not be applied. . Furthermore, since the inner diameter is as large as 1 mm or more, clogging is less likely to occur. On the other hand, a tubular reactor having an inner diameter of 20 mm or less is preferable because the diffusion distance of substances is shorter than that of a conventional reactor, and thus the apparent reaction rate is increased and the reaction is quickly completed.
- the obtained reaction solution may be brought into contact with an ion exchange resin packed in a column.
- an ion exchange resin packed in a column.
- the catalyst and ionic impurities such as metals can be continuously removed from the reaction solution.
- Ion exchange resins can be used repeatedly by regenerating them, which is preferable in terms of resources and economy.
- the silicone polymer and its composition produced by the method for producing a silicone polymer of the present invention can be formed into a coating film by a general method such as spin coating.
- a general method such as spin coating.
- the silicone polymer and its composition when applied to a substrate, they can form a thin film on the substrate, and heat can be applied to create a thermosetting film on the substrate. Since the thermosetting film thus formed has excellent transparency and heat resistance, it can be used as a protective film and a resist underlayer film for semiconductors and displays.
- the manufactured silicone polymer does not contain metals as a raw material, so it can be suitably used for electronic information materials such as displays and semiconductors. Furthermore, it can be applied not only to the field of electronic information materials, but also to a wide range of fields such as paints and adhesives.
- FIG. 1 is a flow diagram illustrating the configuration of a production apparatus used in the method for producing a silicone polymer of the present invention.
- the method for producing a silicone polymer of the present invention comprises a compound represented by the following general formula (1), R a Si(OR 1 ) 4-a (1) (Wherein, R is a hydrogen atom or a monovalent organic group, R 1 is a monovalent organic group, and a is an integer of 1 to 2.) and a compound represented by the following general formula (2), Si(OR 2 ) 4 (2) (In the formula, R2 represents a monovalent organic group.) Using a solution A containing at least one silane compound selected from, a solution B containing a catalyst, the solution A or solution B containing water, these are continuously supplied to a mixer and mixed, after which the inner diameter is 1 to This is a method for producing a silicone polymer that is supplied to a 20 mm tubular reactor and reacted.
- the apparatus for producing a silicone polymer includes a monomer tank 1 for preparing a solution A containing a silane compound, a catalyst tank 2 for preparing a solution B containing a catalyst, a mixer 4 for mixing the solutions A and B, It consists of a tubular reactor 5 in which mixed solutions A and B are reacted. Further, a column 6 filled with an ion exchange resin may be connected to the tubular reactor 5 .
- the monomer tank 1 At least one silane compound selected from the compound represented by the general formula (1) and the compound represented by the general formula (2) and a solvent are weighed, charged, mixed, and taken out. , an apparatus for preparing a monomer solution (solution A), having means for each of the operations described above.
- the monomer tank 1 may be either batch type or continuous type, or may be a combination thereof.
- a monomer solution (solution A) prepared in the monomer tank 1 is supplied to the mixer 4 via a pump 3 such as a dual plunger pump and flow control means.
- the catalyst tank 2 is a device for preparing a catalyst solution (solution B) by weighing, charging, mixing, and taking out the catalyst and its solvent, and has means for each operation described above.
- the catalyst tank 2 may be either batch type or continuous type, or may be a combination thereof.
- a catalyst solution (solution B) prepared in the catalyst tank 2 is supplied to the mixer 4 via a pump 3 such as a dual plunger pump and flow control means.
- the mixer 4 is preferably a static mixing stirrer such as a static mixer or a micromixer.
- the mixer 4 mixes the supplied monomer solution (solution A) and catalyst solution (solution B) to prepare a raw material solution.
- the obtained raw material solution is supplied to the tubular reactor 5 as it is.
- the tubular reactor 5 is a reactor with an inner diameter of 1 to 20 mm.
- the material of the tubular reactor 5 is not particularly limited, and may be a rigid material such as metal or a relatively flexible material such as resin.
- the silane compound, catalyst, and water contained in the supplied raw material solution react to polymerize the silicone polymer.
- the tubular reactor 5 has means for appropriately adjusting polymerization conditions such as temperature, pressure and residence time. Also, a reaction liquid containing the obtained silicone polymer, catalyst and the like is sent out.
- the reaction liquid sent out from the tubular reactor 5 is preferably supplied to a column 6 packed with an ion exchange resin, and the catalyst in contact with the ion exchange resin is removed.
- the column 6 has means for appropriately adjusting contact conditions with the ion exchange resin such as temperature, pressure and residence time.
- the reaction solution containing the silicone polymer and from which the catalyst has been removed is sent out from the column 6 and collected in a product container or the like.
- the solution A containing the silane compound is a solution in which at least one silane compound selected from the compound represented by the general formula (1) and the compound represented by the general formula (2) is dissolved in a solvent.
- solvents include water; alcohols such as methanol, ethanol, n-propanol and isopropanol; aprotic solvents such as toluene and xylene; ketone solvents such as methyl ethyl ketone and methyl isobutyl ketone; ether solvents such as diethyl ether and tetrahydrofuran. , propylene glycol monomethyl ether, propylene glycol monoethyl ether, and ethyl lactate. Two or more kinds of solvents may be included.
- R and R 1 are independent of each other and may be the same organic group or different organic groups. Further, when a is 2, Rs are independent of each other and may be one kind of monovalent organic group or two kinds of monovalent organic groups. Furthermore, two or more R 1 are independent of each other and may be one type of monovalent organic group or two or more types of monovalent organic groups. Examples of monovalent organic groups for R and R 1 include alkyl groups, aryl groups, vinyl groups, allyl groups and glycidyl groups. Moreover, in general formula (1), R is preferably a monovalent organic group, particularly an alkyl group, an aryl group, or a vinyl group.
- the alkyl group includes a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, etc., preferably an alkyl group having 1 to 5 carbon atoms. , may be branched, and the hydrogen atoms of the alkyl group may be substituted with a functional group containing a fluorine atom or a heteroatom.
- examples of the aryl group include a phenyl group, a naphthyl group, a methylphenyl group, an ethylphenyl group, a chlorophenyl group, a bromophenyl group, and a fluorophenyl group.
- Specific examples of the compound represented by formula (1) include methyltrimethoxysilane, methyltriethoxysilane, methyltri-n-propoxysilane, methyltri-iso-propoxysilane, methyltri-n-butoxysilane, methyltri-sec.
- Preferred compounds as compound (1) include methyltrimethoxysilane, methyltriethoxysilane, methyltri-n-propoxysilane, methyltri-iso-propoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltrimethoxysilane, Ethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, diphenyldimethoxysilane, diphenyldiethoxysilane and the like are preferred because they are industrially readily available. These may be used singly or in combination of two or more.
- examples of the monovalent organic group represented by R 2 include the same organic groups as those of R 1 in the general formula (1). Also, the four R 2 may be independent of each other and may be one kind of monovalent organic group or two or more kinds of monovalent organic groups.
- Specific examples of the compound represented by the general formula (2) include tetramethoxysilane, methoxytriethoxysilane, dimethoxydiethoxysilane, trimethoxyethoxysilane, tetraethoxysilane, tetra-n-propoxysilane, tetra-iso- Propoxysilane, tetra-n-butoxysilane, tetra-sec-butoxysilane, tetra-tert-butoxysilane, tetraphenoxysilane and the like are used. Among them, tetramethoxysilane and tetraethoxysilane are preferable because they are easily available industrially.
- a solution B containing a catalyst is a solution in which the catalyst is dissolved in the solvent.
- solvents include water; alcohols such as methanol, ethanol, n-propanol and isopropanol; aprotic solvents such as toluene and xylene; ketone solvents such as methyl ethyl ketone and methyl isobutyl ketone; ether solvents such as diethyl ether and tetrahydrofuran. , propylene glycol monomethyl ether, propylene glycol monoethyl ether, and ethyl lactate. Two or more kinds of solvents may be included.
- Either an acid catalyst or a base catalyst can be used as the catalyst.
- acid catalyst acid catalysts other than hydrochloric acid are preferred, and both inorganic acids and organic acids can be used.
- inorganic acids include nitric acid, sulfuric acid, hydrofluoric acid, and phosphoric acid.
- organic acids include acetic acid, propionic acid, butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, oxalic acid, maleic acid, methylmalonic acid, adipic acid, sebacic acid, and gallic acid.
- inorganic bases and organic bases can be used as the base catalyst.
- inorganic bases include lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, barium hydroxide, sodium carbonate, calcium carbonate, sodium hydrogen carbonate and the like.
- organic base specifically, a quaternary ammonium compound is preferably used for electronic information materials because it contains no metal. Among them, a quaternary ammonium compound containing a hydroxyl group is preferable.
- Examples of the quaternary ammonium compounds include hydroxymethyltrimethylammonium hydroxide, 1-hydroxyethyltrimethylammonium hydroxide, 2-hydroxyethyltrimethylammonium hydroxide, 1-hydroxypropyltrimethylammonium hydroxide, 2-hydroxypropyltrimethyl ammonium hydroxide, 3-hydroxypropyltrimethylammonium hydroxide, hydroxymethyltriethylammonium hydroxide, 1-hydroxyethyltriethylammonium hydroxide, 2-hydroxyethyltriethylammonium hydroxide, 1-hydroxypropyltriethylammonium hydroxide, 2-hydroxy propyltriethylammonium hydroxide, 3-hydroxypropyltriethylammonium hydroxide, hydroxymethyltripropylammonium hydroxide, 1-hydroxyethyltripropylammonium hydroxide, 2-hydroxyethyltripropylammonium hydroxide, 1-hydroxypropyltripropy
- 2-hydroxyethyltrimethylammonium hydroxide 2-hydroxyethyltriethylammonium hydroxide, 2-hydroxyethyltripropylammonium hydroxide, 2-hydroxyethyltributylammonium hydroxide, dimethylbis(2-hydroxyethyl)ammonium are preferred.
- Tetramethylammonium hydroxide is inexpensive and reaction control is easy, and 2-hydroxyethyltrimethylammonium hydroxide, dimethylbis(2-hydroxyethyl)ammonium hydroxide, and tris(2-hydroxyethyl)methylammonium hydroxide are 2-Hydroxyethyltrimethylammonium hydroxide and dimethylbis(2-hydroxyethyl) are generally obtained by the addition reaction of trimethylamine, dimethylamine, and methylamine with ethylene oxide.
- Ammonium hydroxide, tris(2-hydroxyethyl)methylammonium hydroxide is preferred as it is readily available in industrial grade.
- the amount of the catalyst used is 0.002 to 0.002 to 1 mol of the total amount of alkoxyl groups in the silane compound composed of the compound represented by the general formula (1) and/or the compound represented by the general formula (2). 2.0 mol is preferred, and 0.005 to 1.0 mol is more preferred.
- the solution B containing the catalyst is easy to add and has excellent workability, and may be an aqueous solution or a solution containing water.
- water is used to hydrolyze and polycondensate the silane compound represented by general formula (1) and/or the silane compound represented by general formula (2).
- the type of water is not particularly limited, but industrial water, city water, well water, distilled water, ion-exchanged water, ultrapure water, and the like are used. One type of water may be used, or two or more types may be used. Among them, ion-exchanged water and ultrapure water having high electrical resistivity are preferable, and ultrapure water having electrical resistivity of 15 M ⁇ cm or more is preferable because of its low metal content.
- Water may be added to the solution A containing the silane compound represented by the general formula (1) and/or the silane compound represented by the general formula (2), or may be added to the solution B containing the catalyst. When added to the solution B containing the catalyst, it is preferable because unintended hydrolysis of the silane compound represented by the general formula (1) and/or the silane compound represented by the general formula (2) does not occur.
- the amount of water to be used is preferably 1.0 to 15 per equivalent of the total amount of alkoxyl groups in the silane compound represented by the following general formula (1) and/or the silane compound represented by the general formula (2). 0 equivalent, more preferably 1.0 to 10.0 equivalent. More preferably, it is 1.0 to 5.0 equivalents. When the amount of water is 1.0 equivalent or more, the hydrolysis and polycondensation reaction of the silane compound proceeds rapidly.
- a solution A containing a silane compound and a solution B containing a catalyst are mixed in a mixer.
- a centrifugal pump, a centrifugal pump, a driven mixing stirrer such as an in-line mixer having stirring blades, a stationary mixing stirrer such as a static mixer, a nozzle, an orifice, a T-shaped reactor, or the like is used as the mixer.
- a static mixing stirrer having no driving part or sliding part that is, a so-called static mixer is preferable because there is no risk of dust generation and oil contamination.
- a micromixer having a flow path of about 1 mm made up of pipes or blocks of a static mixer is preferable because, when mixing involves a reaction, the diffusion distance of substances is limited, and the reaction progresses rapidly.
- the inner diameter of the pipe used for the static mixer is preferably 1-20 mm, more preferably 1-10 mm. If the inner diameter is 1 mm or more, the pressure loss is small and the risk of clogging is small. If the inner diameter is 20 mm or less, the reaction proceeds quickly, which is preferable.
- static mixers and micromixers rectangular plates twisted 180 degrees in opposite directions are alternately arranged in a tube.
- the number of elements is preferably 12 or more, more preferably 18 or more.
- Mixer materials include stainless steel such as SUS304 and SUS316, carbon steel such as SS41, SC and SCM, metals such as Hastelloy, titanium, monel, nickel, carpenter and tantalum, Teflon (registered trademark), PFA, PVC, FRP, Resins such as CFRP, ceramics, rubber linings, Teflon linings, and glass linings on metals are used.
- the use of Teflon or a Teflon-lined material is preferable because the metal does not elute into the mixture.
- Kenics mixer type Sulzer SMV type, Sulzer SMX type, Toray Hi-mixer type, Komax mixer type, Lightning mixer type, Ross ISG type, Bran & Lube mixer type, YMC Deneb type, YMC Spica type, YMC Hadar type , IMM CPMM-R300 and other static mixers.
- the pressure during mixing in the mixer is preferably from 0 MPa to 5 MPa, more preferably from 0 MPa to 2 MPa.
- the temperature during mixing in a mixer is preferably 0 to 100°C, more preferably 5 to 80°C. If the temperature is 0° C. or higher, the mixture is sufficiently mixed, and if the temperature is 100° C.
- the reaction can be easily controlled, which is preferable.
- the mixing time in the mixer is preferably 0.1 to 600 seconds, more preferably 1 to 300 seconds, depending on the feed rate of the raw materials and the design of the mixer. If the time is 0.1 seconds or longer, sufficient mixing is achieved, and if the time is 600 seconds or shorter, it is preferable because it has less influence on the control of the reaction time.
- a pump is used to supply raw materials to the mixer. It is preferable to use a personal computer (hereinafter sometimes referred to as "PC") or the like to control the pressure and flow rate of the pump, which leads to automation and labor saving.
- PC personal computer
- the reaction is carried out in a tubular reactor with an inner diameter of 1 to 20 mm.
- a tubular reactor is a reactor in which a fluid is allowed to flow through a tube for reaction.
- the inner diameter is 1 to 20 mm, more preferably 1 to 10 mm. If the inner diameter is 1 mm or more, the pressure loss is small and the risk of clogging is small. If the inner diameter is 20 mm or less, the reaction proceeds quickly, which is preferable.
- Materials are not particularly limited, but include stainless steel such as SUS304 and SUS316, carbon steel such as SS41, SC and SCM, metals such as Hastelloy, titanium, monel, nickel, carpenter and tantalum, Teflon, PFA, PVC, FRP and CFRP.
- materials such as ceramics, rubber lining, Teflon lining, and glass lining are used for metals and the like.
- the use of Teflon, PFA, or a material lined with Teflon is preferable because the metal does not elute into the mixed liquid.
- the pressure during the reaction in the tubular reactor is preferably 0 MPa to 5 MPa, more preferably 0 MPa to 2 MPa.
- a pressure of 0 MPa or higher is preferable because the reaction can be performed at a temperature equal to or higher than the boiling point of the solvent, and a pressure of 5 MPa or lower is preferable because the apparatus can be simplified.
- the temperature in the tubular reactor is preferably 0 to 200°C, more preferably 5 to 150°C.
- the reaction time in the tubular reactor is preferably 1 to 900 seconds, more preferably 10 to 600 seconds, depending on the volume of the tubular reactor and the feed rate of the raw materials. If the time is 1 second or more, the polymerization will be sufficient, and if it is 900 seconds or less, it is economically preferable.
- the reaction liquid to be reacted in the tubular reaction tube may be a mixed liquid obtained by mixing the solution A containing the silane compound and the solution B containing the catalyst with a mixer, or the solution A containing the silane compound and the solution B containing the catalyst. and may be mixed in a general reaction tank.
- a mixed solution mixed by a mixer is used, the solution A containing the silane compound and the solution B containing the catalyst can be stored separately, which is preferable because there is no need to consider the pot life.
- a mixed solution mixed in a general reaction tank only one reaction tank and one pump are required, which is preferable because the apparatus becomes simple.
- the reaction liquid containing the catalyst sent out from the tubular reactor may be brought into contact with the ion exchange resin.
- the ion exchange resin may be either a cation exchange resin or an anion exchange resin. It is preferable that the reaction liquid containing the acid catalyst is brought into contact with the anion exchange resin, and the reaction liquid containing the base catalyst is brought into contact with the cation exchange resin.
- the cation exchange resin may be a strongly acidic cation exchange resin or a weakly acidic cation exchange resin.
- cation exchange resin a strongly acidic cation exchange resin is preferred.
- the anion exchange resin may be either a strongly basic anion exchange resin or a weakly basic anion exchange resin, preferably a strongly basic anion exchange resin.
- anion exchange resins examples include Amberlist (manufactured by Organo Corporation), Lewatit (manufactured by Lanxess KK), Diaion (manufactured by Mitsubishi Chemical Corporation), and Monosphere (manufactured by Dow Chemical Company).
- the reaction liquid reacted in a tubular reactor with the ion exchange resin for example, a method of passing the reaction liquid through a column filled with an ion exchange resin, or a method of adding an ion exchange resin to the reaction liquid. and a method of stirring the mixture.
- the ion exchange resin should be removed by filtration or the like after treatment.
- the reaction solution containing the silicone polymer, the quaternary ammonium compound, and water is allowed to flow through a tank filled with a cation exchange resin and brought into contact with the cation exchange resin.
- the amount of ion exchange resin (preferably cation exchange resin) is preferably 1.0 to 10.0 equivalents, more preferably 1.1 equivalents per equivalent of the catalyst (preferably quaternary ammonium compound) used. 8.0 equivalents, more preferably 1.2 to 5.0 equivalents. If the amount of the cation exchange resin is 1.0 equivalents or more, the catalyst in the reaction solution can be removed. It is economically preferable because the amount to be used is small.
- the temperature at which the reaction solution is brought into contact with the ion exchange resin is preferably 0 to 60°C, more preferably 5 to 50°C. If the temperature is 0°C or higher, the catalyst such as the quaternary ammonium compound is sufficiently removed, and if the temperature is 60°C or lower, the silicone polymer is stable, which is preferable.
- the time for which the reaction solution is brought into contact with the ion exchange resin is preferably 5 minutes to 6 hours, more preferably 10 minutes to 3 hours. If the contact time is 5 minutes or more, the catalyst such as the quaternary ammonium compound can be removed, and if it is 6 hours or less, the silicone polymer is stable and preferable.
- an alcohol may be added when reacting the silane compound composed of the compound represented by general formula (1) and/or the compound represented by general formula (2).
- examples of alcohols include methanol, ethanol, n-propanol, isopropanol, n-butanol, t-butanol, propylene glycol monomethyl ether and propylene glycol monoethyl ether.
- methanol is preferable because it is easily distilled off. Two or more alcohols may be used.
- the alcohol is preferably at least 0.5 times by mass, 1.0 to 10 times by mass the mass of the silane compound represented by general formula (1) and/or the mass of the silane compound represented by general formula (2). is more preferable, more preferably 1.2 to 8 times by mass, and even more preferably 1.5 to 5 times by mass. If the alcohol is at least 0.5 times the mass of the silane compound, the mass of the silane compound represented by the general formula (1) and/or the silane compound represented by the general formula (2) and water are easily mixed, In addition, gelation of the silicone polymer is suppressed and stabilized. If it is 10 times or less by mass, it is economically preferable.
- a solvent may be added in the method for producing a silicone polymer.
- the solvent include aprotic solvents such as toluene and xylene, ketone solvents such as methyl ethyl ketone and methyl isobutyl ketone, ether solvents such as diethyl ether and tetrahydrofuran, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, diethylene glycol monomethyl ether, High boiling solvents such as propylene glycol monoethyl ether, ethyl lactate can be used. Two or more kinds of solvents may be used.
- the weight average molecular weight of the produced silicone polymer is preferably 300 to 100,000, more preferably 500 to 50,000, still more preferably 1,000 to 20,000. is.
- a weight-average molecular weight of 300 or more can form a coating film, and a weight-average molecular weight of 100,000 or less is preferred because it is soluble in an organic solvent.
- the dispersity (Mw/Mn) obtained by dividing the weight average molecular weight (Mw) by the number average molecular weight (Mn) is preferably 1-20, more preferably 1-5.
- the weight average molecular weight (Mw), number average molecular weight (Mn) and Z average molecular weight (Mz) of the silicone polymer are measured using gel permeation chromatography (GPC), and are obtained by standard polystyrene conversion. can be done.
- the higher-order structure of the resulting silicone polymer may be cage-shaped.
- the silicone polymer obtained by the method for producing a silicone polymer of the present invention may be dissolved in a solvent.
- a solvent an alcoholic solvent or a high boiling point solvent is used.
- Alcohol-based solvents include alcohol-based solvents such as methanol, ethanol, and isopropanol
- high-boiling solvents include propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether, propylene glycol monoethyl ether acetate, and diethylene glycol monomethyl ether. , ethyl lactate, and the like.
- a method for obtaining a coating film from a silicone polymer obtained by a method for producing a silicone polymer includes, for example, a method for forming a film in which the silicone polymer is applied to a substrate and heated.
- the coating film is produced by spin-coating the silicone polymer onto the substrate to form a thin film, which is then heated to obtain the coating film.
- Substrates include, for example, substrates formed from glass, silicon wafers, and resins such as polyethylene, polypropylene, and polypropylene terephthalate.
- the thin film formed on the substrate is placed on a hot plate or an incubator and heated to remove the solvent and hydrolyze and polycondensate the silicone polymer to create a coating film.
- the film can be produced by heating at a temperature of preferably 80° C. or higher, more preferably 100° C. or higher.
- the coating film thus prepared is a very hard film having a pencil hardness of preferably 4H or more and is excellent in scratch resistance.
- the pencil hardness can be measured according to JIS K5600-5-4 (1999).
- the silicone polymer obtained by the method for producing a silicone polymer of the present invention is suitable for producing semiconductors, displays, etc., because a coating film can be easily obtained.
- TSKgel SuperHZ3000, TSKgel SuperHZ2000, and TSKgel SuperHZ1000 manufactured by Tosoh Corporation were connected in series for analysis. Detection was performed by RI (refractometer), and one TSKgel SuperH-RC was used as a reference column. Tetrahydrofuran manufactured by Wako Pure Chemical Industries, Ltd. was used as a developing solvent, and the flow rate between the column and the reference column was 0.35 mL/min. The measurement temperature was 40° C. for both the plunger pump and the column.
- the sample was prepared by injecting 25 ⁇ L of about 0.025 g of silicone polymer diluted with 10 mL of tetrahydrofuran.
- Tosoh TSK standard polystyrene (A-500, A-1000, A-2500, A-5000, F-1, F-2, F-4, F-10, F-20, F -40, F-80) were used as standards.
- Example 1 As a flow reactor, KeyChem Integral (manufactured by YMC Co., Ltd.) consisting of two dual plunger pumps, a micromixer, a controller and a control PC was used.
- the dual plunger pumps are each connected to a micromixer.
- the micromixer is connected to a 500 ml column with a tube (tubular reactor) having an inner diameter of 1 mm and a length of 8 m. Cation exchange resin) 450 ml is filled.
- the reaction solution that has passed through the 500 ml column is collected in an eggplant flask.
- the liquid feeding speed of the pump A for supplying the monomer solution was 3.00 ml/min
- the liquid feeding speed of the pump B for feeding the catalyst solution was 0.75 ml/min
- the temperature of the micromixer was 25°C.
- a reaction liquid consisting of a monomer solution and a catalyst solution mixed by a micromixer was reacted in a tube (tubular reactor) having an inner diameter of 1 mm and a length of 8 m.
- the residence time of the reaction liquid in the tube is 100 seconds.
- the catalyst was removed by bringing the reaction solution sent out from the tubular reactor into contact with an ion exchange resin packed in a column.
- Example 2 In Example 1, the tube connecting the micromixer and the 500 ml column was changed from an inner diameter of 1 mm and a length of 8 m to an inner diameter of 2.4 mm and 1.4 m (that is, the reaction solution stays in the tube for 100 seconds.
- 348.9 g of a colorless transparent liquid silicone polymer was obtained in the same manner as in Example 1 except for ).
- the obtained silicone polymer had a weight average molecular weight (Mw) of 2,340, a dispersity (Mw/Mn) of 1.83, and a solid content of 10.0% by mass.
- the yield of silicone polymer determined from solids was 85.3%.
- the operations up to the operation of concentrating the reaction solution under reduced pressure were carried out automatically using a control PC.
- Example 3 In Example 1, the tube connecting the micromixer and the 500 ml column was changed from an inner diameter of 1 mm and a length of 8 m to an inner diameter of 2.4 mm and 2.8 m (that is, the reaction solution stays in the tube for 200 seconds. ) was carried out in the same manner as in Example 1 to obtain 256.7 g of a colorless transparent liquid silicone polymer.
- the obtained silicone polymer had a weight average molecular weight (Mw) of 2,400, a dispersity (Mw/Mn) of 1.78, and a solid content of 10.2% by mass.
- the yield of silicone polymer determined from solids was 63.8%.
- the operations up to the operation of concentrating the reaction solution under reduced pressure were carried out automatically using a control PC.
- Example 4 As a flow reactor, KeyChem Integral (manufactured by YMC Co., Ltd.) consisting of two dual plunger pumps, a micromixer, a controller and a control PC was used.
- the dual plunger pumps are each connected to a micromixer.
- the micromixer is connected to a 500 ml column with a tube (tubular reactor) having an inner diameter of 2.4 mm and a length of 1.38 m. , cation exchange resin manufactured by Organo Co.) is filled.
- the reaction solution that has passed through the 500 ml column is collected in an eggplant flask.
- the liquid feeding speed of the pump A for supplying the monomer solution was 3.314 ml/min
- the liquid feeding speed of the pump B for supplying the catalyst solution was 0.436 ml/min
- the temperature of the micromixer was 25°C.
- a reaction liquid consisting of a monomer solution and a catalyst solution mixed by a micromixer was reacted in a tube (tubular reactor) having an inner diameter of 2.4 mm and a length of 1.38 m.
- the residence time of the reaction liquid in the tube is 100 seconds.
- the catalyst was removed by bringing the reaction solution sent out from the tubular reactor into contact with an ion-exchange resin packed in a column.
- Comparative example 1 A 500 mL four-necked flask was charged with 70.5 g of propylene glycol monomethyl ether, 95.4 g (0.70 mol) of methyltrimethoxysilane, and 45.7 g (0.30 mol) of tetramethoxysilane. Then, 84.6 g of a 48% aqueous solution of choline (2-hydroxyethyltrimethylammonium hydroxide) was added dropwise. After aging at 20-30° C. for 4 hours, it was neutralized with hydrochloric acid equivalent to 2-hydroxyethyltrimethylammonium hydroxide.
- Comparative example 2 A 500 mL four-necked flask was charged with 97.1 g of methanol and 70.6 g of a 25% aqueous solution of tetramethylammonium hydroxide (TMAH). Further, a mixed liquid of 50.8 g (0.373 mol) of methyltrimethoxysilane and 18.9 g (0.124 mol) of tetramethoxysilane was added dropwise. After raising the temperature to 60° C. and aging for 4 hours, the mixture was cooled to 10° C. or less and transferred to a dropping funnel.
- TMAH tetramethylammonium hydroxide
- the obtained oil layer was transferred to an eggplant flask, diluted with 257.1 g of propylene glycol monoethyl ether, and concentrated by an evaporator to obtain 172.6 g of a colorless and transparent silicone polymer.
- the obtained silicone polymer had a weight average molecular weight (Mw) of 1,610, a dispersity (Mw/Mn) of 1.11, and a solid content of 10.1% by mass.
- the yield of silicone polymer determined from solids was 55.6%.
- Example 5 As a flow reactor, KeyChem Integral (manufactured by YMC Co., Ltd.) consisting of two dual plunger pumps, a micromixer, a controller and a control PC was used.
- the dual plunger pumps are each connected to a micromixer.
- the micromixer is connected to a tube (tubular reactor) having an inner diameter of 2.4 mm and a length of 5.52 m, and the reaction liquid that has passed through the tube is collected in an eggplant flask via a back pressure valve.
- the tube was temperature-controlled in a water bath.
- a plastic container containing the monomer solution (solution A) and a plastic container containing the catalyst solution (solution B) were each connected to a dual plunger pump and sent to the micromixer.
- the liquid feeding speed of the pump A for supplying the monomer solution was 0.86 ml/min
- the liquid feeding speed of the pump B for feeding the catalyst solution was 1.01 ml/min
- the temperature of the micromixer was 80°C.
- a reaction liquid consisting of a monomer solution and a catalyst solution mixed by a micromixer was reacted in a tube (tubular reactor) having an inner diameter of 2.4 mm and a length of 5.52 m.
- the residence time of the reaction solution in the tube is 800 seconds.
- the temperature of the tube was adjusted to 80°C in a water bath.
- Example 6 In Example 5, as the catalyst solution (solution B), 0.43 g of methanesulfonic acid was weighed in a 250 ml plastic container, and 96.38 g of ion-exchanged water was added to dissolve methanesulfonic acid. 181.34 g of a colorless transparent liquid silicone polymer was obtained in the same manner as in Example 5. The obtained silicone polymer had a weight average molecular weight (Mw) of 1,550, a dispersity (Mw/Mn) of 1.09, and a solid content of 9.6% by mass. In addition, except for the operation of preparing the raw materials, the operations up to the operation of concentrating the reaction solution under reduced pressure were carried out automatically using a control PC.
- Mw weight average molecular weight
- Mw/Mn dispersity
- Comparative example 3 A 500 mL four-necked flask was charged with 166.4 g of propylene glycol monoethyl ether, 9.9 g (0.072 mol) of methyltrimethoxysilane, and 25.7 g (0.17 mol) of tetramethoxysilane. Then, an aqueous solution prepared by dissolving 1.61 g of oxalic acid in 96.4 g of deionized water was added dropwise. After aging at 60° C. for 10 hours, the solution was transferred to an eggplant flask and concentrated at about 40° C. and 40 torr to obtain 142.3 g of silicone polymer as a colorless transparent liquid. The obtained silicone polymer had a weight average molecular weight (Mw) of 1,450, a dispersity (Mw/Mn) of 1.06, and a solid content of 13.2% by mass.
- Mw weight average molecular weight
- Mw/Mn dispersity
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Abstract
Description
RaSi(OR1)4-a ・・・・・(1)
(式中、Rは水素原子または1価の有機基、R1は1価の有機基、aは1~2の整数を示す。)
および下記一般式(2)で表される化合物、
Si(OR2)4 ・・・・・(2)
(式中、R2は1価の有機基を示す。)
から選ばれた少なくとも1種のシラン化合物を含む溶液A、触媒を含む溶液Bを用い、前記溶液Aまたは溶液Bが水を含み、これらをミキサーに連続的に供給し混合した後、内径1~20mmの管型反応器に供給し反応させることを特徴とする。
RaSi(OR1)4-a ・・・・・(1)
(式中、Rは水素原子または1価の有機基、R1は1価の有機基、aは1~2の整数を示す。)
および下記一般式(2)で表される化合物、
Si(OR2)4 ・・・・・(2)
(式中、R2は1価の有機基を示す。)
から選ばれた少なくとも1種のシラン化合物を含む溶液A、触媒を含む溶液Bを用い、前記溶液Aまたは溶液Bが水を含み、これらをミキサーに連続的に供給し混合した後、内径1~20mmの管型反応器に供給し反応させるシリコーン重合体の製造方法である。
酸触媒としては、塩酸を除く酸触媒が好ましく、無機酸、有機酸のいずれも用いることができる。無機酸としては、例えば、硝酸、硫酸、フッ酸、リン酸等が挙げられる。有機酸としては、例えば、酢酸、プロピオン酸、ブタン酸、ペンタン酸、ヘキサン酸、ヘプタン酸、オクタン酸、ノナン酸、デカン酸、シュウ酸、マレイン酸、メチルマロン酸、アジピン酸、セバシン酸、没食子酸、酪酸、メリット酸、アラキドン酸、ミキミ酸、2-エチルヘキサン酸、オレイン酸、ステアリン酸、リノール酸、リノレイン酸、サリチル酸、安息香酸、p-アミノ安息香酸、p-トルエンスルホン酸、メタンスルホン酸、ベンゼンスルホン酸、モノクロロ酢酸、ジクロロ酢酸、トリクロロ酢酸、トリフルオロ酢酸、ギ酸、マロン酸、スルホン酸、フタル酸、フマル酸、クエン酸、酒石酸等が挙げられる。中でも有機酸を用いると、有機溶媒との相溶性が高く好ましい。好ましい有機酸は、シュウ酸、マレイン酸、メタンスルホン酸である。酸触媒は2種類以上用いてもよい。
このように作製した塗膜は、鉛筆硬度が好ましくは4H以上の非常に硬い膜が得られ、耐傷性に優れる。なお、鉛筆硬度は、JIS K5600-5-4(1999)に準じて測定することができる。
東ソー社製HLC-8220GPCシステムを使用し、東ソー社製TSKgel SuperHZ3000、TSKgel SuperHZ2000、TSKgel SuperHZ1000を直列に接続して分析を行った。検出はRI(屈折率計)で行い、リファレンスカラムとしてTSKgel SuperH-RCを1本使用した。展開溶媒には和光純薬社製テトラヒドロフランを使用し、カラムとリファレンスカラムの流速は0.35mL/分で行った。測定温度はプランジャーポンプ、カラム共に40℃で行った。サンプルの調製にはシリコーン重合体約0.025gを10mLのテトラヒドロフランで希釈したものを25μL打ちこむ設定で行った。分子量分布計算には、東ソー社製TSK標準ポリスチレン(A-500、A-1000、A-2500、A-5000、F-1、F-2、F-4、F-10、F-20、F-40、F-80)を標準物質として使用した。
シリコーン重合体を含む溶液約1.0gをアルミカップに入れ精秤し、ホットプレートを用いて175℃で1時間焼成することで、シリコーン重合体を含む溶液約1.0gに対する固形分の質量を測定し、シリコーン重合体を含む溶液の固形分濃度(質量%)を算出した。
フローリアクターとして、デュアルプランジャーポンプ2基、マイクロミキサー、コントローラーおよび制御用PCからなる、KeyChem Integral(株式会社ワイエムシィ製)を用いた。デュアルプランジャーポンプは、それぞれマイクロミキサーと接続している。さらに、マイクロミキサーは、500mlのカラムと、内径1mm長さ8mのチューブ(管型反応器)で接続しており、500mlのカラムには前処理されたイオン交換樹脂(アンバーリスト15JWET、オルガノ社製 陽イオン交換樹脂)450mlが充填されている。500mlのカラムを通過した反応液は、ナスフラスコで収集される。
実施例1において、マイクロミキサーと500mlカラムとを接続するチューブを、内径1mm、長さ8mから内径2.4mm、1.4mに変更した(すなわち反応液がチューブに滞留する時間は100秒である)以外は、実施例1と同様にして無色透明液体であるシリコーン重合体348.9gを得た。得られたシリコーン重合体の重量平均分子量(Mw)は2,340、分散度(Mw/Mn)は1.83、固形分は10.0質量%であった。固形分から求められるシリコーン重合体の収率は85.3%であった。また、原料の仕込み作業を除くと、反応液の減圧濃縮操作までは、制御用PCを用いた自動運転で行った。
実施例1において、マイクロミキサーと500mlカラムとを接続するチューブを、内径1mm、長さ8mから内径2.4mm、2.8mに変更した(すなわち反応液がチューブに滞留する時間は200秒である)以外は、実施例1と同様にして無色透明液体であるシリコーン重合体256.7gを得た。得られたシリコーン重合体の重量平均分子量(Mw)は2,400、分散度は(Mw/Mn)1.78、固形分は10.2質量%であった。固形分から求められるシリコーン重合体の収率は63.8%であった。また、原料の仕込み作業を除くと、反応液の減圧濃縮操作までは、制御用PCを用いた自動運転で行った。
フローリアクターとして、デュアルプランジャーポンプ2基、マイクロミキサー、コントローラーおよび制御用PCからなる、KeyChem Integral(株式会社ワイエムシィ製)を用いた。デュアルプランジャーポンプは、それぞれマイクロミキサーと接続している。さらに、マイクロミキサーは、500mlのカラムと、内径2.4mm長さ1.38mのチューブ(管型反応器)で接続しており、500mlのカラムには前処理されたイオン交換樹脂(アンバーリスト15JWET、オルガノ社製 陽イオン交換樹脂)450mlが充填されている。500mlのカラムを通過した反応液は、ナスフラスコで収集される。
500mLの4つ口フラスコに、プロピレングリコールモノメチルエーテル70.5g、メチルトリメトキシシラン95.4g(0.70mol)、テトラメトキシシラン45.7g(0.30mol)を仕込んだ。次いで、コリン(2-ヒドロキシエチルトリメチルアンモニウムヒドロキシド)の48%水溶液84.6gを滴下した。20~30℃で4時間熟成後、2-ヒドロキシエチルトリメチルアンモニウムヒドロキシドと当量の塩酸で中和した。反応液に、酢酸エチル423.4gと超純水141.2gを加え、撹拌の後、分液した。得られた油層に、イオン交換水141.4gを加え撹拌の後、分液した。この操作を2回繰り返した後、約40℃、160torrで濃縮した。濃縮液にプロピレングリコールモノメチルエーテル77.1gを加えることで、溶媒置換し、シリコーン重合体固形分が10質量%のプロピレングリコールモノメチルエーテル溶液(630g)を得た。固形分から求められるシリコーン重合体の収率は90.0%であった。得られたシリコーン重合体の重量平均分子量(Mw)は3,560、分散度(Mw/Mn)は1.98であった。
500mLの4つ口フラスコに、メタノール97.1g、テトラメチルアンモニウムヒドロキシド(TMAH)25%水溶液70.6gを仕込んだ。さらにメチルトリメトキシシラン50.8g(0.373mol)、テトラメトキシシラン18.9g(0.124mol)の混合液を滴下した。60℃に昇温し4時間熟成後、10℃以下に冷却し、滴下ロートに移液した。再度500mlの4つ口フラスコにマレイン酸27.5gを計量しイオン交換水42.6gで溶解し、攪拌しながら滴下ロートから重合液を滴下することで中和した。1-ブタノール257.1g、イオン交換水514.2gを加え、攪拌の後分液した。その後、油層にイオン交換水257.1gを加え、攪拌の後分液する操作を3回繰り返すことで水洗をおこなった。得られた油層をナスフラスコに移液しプロピレングリコールモノエチルエーテル257.1gで希釈し、エバポレーターで濃縮することで無色透明のシリコーン重合体172.6gを得た。得られたシリコーン重合体の重量平均分子量(Mw)は1,610、分散度(Mw/Mn)は1.11、固形分は10.1質量%であった。固形分から求められるシリコーン重合体の収率は55.6%であった。
フローリアクターとして、デュアルプランジャーポンプ2基、マイクロミキサー、コントローラーおよび制御用PCからなる、KeyChem Integral(株式会社ワイエムシィ製)を用いた。デュアルプランジャーポンプは、それぞれマイクロミキサーと接続している。さらに、マイクロミキサーは、内径2.4mm長さ5.52mのチューブ(管型反応器)と接続しており、チューブを通過した反応液は、背圧弁を経由してナスフラスコで収集される。チューブはウォーターバスで温調した。
実施例5において、触媒溶液(溶液B)として、250mlポリ容器にメタンスルホン酸0.43gを計量し、イオン交換水96.38gを加えメタンスルホン酸を溶解したものに変更した以外は、実施例5と同様にして無色透明液体であるシリコーン重合体181.34gを得た。得られたシリコーン重合体の重量平均分子量(Mw)は1,550、分散度(Mw/Mn)は1.09、固形分は9.6質量%であった。また、原料の仕込み作業を除くと、反応液の減圧濃縮操作までは、制御用PCを用いた自動運転で行った。
500mLの4つ口フラスコに、プロピレングリコールモノエチルエーテル166.4g、メチルトリメトキシシラン9.9g(0.072mol)、テトラメトキシシラン25.7g(0.17mol)を仕込んだ。次いで、シュウ酸1.61gをイオン交換水96.4gに溶かした水溶液を滴下した。60℃で10時間熟成後、ナスフラスコに移液して約40℃、40torrで濃縮することで、無色透明液体であるシリコーン重合体142.3gを得た。得られたシリコーン重合体の重量平均分子量(Mw)は1,450、分散度(Mw/Mn)は1.06、固形分は13.2質量%であった。
2 触媒槽
3 ポンプ
4 ミキサー
5 管型反応器
6 カラム
Claims (12)
- 下記一般式(1)で表される化合物、
RaSi(OR1)4-a ・・・・・(1)
(式中、Rは水素原子または1価の有機基、R1は1価の有機基、aは1~2の整数を示す。)
および下記一般式(2)で表される化合物、
Si(OR2)4 ・・・・・(2)
(式中、R2は1価の有機基を示す。)
から選ばれた少なくとも1種のシラン化合物を含む溶液A、触媒を含む溶液Bを用い、前記溶液Aまたは溶液Bが水を含み、これらをミキサーに連続的に供給し混合した後、内径1~20mmの管型反応器に供給し反応させるシリコーン重合体の製造方法。 - 前記管型反応器で反応させた反応液を、カラムに充填したイオン交換樹脂に、連続的に供給し接触させる請求項1記載のシリコーン重合体の製造方法。
- 前記触媒を含む溶液Bが、触媒と水を含む請求項1または2記載のシリコーン重合体の製造方法。
- 前記触媒が、塩酸を除く酸触媒または塩基触媒である請求項1~3のいずれかに記載のシリコーン重合体の製造方法。
- 前記酸触媒が、シュウ酸、マレイン酸、リン酸、または、メタンスルホン酸である請求項4記載のシリコーン重合体の製造方法。
- 前記塩基触媒が、第四級アンモニウム化合物である請求項4に記載のシリコーン重合体の製造方法。
- 前記第四級アンモニウム化合物が、水酸基を含有する第四級アンモニウム化合物である請求項6に記載のシリコーン重合体の製造方法。
- 前記水酸基を含有する第四級アンモニウム化合物が、2-ヒドロキシエチルトリメチルアンモニウムヒドロキシド、ジメチルビス(2-ヒドロキシエチル)アンモニウムヒドロキシド、または、トリス(2-ヒドロキシエチル)メチルアンモニウムヒドロキシドである請求項7記載のシリコーン重合体の製造方法。
- 前記溶液Aおよび/または溶液Bが、アルコールを含む請求項1~8のいずれかに記載のシリコーン重合体の製造方法。
- 前記アルコールを、前記少なくとも1種のシラン化合物に対し1.0~10質量倍使用する請求項9記載のシリコーン重合体の製造方法。
- 請求項1~10のいずれかに記載のシリコーン重合体を基板に塗布し、加熱することを特徴とする膜の形成方法。
- 請求項11記載の膜の形成方法によって得られる膜。
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