TW201623340A - 懸浮聚合用分散安定劑及乙烯系樹脂之製造方法 - Google Patents
懸浮聚合用分散安定劑及乙烯系樹脂之製造方法 Download PDFInfo
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- TW201623340A TW201623340A TW104136783A TW104136783A TW201623340A TW 201623340 A TW201623340 A TW 201623340A TW 104136783 A TW104136783 A TW 104136783A TW 104136783 A TW104136783 A TW 104136783A TW 201623340 A TW201623340 A TW 201623340A
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- vinyl
- pva
- polymerization
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- dispersion stabilizer
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Abstract
本發明提供一種懸浮聚合用分散安定劑,其含有濃度0.1質量%水溶液之在波長280nm的吸光度(a1)係小於0.25、該水溶液之在波長320nm的吸光度(a2)係小於0.030、皂化度係68莫耳%以上98莫耳%以下、黏度平均聚合度係超過1500小於4500、且為粉末形狀之YI值係5以上的乙烯醇系聚合物(A)。該分散安定劑,可得到聚合安定性優異、粒子徑小、使容積比重提升的乙烯系樹脂。
Description
本發明係關於一種包含乙烯醇系聚合物之懸浮聚合用分散安定劑。又,本發明係關於一種使用該分散安定劑將乙烯系單體懸浮聚合的乙烯系樹脂之製造方法。
在工業上製造氯乙烯樹脂等之乙烯系聚合物的情況中,係廣泛實施在水性介質中使用分散安定劑,使氯乙烯等之乙烯系單體分散,並使用油溶性觸媒進行聚合之懸浮聚合。一般而言。作為支配乙烯系聚合物之品質的因子,可舉出聚合率、聚合溫度、觸媒之種類及量、聚合槽之型式、攪拌速度、分散安定劑之種類等。其中分散安定劑之種類所導致的影響非常大。氯乙烯之懸浮聚合中,主要使用乙烯醇系聚合物(以下有時將乙烯醇系聚合物縮寫為PVA)作為分散安定劑。該情況中,宜使用部分皂化PVA作為PVA。在使用PVA作為分散安定劑並於水性介質中進行氯乙烯之懸浮聚合的情況中,可得
到粒子形狀的氯乙烯樹脂。
作為分散安定劑所需要的性能,可舉出(1)所得到的聚合物之粗大粒子的數目少;(2)所得到的聚合物之粒度分布為尖銳;(3)所得到的聚合物之容積比重(bulk specific gravity)高,每一單位體積的質量大等。
一般的部分皂化PVA難以滿足上述性能,因此進行各式各樣的嘗試。例如,專利文獻1中,有記載將乙醛導入至乙烯醇系聚合物之末端,並且施加熱處理而成的分散安定劑。藉由熱處理,雖該分散安定劑之性能與以往品相比為提升,但難以說是完全滿足上述需求性能。
[專利文獻1]日本特開平8-283313號公報
本發明的目的在於提供一種可獲得具備上述(1)~(3)之性能、特別是聚合安定性優異、粒子徑小、且容積比重高的乙烯系樹脂之懸浮聚合用分散安定劑以及乙烯系樹脂之製造方法。
本案發明人鑑於如上述的現狀而仔細探討的結果發現:可藉由包含在特定波長中之水溶液的吸光度、皂化度、黏度平均聚合度、及粉體形狀之YI的數值為
特定範圍內之PVA(A)的懸浮聚合用分散安定劑解決上述課題。
亦即,本發明係關於下述者。
[1]一種懸浮聚合用分散安定劑,其含有濃度0.1質量%水溶液之在波長280nm的吸光度(a1)小於0.25、該水溶液之在波長320nm的吸光度(a2)小於0.030、皂化度為68莫耳%以上98莫耳%以下、黏度平均聚合度超過1500小於4500、且為粉末形狀之YI值為5以上的乙烯醇系聚合物(A)。
[2]如[1]記載之懸浮聚合用分散安定劑,其進一步含有濃度0.1質量%水溶液之在波長280nm的吸光度(b1)為0.25以上、該水溶液之在波長320nm的吸光度(b2)為0.030以上、皂化度為65莫耳%以上82莫耳%以下、且黏度平均聚合度為500以上1500以下的乙烯醇系聚合物(B)。
[3]如[2]記載之懸浮聚合用分散安定劑,其中乙烯醇系聚合物(A)及乙烯醇系聚合物(B)之質量比(A/B)為6/94以上60/40以下。
[4]一種乙烯系樹脂之製造方法,其係使用如[1]至[3]中任一項記載之懸浮聚合用分散安定劑,在水性介質中將乙烯系單體懸浮聚合。
[5]如[4]記載之乙烯系樹脂之製造方法,其中在懸浮聚合使用的乙烯系單體與水性介質之質量比(乙烯系單體/水性介質)為0.75以上。
[6]如[4]或[5]記載之乙烯系樹脂之製造方法,其中乙烯系單體為氯乙烯。
使用本發明之懸浮聚合用分散安定劑進行乙烯系單體之懸浮聚合時,可得到具備需求性能的乙烯系樹脂。特別是本發明的懸浮聚合用分散安定劑可提供聚合安定性優異、粒徑小、使容積比重提升之乙烯系樹脂。
<懸浮聚合用分散安定劑>
本發明的懸浮聚合用分散安定劑係含有濃度0.1質量%水溶液之在波長280nm的吸光度(a1)小於0.25、該水溶液之在波長320nm的吸光度(a2)小於0.030、皂化度為68莫耳%以上98莫耳%以下、黏度平均聚合度超過1500小於4500、且為粉末形狀之YI值為5以上的乙烯醇系聚合物(A)者。
在此,關於上述波長之吸收帶的歸屬,如日本特開2004-250695公報等所記載,波長280nm之吸收歸屬於PVA中之-CO-(CH=CH)2-的結構,波長320nm之吸收歸屬於PVA中之-CO-(CH=CH)3-的結構。
[PVA(A)]
本發明所使用的PVA(A),其濃度0.1質量%水溶液之在波長280nm的吸光度(a1)小於0.25,且該水溶液之在波長320nm的吸光度(a2)小於0.030。上述吸光度(a1)較佳為0.20以下,更佳為0.15以下。上述吸光度(a2)較佳為0.020
以下,更佳為0.015以下。上述吸光度(a1)為0.25以上,或者(a2)為0.030以上時,有PVA本身熱劣化而得不到足夠的性能之虞。
就分散安定劑的性能之方面而言,本發明所使用的PVA(A)之皂化度必須為68莫耳%以上98莫耳%以下。皂化度若小於68莫耳%,則PVA(A)變成不溶於水,有處理性惡化之虞。再者,乙烯系單體之懸浮聚合變不安定,有所得到的乙烯系樹脂粒子粗粒化之虞。另一方面,皂化度若超過98莫耳%,則相對於冷水的溶解性下降,有處理性惡化之虞。再者,乙烯系單體之懸浮聚合變不安定,有所得到的乙烯系聚合物粒子粗粒化之虞。PVA(A)的皂化度較佳為70莫耳%以上,更佳為72莫耳%以上。另一方面,皂化度較佳為95莫耳%以下,更佳為92莫耳%以下。
上述PVA(A)的皂化度係依據JIS-K6726(1994)進行測定。
本發明所使用的PVA(A)之黏度平均聚合度係超過1500小於4500。PVA(A)之黏度平均聚合度若成為1500以下,則乙烯系單體之懸浮聚合的安定性下降,所得到的乙烯系聚合物粒子容易變成粗粒。再者,產生得不到粒徑之均一性高的粒子等之問題。另一方面,黏度平均聚合度若成為4500以上,則有PVA之水溶性下降而處理性惡化之虞。黏度平均聚合度較佳為超過1700,更佳為超過1800。另一方面,黏度平均聚合度較佳為小於4000,更佳為小於3500。
PVA(A)之黏度平均聚合度,係在將PVA系聚合物實質上完全皂化後,進行乙醯化而成為乙烯酯系聚合物後,根據丙酮溶液中之極限黏度的測定,使用中島的式(中島章夫:高分子化學6(1949))所算出者。
本發明所使用的PVA(A)之為粉體形狀的YI(黃色指數)值為5以上。YI值若小於5,則乙烯系單體的懸浮聚合之安定性下降,所得到的乙烯系聚合物粒子成為粗粒。又,因得不到粒徑之均一性高的粒子,亦產生容積比重下降等之問題。YI值較佳為10以上,更佳為15以上。YI值之上限沒有特別限制,但在乙烯系單體之懸浮聚合中使用本發明的分散安定劑時,從所得到之乙烯系樹脂的色相之觀點而言,較佳為90以下,更佳為85以下。再者,YI值,可藉由控制在PVA(A)的製造時之皂化觸媒的量等之皂化條件、溫度或時間等之熱處理條件而任意調整。在進行熱處理之際所填充的氣體並沒有特別限制,可使用氮等之惰性氣體、氧、空氣等。其中,從簡便的方面、或進一步提升上述性能的方面而言,較佳為在空氣中進行熱處理。
上述PVA(A),可藉由下述方法製造:依據以往周知的方法聚合乙烯酯單體,將所得到的聚合物藉由常法進行皂化而合成PVA,並對其施加熱處理。作為聚合乙烯酯單體的方法,可應用溶液聚合法、塊狀聚合法、懸浮聚合法、乳化聚合法等之以往周知的方法。作為聚合觸媒,係因應聚合方法而適當選擇偶氮系觸媒、過氧化物系觸媒、氧化還原系觸媒等。皂化反應,可應用
使用以往周知的鹼觸媒或酸觸媒之醇解、水解等,該等之中,將甲醇作為溶劑,並使用苛性鈉(NaOH)觸媒的皂化反應為簡便,且最為理想。
上述PVA(A),可藉由使熱處理條件適當化而製造。將本發明之PVA(A)使用於氯乙烯的懸浮聚合之際的作用機構雖不明確,但可推定如下述。藉由將PVA進行熱處理,引起分子中的羥基之脫水反應而生成烯酮(enone)結構。此時,在分子鏈之末端導入羰基的PVA中,有熱處理所致之脫水係將羰基作為起點自分子末端優先地引起,而無法將烯酮結構均勻地導入至分子鏈中的情況。該情況中,以在分子中無規地導入烯酮結構為目的,使熱處理條件變嚴苛的話,超出需要的烯酮結構被導入至分子中,對水之溶解性會下降。另一方面,本發明的PVA(A)因為在較長的分鏈中無規地具有烯酮結構,所以利用對氯乙烯單體之吸附、或接著其之接枝反應,容易達成loop-train-tail形態之安定的結合狀態,因此可期待保護膠體性能之提升等。特別是在懸浮聚合反應最後階段的粒子控制之階段中,使所得到的乙烯系樹脂之粒徑縮小,或者在容積比重提升發揮性能。
作為構成上述PVA(A)的乙烯酯單元,有源自各式各樣的乙烯酯化合物之單元,例如,可舉出甲酸乙烯酯、乙酸乙烯酯、丙酸乙烯酯、丁酸乙烯酯、異丁酸乙烯酯、三甲基乙酸乙烯酯、新癸酸(versatic acid)乙烯酯、己酸乙烯酯、辛酸乙烯酯、月桂酸乙烯酯、棕櫚酸乙烯酯、硬脂酸乙烯酯、油酸乙烯酯、苯甲酸乙烯酯。
其中尤以乙酸乙烯酯最為理想。
合成本發明所使用的PVA(A)之際,在不損及本發明的效果之範圍亦可使其他的單體共聚合。作為可使用之單體,例如,可舉出乙烯、丙烯、正丁烯、異丁烯等之α-烯烴;丙烯酸及其鹽;丙烯醯胺;N-甲基丙烯醯胺、N-乙基丙烯醯胺、N,N-二甲基丙烯醯胺、二丙酮丙烯醯胺、丙烯醯胺丙磺酸及其鹽、丙烯醯胺丙基二甲基胺及其鹽或其4級鹽、N-羥甲基丙烯醯胺及其衍生物等之丙烯醯胺衍生物;甲基丙烯醯胺;N-甲基甲基丙烯醯胺、N-乙基甲基丙烯醯胺、甲基丙烯醯胺丙磺酸及其鹽、甲基丙烯醯胺丙基二甲基胺及其鹽或其4級鹽、N-羥甲基甲基丙烯醯胺及其衍生物等之甲基丙烯醯胺衍生物;甲基乙烯醚、乙基乙烯醚、正丙基乙烯醚、異丙基乙烯醚、正丁基乙烯醚、異丁基乙烯醚、三級丁基乙烯醚、十二烷基乙烯醚、硬脂基乙烯醚、2,3-二乙醯氧基-1-乙烯氧基丙烷等之乙烯醚類;丙烯腈、甲基丙烯腈等之腈類;氯乙烯、氟乙烯等之鹵乙烯類(vinyl halides);偏二氯乙烯、偏二氟乙烯等之偏二鹵乙烯類(vinylidene halides);乙酸烯丙酯、2,3-二乙醯氧基-1-烯丙氧基丙烷、烯丙氯等之烯丙基化合物;馬來酸、伊康酸、富馬酸等之不飽和二羧酸及其鹽或其酯;乙烯三甲氧矽烷等之乙烯矽基(vinyl silyl)化合物;乙酸異丙烯酯等。
又,合成PVA(A)之際,在不損及本發明的效果之範圍,以調整其聚合度,或在末端導入變性種為目的,亦可使用鏈轉移劑。作為鏈轉移劑,可舉出2-羥基
乙硫醇、3-硫醇基丙酸、十二烷硫醇、硫代乙酸等之硫醇類;四氯化碳、三氯乙烯、全氯乙烯等之鹵化烴類;膦酸鈉1水合物等之膦酸鹽類。其中尤能適用硫醇類。鏈轉移劑之添加量,只要因應添加的鏈轉移劑之鏈轉移常數及作為目的之聚乙烯酯的聚合度來決定即可。一般較佳為相對於乙烯酯單體為0.1質量%以上10質量%以下。在此,若使用乙醛、丙醛等之醛類作為鏈轉移劑,則經由皂化後之熱處理,自PVA末端雙鍵變得容易鏈鎖,而有變得難以將濃度0.1質量%水溶液之在波長320nm的吸光度(a2)作成為小於0.030的情況。
上述PVA(A)之重量平均分子量/數量平均分子量(Mw/Mn)的值,並沒有特別限制,但通常為10以下,較佳為6以下。
上述PVA(A)的殘留乙烯酯基的嵌段特性(block character)並沒有特別限制,但通常為1.0以下,從乙烯系單體的聚合安定性之觀點而言,較佳為0.8以下。
[PVA(B)]
本發明中,較佳為將濃度0.1質量%水溶液之在波長280nm的吸光度(b1)為0.25以上且該水溶液之在波長320nm的吸光度(b2)為0.030以上的PVA(B)與PVA(A)併用而使用。本發明的分散安定劑,較佳為進一步含有PVA(B)。上述吸光度(b1)更佳為0.30以上,再佳為0.40以上。又,上述吸光度(b2)更佳為0.050以上,再佳為0.15以上。吸光度(b1)小於0.25或(b2)小於0.030時,因為在懸浮聚合之初期階段起因於對PVA(B)的乙烯系單體之吸
附力不足,所得到的乙烯系樹脂粒子粗粒化,所以有容積比重下降之虞。
從作為分散安定劑之性能面而言,上述PVA(B)的皂化度較佳為65莫耳%以上82莫耳%以下。皂化度更佳為68莫耳%以上。又,皂化度更為80莫耳%以下,再佳為77莫耳%以下。
上述PVA(B)的皂化度係藉由依據JIS-K6726(1994)進行測定而得到。
上述PVA(B)的黏度平均聚合度較佳為500以上1500以下。黏度平均聚合度更佳為600以上。另一方面,黏度平均聚合度更佳為1200以下,再佳為1000以下。
上述PVA(B)的黏度平均聚合度,係將PVA實質上完全皂化後,進行乙醯化而成為乙烯酯系聚合物後,根據丙酮溶液中之極限黏度的測定,使用中島的式(中島章夫:高分子化學6(1949))而算出。
在乙烯系單體之懸浮聚合中,較佳為將PVA(A)及PVA(B)使用於分散安定劑,PVA(A)及PVA(B)之質量比(A/B)較佳為6/94以上60/40以下,更佳為10/90以上50/50以下。
PVA(A)與PVA(B)之對聚合槽的加入方法並沒有特別限制,可同時使之溶解而使用,亦可各別使之溶解而分別加入。又,亦可使用有機溶劑等,使PVA(A)或PVA(B)溶解。
[其他的成分]
除了PVA(A)、PVA(B)以外,在不損及本發明之宗旨
的範圍,亦可含有其他之各種添加劑。作為上述添加劑,例如,可舉出為了提高所得到的乙烯系樹脂之塑化劑吸收性而使用的低皂化度PVA等之在水性介質中懸浮聚合之際通常使用的PVA;甲基纖維素、羥乙基纖維素、羥丙基纖維素、羥丙基甲基纖維素等之水溶性纖維素醚;明膠等之水溶性聚合物;山梨醇酐單月桂酯、山梨醇酐三油酸酯、甘油三硬脂酸酯、氧化乙烯氧化丙烯嵌段共聚合物等之油溶性乳化劑;聚氧乙烯山梨醇酐單月桂酯、聚氧乙烯甘油油酸酯、月桂酸鈉等之水溶性乳化劑;醛類、鹵化烴類、硫醇類等之聚合調節劑;酚化合物、硫化合物、N-氧化物化合物等之聚合抑制劑;pH調整劑;交聯劑;防腐劑;防黴劑;抗黏結劑;消泡劑。關於其添加量並沒有特別限制,但較佳為相對於乙烯系單體100質量份為1.0質量份以下。
<乙烯系樹脂之製造>
使用該分散安定劑於水性介質中將乙烯系單體懸浮聚合的乙烯系樹脂之製造方法為本發明之適當的實施態樣。作為本發明的乙烯系樹脂之製造方法所使用的乙烯系單體,可舉出氯乙烯等之鹵乙烯;乙酸乙烯酯、丙酸乙烯酯等之乙烯酯;丙烯酸、甲基丙烯酸、該等之酯及鹽;馬來酸、富馬酸、該等之酯及酐;苯乙烯、丙烯腈、偏二氯乙烯、乙烯醚等。該等的乙烯系單體之中,特佳為氯乙烯。本發明之製造方法,在將氯乙烯單獨懸浮聚合、或將氯乙烯及可與氯乙烯共聚合的單體一起懸浮聚合之際特別適合使用。作為可與氯乙烯共聚合的單體
,可舉出乙酸乙烯酯、丙酸乙烯酯等之乙烯酯;(甲基)丙烯酸甲酯、(甲基)丙烯酸乙酯等之(甲基)丙烯酸酯;乙烯、丙烯等之α-烯烴;馬來酸酐、伊康酸等之不飽和二羧酸類;丙烯腈;苯乙烯;偏二氯乙烯;乙烯醚等。
在乙烯系單體之懸浮聚合中,可使用從以往開始便使用於氯乙烯單體等之聚合的油溶性或水溶性之聚合起始劑。作為油溶性的聚合起始劑,例如,可舉出過氧化二碳酸二異丙酯、過氧化二碳酸二-2-乙基己酯、過氧化二碳酸二乙氧乙酯等之過碳酸酯化合物;過氧化新癸酸第三丁酯、過氧化三甲基乙酸三級丁酯、過氧化三甲基乙酸三級己酯、過氧化新癸酸α-異丙苯酯(α-cumyl peroxyneodecanate)等之過氧酸酯(perester)化合物;乙醯基過氧化環己基磺醯(acetyl cyclohexyl sulfonyl peroxide)、2,4,4-三甲基戊基-2-過氧化苯氧基乙酸酯、3,5,5-三甲基過氧化己醯基、過氧化月桂醯基等之過氧化物;偶氮雙-2,4-二甲基戊腈、偶氮雙(4-2,4-二甲基戊腈)等之偶氮化合物等。作為水溶性的聚合起始劑,例如,可舉出過硫酸鉀、過硫酸銨、過氧化氫、氫過氧化異丙苯。該等之油溶性或水溶性的聚合起始劑,可單獨使用、或組合2種以上使用。
在乙烯系單體之懸浮聚合之際,聚合溫度沒有特別限制,可從原本為20℃左右的低溫度,調整為超過90℃的高溫度。又,為了提高聚合反應系統之除熱效率,使用附有回流冷凝器的聚合器也為較佳的實施態樣之一。
使用於乙烯系單體之懸浮聚合的水性介質,只要在不阻礙本發明之效果的範圍,亦可含有水溶性之有機溶劑。該水性介質中之水的量較佳為90質量%以上,更佳為該水性溶媒為水。
在乙烯系單體之懸浮聚合之際,加入的乙烯系單體與水性介質之質量比,並沒有特別限定。一般而言,乙烯系單體相對於水性介質之比例越低,聚合越安定但生產性會變低,乙烯系單體相對於水性介質之比例越高,生產性越高,但聚合會變得不安定。在本發明的乙烯樹脂之製造方法中,乙烯系單體相對於水性介質之質量比(乙烯系單體/水性介質),較佳為0.57~1.25,更佳為0.57~1.11。質量比(乙烯系單體/水性介質)小於0.57時,有所得到的乙烯樹脂之生產性變低之虞。另一方面,質量比(乙烯系單體/水性介質)超過1.25時,聚合安定性會下降,而有產生粗大樹脂粒子之虞。在特別欲提升乙烯系樹脂之生產性的情況中,乙烯系單體相對於水性介質的質量比(乙烯系單體/水性介質)較佳為0.75以上。
使用PVA(A)及PVA(B),在水性介質中將乙烯系單體懸浮聚合的乙烯系樹脂之製造方法亦為本發明之適當的實施態樣。PVA(A)及PVA(B)對聚合槽之加入方法,沒有特別限制,亦可加入PVA(A)及PVA(B)之混合物,也可分別加入PVA(A)及PVA(B)。在該方法中,可適當使用上述本發明的分散安定劑。
以下根據實施例進一步詳細地說明本發明。
在以下的實施例及比較例中,只要沒有特別說明,「份」及「%」係分別表示質量份及質量%。
針對利用下述之製造例而得到的PVA,依據以下的方法進行評價。
[PVA的黏度平均聚合度]
PVA之黏度平均聚合度,係在將PVA實質上完全皂化後,進行乙醯化而成為乙烯酯系聚合物後,根據丙酮溶液中之極限黏度的測定,使用中島的式(中島章夫:高分子化學6(1949))而算出。
[PVA之皂化度]
PVA之皂化度係以JIS K6726(1994)記載的方法求出。
[水溶液之吸光度]
製備0.1質量%的PVA水溶液,使用島津製作所公司製吸光光度計「UV2100」測定波長280nm及320nm之吸光度(光徑長度10mm)。
[黃色指數(YI)]
PVA的色相:以Suga Test Instruments製Colorimeter「SM-T-H1」,使用粉體測定用單元進行測定。
[製造例]
PVA(A1)之製造
將乙酸乙烯酯(以下簡稱為VAc)1400份、甲醇600份加入聚合罐,氮取代後進行加熱,升溫直到沸點後,相對於VAc加入0.05%的偶氮雙異丁腈、甲醇10份。在聚合率成為40%時停止聚合,在減壓下一邊添加甲醇,一邊將殘留的VAc與甲醇一起排出至系統外,得到聚乙酸乙
烯酯(以下簡稱為PVAc)的甲醇溶液(濃度40%)。接著,在PVAc濃度30%、溫度40℃之甲醇溶液中,相對於PVAc以莫耳比0.0047之比例,將氫氧化鈉作為皂化觸媒使用,開始皂化反應。因23分鐘後膠化,因此暫時將內容物取出後,使用混合器進行粉碎,再度恢復至40℃,以使在40℃之反應時間成為共計1小時之方式進行反應。反應結束後,減壓下進行乾燥去除甲醇之後,在常壓、空氣環境下,於80℃進行1小時,接著於90℃進行1小時,再於120℃進行4小時的熱處理,得到PVA(A1)。PVA(A1)的黏度平均聚合度為1550,皂化度為80莫耳%,濃度0.1%水溶液之在波長280nm的吸光度(a1)及在320nm的吸光度(a2)分別為0.008、0.004,YI的值為41。
PVA(A2~A7、A9、A12~A14)之製造
除了變更乙酸乙烯酯及甲醇之加入量、在聚合時使用的起始劑使用量、目標聚合率等之聚合條件、氫氧化鈉的量等之皂化條件、時間或溫度等之熱處理條件以外,係與PVA(A1)同樣地進行,製造表1所示的PVA(A2~A7、A9、A12~A14)。
PVA(A8、A10)之製造
除了與日本特開平8-283313號公報所記載的方法同樣地進行,在聚合時將乙醛使用作為鏈轉移劑,根據其使用量控制聚合度,並變更乙酸乙烯酯及甲醇之加入量、在聚合時使用的起始劑使用量、目標聚合率等之聚合條件、氫氧化鈉的量等之皂化條件、時間或溫度等之熱處理條件以外,係與PVA(A1)同樣地進行,製造表1所示
的PVA(A8、A10)。
PVA(A11)之製造
在PVA(A1)的製造步驟中,未進行熱處理而得到者為PVA(A11)。除了未進行熱處理以外,係與PVA(A1)同樣地進行而得到PVA(A11)。
PVA(B1~B3)之製造
除了與日本特開平8-283313號公報所記載的方法同樣地進行,變更在聚合時使用的乙醛之使用量、乙酸乙烯酯及甲醇之加入量、在聚合時使用的起始劑使用量、目標聚合率等之聚合條件、氫氧化鈉的量等之皂化條件、時間或溫度等之熱處理條件以外,係與PVA(A8)同樣地進行,製造表1所示的PVA(B1~B3)。
實施例1
在容量5L的高壓釜中,加入相對於氯乙烯成為880ppm的量之PVA(A1)溶解的去離子水溶液100份,且以去離子水之合計成為1200份之方式追加去離子水並加入。接著,將過氧化新癸酸異丙苯酯(cumyl peroxyneodecanate)之70%甲苯溶液0.65份及過氧化新十二酸三級丁酯(t-butyl peroxyneododecanate)之70%甲苯溶液1.05份加入至高壓釜。在高壓釜內以成為壓力0.2MPa之方式導入氮,之後施行共計5次之進行氮之吹淨的作業,且將高壓釜內充分地氮取代而去除氧後,加入氯乙烯940份。將高壓釜內的內容物升溫至57℃,並於攪拌下開始氯乙烯單體之聚合。聚合起始時之高壓釜內的壓力為0.80MPa。自開始聚合起經過約3.5小時後,在高壓釜內的壓力成為0.70MPa的時間點停止聚合,並去除未反應的氯乙烯單體後,取出聚合反應物,在65℃進行16小時乾燥,得到氯乙烯樹脂粒子。以下述所示的方法評價所得到的粒子。
(氯乙烯樹脂粒子之評價)
針對所得到的氯乙烯樹脂粒子,依據以下的方法評價(1)平均粒徑、(2)粒度分布、(3)容積比重。將評價結果示於表2。
(1)平均粒徑
使用泰勒網格(Tyler mesh)基準的金屬絲網,藉由記載於JIS Z8815的乾篩法測定粒度分布。根據其結果,使用Rosin-Rammler圖表算出平均粒徑。將評價結果示於表2。
(2)粒度分布
將所得到的氯乙烯樹脂粒子中之JIS標準篩選之42mesh-on的樹脂粒子之含量以質量%表示。將評價結果示於表2。
A:小於0.5%
B:0.5%以上且小於1%
C:1%以上
將所得到的氯乙烯樹脂粒子中之JIS標準篩選之60mesh-on的樹脂粒子之含量以質量%表示。
A:小於5%
B:5%以上且小於10%
C:10%以上
再者,42mesh-on的樹脂粒子之含量及60mesh-on的樹脂粒子之含量皆為值越小粗大粒子越少且粒度分布為尖銳,顯示聚合安定性優異。
(3)容積比重
依據JIS K6721,測定氯乙烯樹脂的容積比重。將評價結果示於表2。
實施例2
除了使用PVA(A1)(相對於氯乙烯為240ppm)與PVA(B1)(相對於氯乙烯為640ppm)溶解的去離子水溶液代替PVA(A1)的去離子水溶液以外,係與實施例1同樣地進行,實施氯乙烯之懸浮聚合,得到氯乙烯樹脂粒子。將氯乙烯樹脂粒子的評價結果示於表2。
實施例3~14
除了將PVA(A)、PVA(B)之種類及使用量變更為如表1所示以外,係與實施例2同樣地進行,實施氯乙烯之懸浮聚合,得到氯乙烯樹脂粒子。將氯乙烯樹脂粒子的評價結果示於表2。
比較例1~6
除了將使用的PVA(A)、PVA(B)之種類及使用量變更為如表1所示以外,係與實施例2同樣地進行,實施氯乙烯之懸浮聚合,得到氯乙烯樹脂粒子。將氯乙烯樹脂粒子的評價結果示於表2。
如在表2中所示,使用包含濃度0.1質量%水溶液之吸光度、皂化度、黏度平均聚合度、為粉體形狀之YI值係規定範圍之PVA(A)的分散安定劑時,即使在乙烯系單體的比例高且容易變不安定的條件下,聚合亦非常安定,可得到粗大粒子之生成少、容積比重高的氯乙烯樹脂粒子(實施例1~14)。特別是包含PVA(A)及PVA(B)的分散安定劑,上述的特性更優異(實施例2~14)。因此,本發明之製造方法的工業上有用性極高。
使用聚合度為800之PVA(A9)的情況(比較例1);使用濃度0.1質量%水溶液之波長280nm的吸光度(a1)為0.452、波長320nm的吸光度(a2)為0.201之PVA(A10)的情況(比較例2);使用YI的值為2之PVA(A11)的情況(比較例3),所得到的氯乙烯樹脂粒子之粒徑均大且為粗粒,42mesh-on、60mesh-on之比例多且聚合不安定,同時容積比重低。
使用皂化度為65莫耳%之PVA(A12),雖嘗試氯乙烯之懸浮聚合,但皂化度過低,PVA(A12)不溶解於水而無法進行聚合(比較例4)。使用皂化度為99莫耳%之PVA(A13)的情況,所得到的氯乙烯樹脂粒子之粒徑大且為粗粒,42mesh-on、60mesh-on之比例多且聚合不安定,同時容積比重低(比較例5)。使用黏度平均聚合度為5000的PVA(A14),雖嘗試氯乙烯之懸浮聚合,但黏度平均聚合度過高,PVA(A14)不溶解於水而無法進行聚合(比較例6)。
Claims (6)
- 一種懸浮聚合用分散安定劑,其含有濃度0.1質量%水溶液之在波長280nm的吸光度(a1)係小於0.25、該水溶液之在波長320nm的吸光度(a2)係小於0.030、皂化度係68莫耳%以上98莫耳%以下、黏度平均聚合度係超過1500小於4500、且為粉末形狀之YI值係5以上的乙烯醇系聚合物(A)。
- 如請求項1之懸浮聚合用分散安定劑,其含有濃度0.1質量%水溶液之在波長280nm的吸光度(b1)為0.25以上、該水溶液之在波長320nm的吸光度(b2)為0.030以上、皂化度為65莫耳%以上82莫耳%以下、且黏度平均聚合度為500以上1500以下的乙烯醇系聚合物(B)。
- 如請求項2之懸浮聚合用分散安定劑,其中乙烯醇系聚合物(A)及乙烯醇系聚合物(B)之質量比(A/B)為6/94以上60/40以下。
- 一種乙烯系樹脂之製造方法,其使用如請求項1至3中任一項之懸浮聚合用分散安定劑,在水性介質中懸浮聚合乙烯系單體。
- 如請求項4之乙烯系樹脂之製造方法,其中乙烯系單體與水性介質之質量比(乙烯系單體/水性介質)為0.75以上。
- 如請求項4或5之乙烯系樹脂之製造方法,其中乙烯系單體為氯乙烯。
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