Method of producing polyarylene sulfide

Patent metadata

Field	Value
Publication number	US-10570255-B2
Application number	US-201615759855-A
Country	US
Kind code	B2
Filing date	Sep 30, 2016
Priority date	Sep 30, 2015
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

Provided is a method of producing polyarylene sulfide at low cost while productivity enhancement and resource saving are attempted by avoiding the use of a complicated step and special apparatus (facility). The method of producing polyarylene sulfide according to an embodiment of the present invention includes: a preparation step of preparing a mixture containing an organic amide solvent, a sulfur source, a dihalo aromatic compound, and an alkali metal hydroxide in an amount less than an equimolar amount relative to an amount of the sulfur source; a first-stage polymerization step of initiating a polymerization reaction by heating the mixture, and producing a prepolymer having a dihalo aromatic compound conversion ratio of 50% or greater; and a second-stage polymerization step of adding an alkali metal hydroxide such that the alkali metal hydroxide is in an amount of 1.00 to 1.10 mol per 1 mol of the sulfur source, and continuing the polymerization reaction in a homogeneous liquid phase condition.

First claim

The invention claimed is:

1. A method of producing polyarylene sulfide in which a sulfur source and a dihalo aromatic compound are polymerized in an organic amide solvent, the method comprising:
a preparation step of preparing a mixture containing an organic amide solvent, a sulfur source, a dihalo aromatic compound, and an alkali metal hydroxide in an amount less than an equimolar amount relative to an amount of the sulfur source;
a first-stage polymerization step of initiating a polymerization reaction by heating the mixture, and producing a prepolymer having a dihalo aromatic compound conversion ratio of 50% or greater; and
a second-stage polymerization step of adding an alkali metal hydroxide such that the alkali metal hydroxide is in an amount of 1.00 to 1.10 mol per 1 mol of the sulfur source, and continuing the polymerization reaction in a homogeneous liquid phase condition,
wherein, in the second-stage polymerization step, a water content per 1 kg of the organic amide solvent is in a range of 0.01 to 3.7 mol.

2. The method according to claim 1 , wherein, in the preparation step, the mixture containing from 0.5 to 0.99 mol of the alkali metal hydroxide per 1 mol of the sulfur source is prepared.

3. The method according to claim 1 , wherein, in the first-stage polymerization step, the prepolymer having the dihalo aromatic compound conversion ratio of 50 to 98% is produced.

4. The method according to claim 1 , comprising no sieving step of sieving polyarylene sulfide.

Assignees

• Kureha Corp

Inventors

• Mokudai Haruki
• Konno Akihiro
• Sato Hiroyuki

Classifications

• C08G75/025 Primary

  Preparatory processes · CPC title

• C08G75/0213

  containing elements other than carbon, hydrogen or sulfur · CPC title

• C08G75/0254 Primary

  using metal sulfides · CPC title