Polymer, production method for same, and molded article

Patent metadata

Field	Value
Publication number	US-10611870-B2
Application number	US-201415029504-A
Country	US
Kind code	B2
Filing date	Oct 14, 2014
Priority date	Oct 16, 2013
Publication date	Apr 7, 2020
Grant date	Apr 7, 2020

Abstract

The present application pertains to a production method for a polymer, including a step for polymerizing a starting material composition (I) that includes: a monomer mixture (I-1) containing a macromonomer (a) represented by the following formula (1), and (b) a vinyl monomer; and 0.01 to 5 parts by mass of a non-metallic chain transfer agent with respect to 100 parts by mass of the monomer mixture (I-1); a polymer obtained by the production method; and a molded article. According to the present invention, there can be provided a polymer having exceptional resistance to dwell-induced degradation, and a molded article having exceptional yellowing resistance, a low haze value, and exceptional pliability.

First claim

The invention claimed is:

1. A method for producing a polymer, comprising:
polymerizing a starting material composition (I) comprising a monomer mixture (I-1) comprising a macromonomer (a) represented by a Formula (1) and a vinyl monomer (b) and 0.07 to 0.5 parts by mass of a non-metallic chain transfer agent with respect to 100 parts by mass of the monomer mixture (I-1):

wherein in Formula (1),
R and R 1 to R n each independently represent an alkyl group having 1 to 4 carbon atoms,
X 1 to X n each independently represent a hydrogen atom or a methyl group,
Z represents a terminal group, and
n represents an integer of 3 to 5,000,
wherein the vinyl monomer (b) includes a vinyl monomer (b-1) having a Tg of homopolymer of 25° C. or higher and a vinyl monomer (b-2) having a Tg homopolymer of lower than 25° C., and
a content (X % by mass) of the vinyl monomer (b-1) in the vinyl monomer (b) satisfy the following Formula (3):
20≤ X≤ 75  (3),

wherein the macromonomer (a) is represented in the above-described Formula (1), R and R 1 to R n represent an alkyl group, X 1 to X n each independently represent a hydrogen atom or a methyl group,
wherein the non-metallic chain transfer agent is sulfur-containing chain transfer agent,
wherein the monomer mixture (I-1) comprises 15 to 60% by weight of the macromonomer (a), and 40 to 85% by weight of the mixture of vinyl monomers (b),
wherein the polymerization of the starting material composition (I) is performed by suspension polymerization,
wherein the macromonomer (a) is obtained by polymerizing a starting material composition (II) that includes: a monomer composition (II-1) containing a (meth)acrylic acid ester; and a cobalt chain transfer agent,
wherein the monomer composition (II-1) contains 85 to 99% by mass of methacrylic acid ester and 1 to 15% by mass of acrylic acid ester with respect to the total mass of the monomer composition (II-1), and,
wherein a 5% by mass reduction temperature of a polymer produced by the method for producing a polymer is 280° C. or higher.

2. The method according to claim 1 , wherein
the vinyl monomer (b) comprises a vinyl monomer (b-1) having a Tg of homopolymer of 25° C. or higher and a vinyl monomer (b-2) having a Tg of homopolymer of lower than 25° C., and
a content (X % by mass) of the vinyl monomer (b-1) in the vinyl monomer (b) and a content (Y % by mass) of the macromonomer (a) in the monomer mixture (I-1) satisfy Formulae (2) and (3):
45≥ Y≥− 0.5 X+ 45  (2)

5≤ X≤ 55  (3).

3. The method according to claim 2 , wherein the vinyl monomer (b) comprises a (meth)acrylic acid ester.

4. The method according to claim 1 , wherein
the vinyl monomer (b) comprises a vinyl monomer (b-1) having a Tg of homopolymer of 25° C. or higher and a vinyl monomer (b-2) having a Tg of homopolymer of lower than 25° C., and
a content (X % by mass) of the vinyl monomer (b-1) in the vinyl monomer (b) and a content (Y % by mass) of the macromonomer (a) in the monomer mixture (I-1) satisfy Formulae (4) and (5):
45≥ Y≥−X+ 75  (4)

30< X< 75  (5)

5. The method according to claim 4 , wherein the vinyl monomer (b) comprises a (meth)acrylic acid ester.

6. The method according to claim 1 , wherein the vinyl monomer (b) comprises a (meth)acrylic acid ester.

7. The method according to claim 1 ,
wherein the content (X % by mass) of the vinyl monomer (b-1) in the vinyl monomer (b) satisfy the following Formula (3):
20≤ X≤ 60  (3).

8. The method according to claim 1 ,
wherein a molded article obtained by molding a molding material comprising the polymer has a haze value with less than 3.6%, or a yellow index with less than 10.4.

9. The method according to claim 8 ,
wherein the molded article has a haze value with 0.1 to 1.5%.

10. The method according to claim 8 ,
wherein the molded article has a yellow index with 1.1 to 3.

11. The method according to claim 1 ,
wherein R and R 1 to R n represent a methyl group, X 1 to X n each independently represent a hydrogen atom or a methyl group, and n is 3 to 5000,
wherein the non-metallic chain transfer agent is sulfur-containing chain transfer agent,
wherein the monomer mixture (I-1) comprising 20 to 40% by weight of the macromonomer (a), and 60 to 80% by weight of the mixture of vinyl monomers (b).

12. A method for producing a polymer, comprising:
polymerizing a starting material composition (I) that includes a monomer mixture (I-1) containing a macromonomer (a) represented by the following Formula (1) and a vinyl monomer (b) and 0.07 to 0.5 parts by mass of a non-metallic chain transfer agent with respect to 100 parts by mass of the monomer mixture (I-1):

wherein in Formula (1),
R and R 1 to R n each independently represent a hydrogen atom, an alkyl group, a cycloalkyl group, an aryl group, or a heterocyclic group,
X 1 to X n each independently represent a hydrogen atom or a methyl group,
represents a terminal group, and
n represents an integer of 3 to 5,000,
wherein the vinyl monomer (b) includes a vinyl monomer (b-1) having a Tg of homopolymer of 100° C. or higher and a vinyl monomer (b-2) having a Tg of homopolymer of lower than 25° C.,
a content (X % by mass) of the vinyl monomer (b-1) in the vinyl monomer (b) and a content (Y % by mass) of the macromonomer (a) in the monomer mixture (I-1) satisfy the following Formulae (2), (4) and (6):
45≥ Y≥− 0.5 X+ 45  (2)

45≥ Y≥−X+ 75  (4)

30≤ X≤ 55  (6),

wherein the polymerization of the starting material composition (I) is performed by suspension polymerization,
wherein the macromonomer (a) is obtained by polymerizing a starting material composition (II) that includes: a monomer composition (II-1) containing a (meth)acrylic acid ester; and a cobalt chain transfer agent,
wherein the monomer composition (II-1) contains 85 to 99% by mass of methacrylic acid ester and 1 to 15% by mass of acrylic acid ester with respect to the total mass of the monomer composition (II-1), and,
wherein a 5% by mass reduction temperature of a polymer produced by the method for producing a polymer is 280° C. or higher.

Assignees

• Mitsubishi Chem Corp

Inventors

• Fujiyama Kousuke
• Nishimura Masanari
• Hikita Shingo
• Nakaya Fuminori
• Oonuma Taeko
• Noda Tetsuya

Classifications

• C08F220/14

  Methyl esters {, e.g. methyl (meth)acrylate} · CPC title

• C08F293/005

  using free radical "living" or "controlled" polymerisation, e.g. using a complexing agent · CPC title

• C08F2/18 Primary

  Suspension polymerisation · CPC title

• C08F210/14

  Monomers containing five or more carbon atoms · CPC title

• C08F2500/12

  Melt flow index or melt flow ratio · CPC title