Manufacturing method for high molecular weight aromatic polycarbonate resin

Patent metadata

Field	Value
Publication number	US-11021571-B2
Application number	US-201716088574-A
Country	US
Kind code	B2
Filing date	Mar 24, 2017
Priority date	Mar 30, 2016
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

Provided is a manufacturing method for a high molecular weight aromatic polycarbonate resin that has superior fluidity and for which a good color and a sufficiently high molecular weight can be achieved. A manufacturing method for a high molecular weight aromatic polycarbonate resin includes: a step in which a dialcohol compound expressed by general formula (1) and a catalyst are mixed to obtain a catalyst composition; a step in which the obtained catalyst composition is kept in a molten state, and is mixed with an aromatic polycarbonate prepolymer within ten hours after obtaining the catalyst composition, to obtain a prepolymer mixture; and a high molecular weight achievement step in which the obtained prepolymer mixture is heat-treated under reduced pressure conditions to obtain a high molecular weight aromatic polycarbonate resin.

First claim

The invention claimed is:

1. A manufacturing method for a high molecular weight aromatic polycarbonate resin, the method comprising:
a step of mixing a dialcohol compound represented by General Formula (1) below and a catalyst to produce a catalyst composition in a liquid form,
a step of mixing the catalyst composition in a liquid form and an aromatic polycarbonate prepolymer within a period of 10 hours from the time of production of the catalyst composition, to obtain a prepolymer mixture, and
a high molecular weight achievement step of heat-treating the obtained prepolymer mixture under reduced pressure conditions to obtain a high molecular weight aromatic polycarbonate resin;

wherein, R 1 to R 4 each independently represent a hydrogen atom, a halogen atom, or a linear or branched alkyl group having 1 to 5 carbons, and Q represents a single bond or a substituted or unsubstituted divalent group comprising at least one member selected from the group consisting of an aliphatic hydrocarbon group, an aromatic hydrocarbon group, an oxygen atom, a sulfur atom, a sulfone group, a sulfoxide group, a carbonyl group, a dialkylsilyl group and a diarylsilyl group.

2. The manufacturing method according to claim 1 , wherein the step of producing the catalyst composition is performed separately in parallel in a plurality of catalyst composition preparation tanks.

3. The manufacturing method according to claim 1 , wherein a molten state of the catalyst composition is maintained in a temperature range from a temperature that is 5° C. higher than a melting point of the dialcohol compound to a temperature that is 250° C. higher than the melting point.

4. The manufacturing method according to claim 1 , wherein the catalyst is at least one member selected from the group consisting of alkali metal salts and alkaline earth metal salts.

5. The manufacturing method according to claim 1 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

6. The manufacturing method according to claim 1 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

7. The manufacturing method according to claim 2 , wherein a molten state of the catalyst composition is maintained in a temperature range from a temperature that is 5° C. higher than a melting point of the dialcohol compound to a temperature that is 250° C. higher than the melting point.

8. The manufacturing method according to claim 2 , wherein the catalyst is at least one member selected from the group consisting of alkali metal salts and alkaline earth metal salts.

9. The manufacturing method according to claim 2 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

10. The manufacturing method according to claim 2 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

11. The manufacturing method according to claim 3 , wherein the catalyst is at least one member selected from the group consisting of alkali metal salts and alkaline earth metal salts.

12. The manufacturing method according to claim 3 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

13. The manufacturing method according to claim 3 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

14. The manufacturing method according to claim 7 , wherein the catalyst is at least one member selected from the group consisting of alkali metal salts and alkaline earth metal salts.

15. The manufacturing method according to claim 4 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

16. The manufacturing method according to claim 4 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

17. The manufacturing method according to claim 7 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

18. The manufacturing method according to claim 7 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

19. The manufacturing method according to claim 8 , wherein the step of producing the catalyst composition is performed in a catalyst composition preparation tank comprising a surface in contact with the catalyst composition, and the surface has an iron content of 80 mass % or less.

20. The manufacturing method according to claim 8 , wherein the step of producing the catalyst composition is performed in an atmosphere having an oxygen content of 10 vol % or less.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Isahaya Yoshinori
• Hirashima Atsushi
• Harada Hidefumi
• Ito Maki
• HAYAKAWA Jun-ya
• Isobe Takehiko
• Shinkai Yousuke
• Shimokawa Keisuke

Classifications

• C08G64/305 Primary

  and alcohols · CPC title

• C08G64/04

  Aromatic polycarbonates · CPC title