Method for producing polyarylene sulfide

Patent metadata

Field	Value
Publication number	US-11795272-B2
Application number	US-202017906583-A
Country	US
Kind code	B2
Filing date	Nov 25, 2020
Priority date	Mar 24, 2020
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

A method for producing PAS having an average particle size of 50 μm or greater and 550 μm or less is provided. The method can include: (1) a preparation step of preparing a prepared mixture containing an organic polar solvent, a sulfur source, and a dihalo aromatic compound; (2) a pre-stage polymerization step of initiating a polymerization reaction by heating the prepared mixture to produce a prepolymer; (3) a phase separation step of adding water as a phase separation agent to a reaction mixture in a reaction system to form a phase separation state; and (4) a post-stage polymerization step of continuing the polymerization reaction after the phase separation step, in which an organic sulfonic acid metal salt having a specific solubility in water is contained in the prepared mixture or the reaction mixture.

First claim

The invention claimed is:

1. A method for producing polyarylene sulfide comprising:
(1) a preparation step of preparing a prepared mixture containing an organic polar solvent, a sulfur source, and a dihalo aromatic compound;
(2) a pre-stage polymerization step of initiating a polymerization reaction by heating the prepared mixture to produce a prepolymer;
(3) a phase separation step of adding water as a phase separation agent to a reaction mixture in a reaction system to form a phase separation state; and
(4) a post-stage polymerization step of continuing the polymerization reaction after the phase separation step,
wherein:
an organic sulfonic acid metal salt is contained in the prepared mixture or the reaction mixture before the post-stage polymerization step,
the organic sulfonic acid metal salt has a solubility of 3 mol or greater per 1 kg of water at 23° C., and
an average particle size of produced polyarylene sulfide is 50 μm or greater and 550 μm or less.

2. The method for producing polyarylene sulfide according to claim 1 , wherein an amount of the organic sulfonic acid metal salt used is 25 mol % or less with respect to a number of moles of the sulfur source.

3. The method for producing polyarylene sulfide according to claim 1 , wherein an amount of the water added in the phase separation step is from 0.1 to 5 mol per 1 mol of the sulfur source.

4. The method for producing polyarylene sulfide according to claim 1 , wherein the organic sulfonic acid metal salt is contained in the prepared mixture.

5. The method for producing polyarylene sulfide according to claim 1 , wherein the organic sulfonic acid metal salt is sodium methanesulfonate.

Assignees

• Kureha Corp

Inventors

• Sato Takeshi
• Suzuki Yoshinori

Classifications

• C08G75/0213 Primary

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

• C08G75/0254

  using metal sulfides · CPC title

• C08G75/0281

  Recovery or purification · CPC title

• C08G75/02 Primary

  Polythioethers · CPC title

• C08G75/0272 Primary

  using other sulfur sources · CPC title