Porous resin particles, method of manufacturing porous resin particles, and use of porous resin particles

Patent metadata

Field	Value
Publication number	US-9814656-B2
Application number	US-201314382631-A
Country	US
Kind code	B2
Filing date	Mar 29, 2013
Priority date	Sep 26, 2012
Publication date	Nov 14, 2017
Grant date	Nov 14, 2017

Abstract

Disclosed are porous resin particles which contain a polymer of a monomer mixture containing, as monomers, at least a monofunctional (meth)acrylic acid ester and a crosslinking monomer. The monofunctional (meth)acrylic acid ester accounts for 1 wt % to 50 wt % of the monomer mixture, and the crosslinking monomer accounts for 50 wt % to 99 wt % of the monomer mixture. The porous resin particles have a specific surface area of 190 m 2 /g to 300 m 2 /g and a bulk specific gravity of 0.25 g/mL to 0.45 g/mL.

First claim

The invention claimed is:

1. Porous resin particles which comprise a polymer of a monomer mixture,
the monomer mixture being
(1) a mixture consisting of a methacrylic acid ester and a crosslinking monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, or
(2) a mixture consisting of a methacrylic acid ester, a crosslinking monomer, and another monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, the another monomer is neither a monofunctional (meth)acrylic acid ester nor the crosslinking monomer,

the methacrylic acid ester accounting for 1 wt % to 50 wt % of the monomer mixture,
the crosslinking monomer accounting for 50 wt % to 99 wt % of the monomer mixture, and
the porous resin particles having a specific surface area of 190 m 2 /g to 300 m 2 /g and a bulk specific gravity of 0.25 g/mL to 0.45 g/mL.

2. The porous resin particles as set forth in claim 1 , wherein the crosslinking monomer is a (meth)acrylic-based crosslinking monomer.

3. The porous resin particles as set forth in claim 1 , having an oil absorption amount of 200 mL/100 g to 700 mL/100 g.

4. The porous resin particles as set forth in claim 1 , having a pore volume of 0.4 mL/g to 0.9 mL/g.

5. The porous resin particles as set forth in claim 1 , having a compression strength of 3.0 MPa to 7.0 MPa when compressed by 10%.

6. An external preparation which comprises the porous resin particles set forth in claim 1 .

7. A coating agent which comprises the porous resin particles set forth in claim 1 .

8. An optical film which comprises a base material and the coating agent set forth in claim 7 , the base material being coated with the coating agent.

9. A resin composition which comprises a base resin and the porous resin particles set forth in claim 1 .

10. A molded object which comprises the resin composition set forth in claim 9 , the resin composition being molded into the molded object.

11. Porous resin particles which comprise a polymer of a monomer mixture,
the monomer mixture being
(1) a mixture consisting of a methacrylic acid ester and a crosslinking monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, or
(2) a mixture consisting of a methacrylic acid ester, a crosslinking monomer, and another monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, the another monomer is neither a monofunctional (meth)acrylic acid ester nor the crosslinking monomer,

the porous resin particles having a specific surface area of 190 m 2 /g to 300 m 2 /g and such optical properties that the porous resin particles reflect, in a 0° direction with an intensity of 45 or greater, light that is incident thereto at an angle of −45° , where the porous resin particles specularly reflect, in a +45° direction with an intensity of 100, light that is incident thereto at an angle of −45° .

12. The porous resin particles as set forth in claim 11 , having an oil absorption amount of 200 mL/100 g to 700 mL/100 g.

13. The porous resin particles as set forth in claim 11 , having a pore volume of 0.4 mL/g to 0.9 mL/g.

14. The porous resin particles as set forth in claim 11 , having a compression strength of 3.0 MPa to 7.0 MPa when compressed by 10%.

15. An external preparation which comprises the porous resin particles set forth in claim 11 .

16. A coating agent which comprises the porous resin particles set forth in claim 11 .

17. An optical film which comprises a base material and the coating agent set forth in claim 16 , the base material being coated with the coating agent.

18. A resin composition which comprises a base resin and the porous resin particles set forth in claim 11 .

19. A molded object which comprises the resin composition set forth in claim 18 , the resin composition being molded into the molded object.

20. A method of manufacturing porous resin particles which comprises:
the polymerization step of suspension polymerizing a monomer mixture in an aqueous medium in the presence of an organic solvent to prepare a suspension containing porous resin particles, the monomer mixture being (1) a mixture consisting of 1 wt % to 50 wt % of a methacrylic acid ester and 50 wt % to 99 wt % of a crosslinking monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, or (2) a mixture consisting of 1 wt % to 50 wt % of a methacrylic acid ester, 50 wt % to 99 wt % of a crosslinking monomer, and another monomer, the methacrylic acid ester being selected from the group consisting of methyl methacrylate and ethyl methacrylate, the another monomer is neither a monofunctional (meth)acrylic acid ester nor the crosslinking monomer; and
the distillation step of distilling the suspension to remove the organic solvent from the suspension after the polymerization step,
the organic solvent being used in 180, exclusive, to 450 parts by weight per 100 parts by weight of the monomer mixture in the polymerization step.

21. The method of manufacturing porous resin particles as set forth in claim 20 , wherein the organic solvent has a boiling point of 69 to 90° C.

22. The method of manufacturing porous resin particles as set forth in claim 20 , wherein the crosslinking monomer is a (meth)acrylic-based crosslinking monomer.

Assignees

• Sekisui Plastics

Inventors

• Hama Yukio
• Okamoto Koichiro
• Hiroi Junko

Classifications

• C08J9/286

  the liquid phase being a solvent for the monomers but not for the resulting macromolecular composition, i.e. macroporous or macroreticular polymers · CPC title

• A61K8/81

  obtained by reactions involving only carbon-to-carbon unsaturated bonds · CPC title

• Y10T428/249953

  Composite having voids in a component [e.g., porous, cellular, etc.] · CPC title

• B01J20/28061

  being in the range 100-500 m2/g · CPC title

• C08F2/18

  Suspension polymerisation · CPC title