JP5415133B2 - Novel process for producing polyphenylene ether - Google Patents

Description

The present invention relates to a novel process for producing polyphenylene ether.
More specifically, in the present invention, a good solvent, a metal salt as a catalyst component, an amine compound, and an oxygen-containing gas are passed through a polymerization solution composed of a phenol compound, and the phenol compound is oxidatively polymerized to obtain a polyphenylene ether. Polymerization solution is mixed with polymerization solution to stop polymerization, and polyphenylene ether solution is added to polyphenylene ether solution obtained by separating the metal salt, chelating agent and water, and polyphenylene ether particles are precipitated. In the method for producing polyphenylene ether, the present invention relates to the above method wherein metal salt, chelating agent and water are effectively separated to obtain polyphenylene ether having excellent color tone and mechanical properties.

  Conventionally, various methods have been disclosed for producing polyphenylene ether by oxidative polymerization of a phenolic compound.

  In Patent Documents 1 to 4, as an effective catalyst for oxidative polymerization of a phenolic compound, a catalyst in which a copper compound and an amine are combined, a catalyst in which a copper compound and a halogen compound are combined, a primary amine, a secondary amine, and a tertiary Catalysts using amines, monoamines, diamines or polyamines, and catalysts using tetraalkyl type diamines such as N, N, N ′, N′-tetramethyl-1,4-butanediamine are disclosed.

  Patent Documents 5 to 6 propose a catalyst in which a copper compound, an iodine compound and a tetraalkyl type diamine are combined as an effective catalyst for oxidative polymerization.

  Further, in Patent Documents 7 to 9, a catalyst obtained by combining a copper compound, a bromine compound and a tertiary amine such as N, N′-di-t-butylethylenediamine, n-butyldimethylamine, a copper compound, a bromine compound and 3 Catalysts in combination with secondary amines and secondary monoamines are disclosed.

  Patent Document 10 discloses a copper compound and a secondary aliphatic amine or secondary aliphatic amine, an aniline having a special structure, and N, N, N ′, N′-tetramethyl-1,3-diaminopropane. A catalyst with improved water resistance is disclosed.

  Furthermore, Patent Documents 8 to 10 describe that it is advantageous to use a quaternary ammonium compound.

  Patent Documents 11 to 13 disclose that the polymerization catalyst and the phenolic compound are prepared in an inert gas atmosphere, whereby the catalyst is highly activated and the productivity of polyphenylene ether is improved.

  Patent Documents 14 and 15 disclose a method of continuously performing liquid-liquid separation using a centrifuge as a method for stopping oxidative polymerization and separating polyphenylene ether and a polymerization catalyst.

  On the other hand, in the oxidative polymerization of a phenolic compound, diphenoquinone is generated as a by-product. Since this diphenoquinone affects the physical properties and color tone of polyphenylene ether, it needs to be treated.

  As a method for treating diphenoquinone, Patent Document 16 discloses a method (reduction removal) in which polyphenylene ether and diphenoquinone are separated by adding an aminocarboxylic acid derivative and a reducing agent to a polymerization solution after oxidative polymerization of a phenolic compound is completed. It is disclosed.

  Patent Documents 17 and 18 disclose a method of reacting diphenoquinone with polyphenylene ether as a method for treating diphenoquinone.

  However, when the catalyst disclosed in Patent Documents 8 to 10 is used to polymerize polyphenylene ether and diphenoquinone is treated to remove the catalyst using the techniques disclosed in Patent Documents 14 and 15, the aqueous phase and If the organic solvent phase is liquid-liquid separated, the interface is not stable, foaming occurs, and if measures such as discarding the interface part are not taken, the metal salt that is the polymerization catalyst component can be completely separated from the polyphenylene ether. There are cases where it is not possible.

  In addition, when a polyphenylene ether is produced using a preferred catalyst described in Patent Documents 8 to 10 and a method similar to the above is applied, the metal salt as a polymerization catalyst component can be separated from the polyphenylene ether. Causes problems in mechanical properties. That is, a technique for efficiently separating a metal salt as a polymerization catalyst component from polyphenylene ether treated with diphenoquinone and obtaining polyphenylene ether excellent in mechanical properties is not disclosed.

Japanese Patent Publication No. 36-018692 US3306875 Specification US 3344116 Specification US3432466 Specification Japanese Examined Patent Publication No. 52-017075 Japanese Examined Patent Publication No. 52-017076 Japanese Patent Publication No.58-053012 Japanese Examined Patent Publication No. 59-023332 Japanese Patent Publication No.59-131627 Japanese Patent Laid-Open No. 60-042422 JP 59-179620 A JP-A 61-001453 JP 2002-003596 A JP 60-051720 A JP-T-2004-504429 JP-A-51-122196 JP 54-033594 A Japanese Patent Laid-Open No. 54-033595

  There is a need for a method for efficiently separating a metal salt that is a polymerization catalyst component from polyphenylene ether to obtain polyphenylene ether having excellent mechanical properties.

  As a result of studying a technique for separating a polymerization catalyst component from a polymerization solution in the conventional oxidative polymerization of a phenolic compound, the present inventors have found a method for efficiently separating a metal salt that is a polymerization catalyst component from polyphenylene ether, and The inventors have found a method for obtaining polyphenylene ether having excellent mechanical properties and have completed the present invention.

（式中、Ｒ_１，Ｒ_２，Ｒ_３，及びＲ_４はそれぞれ独立に炭素数１から２２の直鎖状又は分岐状アルキル基、Ｘは対となる陰イオンである。）

（式中、Ｒ_８及びＲ_９は炭素素数１から２２の直鎖状又は分岐状アルキル基を表し、Ｒ_１０はＲ_８に定義した基、又は−（ＣＨ_２ＣＨ_２Ｏ）_ｎ−Ｈ（ｎは１から４０の整数）で表される基であり、Ｒ_１１は−（ＣＨ_２ＣＨ_２Ｏ）_ｎ−Ｈ（ｎは１から４０の整数）で表される基であり、Ｘは対となる陰イオンである。）
５．前記イオン触媒（Ｄ）が、トリオクチルメチルアンモニウムクロリドである、上記１〜４のいずれか一項に記載の方法。
６．重合溶液にキレート剤水溶液を混合して重合を停止した後に、副生物として生成するジフェノキノン化合物をキノン結合処理する、上記１〜５のいずれか一項に記載の方法。
７．前記酸素含有ガスが、酸素濃度１０〜２５容量％の酸素含有ガスである、上記１〜６のいずれか一項に記載の方法。
８．酸素分圧が０．０１４７ＭＰａ以上０．０８８３ＭＰａ以下の酸素含有ガスを使用し、かつ、反応器気相部の絶対圧力を０．０９８ＭＰａ以上０．３９２ＭＰａ未満に制御する、上記１〜７のいずれか一項に記載のポリフェニレンエーテルの製造方法。 That is, the present invention is as follows.
1. A total of 100 parts by mass of phenolic compound (M) 10-25 parts by mass and aromatic solvent (A) 75-90 parts by mass, and catalyst (C) 0.1-10 parts by mass containing a metal salt as a component Preparing a polymerized solution,
The phenolic compound (M) is subjected to oxidative polymerization by passing an oxygen-containing gas through the polymerization solution,
Mixing the polymerization solution with an aqueous chelating agent solution to stop the polymerization,
Diphenoquinone compound produced as a by-product is subjected to quinone binding treatment or reduction removal,
Thereafter, a method for producing a polyphenylene ether comprising separating the aqueous phase by liquid-liquid separation to obtain polyphenylene ether,
The method as described above, wherein 0.001 to 0.004 part by weight of an ion catalyst (D) is added to the polymerization solution from the time when the polymerization solution is prepared until the polymerization is stopped.
2. 2. The method according to 1 above, wherein the ion catalyst (D) is added to the polymerization solution when the polymerization solution is prepared.
3. 3. The method according to 1 or 2 above, wherein 0.001 to 0.003 parts by mass of the ion catalyst (D) is added.
4). Any one of the above 1-3, wherein the ion catalyst (D) is a tetraalkylammonium salt compound represented by the following formula (4) or a polyethylene glycol group-containing alkylammonium salt compound represented by the following formula (5): The method according to one item.

(Wherein R ₁ , R ₂ , R ₃ , and R ₄ are each independently a linear or branched alkyl group having 1 to 22 carbon atoms, and X is a paired anion.)

(Wherein R ₈ and R ₉ represent a linear or branched alkyl group having 1 to 22 carbon atoms, and R ₁₀ represents a group defined as R ₈ , or — (CH ₂ CH ₂ O) _n —H ( n is an integer of 1 to 40), R ₁₁ is a group represented by — (CH ₂ CH ₂ O) _n —H (n is an integer of 1 to 40), and X is a pair Anion that becomes.)
5. The method according to any one of 1 to 4 above, wherein the ion catalyst (D) is trioctylmethylammonium chloride.
6). 6. The method according to any one of 1 to 5 above, wherein the diphenoquinone compound produced as a byproduct is subjected to a quinone bond treatment after mixing the aqueous solution of the chelating agent with the polymerization solution to stop the polymerization.
7). The method according to any one of 1 to 6 above, wherein the oxygen-containing gas is an oxygen-containing gas having an oxygen concentration of 10 to 25% by volume.
8). Any one of 1 to 7 above, wherein an oxygen-containing gas having an oxygen partial pressure of 0.0147 MPa or more and 0.0883 MPa or less is used, and the absolute pressure of the gas phase part of the reactor is controlled to 0.098 MPa or more and less than 0.392 MPa. A method for producing a polyphenylene ether according to one item.

  According to the present invention, it is possible to efficiently separate a metal salt that is a polymerization catalyst component from polyphenylene ether and to obtain polyphenylene ether having excellent mechanical properties.

  The present invention will be specifically described below.

（上記式（１）中、Ｒ_１及びＲ_４は、それぞれ独立して、水素、第一級又は第二級の低級アルキル、フェニル、アミノアルキル、炭化水素オキシを表す。Ｒ_２及びＲ_３は、それぞれ独立して、水素、第一級又は第二級の低級アルキル、フェニルを表す。） Examples of the polyphenylene ether of the present invention include a homopolymer or a copolymer having a repeating unit represented by the following formula (1).

(In the above formula (1), R ₁ and R ₄ each independently represent hydrogen, primary or secondary lower alkyl, phenyl, aminoalkyl, hydrocarbon oxy. R ₂ and R ₃ are And each independently represents hydrogen, primary or secondary lower alkyl, or phenyl.)

  Specific examples of the homopolymer of polyphenylene ether resin include, for example, poly (2,6-dimethyl-1,4-phenylene) ether, poly (2-methyl-6-ethyl-1,4-phenylene) ether, poly (2,6-diethyl-1,4-phenylene) ether, poly (2-ethyl-6-n-propyl-1,4-phenylene) ether, poly (2,6-di-n-propyl-1,4) -Phenylene) ether, poly (2-methyl-6-n-butyl-1,4-phenylene) ether, poly (2-ethyl-6-isopropyl-1,4-phenylene) ether, poly (2-methyl-6) -Hydroxyethyl-1,4-phenylene) ether, poly (2-methyl-6-chloroethyl-1,4-phenylene) ether and the like.

Of these, poly (2,6-dimethyl-1,4-phenylene) ether is particularly preferred.
The polyphenylene ether resin copolymer is a copolymer containing a phenylene ether unit as a single unit. Specific examples thereof include, for example, a copolymer of 2,6-dimethylphenol and 2,3,6-trimethylphenol, a copolymer of 2,6-dimethylphenol and o-cresol, or 2,6-dimethylphenol, Examples thereof include a copolymer of dimethylphenol, 2,3,6-trimethylphenol, and o-cresol.

（上記式（２）中、Ｒ_５及びＲ_７は、それぞれ独立して、水素、第一級又は第二級の低級アルキル、フェニル、アミノアルキル、炭化水素オキシを表す。Ｒ_６及びＲ_８は、それぞれ独立して、水素、第一級又は第二級の低級アルキル、フェニルを表す。） The phenolic compound used in the present invention is a compound having a structure represented by the following formula (2).

(In the above formula (2), R ₅ and R ₇ each independently represent hydrogen, primary or secondary lower alkyl, phenyl, aminoalkyl, hydrocarbon oxy. R ₆ and R ₈ are And each independently represents hydrogen, primary or secondary lower alkyl, or phenyl.)

  Examples of such compounds include 2,6-dimethylphenol, 2,3,6-trimethylphenol, 2-methyl-6-ethylphenol, 2,6-diethylphenol, 2-ethyl-6-n-propylphenol. 2-methyl-6-chlorophenol, 2-methyl-6-bromophenol, 2-methyl-6-isopropylphenol, 2-methyl-6-n-propylphenol, 2-ethyl-6-bromophenol, 2- Methyl-6-n-butylphenol, 2,6-di-n-propylphenol, 2-ethyl-6-chlorophenol, 2-methyl-6-phenylphenol, 2,6-diphenylphenol, 2,6-bis- (4-fluorophenyl) phenol, 2-methyl-6-tolylphenol, 2,6-ditolylphenol, etc. It is. These compounds may be used alone or in combination of two or more. Moreover, even if it contains a small amount of phenol, o-cresol, m-cresol, p-cresol, 2,4-dimethylphenol, 2-ethylphenol, etc., it does not interfere.

  Among these phenolic compounds, 2,6-dimethylphenol or a mixture of 2,6-dimethylphenol and 2,3,6-trimethylphenol is preferable, and 2,6-dimethylphenol is particularly preferable.

  The aromatic solvent used in the present invention is not particularly limited, but dissolves a low molecular weight phenolic compound and dissolves part or all of the catalyst mixture. Examples of such solvents include aromatic hydrocarbons such as benzene, toluene, xylene, and ethylbenzene, halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene, and trichlorobenzene, and nitro compounds such as nitrobenzene. be able to.

  As the aromatic solvent used in the present invention, toluene, xylene or ethylbenzene is preferable, and toluene is very preferable.

  In an amount as long as the effects of the present invention are not hindered, the aromatic solvent can be mixed with a solvent having a property compatible with water. Solvents that are compatible with water include, for example, alcohols such as methanol, ethanol, and propanol, ketones such as acetone and methyl ethyl ketone, esters such as ethyl acetate and ethyl formate, amides such as dimethylformamide, and dimethyl sulfoxide. And sulfoxides such as One or more solvents can be further mixed and used if necessary.

  The present invention can act particularly preferably as long as the solvent used is substantially incompatible with water. Examples of frequently used solvents are aromatic hydrocarbon solvents such as toluene and xylene. By selecting the ratio of good solvent and poor solvent for polyphenylene ether, which is a polymer obtained by oxidative polymerization of phenolic compounds, it can be used as a solution polymerization method, and by increasing the ratio of poor solvent, It is also a precipitation polymerization method in which the coalesced precipitate as particles in the reaction solvent.

  The catalyst (C) used in the present invention produces polyphenylene ether by efficiently oxidizing and polymerizing a phenolic compound by passing an oxygen-containing gas through a polymerization solution comprising a phenolic compound, an aromatic solvent, and a catalyst. Therefore, it is an effective oxidation catalyst.

  As the catalyst (C) used in the present invention, a catalyst composed of one or more selected from copper compounds and bromine compounds, diamine compounds, tertiary monoamine compounds, and secondary monoamine compounds can be used. In particular, a catalyst having a copper compound, a bromine compound, a diamine compound, a tertiary monoamine compound, and a secondary monoamine compound as essential components can be used more preferably.

  As a copper compound used as a component of the catalyst (C) in the present invention, a cuprous compound, a cupric compound or a mixture thereof can be used. Examples of the cuprous compound include cuprous oxide, cuprous chloride, cuprous bromide, cuprous sulfate, and cuprous nitrate. Examples of cupric compounds include cupric chloride, cupric bromide, cupric sulfate, and cupric nitrate. Among these, preferred compounds are cuprous oxide, cuprous chloride, cupric chloride, cuprous bromide and cupric bromide for cuprous and cupric compounds. Moreover, you may synthesize | combine these copper salts from the halogen or acid corresponding to an oxide, carbonate, a hydroxide, etc. at the time of use. For example, it can be obtained by mixing cuprous oxide and hydrogen bromide (solution). A particularly preferable copper compound is a cuprous compound. These copper compounds may be used alone or in combination of two or more.

  Examples of the bromine compound used as a component of the catalyst (C) in the present invention are hydrogen bromide, sodium bromide, potassium bromide, tetramethylammonium bromide, tetraethylammonium bromide and the like. These can be used as an aqueous solution or a solution using an appropriate solvent. These bromine compounds may be used alone or in combination of two or more. The most preferred combination of copper compound and bromine compound is an aqueous solution of cuprous oxide and hydrogen bromide. Although the usage-amount of these compounds is not specifically limited, 2 times or more and 10 times or less are preferable as a bromine atom with respect to the molar amount of a copper atom, From 0.02 mol as a copper atom with respect to 100 mol of a phenolic compound. The range is 0.6 mol.

（上記式（３）中、Ｒ_１，Ｒ_２，Ｒ_３，及びＲ_４はそれぞれ独立に、水素、炭素数１から６の直鎖状又は分岐状アルキル基であり、全てが同時に水素ではない。Ｒ_５は炭素数２から５の直鎖状又はメチル分岐を持つアルキレン基である。） The diamine compound used as a component of the catalyst (C) in the present invention is a diamine compound represented by the following formula (3). Of the diamine compounds having the above structure, a preferred diamine compound is N, N′-di-t-butylethylenediamine. Although the usage-amount of a diamine compound is not specifically limited, It is 0.5 times mole amount or more with respect to the number-of-moles of copper atom normally used, and an upper limit is not critical.

(In the above formula (3), R ₁ , R ₂ , R ₃ , and R ₄ are each independently hydrogen, a linear or branched alkyl group having 1 to 6 carbon atoms, and all are not hydrogen at the same time. R ₅ is a linear or methyl branched alkylene group having 2 to 5 carbon atoms.)

  The tertiary monoamine compound used as a component of the catalyst (C) in the present invention is an aliphatic tertiary amine including an alicyclic tertiary amine. Examples include trimethylamine, triethylamine, tripropylamine, tributylamine, triisobutylamine, dimethylethylamine, dimethylpropylamine, allyldiethylamine, dimethyl-n-butylamine, diethylisopropylamine, N-methylcyclohexylamine and the like. These tertiary monoamines may be used alone or in combination of two or more. The amount of these used is not particularly limited, but is preferably in the range of 0.1 mol to 15 mol with respect to 100 mol of the phenolic compound.

  The secondary monoamine compound used as a component of the catalyst (C) in the present invention is dimethylamine, diethylamine, di-n-propylamine, diisopropylamine, di-n-butylamine, diisobutylamine, di-t-butylamine, dipentylamines. , Dihexylamines, dioctylamines, didecylamines, dibenzylamines, methylethylamine, methylpropylamine, methylbutylamine, cyclohexylamine and the like. Examples of N- (substituted or unsubstituted phenyl) alkanolamines include N-phenylmethanolamine, N-phenylethanolamine, N-phenylpropanolamine, N- (m-methylphenyl) ethanolamine, N- (p-methyl). Phenyl) ethanolamine, N- (2 ′, 6′-dimethylphenyl) ethanolamine, N- (p-chlorophenyl) ethanolamine and the like. Examples of the N-hydrocarbon substituted aniline include N-ethylaniline, N-butylaniline, N-methyl-2-methylaniline, N-methyl-2,6-dimethylaniline, diphenylamine, and the like. It is not limited to. These secondary monoamine compounds may be used alone or in combination of two or more. The amount used is not particularly limited, but is generally in the range of 0.05 mol to 15 mol with respect to 100 mol of the phenolic compound.

  The catalyst (C) in the present invention contains all components of a copper compound, a bromine compound, a diamine compound, a secondary monoamine compound, and a tertiary monoamine compound.

  In the catalyst (C) of the present invention, the copper compound is used as a copper atom in the range of 0.02 mol to 0.6 mol with respect to 100 mol of the phenolic compound, and the bromine compound is used as the bromine atom. In the range of 0.04 mol to 6 mol per mol, the diamine compound is in the range of 0.5 times the molar amount of copper atoms or more, and the secondary monoamine compound is 0.1 mol per 100 mol of phenolic compound. It is preferable that the tertiary monoamine compound is contained in the range of 0.05 mol to 15 mol with respect to 100 mol of the phenolic compound in the range of mol to 15 mol.

  In the catalyst (C) in the present invention, the copper compound is used as a copper atom in the range of 0.03 mol to 0.4 mol with respect to 100 mol of the phenolic compound, the bromine compound is used as the bromine atom, and 100 of the phenolic compound. In the range of 0.06 mol to 4 mol with respect to mol, the diamine compound, the secondary monoamine compound in the range of 0.6 to 2 mol amount of the copper atom in the copper compound, and the phenolic compound More preferably, the tertiary monoamine compound is contained in a range of 0.1 mol to 5 mol with respect to 100 mol of the phenolic compound in a range of 0.2 mol to 5 mol with respect to 100 mol.

  In the method for preparing a polymerization solution in the method for producing polyphenylene ether of the present invention, the components of the phenolic compound (M), the aromatic solvent (A), and the catalyst (C) may be independently introduced into the reactor, Alternatively, the phenolic compound (M) and the catalyst (C) may be previously dissolved in the aromatic solvent (A) and both introduced into the reactor.

  A preferable method for preparing a polymerization solution in the method for producing a polyphenylene ether of the present invention is to first introduce a catalyst (C) previously dissolved in a part of the aromatic solvent (A) into a reactor, and then continue the remaining fragrance. In this method, the phenolic compound (M) dissolved in the group solvent (A) is introduced into the reactor.

  In the method for producing the polyphenylene ether of the present invention, the weights of the phenolic compound (M), aromatic solvent (A) and catalyst (C) in the polymerization solution are the same as those in the preparation of the polymerization solution. The weight when the introduction of the catalyst (C) into the reactor is completed.

  In this invention, it is preferable that the density | concentration of the phenolic compound with respect to a total of 100 mass parts of a phenolic compound (M) and an aromatic solvent (A) is 10-25 mass parts. In the present invention, the concentration of the phenolic compound is more preferably 12 to 23 parts by mass, particularly preferably 13 to 21 parts by mass, and most preferably 14 to 20 parts by mass.

  In this invention, the density | concentration of the catalyst (C) with respect to a total of 100 mass parts of a phenolic compound (M) and an aromatic solvent (A) is 0.1-10 mass%.

  In the present invention, after oxidative polymerization of the phenolic compound (M), the polymerization solution is mixed with an aqueous solution of a chelating agent to stop the polymerization, the diphenoquinone compound produced as a by-product is treated, and liquid-liquid separation is performed to obtain a polymerization catalyst component. In the method of obtaining a polyphenylene ether by separating the metal salt, chelating agent, and water, that is, the aqueous phase, the catalyst (C) and the ionic catalyst (D) 0.001 to 0.004 wt. To improve productivity, stabilize the interface between the aqueous phase and the organic solvent phase during liquid-liquid separation, and effectively separate the metal salt that is a polymerization catalyst component from polyphenylene ether Can do.

  The ion catalyst (D) of the present invention stabilizes the interface between the aqueous phase and the organic solvent phase.

（上記式（４）中、Ｒ_１，Ｒ_２，Ｒ_３，Ｒ_４はそれぞれ独立に炭素数１から２２の直鎖状又は分岐状アルキル基、Ｘは対となる陰イオン、好ましくは、Ｃｌ⁻、Ｂｒ⁻より選択される陰イオンである。）

（上記式（５）中、Ｒ_８及びＲ_９は炭素素数１から２２の直鎖状又は分岐状アルキル基を表し、Ｒ_１０はＲ_８に定義した基、又は−（ＣＨ_２ＣＨ_２Ｏ）_ｎ−Ｈ（ｎは１から４０の整数）で表される基であり、Ｒ_１１は−（ＣＨ_２ＣＨ_２Ｏ）_ｎ−Ｈ（ｎは１から４０の整数）で表される基であり、Ｘは対となる陰イオン、好ましくは、Ｃｌ⁻、Ｂｒ⁻より選択される陰イオンである。） The ion catalyst (D) of the present invention is preferably a tetraalkylammonium salt compound represented by the following formula (4) or a polyethylene glycol group-containing alkylammonium salt compound represented by the following formula (5).

(In the above formula (4), R ₁ , R ₂ , R ₃ , R ₄ are each independently a linear or branched alkyl group having 1 to 22 carbon atoms, X is a paired anion, preferably Cl ^-, Br ^- is an anion selected from).

(In the above formula (5), R ₈ and R ₉ represent a linear or branched alkyl group having 1 to 22 carbon atoms, and R ₁₀ is a group defined as R ₈ or — (CH ₂ CH ₂ O). _n— H (n is an integer of 1 to 40), and R ₁₁ is a group represented by — (CH ₂ CH ₂ O) _n —H (n is an integer of 1 to 40). , X is a pairing anion, preferably an anion selected from Cl ⁻ and Br ⁻ .)

  Particularly preferred as the ion catalyst (D) of the present invention is trioctylmethylammonium chloride.

  In the present invention, a total of 100 parts by mass of the phenolic compound (M) and the aromatic solvent (A) in the polymerization solution is added to the polymerization solution from the time when the polymerization solution is prepared until the polymerization is stopped. The ion catalyst (D) is added in an amount of 0.001 to 0.004 parts by weight, preferably 0.001 to 0.003 parts by weight of the ion catalyst (D).

  When the ion catalyst (D) of the present invention is used in an amount of 0.001 part by mass or more with respect to 100 parts by mass in total of the parts by mass of the phenolic compound (M) and the aromatic solvent (A) in the polymerization solution, liquid-liquid separation is performed. Improves. Moreover, if the ion catalyst (D) of this invention is used at 0.004 mass part or less with respect to 100 mass parts in total of the phenolic compound (M) in a polymerization solution and the mass part of an aromatic solvent (A). The mechanical properties of the polyphenylene ether composition containing the obtained polyphenylene ether as a component are not affected.

  It is preferable to add the ion catalyst (D) to the polymerization solution simultaneously with the catalyst (C) at the time of preparing the polymerization solution because the polymerization activity is improved.

  In the method for producing a polyphenylene ether of the present invention, the start of aeration of the oxygen-containing gas is not particularly limited. In the preparation of the polymerization solution, any of the phenolic compound (M), the aromatic solvent (A), and the catalyst (C) It is preferable to start venting the oxygen-containing gas after introducing the gas into the reactor.

  The oxygen-containing gas in the present invention is prepared by mixing oxygen and an arbitrary inert gas so that the oxygen concentration is in the range of the present invention, using air, or mixing air and an arbitrary inert gas. Prepare. Any inert gas can be used as long as it has no great influence on the polymerization reaction. Typically nitrogen.

  In the present invention, the oxygen-containing gas is preferably an oxygen-containing gas having an oxygen concentration of 10 to 25% by volume. In the present invention, an oxygen-containing gas obtained by diluting air with a nitrogen-containing gas and adjusting the oxygen concentration to 10 to 20% by volume is more preferable.

  As a method for producing the polyphenylene ether of the present invention, an oxygen-containing gas having an oxygen partial pressure of 0.0147 MPa or more and 0.0883 MPa or less is used, and the absolute pressure in the reactor gas phase is 0.098 MPa or more and less than 0.392 MPa. It is preferable to control.

  The aeration rate of the oxygen-containing gas of the present invention is not particularly limited, but a preferred aeration rate is 0.5 Nl / min to 15 Nl / min with respect to 1 kg of the phenolic compound subjected to the polymerization reaction. This amount is not critical, but if it is too small, it takes a very long time to reach the desired molecular weight and the productivity deteriorates. On the other hand, if the amount is too large, problems such as excessive equipment and an increased amount of exhaust gas occur, which impairs economic efficiency.

  Regarding the temperature of the polymerization solution of the present invention, if the temperature is too low, the reaction is difficult to proceed, and if it is too high, the catalyst may be deactivated, so that the temperature is 0 to 80 ° C., preferably 10 to 60 ° C. Is preferred.

  The method for stopping the polymerization reaction of the present invention is not particularly limited.

    In the present invention, the oxygen-containing gas is stopped from flowing, and the catalyst is deactivated by adding an acid such as hydrochloric acid or acetic acid, or an aqueous chelating agent solution such as ethylenediaminetetraacetic acid (EDTA) and its salt, nitrilotriacetic acid and its salt, to the reaction solution. And a method of stopping the polymerization can be preferably employed.

  In the present invention, the method for treating the diphenoquinone compound produced as a by-product during the polymerization is not limited.

  In the present invention, a method of quinone bond treatment or reduction removal of a diphenoquinone compound produced as a by-product during polymerization can be preferably employed.

  In this invention, the quinone coupling | bonding process which makes a diphenoquinone compound and polyphenylene ether react and processes a diphenoquinone compound can be employ | adopted as a more preferable method.

  In the present invention, after mixing the aqueous solution of the chelating agent with the polymerization solution to stop the polymerization, the temperature of the polymerization solution is set to 60 to 120 ° C., and the quinone bond treatment for maintaining this temperature for about 20 minutes to 150 minutes is extremely performed. preferable.

  In the present invention, the method for separating the polyphenylene ether from the polymerization solution is not limited.

  In the present invention, a method in which the polymerization solution is precipitated in a solvent that does not dissolve polyphenylene ether, such as methanol, and is filtered and dried to separate the polyphenylene ether is preferably employed.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to the following examples.

    A general procedure in Examples and Comparative Examples is described below.

(General procedure)
In Examples and Comparative Examples of the present invention, as a reactor, a sparger for introducing an oxygen-containing gas, a stirring turbine blade, and a sampling discharge valve are provided at the bottom of a cylindrical reactor having an inner diameter of 16 cm. A control valve with a baffle, temperature control device on the side, and a viewing window for confirming the internal state, an inlet for the polymerization solution component at the top of the reactor, and a decanter for condensate separation in the vent gas line A 10 liter jacketed autoclave reactor equipped with a reflux condenser attached was used.

  In Examples and Comparative Examples of the present invention, 2,6-dimethylphenol was used as the phenolic compound (M).

  In the examples and comparative examples of the present invention, toluene was used as the aromatic solvent (A).

  The specified amount of each component of the catalyst (C) used in all Examples and Comparative Examples of the present invention is 1.288 g of cuprous oxide, hydrogen bromide with respect to 1000 g of 2,6-dimethylphenol. It was set as 7.749 g of 47% aqueous solution, 3.104 g of N, N'-di-t-butylethylenediamine, 38.11 g of dimethyl-n-butylamine, and 15.03 g of di-n-butylamine.

  In the examples and comparative examples of the present invention, trioctylmethylammonium chloride was used as the ion catalyst (D).

  In Examples and Comparative Examples of the present invention, an oxygen-containing gas having an oxygen concentration of 9% was used as the oxygen-containing gas to be vented.

  In Examples and Comparative Examples of the present invention, the oxygen-containing gas was vented at a rate of 4 Nl / min · kg with respect to 1 kg of 2,6-dimethylphenol in the polymerization solution.

  In the examples and comparative examples of the present invention, the control valve downstream of the reflux condenser was adjusted to control the absolute pressure in the reactor gas phase to 0.25 MPa.

  In the examples and comparative examples of the present invention, first, a polymerization solution comprising toluene, 2,6-dimethylphenol, catalyst (C), and catalyst (D) in the amounts specified in the examples and comparative examples was prepared. Was introduced into the inlet of the reactor, and the temperature of the polymerization solution was adjusted to 40 ° C. Until the completion of oxidative polymerization, the temperature of the polymerization solution was adjusted to 40 ° C.

  In the examples and comparative examples of the present invention, the polymerization solution was stirred and an oxygen-containing gas was introduced from a sparger to perform oxidative polymerization. The time when the introduction of the oxygen-containing gas was started was taken as the polymerization start time.

  In the examples and comparative examples of the present invention, an aqueous solution of EDTA tetrasodium salt was added from the inlet and stirred for 10 minutes to stop the oxidative polymerization.

  In the examples and comparative examples of the present invention, after the polymerization is stopped, the polymerization solution is adjusted to 80 ° C. for 60 minutes, thereby performing a quinone bond treatment for reacting diphenoquinone and polyphenylene ether, thereby treating diphenoquinone by-produced during the polymerization. did.

  In the examples and comparative examples of the present invention, after separating the aqueous phase from the polymerization solution, the polymerization solution was dropped into an equal volume of methanol to precipitate polyphenylene ether (after quinone treatment).

  In Examples and Comparative Examples of the present invention, a part of the polymerization solution was collected immediately after oxidative polymerization was stopped. Hydroquinone was added thereto and the aqueous phase was separated, and then the polymerization solution was dropped into an equal volume of methanol to precipitate polyphenylene ether (after polymerization was stopped).

  In Examples and Comparative Examples of the present invention, the precipitated polyphenylene ether was further washed three times with an equal volume of methanol, filtered, and vacuum dried at 145 ° C.

  In Examples and Comparative Examples of the present invention, chloroform solutions having a polyphenylene ether concentration of 0.5 g / dl were prepared, and ηsp / c was measured using an Ubbelohde viscometer.

  In Examples and Comparative Examples of the present invention, the obtained polyphenylene ether (after quinone treatment) and other composition components were melt-kneaded using a ZSK-25 type twin screw extruder to obtain a polyphenylene ether composition. .

The composition components used in Examples and Comparative Examples of the present invention are as follows.
Polyphenylene ether (PPE): Polyphenylene ether (after quinone treatment) obtained in each Example and Comparative Example.
High impact polystyrene (HIPS): Using 0.5% toluene solution, the value of ηsp / C measured at 30 ° C. using an Ubbelohde viscometer is 0.73 dl / g, and the rubber concentration is 7.6% by mass. A high impact polystyrene having an average rubber particle size of 1.0 μm as measured by the call counter method.
Hydrogenated block copolymer (HTR): SBS type block comprising a styrene polymer block (S block) having a number average molecular weight of about 23,000 and a butadiene block (B block) having a 1,2-vinyl structure of about 35% Copolymer hydrogenated product.
Condensed phosphate ester flame retardant (CR): manufactured by Daihachi Chemical Co., Ltd., trade name CR-741.
Polyethylene (PE): Low density polyethylene having an MFR of 21 g / 10 min measured at 190 ° C. under a load of 2.16 kg according to ASTM D1238.

  In the examples and comparative examples of the present invention, the cylinder temperature of the twin screw extruder is adjusted to 310 ° C., and the prescribed amounts of the PPE, HIPS, HTR, and PE are dry blended and quantitatively determined from the main supply port. At the same time, a prescribed amount of the heated liquid CR was supplied from the side supply port using a metering pump, and melted and kneaded to obtain a polyphenylene ether composition. The extrusion rate was set at 12 kg / hour.

  In the examples and comparative examples of the present invention, the component structure of the polyphenylene ether composition was PPE: HIPS: HTR: PE: CR = 56: 24: 2: 2: 16.

In Examples and Comparative Examples of the present invention, the following physical properties were measured for the obtained polyphenylene ether compositions.
Notched Izod impact strength: measured according to ASTM D256. The test piece was prepared by adjusting the cylinder temperature to 260 ° C. using an injection molding machine manufactured by Toshiba Machine Co., Ltd.
Chemical resistance: Using a test piece having a thickness of 1/8 according to ASTM D638, the tensile strength was measured, and the tensile strength (TS-Blank) before chemical treatment was measured. After attaching another test piece to the bending jig and adjusting the surface strain to 1%, the specimen was immersed in a mixed solution of isopropanol / cyclohexane (60/40) for 30 minutes, and then the tensile strength was measured for this test piece. The tensile strength (TS-S) after chemical treatment was measured. (TS-S) / (TS-Blank) was defined as the chemical resistance retention rate.
Color tone: The color tone of the test piece was visually determined.

Example 1
A polymerization solution composed of 1.26 kg of 2,6-dimethylphenol, 5.74 kg of toluene, and 250 mg of the specified amount of catalyst (C) and ion catalyst (D) defined in the above general procedure was prepared. Is introduced into the reactor, the control valve downstream of the reflux condenser is adjusted, the liquid temperature is adjusted to 40 ° C., this is introduced into the reactor, the control valve downstream of the reflux condenser is adjusted, and the liquid temperature is adjusted to 40 ° C. After adjusting, 2,6-dimethylphenol was oxidatively polymerized by passing an oxygen-containing gas through a sparger. 150 minutes after the start of oxidative polymerization, an aqueous solution of EDTA tetrasodium salt was mixed with the polymerization solution and stirred for 10 minutes to stop the oxidative polymerization. At this time, a part of the polymerization solution was taken out and polyphenylene ether (after polymerization was stopped) was collected. Thereafter, the diphenoquinone was treated by quinone binding treatment in which the polymerization solution was heated to 80 ° C. and stirred for 60 minutes. This polymerization solution was transferred to a separatory funnel, 1 kg of water was added, and then an organic phase containing polyphenylene ether and an aqueous phase containing a catalyst were separated. At this time, there was no foaming at the interface between the organic phase and the aqueous phase, and separation was easy. Furthermore, after adding 1 kg of water and stirring, the organic phase and the aqueous phase were separated and treated according to the above general procedure to obtain polyphenylene ether (after quinone treatment).
Ηsp / c of polyphenylene ether (after polymerization was stopped) and ηsp / c of polyphenylene ether (after quinone treatment) were measured.
According to the above general procedure, polyphenylene ether (after quinone treatment) and other composition components were melt-kneaded to prepare a polyphenylene ether composition, and Izod impact strength, chemical resistance retention, and color tone were measured.
The measurement results are summarized in Table 1.

(Example 2)
2,6-dimethylphenol; 1.26 kg and toluene; 5.74 kg, a polymerization solution composed of a prescribed amount of catalyst (C) and ion catalyst (D) 150 mg defined in the above general procedure was prepared. In the same procedure as in Example 1, polyphenylene ether (after polymerization was stopped) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Further, in the same manner as in Example 1, a polyphenylene ether composition was prepared, and Izod impact strength, chemical resistance retention rate, and color tone were measured.
The measurement results are summarized in Table 1.

(Comparative Example 1)
A polymerization solution composed of 1.26 kg of 2,6-dimethylphenol and 5.74 kg of toluene and a specified amount of the catalyst (C) defined in the above general procedure was prepared. Polyphenylene ether (after polymerization was stopped) and polyphenylene ether (after quinone treatment) were obtained. After transferring this polymerization solution to a separatory funnel and adding 1 kg of water, when the organic phase and the aqueous phase were separated, the interface between the organic phase and the aqueous phase foamed, making it difficult to separate. About 100 g of the interface portion was discarded. Ηsp / c was measured in the same manner as in Example 1. Further, in the same manner as in Example 1, a polyphenylene ether composition was prepared, and Izod impact strength, chemical resistance retention rate, and color tone were measured.
The measurement results are summarized in Table 2.
The obtained polyphenylene ether composition showed a reddish brown color tone.

(Comparative Example 2)
A polymerization solution composed of 1.26 kg of 2,6-dimethylphenol, 5.74 kg of toluene and 450 mg of the specified amount of catalyst (C) and ion catalyst (D) defined in the above general procedure was prepared and carried out. In the same procedure as in Example 1, polyphenylene ether (after polymerization was stopped) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Further, in the same manner as in Example 1, a polyphenylene ether composition was prepared, and Izod impact strength, chemical resistance retention rate, and color tone were measured.
The measurement results are summarized in Table 2.
The obtained polyphenylene ether composition was inferior in Izod impact strength and chemical resistance retention compared to the polyphenylene ether compositions of the examples.

(Comparative Example 3)
2,6-dimethylphenol; 1.26 kg and toluene; 5.74 kg, a polymerization solution composed of a prescribed amount of catalyst (C) and ion catalyst (D) 50 mg defined in the above general procedure, In the same procedure as in Example 1, polyphenylene ether (after polymerization was terminated) and polyphenylene ether (after quinone treatment) were obtained. After transferring this polymerization solution to a separatory funnel and adding 1 kg of water, when the organic phase and the aqueous phase were separated, the interface between the organic phase and the aqueous phase foamed, making it difficult to separate. About 50 g of the interface portion was discarded. Ηsp / c was measured in the same manner as in Example 1. Further, in the same manner as in Example 1, a polyphenylene ether composition was prepared, and Izod impact strength, chemical resistance retention rate, and color tone were measured.
The measurement results are summarized in Table 2.
The resulting polyphenylene ether composition exhibited a light brown color tone.

(Example 3)
Polymerization solution composed of 1.47 kg of 2,6-dimethylphenol, 5.53 kg of toluene, 1.17 times the specified amount defined in the above general procedure, and 250 mg of ion catalyst (D) In the same manner as in Example 1, polyphenylene ether (after polymerization was terminated) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Moreover, the polyphenylene ether composition was prepared similarly to Example 1, and Izod impact strength, chemical-resistance retention, and color tone were measured.
The measurement results are summarized in Table 1.

Example 4
Polymerization solution composed of 0.77 kg of 2,6-dimethylphenol, 6.23 kg of toluene, and 0.61 times the specified amount defined in the above general procedure (C) and 100 mg of ion catalyst (D) In the same manner as in Example 1, polyphenylene ether (after polymerization was terminated) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Moreover, the polyphenylene ether composition was prepared similarly to Example 1, and Izod impact strength, chemical-resistance retention, and color tone were measured.
The measurement results are summarized in Table 1.

(Comparative Example 4)
Polymerization solution composed of 1.47 kg of 2,6-dimethylphenol, 5.53 kg of toluene, 1.17 times the specified amount defined in the above general procedure (C) and 400 mg of ion catalyst (D) In the same manner as in Example 1, polyphenylene ether (after polymerization was terminated) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Moreover, the polyphenylene ether composition was prepared similarly to Example 1, and Izod impact strength, chemical-resistance retention, and color tone were measured.
The measurement results are summarized in Table 2.
The obtained polyphenylene ether composition was inferior in Izod impact strength and chemical resistance retention compared to the polyphenylene ether compositions of the examples.

(Comparative Example 5)
Polymerization solution composed of 0.77 kg of 2,6-dimethylphenol, 6.23 kg of toluene, and 0.61 times the specified amount defined in the above general procedure (C) and 500 mg of ion catalyst (D) In the same manner as in Example 1, polyphenylene ether (after polymerization was terminated) and polyphenylene ether (after quinone treatment) were obtained. When the organic phase and the aqueous phase were separated, there was no foaming at the interface, and the separation was easy. Ηsp / c was measured in the same manner as in Example 1. Moreover, the polyphenylene ether composition was prepared similarly to Example 1, and Izod impact strength, chemical-resistance retention, and color tone were measured.
The measurement results are summarized in Table 2.
The obtained polyphenylene ether composition was inferior in Izod impact strength and chemical resistance retention compared to the polyphenylene ether compositions of the examples.

(Comparative Example 6)
A polymerization solution composed of 1.47 kg of 2,6-dimethylphenol, 5.53 kg of toluene, and 0.61 times the catalyst (C) as defined in the above general procedure was prepared, and this was added to the reactor. In the same manner as in Example 1, polyphenylene ether (after polymerization was stopped) was obtained. After treating diphenoquinone, 300 mg of trioctylmethylammonium chloride (ion catalyst (D) was added to the polymerization solution, and polyphenylene ether (after quinone treatment) was obtained in the same procedure as in Example 1. Organic phase and aqueous phase When separating, there was no bubbling at the interface, and it was easily separated.
Ηsp / c of polyphenylene ether (after polymerization was stopped) and ηsp / c of polyphenylene ether (after quinone treatment) were measured.
According to the above general procedure, polyphenylene ether (after quinone treatment) and other composition components were melt-kneaded to prepare a polyphenylene ether composition, and Izod impact strength, chemical resistance retention, and color tone were measured.
The measurement results are summarized in Table 2.
The obtained polyphenylene ether composition was inferior in Izod impact strength and chemical resistance retention compared to the polyphenylene ether compositions of the examples.

  The present invention makes it possible to completely and efficiently separate a metal salt that is a polymerization catalyst component from polyphenylene ether in oxidative polymerization of a phenolic compound, and production efficiency and yield are improved compared to conventional methods. improves.

Claims (6)

It is composed of 10 to 25 parts by mass of the phenolic compound (M) and 75 to 90 parts by mass of the aromatic solvent (A), and 0.1 to 10 parts by mass of the catalyst (C) containing a metal salt as a component. A polymerization solution to be prepared,
The phenolic compound (M) is subjected to oxidative polymerization by passing an oxygen-containing gas through the polymerization solution,
Mixing the polymerization solution with an aqueous chelating agent solution to stop the polymerization,
The diphenoquinone compound produced as a by-product to a quinone binding processing,
Thereafter, a method for producing a polyphenylene ether comprising separating the aqueous phase by liquid-liquid separation to obtain polyphenylene ether,
Following formula (4)

(Wherein R ₁ , R ₂ , R ₃ , and R ₄ are each independently a linear or branched alkyl group having 1 to 22 carbon atoms, and X is a paired anion.)
The method as described above, wherein 0.001 to 0.004 parts by weight of the tetraalkylammonium salt compound (D) represented by the formula (1) is added to the polymerization solution from the time when the polymerization solution is prepared until the polymerization is stopped. The method according to claim 1, wherein the tetraalkylammonium salt compound (D) is added to the polymerization solution when the polymerization solution is prepared. The method according to claim 1 or 2, wherein 0.001 to 0.003 parts by mass of the tetraalkylammonium salt compound (D) is added. Tetraalkyl ammonium salt compound (D) is trioctylmethylammonium chloride method according to any one of claims 1-3. The method according to any one of claims 1 to 4 , wherein the oxygen-containing gas is an oxygen-containing gas having an oxygen concentration of 10 to 25% by volume. Oxygen partial pressure using 0.0883MPa following oxygen-containing gas or 0.0147MPa, and controls the absolute pressure in the reactor vapor phase to less than 0.098 MPa 0.392 MPa, more of claims 1 to 5 The method according to claim 1.