KR101888062B1 - Polyketone solution - Google Patents

Abstract

The present invention relates to polyketone copolymers wherein at least 90% by weight of the copolymer of carbon monoxide and one or more olefins have carbon monoxide units and olefin units; And a solvent which is an aqueous solution containing a metal salt of calcium chloride / zinc chloride / lithium chloride, and a polyketone fiber produced from the polyketone solution.

Description

Polyketone solution

The present invention relates to polyketone copolymers wherein at least 90% by weight of the copolymer of carbon monoxide and one or more olefins have carbon monoxide units and olefin units; And a solvent which is an aqueous solution containing a metal salt of calcium chloride / zinc chloride / lithium chloride, and a polyketone fiber made from the polyketone solution.

It is a known fact that olefins such as carbon monoxide and ethylene and propylene are polymerized by using a transition metal complex such as palladium or nickel as a catalyst to obtain a polyketone in which carbon monoxide and olefin alternate.

Polyketone is preferably thermally crosslinked when it melts, so it is preferable to use wet spinning in the case of fiberization. Particularly, polyketone (poly (1-oxotrimethylene)) fibers having substantially excellent physical properties and substantially containing only carbon monoxide and ethylene are apt to undergo thermal crosslinking. Thus, the fibers are very difficult to produce by melt spinning and can only be obtained substantially by wet spinning.

When the polyketone is wet-spun, examples of the solvent to be used include hexafluoroisopropanol and an organic solvent such as m-cresol, phenolic solvent such as resorcinol / water, and resorcinol / carbonate 2-112413, 4-228613, and 7-508317). However, the fibers obtained by wet spinning using such a solvent tend to be easily dispersed, and fatigue resistance and workability are insufficient for use as an industrial material. In addition, such a solvent has high toxicity and flammability, and there is a problem that a large measure against the toxicity and flammability of a solvent is required to make a spinning facility of an industrial scale.

Further, a method of radiating using a polyketone solution prepared by dissolving a polyketone in an aqueous solution containing zinc chloride at a specific concentration, zinc halide such as zinc bromide, or lithium salt such as lithium chloride, lithium iodide and lithium thiocyanate (WO99 / 18143, USP5955019). These aqueous solutions are relatively inexpensive, have low toxicity and are non-flammable and are excellent as polyketone solvents.

Zinc chloride used as a solvent for polyketones contains a large amount of ammonium salts such as ammonium chloride in the case of industrial low-cost zinc chloride. When the content of the ammonium salt is large, problems such as coloration, three-dimensional crosslinking and decomposition of the polyketone solution tend to occur at the time of dissolution. Also, the ultimate strength of the polyketone fibers is lowered, and the radioactivity and extensibility of the fibers such as single yarns increase during the manufacturing process. However, the patents disclosed in the existing literature do not disclose a suitable content of the ammonium component which may cause such property deterioration.

Korea Patent No. 1205940 Korean Patent No. 607086

In order to solve the above problems, the present invention provides a polyketone solution and a polyketone fiber produced by using a polyketone copolymer composed of carbon monoxide and at least one olefinically unsaturated hydrocarbon, and a process for producing the same do.

In order to attain the above object, the present invention provides a poly (methyl methacrylate) having a y / x of 0 to 0.1 and an intrinsic viscosity of 5 to 7 dl / g, which is composed of the repeating units represented by the following general formulas (1) and A ketone copolymer; And a solvent which is an aqueous solution containing a metal salt of calcium chloride / zinc chloride / lithium chloride, wherein the content of ammonium chloride in the zinc chloride is less than 0.5% by weight.

- [- CH2CH2-CO-] x- (1)

- [- CH2 --CH (CH3) - CO--] y- (2)

(x and y are mole% of each of the general formulas (1) and (2) in the polymer)

Specifically, the zinc chloride is 20 to 30% by weight, the yellowness index (YI) of the polyketone solution is 0.5 to 2.5, and the rate of viscosity increase at 80 DEG C is 0.1 to 1.0 poise / min. Ketone solution.

Further, the present invention is characterized in that the component of the catalyst composition used in the polymerization of the polyketone copolymer is (cyclohexane-1,1-diylbis (methylene)) bis (bis (2-methoxyphenyl) .

The polyketone solution is extruded through a spinning nozzle to obtain an unstretched fiber, followed by treatment with a heat stabilizer, followed by drying in a hot-roll type, further treating the dried unstretched fiber with a heat stabilizer, Lt; / RTI > fibers.

The present invention relates to a process for producing a polyketone solution from carbon monoxide, at least one olefin-based copolymer, which is an aqueous solution containing a polyketone copolymer and a metal salt of calcium chloride / zinc chloride / lithium chloride, And a crosslinking reaction is suppressed due to a low viscosity increase rate, thereby increasing the solution crystallinity and enabling stable spinning, and a polyketone fiber prepared using the same.

1 is a view schematically showing the role of a heat-resistant stabilizer according to the prior art.
2 is a schematic view of a conventional hot air drying type dryer.
3 is a schematic view of a hot roll drying method according to the present invention.
Fig. 4 is a cross-sectional view of the dry irradiation according to the conventional hot air drying method.
Fig. 5 is a cross-section view of a dry-type drying method according to the present invention.

Hereinafter, the present invention will be described.

The present invention relates to a polyketone copolymer comprising repeating units represented by the following general formulas (1) and (2), having y / x of 0 to 0.1 and an intrinsic viscosity of 5 to 7 dl / g; And a solvent which is an aqueous solution containing a metal salt of calcium chloride / zinc chloride / lithium chloride, wherein the content of ammonium chloride in the zinc chloride is less than 0.5% by weight.

- [- CH2CH2-CO-] x- (1)

- [- CH2 --CH (CH3) - CO--] y- (2)

(x and y are mole% of each of the general formulas (1) and (2) in the polymer)

Specifically, the zinc chloride is 20 to 30% by weight, the yellowness index (YI) of the polyketone solution is 0.5 to 2.5, and the rate of viscosity increase at 80 DEG C is 0.1 to 1.0 poise / min. Ketone solution.

Further, the present invention is characterized in that the component of the catalyst composition used in the polymerization of the polyketone copolymer is (cyclohexane-1,1-diylbis (methylene)) bis (bis (2-methoxyphenyl) .

The polyketone solution is extruded through a spinning nozzle to obtain an unstretched fiber, followed by treatment with a heat stabilizer, followed by drying in a hot-roll type, further treating the dried unstretched fiber with a heat stabilizer, Lt; / RTI > fibers.

Hereinafter, the polymerization method of the polyketone used in the present invention will be described in detail.

One or more olefinically unsaturated compounds (simply referred to as " A "), wherein the monomer units are alternating, and thus the polymer is composed of units of the formula - (CO) -A'- wherein A 'represents the monomer units derived from the applied monomer A ) And a high molecular weight linear polymer of carbon monoxide can be prepared by contacting monomers with a solution of a palladium-containing catalyst composition in a dilute solution in which the polymer does not dissolve or actually dissolve. During the polymerization process, the polymer is obtained in the form of a suspension in a diluent. The polymer preparation is carried out primarily batchwise.

The batchwise preparation of the polymer is typically carried out by introducing the catalyst into a reactor containing the diluent and the monomer and having the desired temperature and pressure. As the polymerization proceeds, the pressure drops, the concentration of the polymer in the diluent increases, and the viscosity of the suspension increases. The polymerization is continued until the viscosity of the suspension reaches a high value, for example, to the point where difficulties associated with heat removal occur. During batch polymer preparation, monomers can be added to the reactor during polymerization, if desired, to maintain the temperature as well as the pressure constant.

In the present invention, not only methanol, dichloromethane or nitromethane, which has been conventionally used for producing polyketones, but also mixed solvents comprising acetic acid and water, ethanol, propanol, and isopropanol can be used as the liquid medium. Particularly, when a mixed solvent of acetic acid and water is used as a liquid medium in the production of polyketone, the catalyst activity can be improved while reducing the production cost of polyketone. Further, since the use of methanol or a dichloromethane solvent forms a mechanism for causing a stopping reaction during the polymerization step, the use of acetic acid or water other than methanol or dichloromethane in the solvent does not have an effect of stopping the catalytic activity stochastically, It plays a big role in improvement.

When a mixed solvent of acetic acid and water is used as a liquid medium, when the concentration of water is less than 10% by volume, the effect of the catalyst is less affected. When the concentration of water is 10% by volume or more, the catalytic activity increases sharply. On the other hand, when the concentration of water exceeds 30% by volume, the catalytic activity tends to decrease. In the present invention, it is preferable to use a mixed solvent comprising 70 to 90% by volume of acetic acid and 30 to 10% by volume of water as the liquid medium.

In the present invention, the organometallic complex catalyst comprises (a) a Group 9, Group 10 or Group 11 transition metal compound of the Periodic Table of the Elements (IUPAC Inorganic Chemical Nomenclature Revised Edition, 1989), (b) And (c) an anion of an acid having a pKa of 4 or less.

Examples of the Group 9 transition metal compound in the ninth, tenth, or eleventh group transition metal compound (a) include complexes of cobalt or ruthenium, carbonates, phosphates, carbamates, and sulfonates, Specific examples thereof include cobalt acetate, cobalt acetylacetate, ruthenium acetate, ruthenium trifluoroacetate, ruthenium acetylacetate and ruthenium trifluoromethanesulfonate.

Examples of the Group 10 transition metal compounds include complexes of nickel or palladium, carbonates, phosphates, carbamates, and sulfonates. Specific examples thereof include nickel acetate, nickel acetyl acetate, palladium acetate, palladium trifluoroacetate , Palladium acetylacetate, palladium chloride, bis (N, N-diethylcarbamate) bis (diethylamine) palladium and palladium sulfate.

Examples of the Group 11 transition metal compound include a complex of copper and silver, a carbonate, a phosphate, a carbamate, and a sulfonate, and specific examples thereof include copper acetate, copper trifluoroacetate, copper acetylacetate, Examples of the trifluoroacetic acid include silver acetyl acetate, trifluoromethanesulfonic acid and the like.

Of these, transition metal compounds (a), which are inexpensive and economically preferable, are nickel and copper compounds, and preferable transition metal compounds (a) in terms of yield and molecular weight of polyketones are palladium compounds, It is most preferable to use palladium acetate.

Examples of ligands (b) having a Group 15 atom include 2,2-bipyridyl, 4,4-dimethyl-2,2-bipyridyl, 2,2- (Diphenylphosphino) propane, 1,4-bis (diphenylphosphino) butane, 1,3-bis (diphenylphosphino) Bis [di (2-methylphenyl) phosphino] propane, 1,3-bis [di (2-isopropyl) Bis (diphenylphosphino) cyclohexane, 1,2-bis (diphenylphosphino) phosphine, ) Benzene, 1,2-bis [(diphenylphosphino) methyl] benzene, 1,2-bis [[di (2-methoxyphenyl) Bis (diphenylphosphino) ferrocene, 2-hydroxy-1,3-bis [di (2-methoxyphenyl) ) Phosphino] propane, 2,2-dimethyl-1,3-bis [di (2-methoxyphenyl) Phosphino] propane and phosphorus ligands such as (cyclohexane-1,1-diylbis (methylene)) bis (bis (2-methoxyphenyl) phosphine.

Among these ligands, preferred ligands (b) having a Group 15 element are phosphorus ligands having an atom of Group 15, and particularly preferred ligands in terms of yield of polyketone are 1,3-bis [di (2- Methoxyphenyl) phosphino] propane and 1,2-bis [[di (2-methoxyphenyl) phosphino] methyl] benzene, Di (2-methoxyphenyl) phosphino] propane, and it is safe in that it does not require an organic solvent. Soluble sodium salts such as 1,3-bis [di (2-methoxy-4-sulfonic acid sodium-phenyl) phosphino] propane, 1,2- ] Methyl] benzene, and 1,3-bis (diphenylphosphino) propane and 1,4-bis (diphenylphosphino) butane are preferred for ease of synthesis and availability in large quantities and economically.

The ligand (b) having a group 15 atom preferred in the present invention, which focuses on the intrinsic viscosity and catalytic activity of the polyketone, is 1,3-bis- [di (2-methoxyphenyl) Bis (bis (methylene)) bis (bis (2-methoxyphenyl) phosphine), and more preferably 1,3-bis Bis (methylene)) bis (bis (2-methoxyphenyl) phosphino] propane or ((2,2-dimethyl-1,3-dioxane-5,5- ) Phosphine) is better.

Bis (bis (2-methoxyphenyl) phosphine) bis ((2,2-dimethyl-1,3-dioxane-5,5-diyl) bis Activity equivalent to that of 3,3-bis- [bis- (2-methoxyphenyl) phosphanylmethyl] -1,5-dioxa-spiro [5,5] undecane, which is known to exhibit the highest activity among polymerization catalysts The structure is simpler and has a lower molecular weight. As a result, the present invention has been able to provide a novel polyketone polymerization catalyst having the highest activity as a polyketone polymerization catalyst of the present invention, while further reducing its manufacturing cost and cost. A method for producing a ligand for a polyketone polymerization catalyst is as follows. ((2,2-dimethyl) -2,3-dioxolane was obtained by using bis (2-methoxyphenyl) phosphine, 5,5-bis (bromomethyl) Bis (bis (methylene)) bis (bis (2-methoxyphenyl) phosphine) is obtained by reacting a bis (methylene) . The process for preparing a ligand for a polyketone polymerization catalyst according to the present invention is a process for producing a ligand for a polyketone polymerization catalyst which comprises reacting 3,3-bis- [bis- (2-methoxyphenyl) phosphanylmethyl] -1,5-dioxa-spiro [5,5] ((2,2-dimethyl-1,3-dioxane-5,5-diyl) bis (methylene)) bis (bis (2- Methoxyphenyl) phosphine) can be commercially synthesized in a large amount.

It is also preferable to use bis (bis (2-methoxyphenyl) phosphine as the ligand (cyclohexane-1,1-diylbis (methylene)) bis Respectively.

In a preferred embodiment, the process for preparing a ligand for a polyketone polymerization catalyst of the present invention comprises: (a) introducing bis (2-methoxyphenyl) phosphine and dimethylsulfoxide (DMSO) into a reaction vessel under nitrogen atmosphere, Adding sodium and stirring; (b) adding 5,5-bis (bromomethyl) -2,2-dimethyl-1,3-dioxane and dimethylsulfoxide to the resulting mixture, followed by stirring and reacting; (c) adding methanol and stirring after completion of the reaction, (d) adding toluene and water, separating the layer, washing the oil layer with water, drying with anhydrous sodium sulfate, filtering under reduced pressure, and concentrating under reduced pressure; And (e) the residue was recrystallized from methanol to obtain ((2,2-dimethyl-1,3-dioxane-5,5- diyl) bis (methylene)) bis (bis (2- methoxyphenyl) And then performing a step of acquiring

The amount of the Group 9, Group 10 or Group 11 transition metal compound (a) varies depending on the kind of the ethylenically unsaturated compound to be selected and other polymerization conditions. But is usually 0.01 to 100 mmol, preferably 0.01 to 10 mmol, per liter of the reaction volume of the reaction zone. The capacity of the reaction zone means the liquid phase capacity of the reactor.

Examples of the anion (c) of the acid having a pKa of 4 or less include an anion of an organic acid having a pKa of 4 or less, such as trifluoroacetic acid, trifluoromethanesulfonic acid, p-toluenesulfonic acid, or m-toluenesulfonic acid; Anions of inorganic acids having a pKa of 4 or less such as perchloric acid, sulfuric acid, nitric acid, phosphoric acid, heteropoly acid, tetrafluoroboric acid, hexafluorophosphoric acid, and fluorosilicic acid; And anions of boron compounds such as trispentafluorophenylborane, trisphenylcarbenium tetrakis (pentafluorophenyl) borate, and N, N-dimethylarinium tetrakis (pentafluorophenyl) borate.

In particular, the anion (c) of the acid having a pKa of 4 or less, which is preferred in the present invention, is p-toluenesulfonic acid, which has not only high catalytic activity when used together with a mixed solvent of acetic acid and water as a liquid medium, It becomes possible to produce a polyketone having a suitable high intrinsic viscosity.

The molar ratio of (a) the ninth, tenth or eleventh group transition metal compound and (b) the ligand having an element of Group 15 element is 0.1 to 20 moles of the Group 15 element of the ligand per 1 mole of the palladium element, Is preferably added in a proportion of 0.1 to 10 moles, more preferably 0.1 to 5 moles. When the ligand is added in an amount of less than 0.1 mole based on the palladium element, the binding force between the ligand and the transition metal decreases, accelerating the desorption of the palladium during the reaction, and causing the reaction to terminate quickly. When the ligand exceeds 20 moles When added, the ligand is shielded from the polymerization reaction by the organometallic complex catalyst, so that the reaction rate is remarkably lowered.

The molar ratio of (a) the anion of the ninth, tenth or eleventh group transition metal compound and (c) the anion of the acid having a pKa of 4 or less is 0.1 to 20 mol, preferably 0.1 to 10 mol, Mol, and more preferably 0.1 to 5 mol. When the acid is added in an amount of less than 0.1 mol based on the palladium element, the effect of improving the intrinsic viscosity of the polyketone is unsatisfactory. If the acid is added in an amount exceeding 20 mol based on the palladium element, the catalytic activity for producing the polyketone tends to be rather reduced. not.

In the present invention, the reaction gas to be reacted with the catalyst for producing polyketone is preferably a mixture of carbon monoxide and an ethylenically unsaturated compound.

Examples of the ethylenically unsaturated compound copolymerized with carbon monoxide in the present invention include ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, - C2 to C20 alpha-olefins including tetradecene, 1-hexadecene, vinylcyclohexane; Styrene, C2-C20 alkenyl aromatic compounds including? -Methylstyrene; But are not limited to, cyclopentene, norbornene, 5-methylnorbornene, 5-phenylnorbornene, tetracyclododecene, tricyclododecene, tricyclo undecene, pentacyclopentadecene, pentacyclohexadecene, C4 to C40 cyclic olefins including cyclododecene; C2 to C10 halogenated vinyls containing vinyl chloride; Ethyl acrylate, methyl acrylate, and mixtures of two or more selected from among C3 to C30 acrylic esters. These ethylenically unsaturated compounds are used singly or as a mixture of plural kinds. Of these, preferred ethylenically unsaturated compounds are? -Olefins, more preferably? -Olefins having 2 to 4 carbon atoms, and most preferably ethylene.

In the production of polyketones, the charging ratio of the carbon monoxide and the ethylenic unsaturated compound is generally 1: 1. In the present invention, the charging ratio of the carbon monoxide and the ethylenic unsaturated compound is adjusted to a molar ratio of 1:10 to 10: 1 . As in the present invention, when an ethylenically unsaturated compound and carbon monoxide are mixed in an appropriate ratio, they are effective also in terms of catalytic activity, and the intrinsic viscosity improvement effect of the produced polyketone can be simultaneously achieved. When carbon monoxide or ethylene is added in an amount of less than 5 mol% or more than 95 mol%, the reactivity is poor and the physical properties of the produced polyketone may be deteriorated.

On the other hand, the polyketone copolymer used as the fiber may be composed of ethylene, propylene and carbon monoxide. As the molar ratio of propylene becomes larger, it is not suitable for ship ropes, and the molar ratio of ethylene to propylene is preferably 100: 0 to 90:10 Do.

That is, y / x of the polyketone copolymer represented by the following general formulas (1) and (2) is preferably 0 to 0.1.

- [- CH2CH2-CO-] x- (1)

- [- CH2 --CH (CH3) - CO--] y- (2)

(x and y are mole% of each of the general formulas (1) and (2) in the polymer)

Here, when y / x is more than 0.1, it is difficult to use as a fiber and the workability also deteriorates.

On the other hand, the molecular weight distribution of the polyketone is preferably in the range of 1.5 to 4.0, and if it is less than 1.5, the polymerization yield is lowered. In order to control the molecular weight distribution, it is possible to adjust proportionally according to the amount of the palladium catalyst and the polymerization temperature. That is, when the amount of the palladium catalyst is increased or when the polymerization temperature is 100 or more, the molecular weight distribution becomes large. The molecular weight distribution of the most preferred polyketones is 2.5 to 3.5.

Particularly preferred are polyketone polymers having a number average molecular weight of from 100 to 200,000, especially from 20,000 to 90,000, as measured by gel permeation chromatography. The physical properties of the polymer are determined according to the molecular weight, depending on whether the polymer is a copolymer or a terpolymer and, in the case of a terpolymer, the properties of the second hydrocarbon part. The melting point of the total of the polymers used in the present invention is 175 to 300 占 폚, and is generally 210 to 270 占 폚. The intrinsic viscosity (LVN) of the polymer measured by HFIP (Hexafluoroisopropylalcohol) at 60 DEG C using a standard tubular viscosity measuring apparatus is 0.5 dl / g to 10 dl / g, and preferably 5.0 dl / g to 7.0 dl / g . At this time, when the intrinsic viscosity of the polyketone polymer is less than 5.0, the mechanical strength is lowered in production of the fiber, and when it exceeds 7.0, the workability is lowered.

The production method of the polyketone solution of the present invention will be described.

As the polyketone copolymer, a polyketone copolymer which has undergone the above polymerization process is used. On the other hand, as the solvent for dissolving the polyketone, it is preferable to use an aqueous solution containing at least one metal salt selected from the group consisting of zinc salts, calcium salts, lithium salts, thiocyanates and iron salts. Specific examples of the zinc salt include zinc bromide, zinc chloride and zinc iodide. Examples of the calcium salt include calcium bromide, calcium chloride and calcium iodide. Examples of the lithium salt include lithium bromide, lithium chloride, lithium iodide . Examples of the iron salts include iron bromide and iron iodide. Among these metal salts, it is particularly preferable to use at least one selected from the group consisting of zinc bromide, calcium bromide, lithium bromide and iron bromide in terms of the solubility of the raw material polyketone and the homogeneity of the polyketone solution.

The concentration of the metal salt in the metal salt aqueous solution of the present invention is preferably 30 to 80% by weight. If the concentration of the metal salt is less than 30% by weight, the solubility is lowered. If the concentration of the metal salt is 80 or more, the cost for concentration increases, which is disadvantageous in terms of economy. As the solvent for dissolving the metal salt, water, methanol, ethanol and the like can be used. In particular, water is used in the present invention because it is economical and advantageous in solvent recovery.

As a key technical point in the present invention, an aqueous solution containing zinc chloride is preferable in order to obtain polyketone fibers which inhibit crosslinking of polyketones in raw materials and have excellent radioactivity and elongation, and it is preferable to use calcium chloride / zinc chloride / .

The weight of zinc chloride in the aqueous solution is preferably 20 to 30% by weight. If the content is less than 20% by weight, the spinnability of the fibers is deteriorated. If the content is more than 30% by weight, the extensibility of the fibers is deteriorated.

The zinc chloride contains a large amount of ammonium salts such as ammonium chloride. In the present invention, calcium chloride / zinc chloride / lithium chloride is dissolved in water at a ratio of 30:22:10 of 62%, and the zinc chloride is 22% It is preferable that the content of ammonium chloride in the raw material is less than 0.5% by weight. When the content of ammonium chloride is 0.5% or more, the yellowness degree of the polyketone solution increases and the viscosity increasing rate is also increased, thereby accelerating the crosslinking reaction, thereby lowering the radioactivity and extensibility of the polyketone fiber to be finally produced.

In the case of the polyketone solution characterized in that the content of ammonium chloride prepared according to the present invention is less than 0.5%, the yellowness of the solution is lowered, the rate of rise in viscosity at 80 ° C is lowered, It is possible to stably radiate to polyketone fibers.

The production method of the polyketone solution is not particularly limited, but an example of a preferable production method will be described below.

The metal salt aqueous solution maintained at 20 to 40 캜 is defoamed at a temperature of 200 torr or less, the polyketone polymer is heated to a temperature of 30 to 100 캜 under a vacuum of 200 torr or less, and stirred for 0.5 to 10 hours to prepare a sufficiently dissolved homogeneous dope .

In the present invention, the polyketone polymer may be mixed with other polymer materials or additives. Examples of the polymer material include polyvinyl alcohol, carboxymethyl polyketone, and polyethylene glycol. Examples of additives include viscosity improvers, titanium dioxide, silica dioxide, carbon, and ammonium chloride.

Hereinafter, a method of producing a polyketone fiber including spinning, washing, drying and stretching the homogeneous polyketone solution of the present invention will be described in more detail. However, the polyketone fibers claimed in the present invention are not limited by the following process.

First, the solution extruded from the spinning nozzle passes through an air gap in a vertical direction and solidifies in a coagulating bath. At this time, the air gap is radiated within a range of about 1 to 300 mm in order to obtain a dense and uniform fiber and to provide a smooth cooling effect.

Thereafter, the filament passing through the coagulation bath passes through the water bath. At this time, the temperature of the coagulation bath and the water bath is maintained at about 0 to 80 ° C to prevent the deterioration of the physical properties due to the formation of pores in the fiber structure due to the rapid desolvation

The fibers having passed through the water-washing tank were subjected to acid washing in an aqueous solution containing the acid, passed through a second water-washing bath to remove the acid, passed through a dryer, and then emulsified in an emulsion- do.

In addition, in order to improve the flatness and improve the property of the housing, it passed the interlace nozzle. At this time, the air pressure was supplied at 0.5 to 4.0 kg / cm 2, and the number of entanglement per filament was 2 to 40.

Thereafter, the filament yarn passed through the interlace nozzle is dried while passing through the drying device. In this case, the drying temperature and the drying method have a great influence on the post-processing and physical properties of the filament.

The filament that has passed through the drying device is finally wound in a winder through a secondary emulsion treatment device.

Further, the stretching process in the polyketone fibers of the present invention is very important for improvement of high strength and water resistance. In the drawing method, hot air heating method and roller heating method are used, but since the filament is in contact with the roller surface in the roller heating method, the fiber surface is likely to be damaged, so that hot air heating method is more effective in manufacturing high strength polyketone fiber. However, the inventors of the present invention have found that by applying a heat-resistant stabilizer while applying a roller heating method, especially a hot-roll drying method, and performing a stretching process of 1.0 to 2.0 times, preferably 1.2 to 1.6 times, High strength multifilament could be obtained. At this time, the strength of the fiber at drawing of less than 1.0 times is lowered, and the workability at the time of drawing of more than 2.0 times is lowered.

That is, the present invention is characterized in that the stretching process is performed by using a method of passing through a heating chamber at 230 ° C to 300 ° C.

On the other hand, as the solvent for dissolving the polyketone, it is preferable to use an aqueous solution containing at least one metal salt selected from the group consisting of zinc salts, calcium salts, lithium salts, thiocyanates and iron salts. Specific examples of the zinc salt include zinc bromide, zinc chloride and zinc iodide. Examples of the calcium salt include calcium bromide, calcium chloride and calcium iodide. Examples of the lithium salt include lithium bromide, lithium chloride, lithium iodide . Examples of the iron salts include iron bromide and iron iodide. Among these metal salts, it is particularly preferable to use at least one member selected from the group consisting of zinc chloride, calcium chloride, lithium chloride and iron chloride in terms of solubility of the raw material polyketone and homogeneity of the polyketone solution. In the present invention, it is preferable that three kinds of metal salts of calcium chloride / zinc chloride / lithium chloride are used together, and the ratio is preferably 62% by weight in a ratio of 30:22:10.

The concentration of the metal salt in the metal salt aqueous solution of the present invention is preferably 30 to 80 wt%. If the concentration of the metal salt is less than 30% by weight, the solubility decreases. If the concentration of the metal salt is more than 80% by weight, the cost for concentration increases, which is disadvantageous in terms of economy. As the solvent for dissolving the metal salt, water, methanol, ethanol and the like can be used. In particular, water is used in the present invention because it is economical and advantageous in solvent recovery.

In order to obtain polyketone fibers having high strength and high fatigue resistance and dimensional stability as core technical features of the present invention, in order to obtain polyketone fibers having excellent radioactivity and extensibility to inhibit crosslinking of polyketones in raw materials, zinc chloride , And it is preferable to use calcium chloride / zinc chloride / lithium chloride together.

The weight of zinc chloride in the aqueous solution is preferably 20 to 30% by weight. If the content is less than 20% by weight, the spinnability of the fibers is deteriorated. If the content is more than 30% by weight, the extensibility of the fibers is deteriorated.

In the present invention, calcium chloride / zinc chloride / lithium chloride is dissolved at a concentration of 62 wt% in a ratio of 30:22:10, and the zinc chloride is contained in an amount of 22 wt% It is preferable that the content of ammonium chloride in the raw material is less than 0.5% by weight. When the content of ammonium chloride is 0.5% by weight or more, the yellowness degree of the polyketone solution increases and the rate of viscosity increase also increases, thereby accelerating the crosslinking reaction, thereby lowering the radioactivity and extensibility of the polyketone fiber finally prepared. More preferably, the content of ammonium chloride is 0.001 to 0.1% by weight.

In the case of the polyketone solution having an ammonium chloride content of less than 0.5% by weight, the yellowness of the solution is lowered, the rate of increase in viscosity at 80 ° C is lowered, and the crystallization degree It becomes possible to stably radiate to polyketone fibers.

The production method of the polyketone solution is not particularly limited, but an example of a preferable production method will be described below.

The metal salt aqueous solution maintained at 20 to 40 캜 is defoamed at a pressure of 200 torr or less, the polyketone polymer is heated to 60 to 100 캜 under a vacuum of 200 torr or less, and stirred for 0.5 to 10 hours to prepare a sufficiently dissolved homogeneous dope .

In the present invention, the polyketone polymer may be mixed with other polymer materials or additives. Examples of the polymer material include polyvinyl alcohol, carboxymethyl polyketone, and polyethylene glycol. Examples of additives include viscosity improvers, titanium dioxide, silica dioxide, carbon, and ammonium chloride.

Hereinafter, a method of producing a polyketone fiber including spinning, washing, drying and stretching the homogeneous polyketone solution of the present invention will be described in more detail. However, the polyketone fibers claimed in the present invention are not limited by the following process.

The spinning process of the method according to the present invention will be described in more detail. An orifice having a diameter of 100 to 500 μm and a length of 100 to 1500 μm, wherein the ratio of the diameter to the length (L / D) is 1 to 3 to 8 times, The spinning stock solution is extruded and spun through a spinning nozzle containing a plurality of orifices having an interval of 1.0 to 5.0 mm to allow the fiber spinning solution to pass through the air layer to reach the coagulation bath and then solidify to obtain multifilaments .

The shape of the spinning nozzle used is usually circular, and the nozzle diameter is 50 to 200 mm, more preferably 80 to 130 mm. When the nozzle diameter is less than 50 mm, the distance between the orifices is too short, so that the adhesion may occur before the discharged solution solidifies. If the nozzle diameter is too large, peripheral devices such as spinning packs and nozzles become large, If the diameter of the nozzle orifice is less than 100 탆, a large number of yarn breaks occur at the time of spinning, which adversely affects radioactivity. If the diameter exceeds 500 탆, the coagulation speed of the solution in the spinning coagulation bath is slow, And water washing becomes difficult.

Considering the orifice spacing for uniform cooling of the solution, the number of orifices should be 100 to 2,200, more preferably 300 to 1,400.

If the number of orifices is less than 100, the fineness of each filament becomes thick and the solvent can not sufficiently escape within a short time, so that the coagulation and flushing can not be completely performed. If the number of orifices is more than 2,200, adjacent filaments are likely to be formed in close contact with each other in the air layer section. As a result, the stability of each filament after spinning is lowered, resulting in deterioration of physical properties and a problem in subsequent twisting and heat treatment.

When the fiber stock solution passing through the spinning nozzle coagulates in the upper coagulating solution, the larger the diameter of the fluid becomes, the larger the difference in the coagulation speed between the surface and the inside becomes, and it becomes difficult to obtain a dense and uniform tissue fiber. Therefore, when the polyketone solution is spun, even if the same discharge amount is maintained, the spun fibers having a smaller diameter can be obtained in the coagulating solution while maintaining an appropriate air layer.

The air layer is preferably 5 to 50 mm, more preferably 10 to 20 mm. It is difficult to increase the spinning speed because the too short air layer distance increases the micropore generation rate due to the rapid surface layer coagulation and desolvation process, and it is difficult to increase the spinning speed. On the other hand, the too long air layer distance is affected by the adhesion of the filament, It is difficult to maintain process stability.

The composition of the coagulating bath used in the present invention is such that the concentration of the metal salt aqueous solution is 1 to 20% by weight. The coagulating bath temperature is maintained at -10 to 60 ° C, more preferably -5 to 20 ° C. In the coagulation bath, when the filament passes through the coagulation bath of the multifilament, when the spinning speed is increased by 500 m / min or more, the coagulation of the coagulating solution becomes severe due to the friction between the filament and coagulating liquid. In order to improve the productivity by increasing the excellent physical properties and the spinning speed through the stretching orientation, such a phenomenon is a factor that hinders the process stability, so that it is necessary to minimize such a phenomenon.

In the present invention, the coagulating bath is characterized by a temperature of -10 to 40 ° C and a metal salt concentration of 1 to 30% by weight, and the water bath is preferably at a temperature of 0 to 40 ° C and a metal salt concentration of 1 to 30% The acid washing bath preferably has a temperature of 0 to 40 캜 and an acid concentration of 0.5 to 2% by weight, and the secondary washing bath for acid removal is maintained at a temperature of 30 to 70 캜.

Also, in the present invention, the temperature of the dryer is 100 ° C or higher, preferably 200 ° C or higher, and the emulsion, heat-resistant agent, antioxidant or stabilizer is added to the fiber passed through the dryer.

Further, the stretching process in the polyketone fibers of the present invention is very important for improvement of high strength and water resistance.

Hereinafter, the stretching process and drying method important in the present invention will be described.

The present invention provides a high-strength fiber by securing the heat stability of the polyketone during wet spinning and by directly drying the fiber. In the conventional spinning process, the maximum strength is 13 g / d even at the time of germination drying and optimization of the stretching temperature. However, the present invention optimizes the heating method and the temperature profile of the drying method to form a dense structure by fusion- As a result, the draw ratio and the strength are improved. Further, in order to prevent thermal deterioration of the polyketone at the time of heating, the stretching magnification and strength are improved by a process including a heat stabilizer during drying and stretching.

Polyketone fibers have oxidation or degradation mechanisms at high temperatures. As a radical oxidation mechanism, polyketone releases carbon dioxide and oxidative degradation occurs when exposed to oxygen at temperatures above 90 ° C. In addition, due to the radical deterioration mechanism, when the polyketone is exposed to a high temperature of 200 ° C or more, carbon monoxide and ethylene are released and thermal degradation occurs. A heat-resistant stabilizer is used to prevent oxidation and deterioration of the polyketone at such a high temperature. As the heat-resistant stabilizer, both of antioxidants capable of preventing radical oxidation and deterioration can be used.

Preferably, phenolic heat stabilizers are used, and one or more heat stabilizers may be used alone or in combination. Oxidation and deterioration prevention mechanisms prevent radicals by radicals by capturing radicals with heat stabilizers (alkyl radicals) generated by heat or ultraviolet rays (see FIG. 1). The heat stabilizer may be used before drying or before stretching, and the immersion or application method may be used alone or in combination. Specifically, in an embodiment of the present invention, 0.1% of a solution of a phenolic heat stabilizer obtained by mixing a phenolic heat stabilizer with a methanol solvent in a pre-drying step and a stretching step is applied in a pre-drying step and a drawing step, Of the heat stabilizer was 250 ppm, but after the drying and the stretching step, 25 ppm remained. The heat stabilizer should be used in an appropriate amount depending on the process. If the heat stabilizer is large, the workability is poor. If the heat stabilizer is small, the heat stabilization effect is not sufficient. The heat stabilizer may be used in one-pot or two-pot or more.

Meanwhile, in order to increase the strength of the fiber, the present invention uses a direct drying method of a hot roller drying method, rather than an indirect drying method of a hot air drying method. In the conventional hot air drying method, a hot air drying method as shown in FIG. 2 was used at a temperature of 180 ° C. for a retention time of about 3 minutes and 30 seconds. This has the effect of achieving uniform drying and improving the affixation, but it is difficult to generate fusion, loops, static electricity, and fusion structure, so that the structure is not as dense (see FIG. 4). The present invention uses a hot-roll drying method as shown in Fig. 3 for a retention time of about 1 minute and 30 seconds at a temperature of 220 to 230 ° C. When such a drying method is used, there is no entanglement, less static electricity is generated, and a fine structure is formed due to the formation of a fusion structure, which is easy to apply for commercialization (see FIG. 5).

In addition, the present invention is subjected to a stretching process in which the fibers are stretched 15 to 18 times. For stretching the polyketone fibers, stretching is carried out in one or more stages. In the case of multi-stage stretching, it is preferable to perform the temperature-raising stretching in which the stretching temperature gradually increases with an increase in the stretching magnification. Specifically, the stretching process is performed at a temperature of 240 to 270 ° C, and the residence time is within about 1 minute and 30 seconds, and the first and second stages are performed. Stretching is carried out from step 1 to step 7, second step to step 2.5, and step 2 is stepwise stretching in a 3 step form. After the first stage, the elongation of the polyketone fibers is 10% and the strength is 8 g / d. After the second stage, the elongation is about 5.2%, and the strength of the polyketone fibers is 20 g / d.

In addition, since the polyketone is thermally deteriorated at a high temperature due to the drying and stretching process as described above, a heat stabilizer is added. It is applied before drying or before stretching. In the present invention, both raw or dip can be used. In general, when the two-dip or more is performed, the elongation of the fiber is decreased independently of the increase in the strength, but in the case of the hot-roll drying method according to the present invention, there is little decrease in elongation.

The multifilament produced by the method according to the present invention is a polyketone multifilament with a total denier range of 500 to 3,500 and a breaking load of 6.0 to 40.0 kg. The multifilament is composed of 100 to 2,200 individual filaments with a fineness of 0.5 to 8.0 denier.

The fiber density of the monofilament is 1.295 to 1.310 g / cm < 3 > by the hot-roll drying method of the present invention and the step of adding the heat stabilizer, and the structure thereof is as shown in Fig. As a result, the initial modulus value of the polyketone monofilament prepared by the above process is 200 g / d or more, elongation at 2.5 g / d at 2.5 g / d and elongation at least 0.5% at 19.0 g / d or more.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail with reference to examples. However, the embodiments according to the present invention can be modified into various other forms, and the scope of the present invention should not be construed as being limited to the embodiments described below. Embodiments of the invention are provided to more fully describe the present invention to those skilled in the art.

Preparation Example: Preparation of polyketone polymer

Linear alternating polyketone copolymers composed of carbon monoxide and ethylene are prepared by reacting palladium acetate, trifluoroacetic acid and a catalyst (cyclohexane-1,1-diylbis (methylene)) bis (bis (2-methoxyphenyl) The polyketone copolymer had a melting point of 240 DEG C, an intrinsic viscosity of 6.0 dl / g measured by HFIP (hexafluoroisopropanol) at 25 DEG C, a MI index of 10 g / 10 min and a molecular weight distribution (MWD) was 3.0.

Example 1

A 62% aqueous solution having a weight ratio of calcium chloride, zinc chloride and lithium chloride of 30:22:10 was injected into the extruder maintained at 30 ° C at an injection temperature of 25 ° C at a rate of 13,000 g / The polyketone powder having a molecular weight distribution of 3.0 and an intrinsic viscosity of 6.0 dl / g was injected into the extruder at a rate of 1160 g / hour by using a screw feeder, the residence time in the extruder swelling zone was set to 0.8 minutes, The powder is sufficiently dissolved in a metal salt solution to prepare a polyketone solution. At this time, the content of ammonium chloride in the zinc chloride was 0.01% by weight. The polyketone content in the polyketone solution was 8% by weight.

Then, the polyketone fibers were produced by dry-wet spinning by operating the screw at 110 rpm while maintaining the block temperature at 55 to 60 DEG C in the melting zone of the extruder.

At this time, a circular nozzle having an odd number of nozzles of 667 and a diameter of 0.18 mm and an L / D of 1 was used, and an air gap was 10 mm. The concentration of the polyketone in the discharged solution was 8.0 wt%, and it was in a homogeneous state in which the undissolved polyketone particles were not contained.

The fiber thus obtained is subjected to stretching at 1.2 times in the course of washing, and the heat stabilizer is dipped in a 0.1% solution of a mixed solution of AO80 and methanol of Adeka as a phenolic heat stabilizer before drying. In the drying process, 1.2-fold stretching was performed by a hot-roll drying method, and then fibers were produced in a heating chamber method at a total stretching magnification of 16.8 times, stretched at a stretch ratio of 7 times at the first stretch, 2.4 times at the second stretch, 1.5, 1.3, and 1.23 times, and each step is performed at temperatures of 240, 255, 265, and 268 ° C.

Example 2

A polyketone solution and a polyketone fiber were prepared in the same manner as in Example 1, except that the ammonium chloride content in the zinc chloride was 0.02 wt%.

Comparative Example 1

A polyketone solution and a polyketone fiber were prepared in the same manner as in Example 1, except that the ammonium chloride content in the zinc chloride was 0.5 wt%.

Yellowness (YI) of the polyketone solutions of Examples 1 and 2 and Comparative Example 1 and the viscosity increase rate at 80 ° C are shown in Table 1 below.

Property evaluation

(1) intrinsic viscosity

0.1 g of the sample was dissolved in a reagent (90 ° C) mixed with phenol and 1,1,2,2-tetrachloroethanol 6: 4 (weight ratio) for 90 minutes, transferred to a Ubbelohde viscometer, For 10 minutes, and use a viscometer and an aspirator to determine the number of drops of the solution. The number of drops of the solvent The RV value and I.V. The values were calculated

R.V. = Sample falling water / solvent falling water water

I.V. = 1/4 x [(R.V.- 1) / C] + 3/4 x (In R.V./C)

In the above equation, C represents the concentration (g / 100 ml) of the sample in the solution.

(2) Molecular weight distribution

A polyketone was dissolved in a hexafluoroisopropanol solution containing 0.01 N sodium trifluoroacetate so as to have a polyketone concentration of 0.01% by weight and measured under the following conditions.

Device: SHIMADZU LC-10Advp

Column: Use the following columns in the order of (a), (b) and (c).

(A): Shodex GPCHFIP-G

(B): Shodex HFIP-606M

(C): Shodex HFIP-606M

Column temperature: 40 ° C

Mobile phase: hexafluoroisopropanol solution containing 0.01 N sodium trifluoroacetate

Flow rate: 0.5 ml / min

Detector: differential refractometer

Injection volume: 30 μl

As a standard sample, polymethyl methacrylate (PMMA) having a monodispersed molecular weight distribution was used (concentration: 0.01% by weight), and the weight of the polyketone in terms of PMMA measured from the calibration curve of PMMA obtained under the same conditions as the above- The average molecular weight (Mw) and the number average molecular weight (Mn) were determined, and Mw / Mn was determined as a molecular weight distribution.

(3) Measurement of yellowness

The yellow index of each polyketone solution was measured using a color difference meter (manufactured by Konica Minolta).

(4) Measurement of viscosity rise rate

Viscosity was measured for each condition using a Brookfield viscometer at 80 ° C, and the ascending rate was measured.

(5) Measurement of solution (doping) crystallization degree

The crystallinity was measured by DSC after the solution (dope) was washed with distilled water and dried at room temperature.

Yellowness (YI) Viscosity increase rate at 80 캜
(poise / min) Solution crystallinity (%) Crosslinking reaction Example 1 1.0 0.3 55 control Example 2 2.0 0.7 53 control Comparative Example 1 3.0 1.5 45 Promotion

It can be seen that the crosslinking reaction is suppressed in Examples 1 and 2 because the polyketone solution has a low yellowing degree and a low viscosity increasing rate as compared with Comparative Examples. As a result, the solution crystallinity increased from 45% to over 53%, and stable emission to polyketone fibers is possible.

Claims (5)

A polyketone copolymer composed of the repeating units represented by the following general formulas (1) and (2), having y / x of 0 to 0.1 and an intrinsic viscosity of 5 to 7 dl / g; And
A solvent which is an aqueous solution containing a metal salt of calcium chloride / zinc chloride / lithium chloride,
The content of zinc chloride is 20 to 30% by weight,
The content of ammonium chloride in the zinc chloride is 0.01 to 0.02% by weight,
The component of the catalyst composition used in the polymerization of the polyketone copolymer is (cyclohexane-1,1-diylbis (methylene)) bis (bis (2-methoxyphenyl)
The yellowness index (YI) is 1.0 to 2.0, and the viscosity increasing rate at 80 DEG C is 0.3 to 0.7 poise / min.
- [- CH2CH2-CO-] x- (1)
- [- CH2 --CH (CH3) - CO--] y- (2)
(x and y are mole% of each of the general formulas (1) and (2) in the polymer)
delete delete delete A polyketone solution according to claim 1, wherein the polyketone solution is extruded through a spinneret to obtain an unstretched fiber, followed by treatment with a heat stabilizer, followed by drying in a hot roll type, further treating a dried heat- Features polyketone fiber.

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