JP6912802B2 - Polyarylate resin and films and laminates made of it - Google Patents

Description

The present invention relates to a polyarylate resin having excellent heat resistance, solubility in a non-halogen organic solvent, water vapor blocking property, mechanical properties, liquid dripping resistance and deformation resistance.

Since polyarylate resin is excellent in heat resistance and transparency, it is expected to be applied in a wide range of fields such as electrical and electronic applications, automobile applications, and mechanical applications. In recent years, polyarylate resins have been studied for application to liquid crystal displays and the like by taking advantage of their characteristics.

When a polyallylate resin is used for a liquid crystal display, the polyallylate resin is dissolved in an organic solvent at room temperature to form a resin solution and coated on the display. Therefore, there is a demand for an organic solvent. From the viewpoint of worker safety, solubility in non-halogen organic solvents is required.

Further, in recent years, the conditions for using a resin used for an optical film in a liquid crystal display or the like have become stricter, so that a resin having higher performance than a general phthalate polyarylate has been required.

In order to solve the above problems, Patent Document 1 comprises 3,3', 5,5'-tetramethyl-4,4'-biphenol residues and terephthalic acid and isophthalic acid residues. It is disclosed that a polyarylate resin is used for a liquid crystal display.

On the other hand, Patent Documents 2 and 3 disclose polyarylate resins containing 2,2-bis (4-hydroxyphenyl) -4-methylpentane.

Japanese Unexamined Patent Publication No. 2002-293944 Japanese Unexamined Patent Publication No. 2013-7806 Japanese Unexamined Patent Publication No. 2013-10913

Furthermore, in recent years, when electrical and electronic components and liquid crystal displays are used for a long period of time, the problem that the electronic components inside the display are deteriorated due to moisture in the air and the propagation delay and / or transmission loss of electrical signals is increased becomes more severe. There is. Therefore, there has been a demand for a material having low water vapor transmission rate and high water vapor blocking property.

In addition, when a load such as external stress and / or internal stress is continuously applied to the polyarylate, the polyarylate itself is deformed due to the viscous behavior of the polyarylate, or the coating or lamination is performed. When used as a body, there was a problem that peeling occurred. Therefore, polyarylate having excellent deformation resistance has been required so that these deformations and peelings do not occur. Specifically, a polyarylate having a small viscous behavior, that is, a polyarylate having a low elastic modulus (E ″), which is an index of the viscoelastic behavior in the dynamic viscoelasticity measurement, has been sought.

The polyarylate resin of Patent Document 1 has a limit in solubility in a non-halogen organic solvent, which has been increasing in demand in recent years, and further improvement of the solubility has been required. Further, the polyarylate resin of Patent Document 1 has problems in water vapor blocking property and deformation resistance (for example, adhesion).

The polyarylate resins of Patent Documents 2 and 3 have problems in heat resistance, mechanical strength, and liquid dripping resistance. For example, when a resin solution obtained from a polyarylate resin having poor liquid dripping resistance is applied, dripping may occur. Liquid dripping is a phenomenon in which a coating film in a solution state immediately after being applied onto a substrate is deformed without being able to maintain its shape. When dripping occurred, the shape and thickness of the coating film could not be controlled, which became a production problem. The problem of dripping occurred not only when the coated surface of the substrate was arranged perpendicularly or inclined with respect to the horizontal plane, but also when it was arranged parallel to the horizontal plane. In particular, when the problem of liquid dripping occurs on the coating surface parallel to the horizontal plane, the coating film that is in a solution state immediately after being applied cannot maintain its shape at its end (edge), and is applied. It was difficult to control the shape and thickness of the film.

The present invention solves the above problems and is excellent in heat resistance, solubility in non-halogen organic solvents, water vapor blocking property, mechanical strength, liquid dripping resistance, and deformation resistance (for example, adhesion). It is an object of the present invention to provide a polyarylate resin.

As a result of diligent studies to solve such a problem, the present inventors have achieved the above object by using the divalent phenol residues represented by the general formula (1) and the general formula (2) in combination. We have arrived at the present invention.

That is, the gist of the present invention is as follows.
(1) A polyarylate resin containing a divalent phenol residue and an aromatic divalent carboxylic acid residue, wherein the divalent phenol residue is 3,3', 5,5'-tetramethyl-4. , 4'-biphenol residue and 2,2-bis (4-hydroxyphenyl) -4-methylpentane residue only, aromatic divalent carboxylic acid residue is terephthalic acid residue and isophthalic acid residue only Polyaromatic resin consisting of.
(2) A film made of the polyarylate resin according to (1).
(3) A laminate in which a layer of the polyarylate resin according to (1) or (2) is provided on a base material.

According to the present invention, a polyarylate resin having excellent heat resistance, solubility in a non-halogen organic solvent, water vapor blocking property, mechanical strength, liquid dripping resistance, and deformation resistance (for example, adhesion) is provided. Can be done. Specifically, the polyarylate resin of the present invention has excellent heat resistance, solubility in non-halogen organic solvents, and mechanical strength, while maintaining water vapor blocking property, liquid dripping resistance, and deformation resistance ( For example, it has excellent adhesion).

The polyarylate resin of the present invention is composed of a divalent phenol residue and an aromatic divalent carboxylic acid residue.

As the divalent phenol residue, it is necessary to contain the residues represented by the general formula (1) and the general formula (2). If the residue represented by the general formula (1) is not contained, the glass transition temperature, mechanical strength, and liquid dripping resistance are lowered, which is not preferable. If the residue represented by the general formula (2) is not contained, non-halogen is used. It is not preferable because the solubility in the organic solvent, the water vapor blocking property, and the deformation resistance (for example, adhesion) are lowered.

In the general formula (1), R ¹ and R ² represent a substituent bonded to the benzene ring, and independently represent a hydrocarbon group having 1 to 6 carbon atoms, an alkyl halide group or a halogen atom. Among these, a methyl group, an ethyl group, a phenyl group, and a cyclohexyl group are preferable, and a methyl group is more preferable, because they are easily industrially available and easily synthesized.

In the general formula (1), p and q represent the number of substituents bonded to the benzene ring, and independently represent an integer of 0 to 4. When p and q are 0, it means that all the hydrogen atoms bonded to the benzene ring are not substituted with ^{R 1} and R ^2. when p is 2 to 4, a plurality of R ¹ may be mutually the same substituent, or may be different substituents. when q is 2 to 4, a plurality of R ² may be mutually the same substituent, or may be different substituents. P and q are preferably 1 to 4 because of their excellent solubility in non-halogen solvents.

From the viewpoint of heat resistance, the content of the divalent phenol that gives the residue represented by the general formula (1) to the total divalent phenol component is preferably 10 mol% or more, preferably 30 mol% or more. From the viewpoint of liquid dripping resistance, it is more preferably 50 mol% or more.

Examples of the divalent phenol giving the residue represented by the general formula (1) include 4,4'-biphenol, 3,3'-dimethyl-4,4'-biphenol, 3,3', 5,5'. -Tetramethyl-4,4'-biphenol, 2,2', 3,3', 5,5'-hexamethyl-4,4'-biphenol, 3,3', 5,5'-tetra-tert-butyl -2,2'-biphenol can be mentioned. Of these, 3,3', 5,5'-tetramethyl-4,4'-biphenol is preferable from the viewpoint of solubility in a non-halogen organic solvent.

In the general formula (2), X represents a linear or branched divalent hydrocarbon group having 4 to 8, preferably 4 to 7, more preferably 5 to 7 or 4 to 6 carbon atoms. When the carbon number of X is less than 4, the water vapor blocking property and / or the solubility in a halogen-based organic solvent may decrease. If the carbon number of X is larger than 8, the high glass transition temperature may decrease. Linear means that the carbon chain is linear in the chemical structural formula of the obtained hydrocarbon compound, assuming that the two bonds of the divalent hydrocarbon group are bonded to a hydrogen atom. .. The branched form means that the carbon chain is branched in the chemical structural formula of the obtained hydrocarbon compound, assuming that two bonds of the divalent hydrocarbon group are bonded to a hydrogen atom. Examples of the divalent hydrocarbon group include an aliphatic hydrocarbon group such as a saturated aliphatic hydrocarbon group and an unsaturated aliphatic hydrocarbon group. Preferred X is a linear or branched divalent aliphatic saturated aliphatic hydrocarbon group, and more preferably a branched divalent saturated aliphatic hydrocarbon group. Specific examples of the linear divalent saturated aliphatic hydrocarbon group include tetramethylene group, pentamethylene group, hexamethylene group, heptamethylene group, octamethylene group, 2,2-butylene group and 2,2-. Examples thereof include a linear alkylene group such as a pentylene group, a 2,2-hexylene group, a 2,2-heptylene group, a 2,2-octylene group and a 3,3-pentylene group. Specific examples of the branched divalent saturated aliphatic hydrocarbon group include 3-methyl-2,2-butylene group, 4-methyl-2,2-pentylene group and 2-ethyl-1,1-hexylene group. , 2-Methyl-1,1-propylene group, 3-methyl-1,1-butylene group and other branched alkylene groups.

Examples of the divalent phenol giving the residue represented by the general formula (2) include 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4-hydroxyphenyl) pentane, and 2,2-. Bis (4-hydroxyphenyl) hexane, 2,2-bis (4-hydroxyphenyl) -3-methylbutane, 2,2-bis (4-hydroxyphenyl) -4-methylpentane, 1,1-bis (4-hydroxyphenyl) Hydroxyphenyl) -2-ethylhexane, 2,2-bis (4-hydroxyphenyl) butane, 1,1-bis (4-hydroxyphenyl) -2-methylpropane, 2,2-bis (4-hydroxyphenyl) Octane, 1,1-bis (4-hydroxyphenyl) -3-methylbutane, 3,3-bis (4-hydroxyphenyl) pentane) can be mentioned. Among these, 2,2-bis (4-hydroxyphenyl) -4-methylpentane is preferable from the viewpoint of water vapor blocking property.

The content of the divalent phenol that gives the residue represented by the general formula (2) to the total divalent phenol component is preferably 10 mol% or more, more preferably 30 mol% or more. From the viewpoint of deformation resistance (for example, adhesion) and water vapor blocking property, it is more preferably 50 mol% or more.

The total content of the divalent phenol that gives the residues represented by the general formula (1) and the general formula (2) to the total divalent phenol component is preferably 90 mol% or more, preferably 95% or more. Is more preferable.

The divalent phenol residue may contain a divalent phenol residue other than the residues represented by the general formulas (1) and (2) as long as the effects of the present invention are not impaired. Examples of the dihydric phenol that gives other divalent phenol residues include 1,1-bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, and 1,1-bis (4). -Methyl-2-hydroxyphenyl) methane, 1,1-bis (3,5-dimethyl-4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) cyclohexane, 2,2-bis (4-) Hydroxyphenyl) propane, 2,2-bis (3-methyl-4-hydroxyphenyl) propane, 2,2-bis (3,5-dimethyl-4-hydroxyphenyl) propane, 1,1-bis (4-hydroxy) Phenyl) -1-phenylethane, 1,1-bis (4-hydroxyphenyl) -2-ethylhexane, 2,2-bis (3-phenyl-4-hydroxyphenyl) propane, 1,1-bis (3-) Methyl-4-hydroxyphenyl) methane, 2,2-bis (4-hydroxyphenyl) butane, 1,1-bis (4-hydroxyphenyl) -2-methylpropane, 1,1-bis (4-hydroxyphenyl) -1-phenylmethane, 2,2-bis (4-hydroxyphenyl) octane, 1,1-bis (3-methyl-4-hydroxyphenyl) cyclohexane, 2,2-bis (3-allyl-4-hydroxyphenyl) ) Propane, 2,2-bis (3-isopropyl-4-hydroxyphenyl) propane, 2,2-bis (3-tert-butyl-4-hydroxyphenyl) propane, 2,2-bis (3-sec-butyl) -4-Hydroxyphenyl) propane, bisphenol fluorene, 1,1-bis (2-methyl-4-hydroxy-5-tert-butylphenyl) -2-methylpropane, 4,4'-[1,4-phenylene- Bis (2-propylidene) -bis (3-methyl-4-hydroxyphenyl)], 1,1-bis (3-phenyl-4-hydroxyphenyl) cyclohexane, 4,4'-dihydroxyphenyl ether, bis (2- Hydroxyphenyl) methane, 2,4'-methylenebisphenol, bis (3-methyl-4-hydroxyphenyl) methane, bis (4-hydroxyphenyl) propane, 1,1-bis (2-hydroxy-5-methylphenyl) Etan, 1,1-bis (4-hydroxyphenyl) -3-methylbutane, bis (2-hydroxy-3,5-dimethylphenyl) methane, 1,1-bis (4-hydroxyphenyl) cyclope Tert, 1,1-bis (3-methyl-4-hydroxyphenyl) cyclopentane, 3,3-bis (4-hydroxyphenyl) pentane, 3,3-bis (3-methyl-4-hydroxyphenyl) pentane, 3,3-bis (3,5-dimethyl-4-hydroxyphenyl) pentane, 2,2-bis (2-hydroxy-3,5-dimethylphenyl) propane, 2,2-bis (4-hydroxyphenyl) nonane , 1,1-bis (3-methyl-4-hydroxyphenyl) -1-phenylethane, 1,1-bis (3,5-dimethyl-4-hydroxyphenyl) cyclohexane, 2,2-bis (4-hydroxy) Phenyl) decane, 1,1-bis (4-hydroxyphenyl) decane, bis (2-hydroxy-3-tert-butyl-5-methylphenyl) methane, bis (4-hydroxyphenyl) diphenylmethane, terpendiphenol, 1 , 1-bis (3-tert-butyl-4-hydroxyphenyl) cyclohexane, 1,1-bis (2-methyl-4-hydroxy-5-tert-butylphenyl) -2-methylpropane, 2,2-bis (3-Cyclohexyl-4-hydroxyphenyl) propane, 1,1-bis (3,5-di-tert-butyl-4-hydroxyphenyl) methane, 1,1-bis (3,5-di-sec-butyl) -4-Hydroxyphenyl) methane, 1,1-bis (3-cyclohexyl-4-hydroxyphenyl) cyclohexane, 1,1-bis (2-hydroxy-3,5-di-tert-butylphenyl) ethane, bis ( 3-Nonyl-4-hydroxyphenyl) methane, 2,2-bis (3,5-di-tert-butyl-4-hydroxyphenyl) propane, bis (2-hydroxy-3,5-di-tert-butyl- 6-Methylphenyl) methane, 1,1-bis (3-phenyl-4-hydroxyphenyl) -1-phenylethane, bis (3-fluoro-4-hydroxyphenyl) methane, bis (2-hydroxy-5-fluoro) Phenyl) methane, 2,2-bis (4-hydroxyphenyl) -1,1,1,3,3,3-hexafluoropropane, 2,2-bis (3-fluoro-4-hydroxyphenyl) propane, bis (3-Fluoro-4-hydroxyphenyl) -phenylmethane, bis (3-fluoro-4-hydroxyphenyl)-(p-fluorophenyl) methane, bis (4-hydroxyphenyl)-(p-fluorophenyl) Enyl) methane, 2,2-bis (3-chloro-4-hydroxy-5-methylphenyl) propane, 2,2-bis (3,5-dichloro-4-hydroxyphenyl) propane, 2,2-bis (3,5-dichloro-4-hydroxyphenyl) propane 3-Chloro-4-hydroxyphenyl) propane, 1,1-bis (3,5-dibromo-4-hydroxyphenyl) methane, 2,2-bis (3,5-dibromo-4-hydroxyphenyl) propane, 2 , 2-bis (3-nitro-4-hydroxyphenyl) propane, bis (4-hydroxyphenyl) dimethylsilane, bis (3-methyl-4-hydroxyphenyl) ether, bis (3,5-dimethyl-4-hydroxy) Phenyl) ether, bis (2,3,5-trimethyl-4-hydroxyphenyl) -phenylmethane, 2,2-bis (4-hydroxyphenyl) dodecane, 2,2-bis (3-methyl-4-hydroxyphenyl) ) Dodecane, 2,2-bis (3,5-dimethyl-4-hydroxyphenyl) dodecane, 1,1-bis (3-tert-butyl-4-hydroxyphenyl) -1-phenylethane, 1,1-bis (3,5-di-tert-butyl-4-hydroxyphenyl) -1-phenylethane, 1,1-bis (2-methyl-4-hydroxy-5-cyclohexylphenyl) -2-methylpropane, 1,1 -Bis (2-hydroxy-3,5-di-tert-butylphenyl) ethane, isatin bisphenol, isatin biscresol, bis (2-hydroxyphenyl) methane, 2,4'-methylenebisphenol, 1,2- Bis (4-hydroxyphenyl) ethane, 2- (4-hydroxyphenyl) -2- (2-hydroxyphenyl) propane, bis (2-hydroxy-3-allylphenyl) methane, 1,1-bis (2-hydroxy) -3,5-dimethylphenyl) -2-methylpropane, 1,1-bis (2-hydroxy-5-tert-butylphenyl) ethane, bis (2-hydroxy-5-phenylphenyl) methane, 1,1-bis (2-Methyl-4-hydroxy-5-tert-butylphenyl) butane, bis (2-methyl-4-hydroxy-5-cyclohexylphenyl) methane, 2,2-bis (4-hydroxyphenyl) pentadecane, 2, 2-bis (3-methyl-4-hydroxyphenyl) pentadecane, 2,2-bis (3,5-dimethyl-4-hydroxyphenyl) pentadecane, 1,2-bis (3,5-di-ter) t-butyl-4-hydroxyphenyl) ethane, bis (2-hydroxy-3,5-di-tert-butylphenyl) methane, 2,2-bis (3-styryl-4-hydroxyphenyl) propane, 1,1 -Bis (4-hydroxyphenyl) -1- (p-nitrophenyl) ethane, bis (3,5-difluoro-4-hydroxyphenyl) methane, bis (3,5-difluoro-4-hydroxyphenyl) phenylmethane, Bis (3,5-difluoro-4-hydroxyphenyl) diphenylmethane, bis (3-fluoro-4-hydroxyphenyl) diphenylmethane, 2,2-bis (3-chloro-4-hydroxyphenyl) propane, 1,1-bis (4-Hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3,5,5-tetramethyl-cyclohexane, 1,1-bis (4-hydroxyphenyl) Hydroxyphenyl) -3,3,4-trimethyl-cyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3-dimethyl-5-ethyl-cyclohexane, 1,1-bis (4-hydroxyphenyl)- 3,3,5-trimethyl-cyclopentane, 1,1-bis (3,5-dimethyl-4-hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 1,1-bis (3,5-diphenyl) -4-Hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 1,1-bis (3-methyl-4-hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 1,1-bis (3) -Phenyl-4-hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 1,1-bis (3,5-dichloro-4-hydroxyphenyl) -3,3,5-trimethyl-cyclohexane, 9,9 -Bis (4-hydroxyphenyl) fluorene, 9,9-bis (3-methyl-4-hydroxyphenyl) fluorene, 1,1-bis (3,5-dibromo-4-hydroxyphenyl) -3,3,5 -Trimethyl-Cyclohexane, bis (4-hydroxyphenyl) sulfone, bis (2-hydroxyphenyl) sulfone, bis (3,5-dimethyl-4-hydroxyphenyl) sulfone, bis (3,5-diethyl-4-hydroxyphenyl) ) Sulfur, bis (3-methyl-4-hydroxyphenyl) sulfone, bis (3-ethyl-4-hydroxyphenyl) sulfone, bis (4-hydroxyphenyl) sul Fido, bis (3,5-dimethyl-4-hydroxyphenyl) sulfide, bis (3,5-diethyl-4-hydroxyphenyl) sulfide, bis (3-methyl-4-hydroxyphenyl) sulfide, bis (3-ethyl) -4-Hydroxyphenyl) sulfide, 2,4-dihydroxydiphenylsulfone, 1,4-dihydroxybenzene, 1,3-dihydroxybenzene, 1,2-dihydroxybenzene can be mentioned. When other dihydric phenols are contained, the content thereof is the total dihydric phenol component from the viewpoints of heat resistance, solubility in non-halogen organic solvents, water vapor blocking property, and deformation resistance (for example, adhesion). It is preferably less than 10 mol%, more preferably 5 mol% or less, and even more preferably substantially free.

Examples of the aromatic divalent carboxylic acid that gives an aromatic divalent carboxylic acid residue include phthalates such as terephthalic acid, isophthalic acid, and orthophthalic acid, 4,4'-biphenyldicarboxylic acid, and 2,2'-biphenyl. Biphenyldicarboxylic acids such as dicarboxylic acids, naphthalenedicarboxylic acids such as 1,5-naphthalenedicarboxylic acid and 2,6-naphthalenedicarboxylic acid, diphenyl ether-2,2'-dicarboxylic acid, diphenyl ether-2,3'-dicarboxylic acid , Diphenyl ether-2,4'-dicarboxylic acid, diphenyl ether-3,3'-dicarboxylic acid, diphenyl ether-3,4'-dicarboxylic acid, diphenyl ether-4,4'-dicarboxylic acid and other diphenyl ether dicarboxylic acids. In the aromatic divalent carboxylic acid, the hydrogen atom bonded to the aromatic ring is a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group and the like. It may be substituted with an alkyl group of. Among the aromatic divalent carboxylic acids, phthalic acids are preferable from the viewpoint of mechanical strength, and terephthalic acid and isophthalic acid are more preferable in combination. When terephthalic acid and isophthalic acid are used in combination in the aromatic divalent carboxylic acid component, the molar ratio of terephthalic acid and isophthalic acid is terephthalic acid / isophthalic acid = 7/3 to 7/3 from the viewpoint of solubility in halogen-based organic solvents. It is preferably 3/7 (molar ratio), and more preferably 6/4 to 4/6 (molar ratio). The total amount of terephthalic acid and isophthalic acid is preferably 90 mol% or more, more preferably 95 mol% or more, based on the total aromatic divalent carboxylic acid component.

In addition to divalent phenol residues and aromatic divalent carboxylic acid residues, the polyallylate resin of the present invention contains aliphatic diols, alicyclic diols, aliphatic dicarboxylic acids, as long as the effects of the present invention are not impaired. Residues of other components such as aliphatic dicarboxylic acids may be contained. Examples of the aliphatic diol include ethylene glycol and propylene glycol. Examples of the alicyclic diol include 1,4-cyclohexanediol, 1,3-cyclohexanediol, and 1,2-cyclohexanediol. Examples of the aliphatic dicarboxylic acid include adipic acid and sebacic acid. Examples of the alicyclic dicarboxylic acid include 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, and 1,2-cyclohexanedicarboxylic acid. The content of the residue of the other component is preferably less than 10 mol% with respect to the total number of moles of the raw material monomer, and more preferably substantially not contained.

The weight average molecular weight of the polyarylate resin of the present invention is preferably 60,000 to 150,000 from the viewpoint of heat resistance, mechanical strength, and processability. If the weight average molecular weight is less than 60,000, the glass transition temperature and / or mechanical strength may decrease. On the other hand, when the weight average molecular weight exceeds 150,000, the solution viscosity and / or the melt viscosity when dissolved in a non-halogen organic solvent may be too high, and the processability may be lowered.

The glass transition temperature of the polyarylate resin of the present invention is preferably 200 ° C. or higher, more preferably 215 ° C. or higher, and most preferably 230 ° C. or higher. When a polyarylate resin is used for a liquid crystal display or the like, it is usual to coat the liquid crystal display, apply an ITO (indium-tin oxide) solution on the liquid crystal display, and then crystallize at a temperature of 200 ° C. or higher. .. By setting the glass transition temperature of the polyarylate resin to 200 ° C. or higher, ITO can be easily crystallized.

From the viewpoint of thermal stability during processing, the thermal decomposition temperature of the polyarylate resin of the present invention preferably has a 10% mass reduction temperature of 370 ° C. or higher, more preferably 380 ° C. or higher, and 390 ° C. or higher. Is most preferable.

The polyarylate resin of the present invention has excellent solubility in non-halogen organic solvents. Examples of the non-halogen organic solvent include aromatic compounds such as toluene, xylene and benzene; cyclic ether compounds such as tetrahydrofuran, 1,4-dioxane and 1,3-dioxolane; and cyclic ketones such as cyclohexanone and cyclopentanone. Examples include compounds. Of these, aromatic compounds (particularly xylene) and cyclic ketone compounds (particularly cyclohexanone) are preferred.

Examples of the method for producing the polyarylate resin of the present invention include a method of reacting in an organic solvent such as an interfacial polymerization method and a solution polymerization method, and a method of reacting in a molten state such as melt polymerization. From the viewpoint of polymerizable property and / or the appearance of the obtained resin, it is preferable to use an interfacial polymerization method capable of reacting in an organic solvent, particularly at a low temperature.

As an interfacial polymerization method, a solution (organic phase) in which divalent carboxylic acid halide is dissolved in an organic solvent that is incompatible with water is mixed with an alkaline aqueous solution (organic phase) containing divalent phenol, an end-capping agent, an antioxidant and a polymerization catalyst. A method of mixing with an aqueous phase) and carrying out a polymerization reaction while stirring at a temperature of 50 ° C. or lower for 1 to 8 hours can be mentioned.

As the solvent used for the organic phase, a solvent that is incompatible with water and dissolves polyarylate is preferable. Examples of such a solvent include methylene chloride and chloroform, and methylene chloride is preferable because it is easy to use in production.

Examples of the alkaline aqueous solution used for the aqueous phase include aqueous solutions of sodium hydroxide, potassium hydroxide and a mixture thereof.

The end sealant is used from the viewpoint of adjusting the molecular weight of the polyarylate resin and improving the thermal stability. Examples of the terminal encapsulant include monohydric phenol, monohydric acid chloride, monohydric alcohol, and monovalent carboxylic acid. Examples of the monovalent phenol include phenol, o-cresol, m-cresol, p-cresol, p-tert-butylphenol, o-phenylphenol, m-phenylphenol, p-phenylphenol, o-methoxyphenol, m-. Methoxyphenol, p-methoxyphenol, 2,3,6-trimethylphenol, 2,3-xylenol, 2,4-xylenol, 2,5-xylenol, 2,6-xylenol, 3,4-xylenol, 3,5 Examples thereof include -xylenol, 2-phenyl-2- (4-hydroxyphenyl) propane, 2-phenyl-2- (2-hydroxyphenyl) propane, and 2-phenyl-2- (3-hydroxyphenyl) propane. Examples of the monovalent acid chloride include benzoyl chloride, benzoic acid chloride, methanesulfonyl chloride, and phenylchloroformate. Examples of the monohydric alcohol include methanol, ethanol, n-propanol, isopropanol, n-butanol, 2-butanol, pentanol, hexanol, dodecyl alcohol, stearyl alcohol, benzyl alcohol and phenethyl alcohol. Examples of the monovalent carboxylic acid include acetic acid, propionic acid, octanoic acid, cyclohexanecarboxylic acid, benzoic acid, toluic acid, phenylacetic acid, p-tert-butylbenzoic acid, and p-methoxyphenylacetic acid. Of these, monohydric phenol (particularly p-tert-butylphenol) is preferable because of its high thermal stability.

Antioxidants are used to prevent the oxidation of divalent phenolic components. Examples of the antioxidant include sodium hydrosulfite, L-ascorbic acid, erythorbic acid, catechin, tocophenol, and butylhydroxyanisole. Of these, sodium hydrosulfite is preferable because it has excellent water solubility.

Examples of the polymerization catalyst include quaternary ammonium salts such as tri-n-butylbenzylammonium halide, tetra-n-butylammonium halide, trimethylbenzylammonium halide, and triethylbenzylammonium halide; and tri-n-butylbenzylphosphonium halide. , Tetra-n-butylphosphonium halide, trimethylbenzylphosphonium halide, quaternary phosphonium salt such as triethylbenzylphosphonium halide and the like. Among them, tri-n-butylbenzylammonium halide, trimethylbenzylammonium halide, tetra-n-butylammonium halide, tri-n-butylbenzylphosphonium halide, and tetra can be obtained because a polymer having a high molecular weight and a low acidity can be obtained. -N-Butylphosphonium halide is preferred.

After being dissolved in an organic solvent, the polyarylate resin of the present invention is coated on a base material and dried, or a molten resin is extruded onto the base material to provide a layer of the polyarylate resin on the base material. A laminated body can be obtained. Further, a film can be obtained by peeling the resin layer from the laminated body. In order to obtain a colorless and transparent film, it is preferable to obtain a film by dissolving it in an organic solvent, coating it on a substrate, drying it, and peeling it off, because the color tone does not deteriorate due to thermal decomposition.

Examples of the organic solvent for dissolving the polyallylate resin include methylene chloride, 1,2-dichloroethane, chloroform, carbon tetrachloride, chlorobenzene, 1,1,2,2-tetrachloroethane, in addition to the non-halogen organic solvent described above. , 1,1,1-Trichloroethane, o-dichlorobenzene, m-dichlorobenzene, p-dichlorobenzene and the like.

Examples of the base material include a PET film, a polyimide film, a glass plate, and a stainless steel plate. Examples of the coating method include wire bar coater coating method, film applicator coating method, brush coating method, spray coating method, gravure roll coating method, screen printing method, reverse roll coating method, lip coating, air knife coating method, and curtain flow. Examples include a coating method and a dip coating method.

From the viewpoint of mechanical strength, the tensile breaking strength of the film obtained from the polyarylate resin of the present invention is preferably 70 MPa or more, more preferably 80 MPa or more, and even more preferably 90 MPa or more. From the viewpoint of toughness, the tensile elongation at break of the film is preferably 60% or more, more preferably 65% or more, and further preferably 70% or more.

The water vapor transmission coefficient of the film obtained from the polyarylate resin of the present invention is preferably 0.80 g · cm / (m ² · day) or less, preferably 0.70 g · cm / (m ² · day) or less. It is more preferable, and it is more preferable that it is 0.65 g · cm / (m ² · day) or less.

The loss elastic modulus (E'') (when the frequency is 1 Hz) of the film obtained from the polyarylate resin of the present invention is preferably 0.20 GPa or less, more preferably 0.15 GPa or less, and 0. It is more preferably .12 GPa or less. By setting the loss elastic modulus to 0.20 GPa or less, it is possible to prevent plastic deformation even under a load.

The polyarylate resin of the present invention, and the films and laminates obtained from it, have heat resistance, solubility in non-halogen organic solvents, water vapor blocking property, mechanical strength, liquid dripping resistance, and deformation resistance (for example, adhesion). Is excellent. Therefore, it can be suitably used in the field of electrical and electronic materials as a substrate film for liquid crystal displays, film capacitors, lighting, solar cells, printed circuits and the like.

In particular, the polyarylate resin of the present invention is excellent in liquid dripping resistance. Specifically, as a guideline for suppressing dripping, the viscosity stabilization time when measuring the solution viscosity is an index. Generally, when a resin solution is measured using a viscometer, the viscosity decreases with the passage of time, and the viscosity stabilizes after a certain period of time. In the present invention, the viscosity stabilization time is the time until the viscosity stabilizes, and means the time until the viscosity does not change with time. Here, it is determined that the longer the viscosity stabilization time, the more difficult it is for the solution to flow with shear. Therefore, the coating film, which is in a solution state immediately after coating, is not easily affected by the force received from the outside and easily retains its shape. The viscosity stabilization time when measuring the solution viscosity is preferably 10 min or more, more preferably 15 min or more, and further preferably 20 min or more from the viewpoint of suppressing dripping.

Next, the present invention will be specifically described with reference to Examples and Comparative Examples, but the present invention is not limited thereto. The physical properties of the polyarylate resin were measured by the following method.

(1) Resin composition The resin composition was determined from the peak intensity of each copolymer component by ¹ H-NMR analysis using a high-resolution nuclear magnetic resonance apparatus (LA-400 NMR manufactured by JEOL Ltd.) (resolution). : 400 MHz, solvent: mixed solvent with deuterated trifluoroacetic acid and deuterated tetrachloroethane in a volume ratio of 1/11, temperature: 50 ° C.).

(2) Number average molecular weight (Mn) and weight average molecular weight (Mw)
Using gel permeation chromatography (GPC), the polystyrene-equivalent number average molecular weight and weight average molecular weight were measured under the following conditions.
Liquid feeder: Isocratic HPLC Pump 1515, manufactured by Waters
Detector: Refractometer Index 2414, manufactured by Waters.
Column: Mixed-D (filled silica gel particle size 5 μm, tube length 300 mm, inner diameter 7.5 mm)
Solvent: Chloroform Flow rate: 1 mL / min Measurement temperature: 35 ° C

(3) Glass transition temperature (Tg) (heat resistance)
Using 10 mg of polyarylate resin as a sample, the temperature is raised at a temperature rise rate of 10 ° C./min using a DSC (Differential Scanning Calorimetry) device (PerkinElmer, DSC7), and the glass transition in the temperature rise curve. The intermediate value of the two bending point temperatures derived from the above was taken as the glass transition temperature.
⊚: 230 ° C or higher (best).
◯: 215 ° C or higher and lower than 230 ° C (good).
Δ: 200 ° C. or higher and lower than 215 ° C. (no problem in practical use).
X: Less than 200 ° C (There is a problem in practical use).

(4) Pyrolysis temperature The polyarylate resin was measured under the following conditions, and the temperature at which the mass was reduced by 10% was determined as the pyrolysis temperature.
Equipment: Hitachi High-Tech Science Corporation, TG / DTA 7200
Temperature rise rate: 10 ° C / min Inflow gas: air, flow velocity 200 mL / min ⊚: 390 ° C or higher (best).
◯: 380 ° C. or higher and lower than 390 ° C. (good).
Δ: 370 ° C or higher and lower than 380 ° C (no problem in practical use).
X: Less than 370 ° C (There is a problem in practical use).

(5) Water vapor permeability coefficient 90 parts by mass of chloroform was added to 10 parts by mass of polyarylate resin to obtain a resin solution. A coating film was formed on the PET film using the obtained resin solution. After air-drying at room temperature, the film was peeled off from the PET film and dried under reduced pressure at 150 ° C. for 24 hours to prepare a film having a thickness of 100 μm. The obtained film was used for measurement under the following conditions.
Test equipment: MOCON water vapor permeability measuring equipment Temperature: 23.0 ° C
Humidity: 80.0%
Measurement time: 24 hours ⊚: 0.65 g · cm / (m ² · day) or less (best).
◯: More than 0.65 g · cm / (m ² · day) 0.70 g · cm / (m ² · day) or less (good).
Δ: 0.70 g · cm / (m ² · day) super 0.80 g · cm / (m ² · day) or less (no problem in practical use).
X: Over 0.80 g · cm / (m ² · day) (There is a problem in practical use).

(6) Tensile breaking strength and tensile breaking elongation The film obtained in (5) was measured according to JIS K7127 under the following conditions.
Test equipment: Model2020, manufactured by Intesco Co., Ltd.
Tensile rate: 50 mm / min Test environment: 23 ° C, 60% RH
-Tensile breaking strength ◎: 90 MPa or more (best).
◯: 80 MPa or more and less than 90 MPa (good).
Δ: 70 MPa or more and less than 80 MPa (no problem in practical use).
X: Less than 70 MPa (there is a problem in practical use).
-Tension breaking elongation ◎: 70% or more (best).
◯: 65% or more and less than 70% (good).
Δ: 60% or more and less than 65% (no problem in practical use).
X: Less than 60% (there is a problem in practical use).

(7) Elastic modulus lost (E'')
Using the film obtained in (5), the film was measured under the following conditions, and the value at a frequency of 1 Hz was defined as the loss elastic modulus (E''). The smaller the elastic modulus (E ″), the better the deformation resistance (for example, adhesion) of the film.
Test equipment: Leometric Viscoelastic Analyzer RSAII
Frequency: 0.159 to 15.9Hz
Temperature: 25.0 ° C
Distortion: 0.20%
⊚: 0.12 GPa or less (best).
◯: More than 0.12 GPa and less than 0.15 GPa (good).
Δ: More than 0.15 GPa and 0.20 GPa or less (no problem in practical use).
X: Over 0.20 GPa (there is a problem in practical use).

(8) Soluble Xylene or cyclohexanone (85 parts by mass) was added to 15 parts by mass of the polyarylate resin, and the mixture was stirred at room temperature using a wave rotor. The state of the resin solution after 1 day was evaluated according to the following criteria.
⊚: The resin solution was fluid and transparent (best).
◯: The resin solution had fluidity, but was slightly cloudy (good).
Δ: The resin solution had fluidity and was cloudy, but there was no problem in practical use.
X: The resin solution did not have fluidity, or the resin was not dissolved at all (there is a problem in practical use).

(9) Viscosity Stabilization Time 90 parts by mass of N-methylpyrrolidone was added to 10 parts by mass of polyarylate resin to obtain a resin solution. The viscosity of the obtained resin solution is measured at a temperature of 25.0 ° C. using a digital viscometer (VISCOMETER TVB-10) manufactured by Toki Sangyo Co., Ltd., an HM-1 type rotor and an HM / H2 small amount sample adapter. At that time, the time from the start of measurement until the viscosity became stable was measured.
⊚: 20 min or more (best).
◯: 15 minutes or more and less than 20 minutes (good).
Δ: 10 minutes or more and less than 15 minutes (no problem in practical use).
X: Less than 10 min (there is a problem in practical use).

Example 1
In a reaction vessel equipped with a stirrer, 10.51 parts by mass of 3,3', 5,5'-tetramethyl-4,4'-biphenol (TMBP) and 2,2-bis (4) as divalent phenol components. -Hydroxyphenyl) -4-methylpentane (BisMIBK) 89.49 parts by mass, p-tert-butylphenol (PTBP) 1.60 parts by mass as an end sealant, sodium hydroxide (NaOH) 32.67 parts by mass as an alkali , 1.56 parts by mass of a 50% by mass aqueous solution of tri-n-butylbenzylammonium chloride (TBBAC) as a polymerization catalyst and 0.51 parts by mass of sodium hydroxide as an antioxidant were added and dissolved in 2500 parts by mass of water. (Aqueous phase). Separately, 75.74 parts by mass of an isophthalic acid chloride / terephthalic acid chloride = 1/1 (molar ratio) mixture (MPC) was dissolved in 2000 parts by mass of methylene chloride (organic phase) (TMBP: BisMIBK). : PTBP: MPC: TBBAC: NaOH = 10.00: 90.00: 2.90: 101.45: 0.34: 222.18 (molar ratio)). The aqueous phase was stirred in advance, the organic phase was added to the aqueous phase under strong stirring, and polymerization was carried out at 15 ° C. for 2 hours by an interfacial polymerization method. After that, stirring was stopped, and the aqueous phase and the organic phase were decanted and separated. After removing the aqueous phase, 500 parts by mass of methylene chloride, 3000 parts by mass of pure water and 10 parts by mass of acetic acid were added to stop the reaction, and the mixture was stirred at 15 ° C. for 30 minutes. Then, the organic phase was washed with pure water 10 times, and the organic phase was added to methanol to precipitate the polymer. After filtering the precipitated polymer, it was vacuum dried at 165 ° C. for 24 hours to obtain a polyarylate resin.
When the composition of the obtained polyarylate resin was analyzed, the resin composition was as follows: TMBP: BisMIBK: PTBP: MPC: TBBAC: NaOH = 10.00: 90.00: 2.90: 101.45: 0.34: 222. It was 18 (molar ratio), which was the same as the charged composition.

Examples 2-9, Comparative Examples 1-5
As shown in Table 1, a polyarylate resin was obtained by performing the same operation as in Example 1 except that the resin composition was changed.

Table 1 shows the evaluation results of the polyarylate resins obtained in Examples 1 to 9 and Comparative Examples 1 to 5.

Since the polyarylate resins of Examples 1 to 9 were composed of divalent phenol residues specified in the present invention, they had high glass transition temperature and thermal decomposition temperature, and also had high solubility in xylene and cyclohexanone. In addition, the water vapor permeability coefficient and loss elastic modulus (E ″) of the film were low, and the tensile breaking strength and the tensile breaking elongation were high. In addition, the viscosity stabilization time was long.

Since the polyarylate resin of Comparative Example 1 used only bisphenol A without using a monomer that imparts residues represented by the general formulas (1) and (2) to the divalent phenol component, it was dissolved in xylene or cyclohexanone. The property was low and the viscosity stabilization time was short.
Since the polyarylate resin of Comparative Example 2 did not use a monomer that gives a residue represented by the general formula (2) to the divalent phenol component, it has a high water vapor permeation coefficient, low solubility in xylene and cyclohexanone, and loss elasticity. The rate (E ") was high.
Since the polyarylate resin of Comparative Example 3 did not use a monomer giving the residue represented by the general formula (1) to the divalent phenol component, the glass transition temperature was low and the viscosity stabilization time was short.
Since the polyarylate resin of Comparative Example 4 uses only a monomer that gives a residue represented by the general formula (1) to the divalent phenol component, it has a high water vapor permeation coefficient, low solubility in xylene and cyclohexanone, and loss elasticity. The rate (E ") was high.
Since the polyarylate resin of Comparative Example 5 used only the monomer giving the residue represented by the general formula (2) to the divalent phenol component, the glass transition temperature was low and the viscosity stabilization time was short.

Claims (3)

It is a polyarylate resin containing a divalent phenol residue and an aromatic divalent carboxylic acid residue , and the divalent phenol residue is 3,3', 5,5'-tetramethyl-4,4'. Poly consisting of only -biphenol residue and 2,2-bis (4-hydroxyphenyl) -4-methylpentane residue , and aromatic divalent carboxylic acid residue consisting of only terephthalic acid residue and isophthalic acid residue. Aromatic resin. A film made of the polyarylate resin according to claim 1. A laminate in which a layer of the polyarylate resin according to claim 1 or 2 is provided on a base material.