Title of Invention

A METHOD FOR PRODUCING A VINYL SULFONIC ACID HOMOPOLYMER OR COPOLYMER

Abstract (1) A vinyl sulfonic acid/ having a double bond content of 95 wt.% or more, and (i) a sodium (Na) content of 1 ppm or less, and (ii) a content of at least one metal selected from the group consisting of alkali earth metal and first row transition metal of 1 ppm or less. Alternatively, (2) a vinyl sulfonic acid, having a double bond content of 95 wt.% or more, and (i) a sodium (Na) content of 100 ppb or less, and (ii) a content of at least one metal selected from the group consisting of alkali earth metal and first row transition metal of 100 ppb or less. Further, a homopolymer or copolymer thereof, a production method thereof, or a thin-film distillation apparatus suited for the production thereof.
Full Text DESCRIPTION
VINYL SULFONIC ACID, POLYMER THEREOF, AND PRODUCTION
METHOD THEREOF
Technical Field
[0001]
The present invention mainly relates to a vinyl
sulfonic acid, a polymer thereof, a production method
thereof, an apparatus suitable for production thereof,
and an electric/electronic material comprising the vinyl
sulfonic acid or polymer thereof.
Background Art
[0002]
Vinyl sulfonic acids are attracting a great deal of
attention as a monomer for constituting a functional
polymer and a conductive material.
[0003]
However, commercially available vinyl sulfonic acids
have a double bond content of 75 wt.% or less.
Consequently, when the vinyl sulfonic acid was to be
polymerized after impregnating in a porous substrate,
polymerization did not proceed sufficiently and thus a
product functioning as a proton conductive polymer could
not be obtained.
[0004]
Patent Document 1 describes a vinyl sulfonic acid
with a purity of 98%. However, the metal content is
several ppm.
[0005]
Recently, vinyl sulfonic acids or polymers thereof
are attracting attention as a component constituting
functional polymers and conductive materials, and as a
material for electronic devices and semiconductors.
[0006]
For example, a vinyl sulfonic acid or polymer
thereof has been reported as being utilized in a resist
resin composition (Patent Document 2), a resin
composition for a resist protection film (Patent
Documents 3 and 4), a CMP slurry (Patent Documents 5 and
6), a separator for an alkali secondary battery (Patent
Documents 7 and 8), a fuel cell electrolyte membrane
(Patent Documents 1 and 9), a conductive polymer dopant
(Patent Documents 10 and 11) and the like.
Patent Document 1: WO 2006/059582
Patent Document 2: Japanese Patent Laid-Open No. 2000-
035672
Patent Document 3: Japanese Patent Laid-Open No. 10-
120968
Patent Document 4: Japanese Patent Laid-Open No. 2006-
259382
Patent Document 5: Japanese Patent Laid-Open No. 2004-
031905
Patent Document 6: Japanese Patent Laid-Open No. 2006-
179678
Patent Document 7: Japanese Patent Laid-Open No. 2 000-
195489
Patent Document 8: Japanese Patent Laid-Open No. 2003-
031198
Patent Document 9: Japanese Patent No. 4048063
Patent Document 10: National Publication of International
Patent Application No. 2005-536595
Patent Document 11: Japanese Patent Laid-Open No. 2005-
190940
[0007]
However, many of these uses dislike metal or
impurity contamination.
[0008]
For example, for a semiconductor material,
impurities, especially metal impurities contained in the
material, can cause problems such as contamination of the
wafer by diffusing into the wafer interior during the
wafer fabrication step. Further, metal contamination can
induce deteriorated reliability of the dielectric film,
current leakage, and abnormalities in film deposition and
the like, and also have an substantial adverse impact on
the semiconductor apparatus (see Patent Documents 12 to
14) .
Patent Document 12: Japanese Patent Laid-Open No. 2007-
150153
Patent Document 13: Japanese Patent Laid-Open No. 2004-
189820
Patent Document 14: Japanese Patent Laid-Open No. 2001-
250807
[0009]
Further, recently, from the perspectives that solid
polymer fuel cells utilizing a polymer electrolyte
membrane have a light burden on the environment and
reduced carbon dioxide emissions, investigations are
being carried out on their various applications, such as
for automobiles and fixed household use.
[0010]
Conventionally, a perfluoroalkyl sulfonate-type
polymer in which sulfonic acid groups are linked to side
chains on a perfluoro skeleton has been used as such a
polymer electrolyte membrane. Further, perfluoroalkyl
sulfonate-type polymers which have undergone various
improvements have been developed. However, since the
polymer production process is complex, and a fluorinated
hydrocarbon-based material, for which large cost
reductions are not easy to achieve, is used, costs
increase.
[0011]
Accordingly, hydrocarbon-based polymer electrolyte
membranes which do not use a fluorine-based polymer and
which have improved proton conductivity have been
developed. Hydrocarbon-based polymer electrolyte
membranes are easy to produce, can be applied in a large
variety of molecular structures, and have easily-
controlled physical properties. Further, from a
recycling perspective, since hydrocarbon-based polymer
electrolyte membranes do not contain a fluorine, they
have the advantage of not producing harmful substances.
[0012]
However, hydrocarbon-based polymers have worse
chemical stability than perfluoroalkyl sulfonate-type
polymers. This is due to the fact that hydrogen and
oxygen crossleak across the electrolyte membrane and
react on the electrode catalyst to produce hydrogen
peroxide, whereby radicals produced from this hydrogen
peroxide cause the membrane to deteriorate. Further,
iron ions act as a catalyst for promoting the oxidation
ability of the hydrogen peroxide, so that the membrane
deterioration is accelerated (see Non-Patent Document 1).
Non-Patent Document 1: Fuel Cell Technology and
Applications / Handbook of Fuel Cells, pp. 647-662, 2003
[0013]
However, a vinyl sulfonic acid or polymer thereof
having a sufficiently reduced metal content is as yet
unknown.
[0014]
On the other hand, various methods are known for
producing a vinyl sulfonic acid (see Non-Patent Document
2). For example, Patent Document 15 describes a method
for producing a vinyl sulfonic acid by performing a
sodium removal treatment on sodium vinyl sulfonate with
hydrochloric acid.
Further, Patent Document 16 describes a method for
producing a vinyl sulfonic acid by dehydrating isethionic
acid using diphosphate pentoxide or pyrophosphoric acid
as a dehydrating agent.
[0015]
However, in the above-described methods, a product
having sufficient quality cannot be obtained.
Non-Patent Document 2: Sango Kunichika, Takao Katagiri,
Journal of the Chemical Society of Japan, Industrial
chemistry section Vol. 64, No. 5, 1961, pp. 929-932
Patent Document 15: U.S. Pat. No. 3312735
Patent Document 16: U.S. Pat. No. 2597696
Disclosure of the Invention
Problems to be Solved by the Invention
[0016]
It is the main object of the present invention to
provide a vinyl sulfonic acid having a high double bond
content and a low metal content. Further, it is an
object of the present invention to provide a homopolymer
and a copolymer comprising this vinyl sulfonic acid as a
constituent component, and a production method thereof.
In addition, it is an object of the present invention to
provide an electric/electronic material comprising this
vinyl sulfonic acid or a polymer thereof. Still further,
it is an object of the present invention to provide an
apparatus or a method suitable for the production of the
above vinyl sulfonic acid.
Means for Solving the Problems
[0017]
Mainly for the purpose of resolving the above-
described problems, and as a result of extensive
investigations, the present invention discovered that a
vinyl sulfonic acid having excellent qualities could be
obtained, and as a result of further extensive
investigations, completed the present invention.
[0018]
Specifically, the present invention provides the
following vinyl sulfonic acids, homopolymers, copolymers,
production methods, apparatuses, and electric/electronic
materials.
[0019]
Item 1. A vinyl sulfonic acid characterized by having:
a double bond content of 95 wt.% or more; and
(i) a sodium (Na) content of 1 ppm or less; and
(ii) a content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 1 ppm or less.
[0020]
Item 1-1. The vinyl sulfonic acid according to item 1,
which is obtained by subjecting a vinyl sulfonate to a
metal removal treatment so that a metal removal rate
represented by the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0021]
Item 1-2. The vinyl sulfonic acid according to item 1,
which is obtained by subjecting a vinyl sulfonate to a
metal removal treatment with a strongly-acidic ion-
exchange resin.
[0022]
Preferably, the vinyl sulfonic acid according to
item 1-2, wherein the metal removal treatment is a
treatment in which a metal removal rate represented by
the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0023]
Item 1-3. The vinyl sulfonic acid according to item 1-1
or 1-2, obtained by purifying the product obtained from
the metal removal treatment by further subjecting such
product to thin-film distillation.
[0024]
Item 2. A vinyl sulfonic acid characterized by having:
a double bond content of 95 wt.% or more; and
(i) a sodium (Na) content of 100 ppb or less; and
(ii) a content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 100 ppb or less.
[0025]
Item 2-1. The vinyl sulfonic acid according to item 2,
which is obtained by subjecting a vinyl sulfonate to a
metal removal treatment so that a metal removal rate
represented by the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0026]
Item 2-2. The vinyl sulfonic acid according to item 2,
which is obtained by subjecting a vinyl sulfonate to a
metal removal treatment with a strongly-acidic ion-
exchange resin.
[0027]
Preferably, the vinyl sulfonic acid according to
item 2-2, wherein the metal removal treatment is a
treatment in which a metal removal rate represented by
the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0028]
Item 2-3. The vinyl sulfonic acid according to item 2-1
or 2-2, obtained by purifying the product obtained from
the metal removal treatment by further subjecting such
product to thin-film distillation.
[0029]
Item 2-4. The vinyl sulfonic acid according to item 2,
obtainable (obtained) by subjecting a vinyl sulfonate to
a metal removal treatment in which a metal removal rate
represented by the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal
removal treatment) / (acid value before metal removal
treatment)} x 100, and
purifying the product obtained from the metal
removal treatment using:
(1) a thin-film distillation apparatus wherein all or a
part of a contact with the vinyl sulfonic acid or a
composition thereof is formed from tantalum, or
(2) the thin-film distillation apparatus according to
the above (1), comprising:
a distillation tower for evaporating a distillation
raw material;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device, which is arranged externally to
the distillation tower, for condensing the vinyl sulfonic
acid vapor obtained from the outlet, and preferably, the
thin-film distillation apparatus according to the above
(1), comprising a distillation tower for evaporating the
vinyl sulfonic acid which has been subjected to the metal
removal treatment, a vinyl sulfonic acid vapor outlet
which is provided in a middle section of the distillation
tower, and a cooling device, which is arranged externally
to the distillation tower, for condensing the vinyl
sulfonic acid vapor obtained from the outlet.
[0030]
Item 2-5. The vinyl sulfonic acid according to item 2,
obtainable (obtained) by subjecting a vinyl sulfonate to
a metal removal treatment by bringing the vinyl sulfonate
into contact with a strongly-acidic ion-exchange resin,
and purifying the product obtained from the metal removal
treatment using:
(1) a thin-film distillation apparatus wherein all or a
part of a contact with the vinyl sulfonic acid or a
composition thereof are formed from tantalum, or
(2) the thin-film distillation apparatus according to
the above (1), comprising:
a distillation tower for evaporating a distillation
raw material;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device, which is arranged externally to
the distillation tower, for condensing the vinyl sulfonic
acid vapor obtained from the outlet, and preferably, the
thin-film distillation apparatus according to the above
(1), comprising a distillation tower for evaporating the
vinyl sulfonic acid which has been subjected to the metal
removal treatment, a vinyl sulfonic acid vapor outlet
which is provided in a middle section of the distillation
tower, and a cooling device, which is arranged externally
to the distillation tower, for condensing the vinyl
sulfonic acid vapor obtained from the outlet.
[0031]
Item A: A raw material for an electric/electronic
material comprising the vinyl sulfonic acid according to
item 1 or 2. Alternatively, use of the vinyl sulfonic
acid according to item 1 or 2 in order to produce an
electric/electronic material.
[0032]
Item 3. A vinyl sulfonic acid homopolymer or copolymer
obtained by polymerizing the vinyl sulfonic acid
according to item 1 or 2 alone or with one or more other
monomers copolymerizable therewith.
[0033]
Item 3-1. A vinyl sulfonic acid homopolymer comprising
the vinyl sulfonic acid according to any of items 1 to 1-
3 as a monomer, or a vinyl sulfonic acid homopolymer
comprising the vinyl sulfonic acid according to any of
items 2 to 2-5 as a monomer.
[0034]
Item 3-2. A vinyl sulfonic acid copolymer obtained by
polymerizing the vinyl sulfonic acid according to any of
items 1 to 1-3 with one or more other monomers
copolymerizable therewith, or a vinyl sulfonic acid
copolymer obtained by polymerizing the vinyl sulfonic
acid according to any of items 2 to 2-5 with one or more
other monomers copolymerizable therewith.
[0035]
Item B. A raw material for an electric/electronic
material comprising the vinyl sulfonic acid homopolymer
or copolymer according to item 3, 3-1, or 3-2.
Alternatively, use of the vinyl sulfonic acid homopolymer
or copolymer according to item 3, 3-1, or 3-2 in order to
produce an electric/electronic material.
[0036]
Item 4. A method for producing a vinyl sulfonic acid
homopolymer or copolymer, comprising a step of subjecting
the vinyl sulfonic acid according to item 1 or 2 alone or
with one or more other monomers copolymerizable therewith
to radical polymerization, photopolymerization, or
radiation polymerization.
[0037]
Item 4-1. A method for producing a vinyl sulfonic acid
homopolymer, characterized by subjecting the vinyl
sulfonic acid according to any of items 1 to 1-3 to
radical polymerization, photopolymerization, or radiation
polymerization, or a method for producing a vinyl
sulfonic acid homopolymer, characterized by subjecting
the vinyl sulfonic acid according to any of items 2 to 2-
5 to radical polymerization, photopolymerization, or
radiation polymerization.
[0038]
Item 4-2. A method for producing a vinyl sulfonic acid
copolymer, comprising subjecting the vinyl sulfonic acid
according to any of items 1 to 1-3 to radical
polymerization, photopolymerization, or radiation
polymerization with one or more other monomers
copolymerizable therewith, or a method for producing a
vinyl sulfonic acid copolymer, comprising subjecting the
vinyl sulfonic acid according to any of items 2 to 2-5 to
radical polymerization, photopolymerization, or radiation
polymerization with one or more other monomers
copolymerizable therewith.
[0039]
Item 5. A thin-film distillation apparatus for vinyl
sulfonic acid purification, wherein all or a part of a
contact with a vinyl sulfonic acid or a composition
thereof are formed from a material having a high
corrosion resistance.
[0040]
Especially, a thin-film distillation apparatus for
vinyl sulfonic acid purification, characterized in that
all or a part of a contact with a vinyl sulfonic acid or
a composition thereof are formed from tantalum.
[0041]
Item 6. The thin-film distillation apparatus according to
item 5, comprising:
a distillation tower for evaporating a distillation
raw material;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device which is arranged externally to the
distillation tower for condensing the vinyl sulfonic acid
vapor obtained from the outlet.
[0042]
Especially, the thin-film distillation apparatus
according to item 5, comprising:
a distillation tower for evaporating a vinyl
sulfonic acid which has been subjected to a metal removal
treatment;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device which is arranged externally to the
distillation tower for condensing the vinyl sulfonic acid
vapor obtained from the outlet.
[0043]
Item 7. A method for producing the vinyl sulfonic acid
according to item 1 or 2, characterized by comprising:
a step of subjecting a vinyl sulfonate to a metal
removal treatment; and
a step of purifying the product obtained from the
metal removal treatment using the thin-film distillation
apparatus according to item 5 or 6.
[0044]
Item C. The vinyl sulfonic acid according to item 1 or 2,
obtainable (obtained) by subjecting a vinyl sulfonate to
a metal removal treatment in which a metal removal rate
represented by the following formula is 95% or more,
Metal removal rate (%} = {(acid value after metal
removal treatment) / (acid value before metal removal
treatment)} x 100, and
purifying the product obtained from the metal
removal treatment using the thin-film distillation
apparatus according to item 5 or 6.
[0045]
Especially, the vinyl sulfonic acid according to
item 2, obtainable (obtained) by subjecting a vinyl
sulfonate to a metal removal treatment in which a metal
removal rate represented by the following formula is 95%
or more:
Metal removal rate (%) = {(acid value after metal
removal treatment) / (acid value before metal removal
treatment)} x 100, and
purifying the product obtained from the metal
removal treatment using the thin-film distillation
apparatus according to item 6.
[0046]
Item D. The vinyl sulfonic acid according to item 1 or 2,
obtainable (obtained) by subjecting a vinyl sulfonate to
a metal removal treatment by bringing the vinyl sulfonate
into contact with a strongly-acidic ion-exchange resin,
and purifying the product obtained from the metal removal
treatment using the thin-film distillation apparatus
according to item 5 or 6.
[0047]
Especially, the vinyl sulfonic acid according to
item 2, obtainable (obtained) by subjecting a vinyl
sulfonate to a metal removal treatment by bringing the
vinyl sulfonate into contact with a strongly-acidic ion-
exchange resin, and purifying the product obtained from
the metal removal treatment using the thin-film
distillation apparatus according to item 6.
[0048]
Item 8. An electric/electronic material comprising the
vinyl sulfonic acid according to item 1 or 2.
[0049]
Item 9. An electric/electronic material comprising the
vinyl sulfonic acid homopolymer or copolymer according to
item 3.
[0050]
Item 10. A polymer electrolyte membrane for a fuel cell
comprising the vinyl sulfonic acid homopolymer or
copolymer according to item 3.
[0051]
Item E. A fuel cell comprising the polymer electrolyte
membrane according to item 10.
[0052]
Item 11. A photoresist composition comprising the vinyl
sulfonic acid according to item 1 or 2 or the vinyl
sulfonic acid homopolymer or copolymer according to item
3.
[0053]
Item 12. A conductive polymer composition comprising the
vinyl sulfonic acid homopolymer or copolymer according to
item 3 as a dopant.
[0054]
The present invention will now be described in more
detail.
[0055]
In the present specification, unless stated
otherwise, "ppm" refers to "weight ppm" and "ppb" refers
to "weight ppb".
[0056]
1. Vinyl sulfonic acid
(1) Double bond content
The vinyl sulfonic acid according to the present
invention has a double bond content of 95 wt.% or more,
especially 97 wt.% or more, and more especially 99 wt.%
or more.
[0057]
In the present invention, "double bond content"
means a value determined by quantifying an amount of
double bonds and calculating this in terms of a purity of
the vinyl sulfonic acid, or in other words, multiplying a
number of moles of double bonds in 100 g of the vinyl
sulfonic acid by 1 gram equivalent of the vinyl sulfonic
acid.
[0058]
A double bond content can be determined from the
following formula based on a measured iodine value.
Double bond content (wt.%) = (iodine value) x
(108.1/2) / 126.9
(Here, 108.1 is the molecular weight of vinyl
sulfonic acid, and 126.9 is the atomic weight of iodine.)
[0059]
(2) Metal content
The vinyl sulfonic acid according to the present
invention has a (i) sodium (Na) content of 1 ppm or less,
preferably 500 ppb or less, and especially preferably 300
ppb or less. Further, the vinyl sulfonic acid according
to the present invention has (ii) a content of at least
one metal selected from the group consisting of alkali
earth metal and first row transition metal of 1 ppm or
less, preferably 800 ppb or less, and especially
preferably 500 ppb or less.
[0060]
Especially, the vinyl sulfonic acid according to the
present invention has a (i) sodium (Na) content of 100
ppb or less, preferably 50 ppb or less, and especially
preferably 10 ppb or less. Further, the vinyl sulfonic
acid according to the present invention has (ii) a
content of at least one metal selected from the group
consisting of alkali earth metal and first row transition
metal of 100 ppb or less, preferably 50 ppb or less, and
especially preferably 20 ppb or less.
[0061]
Examples of alkali earth metal include calcium (Ca).
[0062]
Examples of first row transition metal include iron
(Fe), chromium (Cr), and nickel (Ni).
[0063]
An example of a preferred vinyl sulfonic acid
according to the present invention has:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of at least one metal selected from
first row transition metal of 1 ppm or less.
[0064]
An example of a more preferred vinyl sulfonic acid
has:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of the metals iron (Fe), chromium
(Cr), and nickel (Ni) of 1 ppm or less, respectively.
[0065]
An example of an especially preferred vinyl sulfonic
acid has:
(i) a sodium (Na) content of 100 ppb or less,
(ii) a calcium (Ca) content of 100 ppb or less, and
(iii) a content of at least one metal selected from
first row transition metal of 100 ppb or less.
[0066]
An example of an even more especially preferred
vinyl sulfonic acid has:
(i) a sodium (Na) content of 100 ppb or less,
(ii) a calcium (Ca) content of 100 ppb or less, and
(iii) a content of the metals iron (Fe), chromium
(Cr), and nickel (Ni) of 100 ppb or less, respectively.
[0067]
Further, it is also preferred that the vinyl
sulfonic acid has a low lithium (Li), magnesium (Mg),
aluminum (Al), potassium (K) , manganese (Mn), copper (Cu),
zinc (Zn), zirconium (Zr), tin (Sn), and lead (Pb)
content, respectively. A vinyl sulfonic acid having a
respective content of these metals of about 100 ppb or
less, and preferably about 50 ppb or less, can be
preferably used.
[0068]
The metal content can be measured based on a well-
known method. For example, methods such as ICP mass
spectrometry (ICP-MS), ICP emission spectrometric
analysis (ICP-OES / ICP-AES), and atomic adsorption
spectrometry can be used. Generally, it is preferred to
use ICP-MS.
[0069]
The vinyl sulfonic acid according to the present
invention has reduced impurity and metal contents, and
can be preferably used as a material for an
electric/electronic material. In other words, the vinyl
sulfonic acid according to the present invention can be
preferably used as a material in a production of an
electric/electronic material.
[0070]
Examples of an electric material include a fuel cell
electrolyte membrane, an organic EL thin film, and a
battery peripheral material. Examples of an electronic
material include a semiconductor peripheral material, a
conductive polymer material, and a circuit board material.
[0071]
For example, a homopolymer formed by impregnating
the vinyl sulfonic acid in a substrate and then carrying
out homopolymerization, or a copolymer formed by
impregnating the vinyl sulfonic acid in a substrate and
then copolymerizing with another polymerizable monomer,
can be used as a fuel cell polymer electrolyte.
[0072]
Further, the vinyl sulfonic acid, or a homopolymer
formed by polymerizing just this vinyl sulfonic acid or a
copolymer formed by copolymerizing the vinyl sulfonic
acid with another polymerizable monomer, can be used as a
material for a photoresist composition, a polymer binder
or a separator for a battery. In addition, the product
obtained by polymerization of the vinyl sulfonic acid can
be used as an anionic polymer acid dispersant in a
polishing slurry for semiconductor fabrication, or as a
conductive polymer dopant used in an EL device, such as
an organic light-emitting diode (OLED).
[0073]
2. Vinyl sulfonic acid production method
A method for producing the vinyl sulfonic acid
according to the present invention is not especially
limited, as long as the vinyl sulfonic acid has the
above-described characteristics. Vinyl sulfonic acids
obtained by the following production methods are
preferred.
[0074]
Production method 1: A method for producing the
vinyl sulfonic acid, comprisng a step of subjecting a
vinyl sulfonate to a metal removal treatment, wherein the
metal removal rate in the metal removal treatment
represented by the following formula is 95% or more:
Metal removal rate (%) = {(acid value after metal
removal treatment) / (acid value before metal removal
treatment)} x 100.
[0075]
Production method 2: A method for producing the
vinyl sulfonic acid, comprisng a step of subjecting a
vinyl sulfonate to a metal removal treatment, wherein the
metal removal treatment is carried out using a strongly-
acidic ion-exchange resin.
[0076]
Production method 3: The production method according
to the above-described production method 1 or 2, further
comprisng a step of purifying the product obtained from
the metal removal treatment using a thin-film
distillation apparatus.
[0077]
Production method 4: The production method according
to the above-described production method 3, wherein the
thin-film distillation apparatus is an apparatus in which
all or a part of a contact with the vinyl sulfonic acid
or a composition thereof are formed from a material
having a high corrosion resistance.
[0078]
Production method 5: The production method according
to the above-described production method 3, wherein the
thin-film distillation apparatus is an apparatus in which
all or a part of a contact with the vinyl sulfonic acid
or a composition thereof are made from tantalum.
[0079]
Production method 6: The production method according
to the above-described production method 4 or 5, wherein
the thin-film distillation apparatus comprises:
a distillation tower for evaporating a distillation
raw material;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device which is arranged externally to the
distillation tower for condensing the vinyl sulfonic acid
vapor obtained from the outlet.
[0080]
Examples of the raw material vinyl sulfonate include
sodium salts, potassium salts, lithium salts, or a
mixture thereof. Of these, it is especially preferred to
use sodium vinyl sulfonate.
[0081]
The vinyl sulfonate may be provided in the form of a
composition. For example, in addition to a vinyl
sulfonate, a composition including an isethionate or a
salt of a bis-sulfoethyl ether may also be used as the
raw material. When using a composition, a ratio of the
vinyl sulfonate based on the whole composition is
generally about 25 wt.% or more.
[0082]
The term "metal removal treatment" refers to a
treatment in which metal is removed from the vinyl
sulfonate and substituted with hydrogen. In other words,
the term "metal removal treatment" refers to a treatment
in which metal ions are removed from the vinyl sulfonate,
which is converted into a vinyl sulfonic acid.
[0083]
The metal removal treatment step can be illustrated
by the following general formula.
CH2=CHS03M -> CH2=CHS03H
(wherein M represents a metal to form a salt,
specifically, sodium, potassium and the like)
[0084]
The metal removal rate is preferably 95% or more,
especially preferably 97% or more, and more especially
preferably 99% or more.
[0085]
The metal removal rate refers to a value calculated
by the following formula.
Metal removal rate (%) = { (acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0086]
Stated another way, the metal removal rate is the
rate of the metal contained in the raw material converted
into hydrogen. For example, if a sodium salt is used as
the raw material, the metal removal rate is the
conversion rate from sodium into hydrogen (the sodium
conversion rate) . Stated even another way, the metal
removal rate is the rate of the decrease of the metal
salt compound contained in the raw material.
[0087]
The metal removal rate may be determined by
measuring an acid value based on a known method. For
example, the metal removal rate may be determined by
measuring an acid value based on neutralization titration.
[0088]
If the metal removal rate is 95% or more, the
degradation of the compound or impact thereof is
substantially reduced. Further, this also allows the
introduction of thin-film distillation into the
purification step carried out after the metal removal
treatment, thereby enabling large-scale distillation to
be carried out at a high recovery rate. In addition, a
high-quality vinyl sulfonic acid can be obtained, which
allows a vinyl sulfonic acid having little discoloration
when it is distilled off in the distillation step to be
obtained. Moreover, a vinyl sulfonic acid which hardly
changes in color over time can be obtained.
[0089]
The metal removal treatment method is not especially
limited, although it is preferred to use a strongly-
acidic ion-exchange resin. In other words, it is
preferred to carry out the metal removal treatment by
bringing the vinyl sulfonate into contact with the
strongly-acidic ion-exchange resin.
[0090]
The method for bringing the vinyl sulfonate into
contact with the strongly-acidic ion-exchange resin can
be carried out by a common method. However, it is
preferred to fill the ion-exchange resin into a column
and pass an aqueous solution of the vinyl sulfonate
therethrough, as this allows ion exchange to be performed
reliably.
[0091]
The type of the strongly-acidic ion-exchange resin
is not especially limited, as long as the advantageous
effects of the present invention can be enjoyed. A known
ion-exchange resin may be appropriately selected. For
example, a compound having a strong acid group on a side
chain of a crosslinked insoluble organic polymer compound
can be used. Examples of the strong acid group include a
sulfuric acid group, a phosphoric acid group, and a
sulfonic acid group.
[0092]
Specific examples of the strongly-acidic ion-
exchange resin include Diaion (registered trademark)
(SK1B, SK116, PK216 etc.), Amberlite (registered
trademark) (IR-120B, IR-124 etc.), Dowex (registered
trademark) (50wx8, HCR-S, Monosphere 650C etc.), and
Lewatit (registered trademark) (S-100 etc.).
[0093]
By carrying out the metal removal treatment using
the strongly-acidic ion-exchange resin, the vinyl
sulfonate content can be reduced by a high ratio,
degradation of the compound can be suppressed, and the
yield can be improved.
[0094]
Further, a vinyl sulfonic acid having excellent
quality and hardly any discoloration can be obtained.
[0095]
Further, by using the strongly-acidic ion-exchange
resin, the metal removal treatment can be carried out
efficiently with just one treatment.
[0096]
In addition, this also allows the introduction of
thin-film distillation into the subsequent purification
step, thereby enabling large-scale distillation to be
carried out.
[0097]
From perspectives such as reducing a generation of
gases and further improving a recovery rate in the
distillation, the metal removal rate in the metal removal
treatment using the strongly-acidic ion-exchange resin is
preferably 95% or more, especially preferably 97% or more,
and more especially preferably 99% or more.
[0098]
It is preferred to further purify the treated
product obtained from the metal removal treatment by a
known method. The term "product obtained from the metal
removal treatment" means the product obtained by
performing the metal removal treatment on the vinyl
sulfonate or composition thereof. Specifically, this
term means the vinyl sulfonic acid or composition thereof
obtained from the metal removal treatment.
[0099]
The purification method can be appropriately set
from among known methods. However, purification carried
out by distillation, especially thin-film distillation,
is preferred.
[0100]
By carrying out the purification by thin-film
distillation, a vinyl sulfonic acid can be obtained which
has excellent quality, little discoloration when it is
distilled off, and hardly any problems with discoloration
over time. Further, this also enables large-scale
purification to be carried out at a high recovery rate.
[0101]
Especially, it is preferred to carry out
purification by thin-film distillation of the treated
product obtained from the metal removal treatment carried
out so that the metal removal rate of the vinyl sulfonate
is 95% or more.
[0102]
Further, it is preferred to carry out purification
by thin-film distillation of the treated product obtained
from the metal removal treatment carried out by bringing
the vinyl sulfonate into contact with the strongly-acidic
ion-exchange resin.
[0103]
Especially, it is preferred to subject the treated
product obtained from the metal removal treatment, which
was carried out by bringing the vinyl sulfonate into
contact with the strongly-acidic ion-exchange resin so
that the metal removal rate is 95% or more, to thin-film
distillation.
[0104]
Consequently, degradation of the compound during
distillation is reduced, and a recovery rate can be
further improved. Further, a generation of gases during
distillation can be reduced, and a degree of vacuum can
be stably maintained. In addition, continuous
distillation becomes possible, and large-scale
distillation can be carried out. Moreover, the residue
can be obtained as a fluid product rather than a high-
viscosity solid. Therefore, cleaning of the apparatus
and equipment is easier. Still further, the obtained
vinyl sulfonic acid has a high quality, and a basically
colorless vinyl sulfonic acid can be obtained when it is
distilled off. Moreover, a vinyl sulfonic acid which
hardly changes in color over time can be obtained.
[0105]
The thin-film distillation can be carried out by a
known method.
[0106]
The thin-film distillation conditions can be
appropriately set. However, usually, the temperature is
about 150 to 250°C, and preferably about 150 to 230°C.
[0107]
In addition, the pressure is usually about 10 to 400
Pa, and preferably about 10 to 200 Pa.
[0108]
Under such conditions, degradation and
polymerization can be further suppressed.
[0109]
The thin-film distillation can optionally be carried
out twice or more, and can even be carried out
continuously.
[0110]
A known thin-film distillation apparatus can be used.
However, an apparatus in which all or a part of a contact
with the vinyl sulfonic acid or a composition thereof is
formed from a material having a high corrosion resistance
is preferred.
[0111]
In addition, so that the distillation residue does
not contaminate the product, the thin-film distillation
apparatus preferably has a vinyl sulfonic acid vapor
outlet which is provided in a middle section of the
distillation tower, and a cooling device which is
arranged externally to the distillation tower.
[0112]
Specific examples of the thin-film distillation
apparatus include the apparatus described in the
following section 3.
[0113]
The method for producing the vinyl sulfonic acid
according to the present invention may optionally include
further steps to those described above, such as a step of
purifying the raw material.
[0114]
Further, known technology relating to the production
of vinyl sulfonic acids may also be included as necessary.
[0115]
From the above-described production methods, a vinyl
sulfonic acid can be obtained which has a high double
bond content and a low metal content. In other words,
the vinyl sulfonic acid used in the present invention
includes the vinyl sulfonic acids which can be obtained
by any of production methods 1 to 6. A vinyl sulfonic
acid obtained by the above-described production methods
has little discoloration and hardly any change in color
over time.
[0116]
3. Apparatus
The present invention provides a thin-film
distillation apparatus which can be preferably used in
the method for producing the vinyl sulfonic acid. In
other words, the present invention provides a thin-film
distillation apparatus for vinyl sulfonic acid production,
or a thin-film distillation apparatus for vinyl sulfonic
acid purification.
[0117]
In the thin-film distillation apparatus according to
the present invention, all or a part of a contact with
the vinyl sulfonic acid or a composition thereof is
formed from a material having a high corrosion resistance.
[0118]
The term "a contact with the vinyl sulfonic acid or
a composition thereof" (hereinafter also referred to as
"vinyl sulfonic acid contact region") means, for example,
a region that is in contact with the vinyl sulfonic acid
composition serving as the distillation raw material
after it has undergone the metal removal treatment, the
evaporated vinyl sulfonic acid vapor, or the condensed
vinyl sulfonic acid formed from the vinyl sulfonic acid
vapor. These regions are also referred to as "liquid
contact region" and/or "gas contact region".
[0119]
Examples of the members included in the vinyl
sulfonic acid contact region include a liquid feed pipe,
the inner walls of the distillation tower, a stirring
member, a wiper member, a cooling member, a stirring seal
member, a distillation raw material introduction port, a
distillate line, a receiver, a residue discharge line and
the like.
[0120]
Examples of the material having a high corrosion
resistance include JIS standard R-3503 borosilicate
glass-1 and metal materials determined as being
completely resistant to corrosion by a corrosion
resistance test.
[0121]
JIS Standard R-3503 borosilicate glass-1 is a glass
which, based on the JIS (Japanese Industrial Standards)
standard R-3503, has been given a rating of having a
linear thermal expansion coefficient of 3.5xl0~6-K_1 or
less and an alkali elution amount of 0.10 mL/g or less or
31 ng/g or less.
[0122]
Further, the term "metal materials determined as
being completely resistant to corrosion by a corrosion
resistance test" refers to metal materials having a rate
of corrosion of 0.05 mm/year or less. Examples of the
corrosion resistance test include a method in which,
based on the method of item a. in "Chemical Apparatus
Handbook" (edited by the Society for Chemical Engineers,
Japan, published by Maruzen, 1970, p. 500), a test piece
is dipped in 165°C vinyl sulfonic acid and then the
change in weight and the change in appearance after a
certain time period are measured.
[0123]
Examples of the glass which is categorized as JIS
Standard borosilicate glass-1 include products such as
Pyrex (registered trademark), Hario (registered
trademark), and Duran (registered trademark).
[0124]
Further, examples of the metal material determined
as being completely resistant to corrosion include
tantalum.
[0125]
If the vinyl sulfonic acid contact region is formed
from the material having a high corrosion resistance,
contamination of impurities from the material or the
region can be suppressed. Conventionally, a material
such as SUS was used as a metal for the vinyl sulfonic
acid contact region, so that impurities from this
material contaminated the vinyl sulfonic acid. However,
according to the above-described configuration, the level
of contamination of impurities due to the material is
reduced.
[0126]
An example in which tantalum is used as the material
having a high corrosion resistance will now be described.
[0127]
The term "all or a part of the vinyl sulfonic acid
contact region is made from tantalum", or in other words,
formed from tantalum, includes a case in which all or at
least one of the members comprised the vinyl sulfonic
acid contact region is/are made from tantalum. Further,
this also includes a case in which at least a part of one
member constituting the vinyl sulfonic acid contact
region is made from tantalum, specifically, is formed
from tantalum.
[0128]
Further, the term "made from tantalum" means being
formed from a material which essentially does not include
components other than tantalum. In other words, the term
"made from tantalum" means being formed from a material
having a content of components other than tantalum of
only less than 0.3 wt.%, and especially less than 300 ppm.
[0129]
Examples of the apparatus according to the present
invention include an apparatus in which only the stirring
rotation member and/or wiper member is made from tantalum,
an apparatus in which the whole stirring rotation member
is made from tantalum, an apparatus in which a part of
the wiper member is made from tantalum, and an apparatus
in which all or a part of the thin-film forming member is
made from tantalum. It is especially preferred that the
members or sections which conventionally are formed from
a metal are made from tantalum.
[0130]
More specifically, for a falling thin-film
distillation apparatus, an example thereof includes an
apparatus in which all or a part of the stirring rotation
member and wiper member is made from tantalum.
Further, for a centrifugal thin-film distillation
apparatus, an example thereof includes an apparatus in
which the rotor member and the disk member are made from
tantalum.
[0131]
An example of the apparatus is the following
apparatus A, which comprises:
an introduction port for the distillation raw
material,
a distillation tower for evaporating the introduced
raw material,
a stirring drive member arranged at the apex of the
distillation tower,
a stirring rotation member made from tantalum, which
is arranged inside the distillation tower,
a wiper member comprising at least a section made
from tantalum, which is connected to the stirring
rotation member,
a vacuum pump suction port connected to the
distillation tower,
a cooling member arranged inside the distillation
tower,
a vinyl sulfonic acid receiver which receives the
vinyl sulfonic acid condensed by the cooling device, and
a residue receiver arranged on the bottom of the
distillation tower.
[0132]
For example, the apparatus illustrated in Figure 1
is included in this example.
[0133]
Further, an example of another apparatus includes an
apparatus configured so that the vinyl sulfonic acid
vapor exits from a middle section of the distillation
tower, and is delivered to a cooling member provided
externally to the distillation tower.
[0134]
Such an apparatus further suppresses contamination
of the distillation residue in the vinyl sulfonic acid
vapor because the cooling member is provided externally
to the distillation tower. Further, since the vinyl
sulfonic acid vapor is discharged from a middle section
of the distillation tower, contamination of impurities
due to corrosion and the like of the tower apex section
of the stirring drive member and the like can be
suppressed.
[0135]
The term "middle section" means, based on a length
from the apex to the bottom of the distillation tower
being 100, a position which is about 30 to 60, and
preferably 40 to 50, the way down from the apex.
[0136]
An example of such an apparatus is the following
apparatus B, which comprises:
an introduction port for the distillation raw
material,
a distillation tower for evaporating the introduced
raw material,
a stirring drive member arranged at the apex of the
distillation tower,
a stirring rotation member made from tantalum, which
is arranged inside the distillation tower,
a wiper member comprising at least a section made
from tantalum, which is connected to the stirring
rotation member,
a residue receiver arranged on the bottom of the
distillation tower,
a vinyl sulfonic acid outlet which is provided in a
middle section of the distillation tower,
a cooling device which is arranged externally to the
distillation tower for condensing the vinyl sulfonic acid
vapor from the outlet,
a vinyl sulfonic acid receiver which receives the
vinyl sulfonic acid condensed by the cooling device, and
a vacuum pump suction port connected to the vinyl
sulfonic acid receiver.
[0137]
For example, the apparatus illustrated in Figure 2
is included in this example.
[0138]
The distillation tower usually has a heating means.
Further, the distillation tower may optionally have a
known means for sensing the temperature and the like.
[0139]
The stirring drive member is a power member for
rotating the stirring rotation member. The stirring
drive member is usually sealed by a stirring seal member
to prevent corrosion due to vapor produced in the
distillation tower.
[0140]
By carrying out purification using the above-
described apparatuses, a vinyl sulfonic acid can be
obtained which has a high double bond content and a low
metal content. In other words, the vinyl sulfonic acid
used in the present invention includes a vinyl sulfonic
acid obtained by carrying out purification using the
above-described thin-film distillation apparatuses.
[0141]
Especially, a vinyl sulfonic acid having:
a double bond content of 95 wt.% or more; and
(i) a sodium (Na) content of 100 ppb or less; and
(ii) a content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 100 ppb or less, can be suitably
produced by carrying out purification using the above-
described apparatuses A and B.
[0142]
Especially, the inventive vinyl sulfonic acid can be
preferably produced using the apparatus B.
[0143]
4. Homopolymer
The vinyl sulfonic acid homopolymer according to the
present invention can be obtained by polymerizing the
above-described vinyl sulfonic acid as a homopolymer. In
other words, the present invention provides a homopolymer
having the above-described vinyl sulfonic acid as a
constituent component.
[0144]
Since the vinyl sulfonic acid homopolymer according
to the present invention is obtained from a vinyl
sulfonic acid having a high double bond content and a low
metal content, the homopolymer has hardly any impurities,
a low metal content, and excellent quality.[0145]
Preferably, as the metal content, the polymer
according to the present invention has (i) a sodium (Na)
content of 1 ppm or less, and (ii) a content of at least
one metal selected from the group consisting of alkali
earth metal and first row transition metal of 1 ppm or
less.
[0146]
Especially:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of at least one metal selected from
first row transition metal of 1 ppm or less.
[0147]
More preferably:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of the metals iron (Fe), chromium
(Cr), and nickel (Ni) of 1 ppm or less, respectively.
[0148]
Especially preferably, the polymer according to the
present invention has, as the metal content, (i) a sodium
(Na) content of 100 ppb or less, and (ii) a content of at
least one metal selected from the group consisting of
alkali earth metal and first row transition metal of 100
ppb or less.
[0149]
Especially, (i) a sodium (Na) content of 100 ppb or
less, (ii) a calcium (Ca) content of 100 ppb or less, and
(iii) a content of at least one metal selected from first
row transition metal of 100 ppb or less.
[0150]
More preferably, (i) a sodium (Na) content of 100
ppb or less, (ii) a calcium (Ca) content of 100 ppb or
less, and (iii) a content of the metals iron (Fe),
chromium (Cr) , and nickel (Ni) of 100 ppb or less,
respectively.
[0151]
The molecular weight of the homopolymer can be based
on the purpose, and may be, but is not limited to, about
500 to 400,000, and especially about 2,000 to 300,000, in
terms of weight average molecular weight as measured by
size exclusion chromatography (hereinafter, "SEC").
[0152]
Although SEC can be divided into gel permeation
chromatography (GPC), in which the mobile phase is an
organic solvent, and gel filtration chromatography (GFC),
in which the mobile phase is an aqueous solution, the SEC
in the present specification includes both of these
methods.
[0153]
The vinyl sulfonic acid homopolymer according to the
present invention has a low impurity content, a low metal
content, excellent quality, and can be preferably used as
a raw material for an electric/electronic material. In
other words, the vinyl sulfonic acid homopolymer
according to the present invention can be preferably used
as a raw material in the production of an
electric/electronic material.
[0154]
Examples of the electric material include an
electrolyte membrane for a fuel cell, an organic EL thin
film, and a battery peripheral material.
[0155]
Examples of the electronic material include a
semiconductor peripheral material, a conductive polymer
material, and a circuit board material.
[0156]
More specifically, the polymer according to the
present invention can be used as a polymer for a fuel
cell electrolyte membrane, a polymer for a photoresist, a
conductive polymer dopant, a polymer for an organic EL
thin film and the like.
[0157]
Especially, the polymer according to the present
invention can be preferably used for the electronic
material, for example in fields in which it is important
to prevent metal contamination, such as semiconductors.
[0158]
5. Homopolymer production method
A method for producing the vinyl sulfonic acid
homopolymer is not especially limited. However,
generally, the method is carried out by radical
polymerization, photopolymerization, or radiation
polymerization.
[0159]
The radical polymerization is carried out by adding
a small amount of an initiator to the vinyl sulfonic acid
or an aqueous solution thereof. As the initiator, a
peroxide, a persulfate, an azo compound or a redox
initiator can be used.
[0160]
The photopolymerization is carried out by
irradiating light on the vinyl sulfonic acid or an
aqueous solution thereof. For example, the irradiation
can be carried out using solar rays, UV rays and the like.
During the irradiation, a photopolymerization initiator,
a photopolymerization promotor and the like may
optionally be added. It is especially preferred to carry
out the photopolymerization in the presence of N,N-
dimethylformamide.
[0161]
The radiation polymerization is carried out by
irradiating radioactive rays on the vinyl sulfonic acid
or an aqueous solution thereof.
[0162]
To further reduce the metal content, the homopolymer
according to the present invention may be purified by a
known method. The purification method is not especially
limited. Examples thereof include solvent
reprecipitation and an ion-exchange method.
[0163]
The solvent reprecipitation is a purification method
in which a polymer is dissolved in as small an amount of
solvent as possible, and then the resultant mixture is
added dropwise to a solvent having a lower solubility for
this polymer to cause a precipitate to form. The ion-
exchange method is a purification method in which a
polymer is dissolved in a solvent, and the metal ions are
exchanged using an ion-exchange resin.
[0164]
6. Copolymer
The copolymer according to the present invention is
a copolymer which has the above-described vinyl sulfonic
acid as a constituent component. More specifically, the
copolymer according to the present invention comprises
the above-described vinyl sulfonic acid as an essential
monomer.
[0165]
The vinyl sulfonic acid copolymer according to the
present invention can be obtained by copolymerizing the
above-described vinyl sulfonic acid with one or two or
more other monomers.
[0166]
These "other monomers" are polymerizable compounds
different from the above-described vinyl sulfonic acid,
which serve as one of the constituent components of the
copolymer.
[0167]
These other monomers are not especially limited, as
long as they are a substance that is copolymerizable with
the above-described vinyl sulfonic acid. A vinyl monomer
can be preferably used as the other monomer.
[0168]
Examples of the vinyl monomer include a vinyl
monomer containing a sulfonic acid group, a vinyl monomer
containing a carboxyl group, a vinyl monomer containing
an ester group, a vinyl monomer containing nitrogen, a
vinyl monomer containing halogen, an aliphatic vinyl
monomer, and an aromatic vinyl monomer.
[0169]
Specifically, examples of the vinyl monomer
containing the sulfonic acid group include acrylamido
methylpropane sulfonic acid, styrene sulfonic acid, and
(meth)allyl sulfonic acid.
[0170]
Examples of the vinyl monomer containing the
carboxyl group include (meth)acrylic acid.
[0171]
Examples of the vinyl monomer containing the ester
group include a (meth)acrylic acid ester and vinyl
acetate.
[0172]
Examples of the (meth)acrylic acid ester include
(meth)acrylic acid esters of monoalcohols, such as methyl
(meth)acrylate, ethyl (meth)acrylate, and hydroxyethyl
(meth)acrylate, and (meth)acrylic acid esters of
polyhydric alcohols, such as trimethylolpropane
tri(meth)acrylate and tetraethylene glycol
di(meth)acrylate.
[0173]
Examples of the vinyl monomer containing nitrogen
include allylamine, vinylpyrrolidone, vinylimidazole,
vinylpyridine, vinylformamide, (meth)acrylamide,
propylacrylamide, (meth)acrylonitrile, and
cyanomethylstyrene.
[0174]
Examples of the vinyl monomer containing halogen
include vinyl chloride, chloroprene, (meth)allylchloride,
and chloroethyl vinyl ether.
[0175]
Examples of the aliphatic vinyl monomer include
ethylene and propylene.
[0176]
Examples of the aromatic vinyl monomer include
styrene, a-methyl styrene, chloromethyl styrene, and
divinyl benzene.
[0177]
As the above-described other monomers, just one kind
or two kinds or more may be used.
[0178]
For example, the copolymer according to the present
invention includes a copolymer obtained by copolymerizing
the vinyl sulfonic acid with at least one kind selected
from the group consisting of (meth)acrylic acid, a
(meth)acrylic acid ester, a (meth)acrylic acid amide, and
a (meth)acrylonitrile.
[0179]
Further, in the present specification,
"(meth)acrylic acid" means acrylic acid and/or
methacrylic acid. Similarly, "(meth)acrylic acid ester"
means acrylic acid ester and/or methacrylic acid ester,
"(meth)acrylic acid amide" means acrylic acid amide
and/or methacrylic acid amide, and "(meth)acrylonitrile"
means acrylonitrile and/or methacrylonitrile.
[0180]
It is preferred that the above-described monomer has
a low metal content.
[0181]
For example, it is preferred to use a monomer
having:
(i) a sodium (Na) content of 100 ppb or less,
especially 50 ppb or less, and
(ii) a content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 100 ppb or less, and especially about
50 ppb or less.
[0182]
Examples of the alkali earth metal include calcium
(Ca) .
[0183]
Examples of the first row transition metal include
iron (Fe), chromium (Cr), and nickel (Ni).
[0184]
It is especially preferred to use a monomer having
(i) a sodium (Na) content of 100 ppb or less, and
especially 50 ppb or less, (ii) a calcium (Ca) content of
100 ppb or less, and especially 50 ppb or less, and (iii)
a content of the metals iron (Fe), chromium (Cr), and
nickel (Ni), respectively, of 100 ppb or less, and
especially 50 ppb or less.
[0185]
The reduction of the metal content in these monomers
can be carried out by a known method, and is usually
carried out by distillation or sublimation.
[0186]
During this process, to prevent polymerization of
the monomer, it is preferred to carry out the process
under a reduced pressure to avoid a high temperature, and
also to add a suitable polymerization inhibitor.
[0187]
Examples of the polymerization inhibitor include
hydroquinone, hydroquinone monomethyl ether,
phenothiazine, 4-tertbutylcatechol, 3,5-dibutyl-4-
hydroxytoluene, and 2,6-dinitro-p-cresol.
[0188]
Since the vinyl sulfonic acid copolymer according to
the present invention is obtained from a vinyl sulfonic
acid having a high double bond content and a low metal
content, the copolymer has a low impurity content, a low
metal content, and excellent quality.
[0189]
The copolymer according to the present invention
comprises copolymers having in the copolymer (i) a sodium
(Na) content of 1 ppm or less, and (ii) a content of at
least one metal selected from the group consisting of
alkali earth metal and first row transition metal of 1
ppm or less.
[0190]
Especially, the copolymer according to the present
invention comprises copolymers having:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of at least one metal selected from
first row transition metal of 1 ppm or less.
[0191]
More especially, the copolymer according to the
present invention comprises copolymers having:
(i) a sodium (Na) content of 1 ppm or less,
(ii) a calcium (Ca) content of 1 ppm or less, and
(iii) a content of the metals iron (Fe), chromium
(Cr), and nickel (Ni) of 1 ppm or less, respectively.
[0192]
The copolymer according to the present invention
comprises copolymers having in the copolymer (i) a sodium
(Na) content of 200 ppb or less, and (ii) a content of at
least one metal selected from the group consisting of
alkali earth metal and first row transition metal of 200
ppb or less.
[0193]
Especially, the copolymer according to the present
invention comprises copolymers having:
(i) a sodium (Na) content of 200 ppb or less,
(ii) a calcium (Ca) content of 200 ppb or less, and
(iii) a content of at least one metal selected from
first row transition metal of 200 ppb or less.
[0194]
More especially, the copolymer according to the
present invention comprises copolymers having:
(i) a sodium (Na) content of 200 ppb or less,
(ii) a calcium (Ca) content of 200 ppb or less, and
(iii) a content of the metals iron (Fe), chromium
(Cr), and nickel (Ni) of 200 ppb or less, respectively.
[0195]
A ratio of the monomers constituting the copolymer
can be set based on the purpose, and is not especially
limited. However, usually, this ratio is 1 to 99 mole%,
and especially about 10 to 90 mole%, of the vinyl
sulfonic acid to 99 to 1 mole%, and especially about 90
to 10 mole%, of the other monomer.
[0196]
For example, the copolymer according to the present
invention comprises copolymers obtained by polymerizing
10 to 90 mole% of the vinyl sulfonic acid and 90 to 10
mole% of the other monomer.
[0197]
The molecular weight of the copolymer can be set
based on the purpose, and may be, but is not limited to,
about 500 to 50,000,000, and especially about 2,000 to
5,000,000, in terms of weight average molecular weight as
measured by SEC.
[0198]
The vinyl sulfonic acid copolymer according to the
present invention has a low metal content, and can be
preferably used as a raw material for an
electric/electronic material.
[0199]
Examples of the electric material include a fuel
cell electrolyte membrane, an organic EL thin film, and a
battery peripheral material.
[0200]
Examples of the electronic material include a
semiconductor peripheral material, a conductive polymer
material, and a circuit board material.
[0201]
More specifically, the copolymer according to the
present invention can be used as a material and/or raw
material thereof for a polymer for a fuel cell
electrolyte membrane, a polymer for a photoresist, a
conductive polymer dopant, a polymer for an organic EL
thin film and the like.
[0202]
Especially, the copolymer according to the present
invention can be preferably used for the electronic
material, for example in fields in which it is important
to prevent metal contamination, such as semiconductors.
[0203]
7. Copolymer production method
A method for producing the vinyl sulfonic acid
copolymer is not especially limited. However, generally,
the method is carried out by radical polymerization,
photopolymerization, or radiation polymerization.
[0204]
The radical polymerization is carried out by mixing
the vinyl sulfonic acid or aqueous solution thereof and
the other monomer or aqueous solution thereof, adding a
small amount of an initiator to the resultant mixture,
and heating. As the initiator, a peroxide, a persulfate,
an azo compound or a redox initiator can be used.
[0205]
The photopolymerization is carried out by mixing the
vinyl sulfonic acid or aqueous solution thereof and the
other monomer or aqueous solution thereof, and
irradiating light on the resultant mixture. For example,
the irradiation can be carried out using solar rays, UV
rays and the like. Further, a photopolymerizable
crosslinking agent, a photopolymerization initiator, a
photopolymerization promotor and the like may optionally
be added. It is especially preferred to carry out the
photopolymerization in the presence of N,N-
dimethylformamide.
[0206]
The radiation polymerization is carried out by
mixing the vinyl sulfonic acid or aqueous solution
thereof and the other monomer or aqueous solution thereof,
and irradiating radioactive rays on the resultant mixture.
[0207]
When using two or more kinds of the other monomer,
these may be simultaneously mixed, or may be successively
mixed.
[0208]
To further reduce the metal content, the copolymer
according to the present invention may be purified by a
known method. The purification method is not especially
limited. Examples thereof include a solvent
reprecipitation and an ion-exchange method.
[0209]
The solvent reprecipitation is a purification method
in which a polymer is dissolved in as small an amount of
solvent as possible, and then the resultant mixture is
added dropwise to a solvent having a lower solubility for
this polymer to cause a precipitate to form. The ion-
exchange method is a purification method in which a
polymer is dissolved in a solvent, and the metal ions are
exchanged using an ion-exchange resin.
[0210]
8. Electric/electronic material
The present invention provides an
electric/electronic material which comprises the above-
described vinyl sulfonic acid, or the homopolymer or
copolymer thereof. In other words, the vinyl sulfonic
acid, or the homopolymer or copolymer thereof, according
to the present invention can be preferably used as a raw
material for producing the electric/electronic material.
[0211]
In the present invention, the term
"electric/electronic material" means an electric and/or
electronic material.
[0212]
Examples of the electric/electronic material
comprising the vinyl sulfonic acid according to the
present invention include a polymer electrolyte membrane
for a fuel cell, an organic EL thin film, a battery
peripheral material, a semiconductor peripheral material,
a conductive polymer material, and a circuit board
material.
[0213]
Further, examples of electric/electronic materials
comprising the homopolymer and/or copolymer of the vinyl
sulfonic acid according to the present invention include
a polymer electrolyte membrane for a fuel cell, an
organic EL thin film, a battery peripheral material, a
semiconductor peripheral material, a conductive polymer
material, and a circuit board material.
[0214]
It is especially preferred to use the homopolymer
and/or copolymer of the vinyl sulfonic acid according to
the present invention as a material for a polymer
electrolyte membrane for a fuel cell, a photoresist
composition, and a conductive polymer composition.
[0215]
(1) Polymer electrolyte membrane for a fuel cell
The polymer electrolyte membrane can be obtained by
forming a film of the homopolymer and/or copolymer of the
vinyl sulfonic acid according to the present invention.
[0216]
The film-forming method is not especially limited.
Examples of methods which can be used include forming the
film from a solution state (solution casting) or forming
the film from a melt state (melt pressing or melt
extrusion). The film thickness is not especially limited,
and can be appropriately set in order to obtain the
desired characteristics. For solution casting, the film
thickness can be controlled based on the solution
concentration or based on the thickness of the coating on
the substrate. For melt pressing or melt extrusion, the
film thickness can be controlled based on the spacer
thickness, the die gap, or the pick-up speed. In
addition, during production of the polymer electrolyte
membrane, additives which are usually used in polymers,
such as a plasticizer, a stabilizing agent, and a release
agent, may be used to the extent that does not hinder the
object of the present invention.
[0217]
The obtained polymer electrolyte membrane can be
preferably used for a fuel cell. The fuel cell
production method is not especially limited. The fuel
cell production can be carried out based on a known
method, as long as such method uses a membrane using the
polymer according to the present invention as the polymer
electrolyte membrane. Further, the structure of the fuel
cell is not especially limited, and a known structure can
be used. Examples thereof include a structure formed
from an oxygen electrode, a fuel electrode, an
electrolyte membrane between the oxygen electrode and the
fuel electrode, an oxidant distribution plate having an
oxidant channel arranged on an external side of the
oxygen electrode, and a fuel distribution plate having a
fuel channel arranged on an external side of the fuel
electrode.
[0218]
(2) Photoresist composition
The photoresist composition can be produced by,
based on a common method, mixing the vinyl sulfonic acid,
or the homopolymer and/or copolymer thereof, according to
the present invention in water or an organic solvent.
The photoresist composition may optionally comprise other
components, such as another water-soluble polymer or
alkali-soluble polymer, a surfactant, a
photopolymerizable crosslinking agent, a
photopolymerization initiator, a sensitizer, and a photo-
acid-generating agent.
[0219]
A ratio of the polymer can be appropriately set
based on whether water or an organic solvent is used, the
other component, and the lithography conditions.
[0220]
A photosensitive film pattern for a semiconductor
device can be formed using the above-described
photoresist composition to form a resist film.
[0221]
Although the resist film can also be formed by a
common method, generally, the resist film is formed by
coating the photoresist composition on a substrate, then
solidifying the composition by heating, and volatilizing
the solvent.
[0222]
Examples of the coating method include rotation
coating, cast coating, roll coating and the like.
Further, examples of the substrate include a silicon
wafer, glass, alumina, Teflon (registered trademark) and
the like.
[0223]
The pattern can be formed by exposing the formed
resist film to light, removing excess portions,
performing etching based on the pattern, and finally
completely removing the resist. Examples of the exposure
source include a semiconductor laser, a metal halide lamp,
a high-pressure mercury lamp, an excimer laser, and an
electron beam.
[0224]
(3) Conductive polymer composition
The vinyl sulfonic acid homopolymer or copolymer
according to the present invention can be used as a
conductive polymer dopant.
[0225]
Examples of the conductive polymer include
polythiophene, polyaniline, and polypyrrole.
[0226]
The conductive polymer composition can be produced
by ionic bonding of the vinyl sulfonic acid homopolymer
or copolymer and the above-described conductive polymer,
or by electropolymerization or chemical polymerization of
the monomers forming the conductive polymer in the
presence of the vinyl sulfonic acid homopolymer or
copolymer.
[0227]
The conductive polymer composition is film-formed
and the film can also be used as a conductive polymer
film. Examples of the film-forming method include
casting method or spin coating method performed by
dissolving in a suitable solvent, a melt method using a
conductive polymer which melts, electropolymerization
method, vacuum vapor deposition method, plasma
polymerization method, Langmuir- Blodgett method, and
molecular self-assembly method.
[0228]
The conductive polymer composition or film obtained
therefrom can be used in various optoelectronic part
applications, such as a polymer light-emitting diode, an
organic photovoltaic generation, a secondary battery, a
conductive polymer sensor, a thin-film transistor device,
an electroluminescent device, and an electrolytic
capacitor.
Advantages of the Invention
[0229]
The vinyl sulfonic acid according to the present
invention has a high double bond content and a low metal
content. According to the present invention, a vinyl
sulfonic acid can be obtained which has little
discoloration, hardly any change in color over time, and
high quality.
[0230]
Further, the vinyl sulfonic acid homopolymer and
copolymer according to the present invention obtained
using this vinyl sulfonic acid for a monomer have almost
no impurities, a low metal content, and excellent quality.
[0231]
Due to having such excellent properties, the vinyl
sulfonic acid, homopolymer, and copolymer according to
the present invention have sufficient durability even in
a harsh environment of a high temperature and strong
oxidizing atmosphere. Therefore, the vinyl sulfonic acid,
homopolymer, and copolymer according to the present
invention can be preferably used for an
electric/electronic material, such as for a fuel cell
electrolyte membrane, a photoresist composition, and a
conductive polymer, or as a raw material thereof.
[0232]
Further, the present invention provides a thin-film
distillation apparatus suited to the production of a
high-quality vinyl sulfonic acid. If purified using the
apparatus according to the present invention, a vinyl
sulfonic acid having a high double bond content and a low
metal content can be obtained. In addition, according to
the present invention, large-scale production of a high-
quality vinyl sulfonic acid can be achieved by continuous
operation of the thin-film distillation apparatus.
[0233]
Thus, the present invention enables industrial
production of a high-quality vinyl sulfonic acid.
Brief Description of the Drawings
[0234]
Figure 1 shows a schematic diagram illustrating a
configuration of the thin-film distillation apparatus
used in Example II-l of the present invention; and
Figure 2 shows a schematic diagram illustrating a
configuration of the thin-film distillation apparatus
used in Examples II-2 to II-4 of the present invention.
Description of the Reference Numerals
[0235]
1 Vinyl sulfonic acid receiver, made from glass (Pyrex
(registered trademark))
2 Residue receiver, made from glass (Pyrex (registered
trademark))
3 Heater
4 Stirring drive member (stirring motor)
5 Stirring rotation member, made from tantalum
6 Cooling member, made from glass (Pyrex (registered
trademark))
7 Stirring seal member, made from fluororesin (Teflon
(registered trademark))
8 Vinyl sulfonic acid composition introduction port
9 Vacuum pump suction port
10 Distillation tower, made from glass (Pyrex
(registered trademark))
11 Wiper member, configured from a section made from
tantalum and a section made from fluororesin (Teflon
(registered trademark))
12 Wall face for recovery of product trickling down the
tower wall, made from glass (Pyrex (registered
trademark))
13 Vinyl sulfonic acid vapor outlet
Best Mode for Carrying Out the Invention
[0236]
Examples and Comparative Examples will now be
illustrated to describe the present invention in more
detail. However, the present invention is not limited to
these.
[0237]
Materials and measurement methods
Sodium vinyl sulfonate was used as the vinyl
sulfonate serving as the raw material.
[0238]
Measurement of the metal content was carried out by
quantifying the amount based on an internal standard
method using an ICP mass spectrometry apparatus (model: X
Series X7 ICP-MS, manufactured by Thermo Fischer
Scientific Inc.), and subtracting an operation blank
value which had been simultaneously quantified to
determine the content.
[0239]
Acid value and iodine value measurement was carried
out based on Japanese Industrial Standards JIS K0070-1992.
The acid value was measured by neutralization titration.
[0240]
The double bond content was calculated from the
following formula based on the measured iodine value.
Double bond content (wt.%) = (iodine value) x (108.1/2) /
126.9
wherein 108.1 is the molecular weight of vinyl
sulfonic acid, and 126.9 is the atomic weight of iodine.
The metal removal rate (sodium removal rate) was
determined from the following formula based on the
measured acid value.
Metal removal rate (%) = {(acid value after metal removal
treatment) / (acid value before metal removal treatment)}
x 100.
[0241]
The production step yield was calculated from the
following formula based on the measured iodine value.
Yield (%) = {(iodine value after metal removal treatment)
/ (iodine value before metal removal treatment)} x 100.
[0242]
The distillation recovery rate was calculated from
the following formula based on the measured iodine value.
Recovery rate (%) = {(iodine value after distillation) /
(iodine value before distillation)} x 100.
[0243]
The weight average molecular weight of the copolymer
was measured under the following condition A or condition
B.
[0244]
Condition A: Measured by size-exclusion chromatography
(SEC) using a 0.2 M aqueous solution of sodium nitrate
for a solvent and polyethylene oxide as a standard sample.
Three columns manufactured by Tosoh Corporation, SEC
columns TSK-Gel ct-2500, cc-3000, and a-4000, connected
together were used for the column.
[0245]
Condition B: Measured by size-exclusion chromatography
(SEC) using a 0.1 wt.% solution of lithium bromide / N,N-
dimethylformamide for a solvent and polystyrene oxide as
a standard sample. Three columns manufactured by Showa
Denko K.K., GPC columns KF-803, KF-804, and KF-805,
connected together were used for the column.
[0246]
Light absorbance was measured at a wavelength of 248
or 365 ran using a UV-visible spectrophotometer (UV-2450,
manufactured by Shimadzu- Corporation) by placing a
measurement sample in a quartz cell having an optical
path length of 1 cm.
[0247]
Simultaneous thermogravimetric/differential thermal
analysis (TG-DTA) was performed at a temperature range of
30 to 450°C at a rate of temperature increase of
10°C/minute under a nitrogen atmosphere using the TG 8120
manufactured by Rigaku. Further, the point at which the
weight had decreased by 10% from the start time in this
measurement was taken as the 10% thermal decomposition
temperature (Tdi0%) .
[0248]
In addition, unless stated otherwise, "%" in the
respective examples represents "mole%" and "yield"
indicates "molar yield".
[0249]
Comparative Example 1-1: Sodium removal treatment using
hydrochloric acid and batch distillation
7.5 kg of a 25% aqueous solution of sodium vinyl
sulfonate (N-SVS-25, manufactured by Asahi Kasei Fine
Chemicals Co., Ltd.) was charged with 3 kg of 35%
hydrochloric acid, and the resultant mixture was stirred
at room temperature for 30 minutes. Next, under reduced
pressure, about 4 L of water was evaporated. The
precipitated salt was separated by filtration to perform
a sodium removal treatment. This sodium removal
treatment was carried out a further two times so that the
sodiums in the sodium vinyl sulfonate were substituted
with hydrogens, to thereby obtain an aqueous solution of
vinyl sulfonic acid.
[0250]
The sodium removal rate determined based on the acid
value before the sodium removal treatment and the acid
value after the three sodium removal treatments was 93.5%.
Further, the yield determined from the iodine value
before the sodium removal treatment and the iodine value
after the three sodium removal treatments was 94.8%.
[0251]
4.5 kg of the obtained aqueous solution of vinyl
sulfonic acid was subjected to distillation under reduced
pressure in a 5 L glass flask to obtain 2.1 kg of vinyl
sulfonic acid. The recovery rate was 67%. The degree of
vacuum was about 500 to 1,000 Pa. The fluctuations were
large, and it was difficult to maintain the degree of
vacuum. The obtained vinyl sulfonic acid had a double
bond content of 98 wt.%, a Fe content of 750 ppb, a Na
content of 5.7 ppm, a Ca content of 240 ppb, a Cr content
of 330 ppb, and a Ni content of 220 ppb. Further, the
vinyl sulfonic acid had a strong dark purple color from
the time of extraction. In addition, a black residue
lacking any fluidity was produced.
[0252]
Comparative Example 1-2: Sodium removal treatment using
strongly-acidic ion-exchange resin and batch
concentration
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%.
[0253]
0.6 kg of dilute vinyl sulfonic acid composition
obtained by this sodium removal treatment was
concentrated under reduced pressure. As a result, a
vinyl sulfonic acid was obtained which had a double bond
content of 75 wt.%, a Fe content of 1,000 ppb, a Na
content of 0.11 wt.%, a Ca content of 430 ppb, a Cr
content of 130 ppb, and a Ni content of 24 ppb.
[0254]
Example 1-1: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0255]
4.2 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 160 to 200°C. Consequently, the degree
of vacuum was maintained at 70 Pa, and the distillation
operation could be stably continued. Further, there was
no odor of sulfurous acid gas, and the recovery rate was
maintained at about 94%.
[0256]
The obtained vinyl sulfonic acid had a double bond
content of 97.5 wt.%, a Fe content of 455 ppb, a Na
content of 4 65 ppb, a Ca content of 50 ppb, and a Cr
content of 120 ppb. The vinyl sulfonic acid had a pale
yellow color when extracted, and no progression in color
was seen even after 6 months had passed. Further,
although a residue was produced during distillation, this
residue had fluidity and a blackish brown color, and was
easily cleaned.
[0257]
Example 1-2: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 96.5%. Further, the yield was 97.0%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0258]
5.2 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 180 to 220°C. Consequently, the degree
of vacuum was maintained at 70 to 90 Pa, and the
distillation operation could be stably continued.
Further, there was no odor of sulfurous acid gas, and the
recovery rate was maintained at about 90%.
[0259]
The obtained vinyl sulfonic acid had a double bond
content of 96 vit.%, a Fe content of 730 ppb, a Na content
of 220 ppb, a Ca content of 130 ppb, a Cr content of 155
ppb, and a Ni content of 145 ppb. The vinyl sulfonic
acid had a pale yellow color when extracted, and no
progression in color was seen even after 6 months had
passed. Further, although a residue was produced during
distillation, this residue had fluidity and a blackish
brown color, and was easily cleaned.
[0260]
Example 1-3: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 96.8%. Further, the yield was 95.3%. 400
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0261]
8.3 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 170 to 190°C. Consequently, the degree
of vacuum was maintained at 55 to 100 Pa, and the
distillation operation could be stably continued.
Further, there was no odor of sulfurous acid gas, and the
recovery rate was maintained at about 73%.
[0262]
The obtained vinyl sulfonic acid had a double bond
content of 97 wt.%, a Fe content of 44 ppb, a Na content
of 35 ppb, a Ca content of 160 ppb, a Cr content of 9 ppb,
and a Ni content of 6 ppb. The vinyl sulfonic acid had a
pale yellow color when extracted, and no progression in
color was seen even after 6 months had passed. Further,
although a residue was produced during distillation, this
residue had fluidity and a blackish brown color, and was
easily cleaned.
[0263]
Example 1-4: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 96.8%. Further, the yield was 95.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0264]
3.5 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 190 to 200°C. Consequently, the degree
of vacuum was maintained at 65 to 130 Pa, and the
distillation operation could be stably continued.
Further, there was no odor of sulfurous acid gas, and the
recovery rate was maintained at about 14%.
[0265]
The obtained vinyl sulfonic acid had a high purity
with a double bond content of 97 wt.%, and had a pale
yellow color when extracted.
[0266]
The residue produced during this distillation was
subjected to continuous distillation under reduced
pressure using a thin-film distillation apparatus under
the same conditions as described above. Consequently, a
recovery rate of about 17% was obtained. Further, the
obtained vinyl sulfonic acid had a high purity with a
double bond content of 98 wt.%, and had a pale yellow
color when extracted.
[0267]
The residue produced during this distillation was
again subjected to continuous distillation under reduced
pressure using a thin-film distillation apparatus under
the same conditions as described above. This operation
was repeated in the same manner 5 times.
[0268]
The vinyl sulfonic acids obtained from these 5
operations all had a double bond content of 99 wt.%, a Fe,
Na, Ca, Cr, and Ni content of less than 1 ppm,
respectively, and a pale yellow color when extracted.
Further, although a residue was produced during
distillation, this residue had fluidity and a blackish
brown color, and was easily cleaned.
[0269]
Example 1-5: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX(registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 99%. Further, the yield was 90%. 300 kg
of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0270]
5.2 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 209 to 221°C. Consequently, the degree
of vacuum was maintained at 15 to 25 Pa, and the
distillation operation could be stably continued.
Further, there was no odor of sulfurous acid gas, and the
recovery rate was maintained at about 90%.
[0271]
The obtained vinyl sulfonic acid had a double bond
content of 97.2 wt.%, a Fe content of 415 ppb, a Na
content of 62 ppb, a Cr content of 141 ppb, and a Ni
content of 113 ppb. The vinyl sulfonic acid had a pale
yellow color when extracted, and no progression in color
was seen even after 6 months had passed. Further,
although a residue was produced during distillation, this
residue had fluidity and a blackish brown color, and was
easily cleaned.
[0272]
Example 1-6: Polymerization of vinyl sulfonic acid by UV-
ray irradiation
In a 20 niL sample bottle, 2 g of the vinyl sulfonic
acid obtained in Example 1-3 and 1 g (0.74 moles based on
1 mole of the vinyl sulfonic acid) of N,N-
dimethylformamide (reagent grade, manufactured by
Katayama Chemical Ltd.) were mixed. The resultant
mixture was then irradiated with 360 nm UV-rays using a
UV irradiation apparatus. After performing
polymerization for 1 hour at a polymerization temperature
of 35 to 45°C, a transparent resin-like solid was formed
in the system.
[0273]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of tetrahydrofuran.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
tetrahydrofuran. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0274]
The obtained polymer was a transparent solid with a
pale yellow color. When measured by size-exclusion
chromatography (hereinafter, "SEC") (condition A), the
polymer product had a weight average molecular weight of
5.0xl04.
[0275]
Example 1-7: Radical polymerization of vinyl sulfonic
acid
In a polymerization tube, 10 g of the vinyl sulfonic
acid obtained in Example 1-3 and 10 g of ion-exchanged
water were mixed. The resultant mixture was charged with
0.2 g of azobisisobutyronitrile. The mixture was charged
into a thoroughly evacuated sealed tube, and polymerized
in a dark location at 60°C.
[0276]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of tetrahydrofuran.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
tetrahydrofuran. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0277]
The obtained polymer was a transparent solid with a
pale yellow color. When measured by SEC (condition A),
the polymer product had a weight average molecular weight
of 3.3xl04.
[0278]
Comparative Example II-l: Sodium removal treatment using
hydrochloric acid
7.5 kg of a 25% aqueous solution of sodium vinyl
sulfonate (N-SVS-25, manufactured by Asahi Kasei Fine
Chemicals Co., Ltd.) was charged with 3 kg of 35%
hydrochloric acid, and the resultant mixture was stirred
at room temperature for 30 minutes. Next, under reduced
pressure, about 4 L of water was evaporated. The
precipitated salt was separated by filtration to perform
a sodium removal treatment. This sodium removal
treatment was carried out a further two times so that the
sodiums in the sodium vinyl sulfonate were substituted
with hydrogens, to thereby obtain an aqueous solution of
vinyl sulfonic acid.
[0279]
The sodium removal rate determined based on the acid
value before the sodium removal treatment and the acid
value after the three sodium removal treatments was 93.5%.
Further, the yield determined from the iodine value
before the sodium removal treatment and the iodine value
after the three sodium removal treatments was 94.8%.
[0280]
4.5 kg of the obtained aqueous solution of vinyl
sulfonic acid was subjected to distillation under reduced
pressure in a 5 L glass flask to obtain 2.1 kg of vinyl
sulfonic acid. The recovery rate was 67%. The degree of
vacuum was about 500 to 1,000 Pa. The fluctuations were
large, and it was difficult to maintain the degree of
vacuum. The obtained vinyl sulfonic acid had a double
bond content of 98 wt.%, a Fe content of 750 ppb, a Na
content of 5.7 ppm, a Ca content of 240 ppb, a Cr content
of 330 ppb, and a Ni content of 220 ppb. Further, the
vinyl sulfonic acid had a strong dark purple color from
the time of extraction. In addition, a black residue
lacking any fluidity was produced.
[0281]
Comparative Example II-2: Sodium removal treatment using
strongly-acidic ion-exchange resin and batch
concentration
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%.
[0282]
0.6 kg of dilute vinyl sulfonic acid composition
obtained by this sodium removal treatment was
concentrated under reduced pressure. As a result, a
vinyl sulfonic acid was obtained which had a double bond
content of 75 wt.%, a Fe content of 1,000 ppb, a Na
content of 0.11 wt.%, a Ca content of 430 ppb, a Cr
content of 130 ppb, and a Ni content of 24 ppb.
[0283]
Comparative Example II-3: Sodium removal treatment using
strongly-acidic ion-exchange resin and thin-film
distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0284]
4.2 kg of the obtained vinyl sulfonic acid
composition was continuously fed into a thin-film
distillation apparatus to try and carry out continuous
distillation under reduced pressure. The temperature
conditions were 160 to 200°C. Consequently, the degree
of vacuum was maintained at 70 Pa, and the distillation
operation could be stably continued. Further, there was
no odor of sulfurous acid gas, and the recovery rate was
maintained at about 94%.
[0285]
The obtained vinyl sulfonic acid had a double bond
content of 97.5 wt.!, a Fe content of 455 ppb, a Na
content of 465 ppb, a Ca content of 50 ppb, and a Cr
content of 120 ppb. The vinyl sulfonic acid had a pale
yellow color when extracted, and no progression in color
was seen even after 6 months had passed. Further,
although a residue was produced during distillation, this
residue had fluidity and a blackish brown color, and was
easily cleaned.
[0286]
Example II-l: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0287]
Using the thin-film distillation apparatus
illustrated in Figure 1, 3.6 kg of the obtained vinyl
sulfonic acid composition was continuously fed into the
apparatus to try and carry out continuous distillation
under reduced pressure. The temperature conditions were
160 to 200°C. Consequently, the degree of vacuum was
maintained at 70 Pa, and the distillation operation could
be stably continued. Further, there was no odor of
sulfurous acid gas, and the recovery rate was maintained
at about 96%.
[0288]
The obtained vinyl sulfonic acid had a high purity
with a double bond content of 97 wt.%, a Fe content of 24
ppb, a Na content of 25 ppb, a Ca content of 30 ppb, a Cr
content of 5 ppb, and a Ni content of 4 ppb. The vinyl
sulfonic acid had a pale yellow color when extracted, and
no progression in color was seen even after 6 months had
passed. Further, although a residue was produced during
distillation, this residue had fluidity and a blackish
brown color, and was easily cleaned.
[0289]
Further, concerning tantalum, a corrosion test was
carried out by dipping the test piece in 165°C vinyl
sulfonic acid based on the method described in Chemical
Apparatus Handbook (edited by the Society for Chemical
Engineers, Japan, published by Maruzen, 1970, p. 500)
item a, and measuring the weight change and change in
appearance after 19 hours. The results showed that the
rate of corrosion was 0.05 mm/year or less.
[0290]
Example II-2: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 98.4%. Further, the yield was 94.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0291]
Using the thin-film distillation apparatus
illustrated in Figure 2, 3.6 kg of the obtained vinyl
sulfonic acid composition was continuously fed into the
apparatus to try and carry out continuous distillation
under reduced pressure. The temperature conditions were
160 to 200°C. Consequently, the degree of vacuum was
maintained at 70 Pa, and the distillation operation could
be stably continued. Further, there was no odor of
sulfurous acid gas, and the recovery rate was maintained
at about 96%.
[0292]
The obtained vinyl sulfonic acid had a high purity
with a double bond content of 97 wt.%, a Fe content of 7
ppb, a Na content of 25 ppb, a Ca content of less than 20
ppb, a Cr content of less than 1 ppb, and a Ni content of
less than 1 ppb. The vinyl sulfonic acid had a pale
yellow color when extracted, and no progression in color
was seen even after 6 months had passed. Further,
although a residue was produced during distillation, this
residue had fluidity and a blackish brown color, and was
easily cleaned.
[0293]
Example II-3: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 96.8%. Further, the yield was 95.3%. 300
kg of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0294]
Using the thin-film distillation apparatus
illustrated in Figure 2, 3.5 kg of the obtained vinyl
sulfonic acid composition was continuously fed into the
apparatus to try and carry out continuous distillation
under reduced pressure. The temperature conditions were
190 to 200°C. Consequently, the degree of vacuum was
maintained at 65 to 130 Pa, and the distillation
operation could be stably continued. Further, there was
no odor of sulfurous acid gas, and the recovery rate was
maintained at about 14%.
[0295]
The obtained vinyl sulfonic acid had a high purity,
with a double bond content of 97 wt.%, and had a pale
yellow color when extracted.
[0296]
The residue produced during this distillation was
subjected to continuous distillation under reduced
pressure using a thin-film distillation apparatus under
the same conditions as described above. Consequently, a
recovery rate of about 17% was obtained. Further, the
obtained vinyl sulfonic acid had a high purity with a
double bond content of 98 wt.%, and had a pale yellow
color when extracted.
[0297]
The residue produced during this distillation was
again subjected to continuous distillation under reduced
pressure using a thin-film distillation apparatus under
the same conditions as described above. This operation
was repeated in the same manner 5 times.
[0298]
The vinyl sulfonic acids obtained from these 5
operations all had a high purity with a double bond
content of 99 wt.%, a Fe content of 10 to 15 ppb, a Na
content of less than 10 ppb, a Ca content of less than 20
ppb, a Cr content of less than 1 ppb, and a Ni content of
less than 1 ppb, and a pale yellow color when extracted.
Further, although a residue was produced during
distillation, this residue had fluidity and a blackish
brown color, and was easily cleaned.
[0299]
Test Example 1
The measurement results of the light absorbance of
the vinyl sulfonic acids obtained in Example 1-2 and
Example II-2 at 248 nm and 365 run are shown in Table 1.
[0300]
[0301]
As shown in Table 1, the vinyl sulfonic acids
obtained in Example 1-2 and Example II-2 both had a small
light absorbance. Especially, it can be seen that the
vinyl sulfonic acid obtained in Example II-2 had a
smaller light absorbance, specifically, a larger
transmittance.
[0302]
Based on these results, it is predicted that if this
vinyl sulfonic acid having a lower metal content is used
in a photoresist composition, the light transmittance
during exposure would be high, and that a resist pattern
of a photoresist film formed after developing could be
formed with a stable line width.
[0303]
Example II-4: Sodium removal treatment using strongly-
acidic ion-exchange resin and thin-film distillation
A column tower having an internal diameter of 200 mm
and a height of 900 mm was filled with 26 L of a
strongly-acidic ion-exchange resin (DOWEX (registered
trademark) Monosphere 650C) which had been regenerated
with hydrochloric acid in advance. A sodium removal
treatment was carried out by flowing 12.2 kg of a 25 wt.%
aqueous solution of sodium vinyl sulfonate (N-SVS-25,
manufactured by Asahi Kasei Fine Chemicals Co., Ltd.) in
from the bottom of the column, and then washing from the
bottom of the column with 100 kg of ion-exchanged water.
The sodium removal rate determined based on the acid
value before and after the one-time sodium removal
treatment was 99%. Further, the yield was 88.4%. 300 kg
of dilute vinyl sulfonic acid composition obtained by
this sodium removal treatment was concentrated under
reduced pressure.
[0304]
Using the thin-film distillation apparatus
illustrated in Figure 2, 15.4 kg of the obtained vinyl
sulfonic acid composition was continuously fed into the
apparatus to try and carry out continuous distillation
under reduced pressure. The temperature conditions were
185 to 200°C. Consequently, the degree of vacuum was
maintained at 100 to 150 Pa, and the distillation
operation could be stably continued. Further, there was
no odor of sulfurous acid gas, and the recovery rate was
maintained at about 80%.
[0305]
The obtained vinyl sulfonic acid had a high purity
with a double bond content of 98.1 wt.%, a Fe content of
1.5 ppb, a Na content of 10 ppb, a Ca content of less
than 20 ppb, a Cr content of less than 1 ppb. The vinyl
sulfonic acid had a pale yellow color when extracted, and
no progression in color was seen even after 6 months had
passed. Further, although a residue was produced during
distillation, this residue had fluidity and a blackish
brown color, and was easily cleaned.
[0306]
Example II-5: Polymerization of vinyl sulfonic acid by
UV-ray irradiation
In a 20 mL sample bottle, 2 g of the vinyl sulfonic
acid obtained in Example II-2 and 1 g (0.74 moles based
on 1 mole of the vinyl sulfonic acid) of N,N-
dimethylformamide (reagent grade, manufactured by
Katayama Chemical Ltd.) were mixed. The resultant
mixture was then irradiated with 360 nm UV-rays using a
UV irradiation apparatus. After performing
polymerization for 1 hour at a polymerization temperature
of 35 to 45°C, a transparent resin-like solid was formed
in the system.
[0307]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of tetrahydrofuran.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
tetrahydrofuran. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0308]
The obtained polymer was a transparent solid with a
pale yellow color. When measured by SEC (condition A),
the polymer product had a weight average molecular weight
of 5.0x10".
[0309]
Example II-6: Radical polymerization of vinyl sulfonic
acid
In a polymerization tube, 10 g of the vinyl sulfonic
acid obtained in Example II-2 and 10 g of ion-exchanged
water were mixed. The resultant mixture was charged with
0.2 g of azobisisobutyronitrile. The mixture was charged
into a thoroughly evacuated sealed tube, and polymerized
in a dark location at 60°C.
[0310]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of tetrahydrofuran.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
tetrahydrofuran. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0311]
The obtained polymer was a transparent solid with a
pale yellow color. When measured by SEC (condition A),
the polymer product had a weight average molecular weight
of 3.3x10".
[0312]
Comparative Example II-4: Sodium polyvinyl sulfonate
The molecular weight of sodium polyvinyl sulfonate
(manufactured by Aldrich) was measured. Also, the
thermal property of this sodium polyvinyl sulfonate was
evaluated. When measured by SEC (condition A), the
sodium polyvinyl sulfonate had a weight average molecular
weight of 9.0xl04.
[0313]
Test Example 2
The measurement results of simultaneous
thermogravimetric/differential thermal analysis (TG-DTA)
for the polymers obtained in Examples 1-7 and II-5 and
the polymer of Comparative Example I1-4 are shown in
Table 2. In Table 2, Tdio% represents the 10% thermal
decomposition temperature.
[0315]
As shown in Table 2, it can be seen that the
polymers obtained using the vinyl sulfonic acid according
to the present invention had a Td10% of 150°C or more.
[0316]
Since the sodium polyvinyl sulfonate of Comparative
Example II-4 was in the form of a sodium salt of a
sulfonic acid group, it can be understood that it had
excellent thermal stability. However, since sodium
polyvinyl sulfonate is a metal salt, it is soluble in
water, and thus ionizes in the presence of water.
Therefore, such a sodium polyvinyl sulfonate is not
suitable for a fuel cell membrane.
[0317]
Vinyl sulfonic acid has a structure which is formed
only from a vinyl group and a sulfonic acid group.
Therefore, a polymer formed from sulfonic acid as a
monomer has a much higher density of sulfonic acid groups
than a polymer formed using another sulfonic-acid-group-
containing vinyl monomer.
[0318]
Further, a polymer obtained using the vinyl sulfonic
acid according to the present invention has a low level
of impurities, and a low metal content, so that the
sulfonic acid group density is increased.
[0319]
In addition, as shown by the results in Table 2, the
polymer obtained using the vinyl sulfonic acid according
to the present invention also had excellent thermal
stability. Therefore, it is predicted that this polymer
would be sufficiently stable from room temperature to
about 120°C, which is the typical operation temperature
of a solid polymer fuel cell.
[0320]
Moreover, the polymer according to the present
invention can be obtained using a vinyl sulfonic acid
having a low metal content. Therefore, it is predicted
that the metal content can be decreased, and the
oxidation resistance of the polymer electrolyte membrane
can be improved.
[0321]
Consequently, it is considered that the polyvinyl
sulfonic acid polymer according to the present invention
can be used as an excellent material for an excellent
polymer electrolyte membrane for a fuel cell.
[0322]
Test Example 3: PEDOT/PVS chemical oxidation
polymerization and electrical conductivity thereof
In an aqueous solution of polyvinyl sulfonic acid
(hereinafter, "PVS")/ 3,4-ethylenedioxythiophene was
subjected to chemical oxidation polymerization to produce
a conductive polymer composition PEDOT/PVS comprised
poly(3,4-ethylenedioxythiophene) (hereinafter, "PEDOT")
and polyvinyl sulfonic acid (PVS).
[0323]
A 100 mL pear-shaped flask was charged with 0.135 g
of the vinyl sulfonic acid of Example II-5, 50 mL of ion-
exchanged water, and 0.71 g of 3,4-ethylenedioxythiophene,
and the resultant mixture was stirred for 1 hour.
[0324]
The mixture was charged with 1.14 g of ammonium
persulfate. Then, the flask was thoroughly purged with
nitrogen, and the mixture was polymerized at room
temperature for 12 hours. After the polymerization
reaction finished, the product underwent dialysis for 3
days with ion-exchanged water using a dialysis membrane
having a molecular weight cutoff of 3,500 (Spectra/Por
(registered trademark), manufactured by Spectrum) to
remove the low molecular weight component.
[0325]
The obtained PEDOT/PVS dispersion was cast onto a
Teflon (registered trademark) substrate, and then heated
and dried at 40°C for one night. The electrical
conductivity was measured at room temperature using a
four-point probe tester (K-705RS, Kyowariken Co., Ltd.).
[0326]
For comparison, the electrical conductivity of
PEDOT/PSS (polystyrene sulfonic acid) (manufactured by
Aldrich) was measured in the same manner. These results
are shown in Table 3.
[0328]
As shown in Table 3, the PEDOT/PVS exhibited a
higher electrical conductivity than the electrical
conductivity of the PEDOT/PSS.
[0329]
It is thought that PEDOT disperses in the water and
PSS is a dopant, and PVS also functioning as a dopant
similar to PSS.
[0330]
Further, structurally, since PSS has an aromatic
ring, it has a high glass transition point, and poor
contact properties with the substrate. On the other hand,
since PVS does not have an aromatic ring, PVS is expected
to have a low glass transition point, and excellent
contact properties with the substrate.
[0331]
More specifically, it is thought that PVS can be
used as a better conductive polymer dopant than PSS.
[0332]
Example III-l: Copolymerization of vinyl sulfonic acid
and methyl methacrylate by UV irradiation
A 4.5 mL quartz cell was charged with 0.5 g of the
vinyl sulfonic acid obtained in Example 1-1, 0.5 g of
methyl methacrylate, and 0.5 g of N,N-dimethylformamide,
and the resultant mixture was uniformly mixed. The
methyl methacrylate was produced by charging methyl
methacrylate (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.) into a four-neck flask made from Pyrex
(registered trademark) glass, adding 0.1 wt.%
hydroquinone monomethyl ether based on the methyl
methacrylate, and carrying out distillation under reduced
pressure to purify the product.
[0333]
The obtained mixture was irradiated with UV-rays for
20 minutes. Subsequently, this reaction solution was
added dropwise to a large amount methanol, and a white
solid product was separated. The obtained white solid
product was heated and dried under vacuum for one day and
night at 50°C to obtain a polymer. The obtained polymer
was a white transparent solid. When measured by SEC
(condition B), the polymer product had a weight average
molecular weight of 1.1x10s.
[0334]
Example III-2: Copolymerization of vinyl sulfonic acid
and methyl methacrylate by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-l,
except that the weights of the vinyl sulfonic acid and
the methyl methacrylate were changed to the values shown
in Table 4.
[0335]
Example III-3: Copolymerization of vinyl sulfonic acid
and methyl methacrylate by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-l,
except that the weights of the vinyl sulfonic acid and
the methyl methacrylate were changed to the values shown
in Table 4.
[0336]
Table 4 shows the weight and mole% of the monomers
used in Examples III-l to III-3, and the weight average
molecular weights of the obtained copolymers. In the
below, the term "mole%" represents a ratio of a number of
moles of each monomer when a number of moles of all the
monomers constituting the copolymer is 100, based on the
number of moles calculated from the weight (g) of the
monomers.
[0338]
Example III-4: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A 50 mL pear-shaped flask was charged with 1.73 g of
the vinyl sulfonic acid obtained Example 1-1, 0.29 g of
acrylic acid (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.), 44 mg of ammonium persulfate as an
initiator, and 4 mL of ion-exchanged water as a reaction
solvent. Here, the 44 mg of ammonium persulfate was
equivalent to 1 mole% based on the total number of moles
of the vinyl sulfonic acid and the acrylic acid.
[0339]
The vinyl sulfonic acid, the acrylic acid and
ammonium persulfate were dissolved. Then, the flask was
thoroughly purged with nitrogen, and the mixture was
stirred for 16 hours at 60°C. After cooling to room
temperature, 15 mL of methanol was added. The mixture
was then filtrated and washed to remove the residual
initiator.
[0340]
The methanol filtrate was concentrated, then added
dropwise to a large amount of tetrahydrofuran, whereby a
white solid product was separated. The obtained white
solid product was heated and dried under vacuum for two
days at 60°C to obtain a polymer.
[0341]
The obtained polymer was soluble in water, methanol,
N,N-dimethylformamide and the like. Further, when
measured by SEC (condition B), the obtained polymer had a
weight average molecular weight of 8xl04.
[0342]
Example III-5: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-4,
except that the weights of the vinyl sulfonic acid and
the acrylic acid were changed to the values shown in
Table 5.
[0343]
Example III-6: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-4,
except that the weights of the vinyl sulfonic acid and
the acrylic acid were changed to the values shown in
Table 5.
[0344]
Table 5 shows the weight and mole% of the monomers
used in Examples III-4 to III-6, and the weight average
molecular weights of the obtained copolymers.
[0346]
Example III-7: Copolymerization of vinyl sulfonic acid
and acrylamide by UV irradiation
A 4.5 mL quartz cell was charged with 0.5 g of the
vinyl sulfonic acid obtained in Example 1-1, 0.5 g of
acrylamide (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.), and 0.5 g of N,N-dimethylformamide.
The resultant mixture was uniformly mixed, and then
subjected to UV irradiation for 20 minutes to obtain a
polymer product.
[0347]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of acetonitrile.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
acetonitrile. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer. When measured by SEC
(condition A), the polymer product had a weight average
molecular weight of 4.0xl05.
[0348]
Example III-8: Copolymerization of vinyl sulfonic acid
and acrylamide by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-7,
except that the weights of the vinyl sulfonic acid and
the acrylamide were changed to the values shown in Table
6.
[0349]
Example III-9: Copolymerization of vinyl sulfonic acid
and acrylamide by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example III-7,
except that the weights of the vinyl sulfonic acid and
the acrylamide were changed to the values shown in Table
6.
[0350]
Table 6 shows the weight and mole% of the monomers
used in Examples III-7 to III-9, and the weight average
molecular weights of the obtained copolymers.
[0352]
Example 111-10: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A 55 mm diameter dish was charged with 0.6 g of the
vinyl sulfonic acid obtained in Example 1-1, 2.0 g of
acrylonitrile, 0.3 g of N,N-dimethylformamide, and 25 mg
of azobisisobutyronitrile, and the resultant mixture was
uniformly mixed. The acrylonitrile was produced by
charging acrylonitrile (reagent, manufactured, by Wako
Pure Chemical Industries, Ltd.) into a four-neck flask
made from Pyrex (registered trademark) glass, adding 0.1
wt.% hydroquinone monomethyl ether based on the
acrylonitrile, and carrying out distillation under
reduced pressure to purify the product. The N,N-
dimethylformamide was produced by charging N,N-
dimethylformamide (reagent, manufactured by Wako Pure
Chemical Industries, Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
[0353]
The mixture was irradiated with UV-rays for 25
minutes. Subsequently, the obtained polymer product was
dissolved in N,N-dimethylformamide, and the resultant
solution was added dropwise to a 20-fold weight of ion-
exchanged water. The resultant precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0354]
The obtained polymer was a white transparent solid.
When measured by SEC (condition B), the polymer product
had a weight average molecular weight of 2.0xl06.
[0355]
Example III-ll: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example 111-10,
except that the weights of the vinyl sulfonic acid, the
acrylonitrile, and the N,N-dimethylformamide were changed
to the values shown in Table 7.
[0356]
Example 111-12: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example 111-10,
except that the weights of the vinyl sulfonic acid, the
acrylonitrile, and the N,N-dimethylformamide were changed
to the values shown in Table 7.
[0357]
Table 7 shows the weight and mole% of the monomers
used in Examples 111-10 to 111-12, and the weight average
molecular weights of the obtained copolymers.
[0359]
As shown in Tables 4 to 7, it can be seen that the
vinyl sulfonic acid copolymers having a sufficient weight
average molecular weight were obtained using the vinyl
sulfonic acid according to the present invention.
[0360]
Example 111-13: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
'A 10 mm quartz cell was charged with 0.9 g of the
vinyl sulfonic acid obtained in Example 1-5, 1.0 g of
acrylonitrile, and 0.45 g of N,N-dimethylformamide, and
the resultant mixture was uniformly mixed. The mixture
was then irradiated with UV-rays for 40 minutes to obtain
a polymer product. The acrylonitrile was produced by
charging acrylonitrile (reagent, manufactured by Tokyo
Chemical Industry Co., Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
The N,N-dimethylformamide was produced by charging N,N-
dimethylformamide (reagent, manufactured by Wako Pure
Chemical Industries, Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
[0361]
The obtained polymer product was dissolved in N,N-
dimethylformamide, and then the resultant solution was
added dropwise to a 20-fold weight of isopropyl alcohol.
The resultant precipitate was filtrated, and washed with
100 mL of isopropyl alcohol, and then heated and dried
under vacuum for one day and night at 50°C to obtain a
0.2 8 g of a polymer.
[0362]
When measured by SEC (condition B), the obtained
polymer product had a weight average molecular weight of
3.2xl06. Further, the ratio of the vinyl sulfonic acid
units in the polymer was measured by subjecting the
polymer to ion-exchange with sodium chloride and then
titrating with aqueous sodium hydroxide. The measurement
value was 12.8 wt.%.
[0363]
From the results of Example 111-13, it was found
that the acrylonitrile copolymer obtained using the vinyl
sulfonic acid having a high purity and a low metal
content was a polymer which comprised a large amount of
vinyl sulfonic acid units and which had a high molecular
weight.
[0364]
The polymer comprised a large amount of vinyl
sulfonic acid units, therefore it is thought that a
polymer electrolyte membrane having excellent proton
conductivity can be obtained by use of the polymer.
[0365]
Further, it is thought that a vinyl sulfonic acid
copolymer having a high molecular weight has good film-
forming properties and can be used to produce a strong
membrane.
[0366]
Example IV-1: Copolymerization of vinyl sulfonic acid and
methyl methacrylate by UV irradiation
A 4.5 mL quartz cell was charged with 0.5 g of the
vinyl sulfonic acid obtained in Example II-l, 0.5 g of
methyl methacrylate, and 0.5 g of N,N-dimethylformamide,
and the resultant mixture was uniformly mixed. The
methyl methacrylate was produced by charging methyl
methacrylate (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.) into a four-neck flask made from Pyrex
(registered trademark) glass, adding 0.1 wt.%
hydroquinone monomethyl ether based on the methyl
methacrylate, and carrying out distillation under reduced
pressure to purify the product.
[0367]
The obtained mixture was irradiated with UV-rays for
20 minutes. Subsequently, this reaction solution was
added dropwise to a large amount methanol, and a white
solid product was separated. The obtained white solid
product was heated and dried under vacuum for one day and
night at 50°C to obtain a polymer.
[0368]
The obtained polymer was a white transparent solid.
When measured by SEC (condition B), the polymer had a
weight average molecular weight of l.lxlO6.
[0369]
Example IV-2: Copolymerization of vinyl sulfonic acid and
methyl methacrylate by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-1,
except that the weights of the vinyl sulfonic acid and
the methyl methacrylate were changed to the values shown
in Table 8.
[0370]
Example IV-3: Copolymerization of vinyl sulfonic acid and
methyl methacrylate by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-1,
except that the weights of the vinyl sulfonic acid and
the methyl methacrylate were changed to the values shown
in Table 8.
[0371]
Table 8 shows the weight and mole% of the monomers
used in Examples IV-1 to IV-3, and the weight average
molecular weights of the obtained copolymers.
[0373]
Example IV-4: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A 50 mL pear-shaped flask was charged with 1.73 g of
the vinyl sulfonic acid obtained Example II-l, 0.29 g of
acrylic acid (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.), 44 mg of ammonium persulfate as an
initiator, and 4 mL of ion-exchanged water as a reaction
solvent. Here, the 44 mg of ammonium persulfate was
equivalent to 1 mole% based on the total number of moles
of the vinyl sulfonic acid and the acrylic acid.
[0374]
The vinyl sulfonic acid, the acrylic acid and the
ammonium persulfate were dissolved. Then, the flask was
thoroughly purged with nitrogen, and the mixture was
stirred for 16 hours at 60°C. After cooling to room
temperature, 15 mL of methanol was added. The mixture
was then filtrated and washed to remove the residual
initiator.
[0375]
The methanol filtrate was concentrated, then added
dropwise to a large amount of tetrahydrofuran, whereby a
white solid product was separated. The obtained white
solid product was heated and dried under vacuum for two
days at 60°C to obtain a polymer.
[0376]
The obtained polymer was soluble in water, methanol,
N,N-dimethylformamide and the like. Further, when
measured by SEC (condition B), the obtained polymer had a
weight average molecular weight of 8xl04.
[0377]
Example IV-5: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-4,
except that the weights of the vinyl sulfonic acid and
the acrylic acid were changed to the values shown in
Table 9.
[0378]
Example IV-6: Radical polymerization of vinyl sulfonic
acid and acrylic acid
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-4,
except that the weights of the vinyl sulfonic acid and
the acrylic acid were changed to the values shown in
Table 9.
[0379]
Table 9 shows the weight and mole% of the monomers
used in Examples IV-4 to IV-6, and the weight average
molecular weights of the obtained copolymers.
[0381]
Example IV-7: Copolymerization of vinyl sulfonic acid and
acrylamide by UV irradiation
A 4.5 mL quartz cell was charged with 0.5 g of the
vinyl sulfonic acid obtained in Example II-2, 0.5 g of
acrylamide (reagent, manufactured by Wako Pure Chemical
Industries, Ltd.), and 0.5 g of N,N-dimethylformamide.
The resultant mixture was uniformly mixed, and then
subjected to UV irradiation for 20 minutes to obtain a
polymer product.
[0382]
The obtained polymer product was dissolved in ion-
exchanged water, and then the resultant aqueous solution
was added dropwise to a 20-fold weight of acetonitrile.
The resultant precipitate was filtrated and dissolved in
ion-exchanged water. Then, the resultant aqueous
solution was again added dropwise to a 20-fold weight of
acetonitrile. The produced precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer. When measured by SEC
(condition A) , the polymer had a weight average molecular
weight of 4.0xl05.
[0383]
Example IV-8: Copolymerization of vinyl sulfonic acid and
acrylamide by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-7,
except that the weights of the vinyl sulfonic acid and
the acrylamide were changed to the values shown in Table
10.
[0384]
Example IV-9: Copolymerization of vinyl sulfonic acid and
acrylamide by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-7,
except that the weights of the vinyl sulfonic acid and
the acrylamide were changed to the values shown in Table
10.
[0385]
Table 10 shows the weight and mole% of the monomers
used in Examples IV-7 to IV-9, and the weight average
molecular weights of the obtained copolymers.
[0387]
Example IV-10: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A 55 mm diameter dish was charged with 0.6 g of the
vinyl sulfonic acid obtained in Example II-2, 2.0 g of
acrylonitrile, 0.3 g of N,N-dimethylformamide, and 25 mg
of azobisisobutyronitrile, and the resultant mixture was
uniformly mixed. The acrylonitrile was produced by
charging acrylonitrile (reagent, manufactured by Wako
Pure Chemical Industries, Ltd.) into a four-neck flask
made from Pyrex (registered trademark) glass, adding 0.1
wt.% hydroquinone monomethyl ether based on the
acrylonitrile, and carrying out distillation under
reduced pressure to purify the product. The N,N-
dimethylformamide was produced by charging N,N-
dimethylformamide (reagent, manufactured by Wako Pure
Chemical Industries, Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
[0388]
The mixture was irradiated with UV-rays for 25
minutes. Subsequently, the obtained polymer product was
dissolved in N,N-dimethylformamide, and the resultant
solution was added dropwise to a 20-fold weight of ion-
exchanged water. The resultant precipitate was filtrated,
and heated and dried under vacuum for one day and night
at 50°C to obtain a polymer.
[0389]
The obtained polymer was a white transparent solid.
When measured by SEC (condition B), the obtained polymer
product had a weight average molecular weight of 2.0xl06.
[0390]
Example IV-11: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-10,
except that the weights of the vinyl sulfonic acid, the
acrylonitrile, and the N,N-dimethylformamide were changed
to the values shown in Table 11.
[0391]
Example IV-12: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A copolymer was obtained by carrying out
polymerization in the same manner as in Example IV-10,
except that the weights of the vinyl sulfonic acid, the
acrylonitrile, and the N,N-dimethylformamide were changed
to the values shown in Table 11.
[0392]
Table 11 shows the weight and mole% of the monomers
used in Examples IV-10 to IV-12, and the weight average
molecular weights of the obtained copolymers.
[0393]
[0394]
As shown in Tables 8 to 11, it can be seen that the
vinyl sulfonic acid copolymer products having a
sufficient weight average molecular weight were obtained
using the vinyl sulfonic acid according to the present
invention.
[0395]
Example IV-13: Copolymerization of vinyl sulfonic acid
and acrylonitrile by UV irradiation
A 10 mm quartz cell was charged with 0.9 g of the
vinyl sulfonic acid obtained in Example II-4, 1.0 g of
acrylonitrile, and 0.45 g of N,N-dimethylformamide, and
the resultant mixture was uniformly mixed. The mixture
was then irradiated with UV-rays for 40 minutes to obtain
a polymer product. The acrylonitrile was produced by
charging acrylonitrile (reagent, manufactured by Tokyo
Chemical Industry Co., Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
The N,N-dimethylformamide was produced by charging N,N-
dimethylformamide (reagent, manufactured by Wako Pure
Chemical Industries, Ltd.) into a four-neck flask made
from Pyrex (registered trademark) glass, and carrying out
distillation under reduced pressure to purify the product.
[0396]
The obtained polymer product was dissolved in N,N-
dimethylformamide, and then the resultant solution was
added dropwise to a 20-fold weight of isopropyl alcohol.
The resultant precipitate was filtrated, and washed with
100 mL of isopropyl alcohol, and then heated and dried
under vacuum for one day and night at 50°C to obtain 0.19
g of a polymer.
[0397]
When measured by SEC (condition B), the obtained
polymer product had a weight average molecular weight of
3.8xl06. Further, the ratio of the vinyl sulfonic acid
units in the polymer was measured by subjecting the
polymer to ion-exchange with sodium chloride and then
titrating with aqueous sodium hydroxide. The measurement
value was 13.8 wt.%.
[0398]
From the results of Example IV-13, it was found that
the acrylonitrile copolymer product obtained using the
vinyl sulfonic acid having a high purity and a low metal
content was a polymer which comprised a large amount of
vinyl sulfonic acid units and which had a high molecular
weight.
[0399]
The polymer comprised a large amount of vinyl
sulfonic acid units, therefore it is thought that a
polymer electrolyte membrane having excellent proton
conductivity can be obtained by use of the polymer.
[0400]
Further, it is thought that a vinyl sulfonic acid
copolymer having a high molecular weight has good film-
forming properties and can be used to produce a strong
membrane.
[0401]
Test Example 4
Using the vinyl sulfonic acid obtained in Example
II-2, a Q value and an e value were determined.
[0402]
Here, the Q value and the e value are constants
represented by the Alfrey-Price formula. These values
can be obtained by hypothesizing that a rate constant ki2
of the following growth reaction,
Mr + M2 ~* M2-
is represented as follows.
[0403]
k12 = PiQ2exp (-eie2)
[0404]
[0405]
In the formula, Pi represents the level of general
reactivity (resonance stabilization) of Mi-, Q2 represents
the level of resonance stabilization of M2, ei and e2
represent the polar effects of Mi-, and M2, respectively.
[0406]
Styrene was selected as a standard. The Q value of
styrene is 1.0, and the e value is -0.8.
[0407]
A copolymer of the vinyl sulfonic acid obtained in
Example II-2 and styrene was produced. The Q value of
the obtained vinyl sulfonic acid was 0.09 and the e value
was 1.3.
[0408]
The vinyl sulfonic acid of Non-Patent Document 2
(ethylene sulfonic acid) is described as having a Q value
of 0.09 and an e value of 1.3.
[0409]
Using those values, based on the following formula,
the reactivity ratios ri and r2 with the various
copolymer monomers were determined.
[Formula 3]

[0410]
In the formula, Qi and ei represent the Q value and
the e value of the vinyl sulfonic acid serving as Mi.
Further, Q2 and e2 represent the Q value and the e value
of the various copolymer monomers serving as M2. The
values shown in the following tables, which are taken
from Polymer Handbook, Fourth Edition (published by John
Wiley & Sons Inc., p. 11-318-319), were used for the Q
value and the e value of the copolymer monomers.
[0412]
The Q value and the e value of the vinyl sulfonic
acid according to the present invention and that
described in Non-Patent Document 2 are shown in Table 13.
Further, the obtained reactivity ratios ri and r2 are
also shown in Table 13.
[0413]
[0414]
The results show that when the vinyl sulfonic acid
according to the present invention was used, ri increased
by a factor of 1.9 to 2.7, so that it can be presumed
that a large amount of vinyl sulfonic acid was
incorporated in the copolymer.
[0415]
Consequently, this suggests that copolymer
efficiency with various vinyl monomers can be
dramatically improved by using the vinyl sulfonic acid
according to the present invention. It is thus
considered that a copolymer having an increased vinyl
sulfonic acid content can be obtained.
[0416]
If the vinyl sulfonic acid content increases, it is
believed that the sulfonic acid group content in the
polymer also increases, and that proton conductivity
improves. Therefore, it is considered that the copolymer
according to the present invention can serve as an
excellent polymer electrolyte membrane for a fuel cell.
[0417]
In addition, by obtaining the vinyl sulfonic acid
polymer according to the present invention using a vinyl
sulfonic acid having a low metal content, the metal
content is also decreased. Therefore, it is considered
that the oxidation resistance of the polymer electrolyte
membrane is also improved.
CLAIMS
1. A vinyl sulfonic acid, having:
a double bond content of 95 wt.% or more; and
(i) a sodium (Na) content of 1 ppm or less; and
(ii) a content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 1 ppm or less.
2. The vinyl sulfonic acid according to claim 1,
having:
the double bond content of 95 wt.% or more; and
(i) the sodium (Na) content of 100 ppb or less; and
(ii) the content of at least one metal selected from
the group consisting of alkali earth metal and first row
transition metal of 100 ppb or less.
3. A vinyl sulfonic acid homopolymer or copolymer
obtained by polymerizing the vinyl sulfonic acid
according to claim 1 or 2 alone or with one or more other
monomers copolymerizable therewith.
4. A method for producing a vinyl sulfonic acid
homopolymer or copolymer, comprising a step of subjecting
the vinyl sulfonic acid according to claim 1 or 2 alone
or with one or more other monomers copolymerizable
therewith to radical polymerization, photopolymerization,
or radiation polymerization.
5. A thin-film distillation apparatus for vinyl
sulfonic acid purification, wherein all or a part of a
contact with a vinyl sulfonic acid or a composition
thereof are formed from a material having a high
corrosion resistance.
6. The thin-film distillation apparatus according to
claim 5, comprising:
a distillation tower for evaporating a distillation
raw material;
a vinyl sulfonic acid vapor outlet which is provided
in a middle section of the distillation tower; and
a cooling device which is arranged externally to the
distillation tower for condensing the vinyl sulfonic acid
vapor obtained from the outlet.
7. A method for producing the vinyl sulfonic acid
according to claim 1 or 2, comprising:
a step of subjecting a vinyl sulfonate to a metal
removal treatment; and
a step of purifying the product obtained from the
metal removal treatment using the thin-film distillation
apparatus according to claim 5 or 6.
8. An electric/electronic material comprising the vinyl
sulfonic acid according to claim 1 or 2.
9. An electric/electronic material comprising the vinyl
sulfonic acid homopolymer or copolymer according to claim
3.
10. A polymer electrolyte membrane for a fuel cell
comprising the vinyl sulfonic acid homopolymer or
copolymer according to claim 3.
11. A photoresist composition comprising the vinyl
sulfonic acid according to claim 1 or 2 or the vinyl
sulfonic acid homopolymer or copolymer according to claim
3.
12. A conductive polymer composition comprising the
vinyl sulfonic acid homopolymer or copolymer according to
claim 3 as a dopant.


(1) A vinyl sulfonic acid/ having a double bond
content of 95 wt.% or more, and (i) a sodium (Na) content
of 1 ppm or less, and (ii) a content of at least one
metal selected from the group consisting of alkali earth
metal and first row transition metal of 1 ppm or less.
Alternatively, (2) a vinyl sulfonic acid, having a double
bond content of 95 wt.% or more, and (i) a sodium (Na)
content of 100 ppb or less, and (ii) a content of at
least one metal selected from the group consisting of
alkali earth metal and first row transition metal of 100
ppb or less. Further, a homopolymer or copolymer thereof,
a production method thereof, or a thin-film distillation
apparatus suited for the production thereof.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=0z532r+tq14XZ4ulpKC6KA==&loc=wDBSZCsAt7zoiVrqcFJsRw==


Patent Number 272856
Indian Patent Application Number 3575/KOLNP/2010
PG Journal Number 19/2016
Publication Date 06-May-2016
Grant Date 29-Apr-2016
Date of Filing 27-Sep-2010
Name of Patentee ASAHI KASEI FINECHEM CO., LTD.
Applicant Address 8-7, FUKUMACHI 1-CHOME, NISHIYODOGAWA-KU, OSAKA-SHI, OSAKA 555-0034, JAPAN
Inventors:
# Inventor's Name Inventor's Address
1 AKIKAZE, HIROSHI C/O DEVELOPMENT-PRODUCTION CENTER OF ASAHI KASEI FINECHEM CO., LTD. 8-7, FUKUMACHI 1-CHOME, NISHIYODOGAWA-KU, OSAKA-SHI, OSAKA 555-0034, JAPAN
2 MIYAI, TAKEHIKO C/O NOBEOKA PLANT OF ASAHI KASEI FINECHEM CO., LTD., 2741-1, BYUMACHI, NOBEOKA-SHI, MIYAZAKI 882-0861, JAPAN
3 ISSHIKI, KAZUHIKO C/O DEVELOPMENT-PRODUCTION CENTER OF ASAHI KASEI FINECHEM CO., LTD. 8-7, FUKUMACHI 1-CHOME, NISHIYODOGAWA-KU, OSAKA-SHI, OSAKA 555-0034, JAPAN
PCT International Classification Number C07C 309/20
PCT International Application Number PCT/JP2009/056286
PCT International Filing date 2009-03-27
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2008-085693 2008-03-28 Japan
2 2008-143072 2008-05-30 Japan
3 2008-167810 2008-06-26 Japan
4 2008-085670 2008-03-28 Japan
5 2008-143400 2008-05-30 Japan