Method for manufacturing polyarylene sulfide resin

Abstract

A method for producing a polyarylene sulfide resin includes allowing a polyhaloaromatic compound (a), an alkali metal hydrosulfide (b), and an organic acid alkali metal salt (c) to react with each other in the presence of a solid alkali metal sulfide and an aprotic polar organic solvent, wherein the reaction is conducted using the organic acid alkali metal salt (c) in a ratio of 0.01 moles or more and less than 0.9 moles relative to a total of 1 mole of the solid alkali metal sulfide and the alkali metal hydrosulfide (b) in a state where the amount of water existing in the reaction system is 0.02 moles or less relative to 1 mole of the aprotic polar organic solvent. Thus, it is possible to provide a method for producing a polyarylene sulfide resin with which high productivity is achieved on an industrial scale, and the molecular weight of the resulting polyarylene sulfide resin can be significantly increased.

1 . A method for producing a polyarylene sulfide resin comprising allowing a polyhaloaromatic compound (a), an alkali metal hydrosulfide (b), and an organic acid alkali metal salt (c) to react with each other in the presence of a solid alkali metal sulfide and an aprotic polar organic solvent, wherein the reaction is conducted using the organic acid alkali metal salt (c) in a ratio of 0.01 moles or more and less than 0.9 moles relative to a total of 1 mole of the solid alkali metal sulfide and the alkali metal hydrosulfide (b) in a state where the amount of water existing in the reaction system is 0.02 moles or less relative to 1 mole of the aprotic polar organic solvent. 
     
     
         2 . The method for producing a polyarylene sulfide resin according to  claim 1 , wherein the organic acid alkali metal salt (c) is an alkali metal salt (c2) of a hydrolysate of an aliphatic cyclic compound (c1) that can be ring-opened by hydrolysis. 
     
     
         3 . A method for producing a polyarylene sulfide resin, comprising, as essential production steps,
 step 1:   a step of producing a slurry (I) containing a solid alkali metal sulfide by allowing a hydrous alkali metal sulfide, or a hydrous alkali metal hydrosulfide and an alkali metal hydroxide, and   an aliphatic cyclic compound (c1) that can be ring-opened by hydrolysis to react with each other while conducting dehydration   in the presence of a non-hydrolyzable organic solvent;   step 2: a step of further adding an aprotic polar organic solvent after the production of the slurry (I), and distilling off water to conduct dehydration; and   step 3: a step of conducting polymerization by allowing a polyhaloaromatic compound (a), an alkali metal hydrosulfide (b), and an alkali metal salt (c2) of a hydrolysate of the compound (c1) to react with each other in the slurry (I) obtained through the dehydration step of the step 2 in a state where the amount of water existing in the reaction system is 0.02 moles or less relative to 1 mole of the aprotic polar organic solvent.   
     
     
         4 . The method for producing a polyarylene sulfide resin according to  claim 3 , wherein the non-hydrolyzable organic solvent is the polyhaloaromatic compound (a). 
     
     
         5 . The method for producing a polyarylene sulfide resin according to  claim 3 , wherein the aprotic polar organic solvent added in the step 2 is the aliphatic cyclic compound (c1) that can be ring-opened by hydrolysis. 
     
     
         6 . The method for producing a polyarylene sulfide resin according to  claim 3 , wherein, in the step 1, the aliphatic cyclic compound (c1) is used in a ratio of 0.01 moles or more and less than 0.9 moles relative to 1 mole of the hydrous alkali metal sulfide or the hydrous alkali metal hydrosulfide. 
     
     
         7 . The method for producing a polyarylene sulfide resin according to  claim 3 , wherein, in the step 2, the amount of aprotic polar organic solvent added in the reaction system is in a ratio of 0.5 to 5 moles relative to 1 mole of sulfur atoms present in the reaction system. 
     
     
         8 . The method for producing a polyarylene sulfide resin according to  claim 3 , wherein the content of the solid alkali metal sulfide in the slurry obtained in the step 1 is 0.1 to 0.99 moles per mole of the hydrous alkali metal sulfide used in the step 1.