Patent Application
20070060737
The present invention relates to a novel polyarylate and a method for preparation thereof. More specifically, the invention relates to a novel polyarylate in which various functional groups can be introduced to the main chain of the polymer as well as the terminal of a polymer, and the concentration of the functional groups can be adjusted, and by these functional groups, the adhesion force is improved when coated onto the substrate or protective layer, thus the polyarylate is suitably used for the coating composition or film and to a method for preparation thereof.
This application claims the benefit of the filing date of Korean Patent Application Nos. 10-2005-0085213, filed on Sep. 13, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
Polyarylate is typically an aromatic polyester composed of bisphenol A isophthalate and terephthalate.
A method of synthesizing such a polyarylate include interfacial polymerization, melt polymerization, solution polymerization and the like, and a suitable method can be selected according to the type and properties of a monomer to be introduced and the degree of the molecular weight to be obtained. As a related art for synthesizing polyarylates, U.S. Pat. No. 4,652,608 describes a polyarylate prepared by polymerizing alkyl-substituted phenolphthalein and bisphenol A, and a method for synthesizing the polyarylate in detail.
The conventionally known polyarylate films have high degree of optical transmission, and are extremely excellent in thermal and mechanical properties. However, the conventional polyarylate films have problems in that the melting temperature and viscosity is high, and positive birefringence is generated in the surface direction during processing.
As a result, in order to use polyarylates for optical films, steady studies have been carried out on the method of controlling the birefringence in the surface direction. Specifically, studies on introducing substituents on a polymer chain or on improving physical and mechanical properties of polyarylate by copolymerizing with other polymers are carried out.
For example, U.S. Pat. Nos. 5,043,413, 4,584,335, 4.929,677 and 4,977,235 describe a method for synthesizing the polyarylate by substituting the alkylene portion of a bisphenol monomer with various substituents, and U.S. Pat. No. 4,853,457 and US Patent Application Laid-Open No. 2002-45715 describe a method for improving physical properties of the polyarylates by forming a graft polymer or an alloy of the other polymers therewith. Also, as a technique for improving physical properties by introducing a third monomer to the polyarylate, U.S. Pat. No. 5,023,314 describes a method for preparing high molecular weight polyarylate through polymerization by mixing the maximum of 1.5% of trisphenol.
However, the polyarylates with improved physical properties described in the related arts have problems in that the control of birefringence is difficult when the birefringence is given by stretching, and that obtaining a desired phase difference is difficult due to reduction in the film thickness when stretching. Further, there are problems in that the adhesion force is not good when the polyarylate is coated on a transparent substrate such as polycarbonate substrate, etc.
U.S. Pat. Nos. 6,100,367 and 6,174,966 describe a method for increasing adhesion force with other substrates by using a small amount of monomers which can provide an alkoxysilyl group when synthesizing polycarbonate or polyarylate. Also, U.S. Pat. No. 5,258,483 describes a polyarylate to which an epoxy group is introduced instead of an alkoxysilyl group. However, there is problem in that the concentration of the epoxy group reaches several tens of ppm by being introduced at the terminal of polyarylates.
[Technical Problem]
In order to solve the above-mentioned problems in the related arts, it is an object of the present invention to provide a novel polyarylate in which various functional groups can be introduced to the main chain of the polymer as well as the terminal of a polymer and the concentration of the functional groups can be adjusted, and by the functional groups introduced to the main chain of the polymer, the adhesion force can be improved by chemical bonds when coated onto the substrate or protective layer, and a method for preparation thereof.
Another object of the invention is to provide a coating composition comprising the novel polyarylate and a film formed therefrom.
[Technical Solution]
In order to the above-mentioned objects, the present invention provides a polyarylate comprising a unit represented by the formula (1) and prepared by a method comprising a step of copolymerizing divalent phenol, divalent aromatic carboxylic acid halide and the allyl bisphenol derivative represented by the following formula (2):
wherein R1 to R8 are each independently hydrogen, alkyl having 1 to 12 carbon atoms, arylalkyl having 7 to 12 carbon atoms, aryl having 6 to 12 carbon atoms, nitrile. alkylenenitrile having 2 to 12 carbon atoms, alkoxy having 1 to 12 carbon atoms, acyl having 1 to 12 carbon atoms, alkenyl having 2 to 12 carbon atoms, alkylalkenyl having 3 to 12 carbon atoms, arylalkenyl having 8 to 12 carbon atoms or halogen, in which the alkenyl of the above substituent(s) may be introduced with at least one functional group of an epoxide group, an alkoxy group, a hydroxy group and an amine group, provided that at least one of R1 to R4 or at least one of R5 to R8 is alkenyl having 2 to 12 carbon atoms, alkylalkenyl having 3 to 12 carbon atoms or arylalkenyl having 8 to 12 carbon atoms, in which the alkenyl of the above substituent(s) may be introduced with at least one functional group of an epoxide group, an alkoxy group, a hydroxy group and an amine group;
W and W′ are each independently directly bonded, or are each independently oxygen, sulfur, sulfoxide, sulfone, alkylidene having 1 to 30 carbon atoms, alkylene having 2 to 30 carbon atoms, cycloalkylidene having 3 to 30 carbon atoms, cycloalkylene having 3 to 30 carbon atoms or phenyl-substituted alkylene having 2 to 30 carbon atoms; and
—OOCYCOO— and —OOCY′COO— are each independently terephthalic acid, isophthalic acid, dibenzoic acid or naphthalene dicarboxylic acid, in which the aromatic group may be substituted with a substituent selected from the group consisting of alkyl having 1 to 8 carbon atoms, aryl, alkylaryl and halogen,
wherein R9 to R12 are each independently hydrogen, alkyl having 1 to 12 carbon atoms, arylalkyl having 7 to 12 carbon atoms, aryl having 6 to 12 carbon atoms, nitrile, alkylenenitrile having 2 to 12 carbon atoms, alkoxy having 1 to 12 carbon atoms, acyl having 1 to 12 carbon atoms, alkenyl having 2 to 12 carbon atoms, alkylalkenyl having 3 to 12 carbon atoms, arylalkenyl having 8 to 12 carbon atoms or halogen, provided that at least one of R9 to R12 is alkenyl having 2 to 12 carbon atoms, alkylalkenyl having 3 to 12 carbon atoms or arylalkenyl having 8 to 12 carbon atoms: and
W is directly bonded, or is oxygen, sulfur, sulfoxide, sulfone, alkylidene having 1 to 30 carbon atoms, alkylene having 2 to 30 carbon atoms, cycloalkylidene having 3 to 30 carbon atoms, cycloalkylene having 3 to 30 carbon atoms or phenyl-substituted alkylene having 2 to 30 carbon atoms.
Further, the invention provides a method for preparing the polyarylate comprising the steps of:
a) copolymerizing divalent phenol, divalent aromatic carboxylic acid halide and the allyl bisphenol derivative represented by the formula (2); and if necessary,
b) introducing at least one functional group of an epoxide group, an alkoxy group, a hydroxy group and an amine group to the copolymer prepared in the step a).
Furthermore, the invention provides a coating composition comprising polyarylate according to the invention and a film formed therefrom.
Hereinbelow, the invention will be described in detail.
The polyarylate of the invention is prepared by a method comprising a step of copolymerizing divalent phenol, divalent aromatic carboxylic acid halide and the ally( bisphenol derivative represented by the formula (2).
The polyarylate prepared by the copolymerizing step contains at least one double bond in the main chain of a polymer via an allyl group of allyl bisphenol derivative represented by the formula (2). For example, an ally group is contained in at least one of R1 to R4 or at least one of R5 to R8 in the formula (1). Therefore, the polyarylate can be introduced with various functional groups on the main chain of a polymer through double bonds contained in the main chain of the polymer.
Further, the concentration of the double bonds and functional groups in the main chain of polyarylate of the invention can be adjusted by controlling the use amount of allyl bisphenol derivatives represented by the formula (2) or using allyl bisphenol derivatives with appropriate number of allyl groups when preparing the polyarylate in the invention. Moreover, the polyarylate according to the invention described above can be polymerized with other polyarylates depending on the content of allyl bisphenol derivative to divalent phenol, and then be introduced with functional groups.
As described above, examples of the functional group, which can be introduced to the polyarylate according to the invention having double bonds in the main chain of the polymer, include an epoxide group, an alkoxy group, a hydroxy group, an amine group or the like. That is, examples of the polyarylate of the invention introduced with the functional group include the polyarylate with the double bond being substituted with epoxide, the polyarylate with the double bond being substituted with alkoxy and hydroxy, the polyarylate with the double bond being substituted with dihydroxy, the polyarylate with the double bond being substituted with alkoxy and amine, or the like. In order to improve the adhesion force in the polyarylate of the invention, it is more preferable that an epoxy group or a hydroxy group is introduced.
Examples of the method for introducing functional groups to the polyarylate according to the invention include a method for substituting an allyl group with epoxide group using an epoxidizing agent, a method for substituting an allyl group with an alkoxy group (—OR) and a hydroxy group (—OH) by adding alcohol to the epoxidized polyarylate, a method for substituting an allyl group with a dihydroxy group by adding water to the epoxidized polyarylate or the like.
Specific examples of the polyarylate of the invention include polyarylates containing a unit selected from the following formulas (3) to (6), but the scope of the invention is not limited thereto.
In the invention, examples of aromatic dihydroxy compounds such as divalent phenol and the allyl bisphenol derivative used in the preparation of polyarylate include bis(4-hydroxyaryl)alkane such as bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxyphenyl)propane (BPA), 2,2-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 2,2-bis(4-hydroxyphenyl)heptane, 2,2-bis(4-hydroxy-3,5-dichlorophenyl)propane, 2,2-bis(4-hydroxy-3,5-dibromophenyl)propane, bis(4-hyroxyphenyl)phenylmethane, 4,4-dihydroxyphenyl-1,1-m-diisopropylbenzene, 4,4-dihydroxyphenyl-9,9-fluorene, 2,2-bis(4-hydroxyphenyl)fluorene (BHPF), 9,9-bis(3,5-dimethyl-4-hydroxyphenyl)fluorene (BDMPF) or 9,9-bis(3,5-dibromo-4-hydroxyphenyl)fluorene (BFBPF); aromatic dihydroxy compounds containing alkenyl such as 4,4′-(1-methylethylidene)bis(2-(2-propenyl)phenol and the like, and these may be used in the mixture of one or more kinds. Further, examples of aromatic dihydroxy compounds include bis(hydroxyaryl)cycloalkane such as 1,1-bis(4,4-hydroxyphenyl)cyclopentane, 1,1-bis(4,4-hydroxyphenyl)cyclohexane, 1-methyl-1-(4-hydroxyphenyl)-4-(dimethyl-4-hydroxyphenyl)cyclohexane, 4-{1-[3-(4-hydroxyphenyl)-4-methylcyclohexyl]-1-methylethyl}phenol, 4,4-[1-methyl-4-(1-methylethyl)-1,3-cyclohexylidyl]bisphenol or 2,2,2,2-tetrahydro-3,3,3.3-tetramethyl-1,1-spirobis-[1H]-indene-6,6-diol, and these may be used in a mixture of one or more kinds. Also, examples of aromatic dihydroxy compounds include dihydroxydiaryl ethers such as bis(4-hydroxyphenyl)ether, bis(4-hydroxy-3,5-dichlorophenyl) ether or 4,4-dihydroxy-3,3-dimethylphenyl ether; dihydroxydiaryl sulfates such as 4,4-dihydroxydiphenyl sulfate or 4,4-dihydroxy-3,3-dimethyldiphenyl sulfate: dihydroxydiaryl sulfoxides such as 4,4-dihydroxydiphenyl sulfoxide or 4,4-dihydroxy-3,3-dimethyldiphenyl sulfoxide; and dihydroxydiaryl sulfones such as 4,4-dihydroxydiphenyl sulfone or 4,4-dihydroxy-3,3-dimethyldiphenyl sulfone; and the like, and these may be used alone or in a mixture of two or more kinds.
In the invention, the kind of divalent aromatic carboxylic acid halide that can be used in preparing the polyarylate is not particularly limited, but terephthalic acid halides, isophthalic acid halides, dibenzoic acid halides, naphthalene dicarboxylic acid halides, or aromatic dicarboxylic acid halides in which the aromatic groups of these compounds are substituted with alkyl having 1 to 8 carbon atoms, aryl, arylalkyl or halogen, can be used. These may be used alone or in a mixture of two or more. In the invention it is more preferable that isophthalic acid halide or terephthalic acid halide is used alone or in a mixture thereof.
In the invention, it is preferable that a dihydroxy monomer including the divalent phenol and the allyl bisphenol derivative, and a divalent aromatic carboxylic acid halide are used in the molar ratio of 1:1. Further, it is preferable that the allyl bisphenol derivative is used in the amount of 0.1 mol % to 99.9 mol % with respect to the divalent phenol. Also, it is preferable that the allyl bisphenol derivative is contained in the amount of 0.01 to 49.9 mol % in the polyarylate of the invention. In addition, it is preferable that the polyarylate according to the invention has the molecular weight of 10,000 g/mol or higher.
In order to improve the surface characteristics or the adhesion force of a film fabricated by polyarylates, additives known in the field of arts can be further used, in addition to the above-mentioned components, when preparing the polyarylate according to the invention.
In the invention, the method for copolymerizing the above-mentioned components is not particularly limited, but a method known in the field of arts can be used. Specific method is exemplified in Examples described below.
The polyarylate prepared as in the above can be prepared in a form of solid, powder, solution or the like, but it can be prepared in any form depending on its use, for example, the coating method to be applied when using as a coating composition.
The invention provides a coating composition comprising polyarylate containing a unit represented by the formula (1) or a film formed from the polyarylate. The coating composition or the film according to the invention can be applied for preparing an optical film or for an optical film.
The coating composition according to the invention can be prepared, for example, in the form of a solution by adding a solvent to the polyarylate according to the invention. Moreover, the film according to the invention can be fabricated, for example by coating the coating composition onto a substrate such as a glass plate or a polycarbonate film at room temperature, and stepwise volatizing the solvent. The coating method is not particularly limited, but a method known in the field of arts, for example, the bar coating can be used. According to the invention, the film thickness is preferably 1 to 100 μm.
In this case, as the solvent, methylene chloride, dichloroethane, dioxalane, tetrahydrofuran and the like can be used. It is preferable that the coating composition containing such the solvent is a solution with the concentration of 5 to 25% by weight.
The polyarylate according to the invention is not only excellent in the adhesion force by chemically bonding through double bonds or functional groups introduced to the main chain of the polymer when coated onto the substrate or supporting layer, but also the polyarylate itself can be used for an optical film or a coating composition for fabricating an optical film without performing the stretching process unlike the conventional optical films.
Hereinbelow, preferred Examples are presented to help the understanding of the invention, but the following Examples only exemplify the present invention, and the scope of the invention is not limited to these Examples.
[Mode for Invention]
The reagents and solvents used in the following Examples were purchased from Sigma-Aldrich Corp. and Merck & Co., Inc. and purified by a standard method. For the method of synthesis of polyarylate, a solution polymerization is possible, but in order to obtain polyarylate in an appropriate molecular weight, the interfacial polymerization was carried out. In order to confirm the structure of the synthesized polyarylate, 400 MHz NMR was used to obtain a spectrum, and GPC (Viscotek. TriSEC Model 302) and DSC (TA Instrument) were used to measure the molecular weights and the glass transition temperatures (Tg).
Synthesis of polyarylate having 3 mol % of allyl bisphenol derivative In dihydroxy bisphenol monomer
To a reactor equipped with a stirrer, 37.0 g of 2,2-bis(4-hydroxyphenyl)propane as divalent phenol, 1.8 g of 2,2-bis(3-(2-propenyl)-4-hydroxyphenyl)propane as allyl bisphenol derivative, 14.9 g of NaOH and 357 g of distilled water were mixed and the mixture was dissolved by stirring. Then, while maintaining the reactor temperature at 20° C., a solution of 0.6 g of benzyltriethyl ammonium bromide in 35.7 g of methylene chloride was added and then stirred vigorously. Next, 1.5 g of 4-t-butylphenol as a molecular weight modifier and an aqueous solution of 0.4 g of NaOH in 10 g of water were added to prepare an aqueous mixed solution.
Apart from the above, 34 g of an aromatic carboxylic acid mixture mixed with the same moles of isophthalic acid chloride and terephthalic acid chloride was dissolved in 452 g of methylene chloride. This solution was added to the previously prepared aqueous mixed solution. After polymerizing it under stirring at 500 rpm for 1 hour, a solution of 0.9 g of benzoic acid in 9.4 g of methylene chloride was added and further stirred for 10 minutes. Then, 15 mL of acetic acid was added to terminate the reaction, and washed multiple times with 1 fold-volute of methylene chloride and 2 fold-volume of distilled water. The washing was repeated until the remaining solution had a conductance of 20 μs/cm or lower, and the solution was added to methanol to precipitate polymers.
The composition of the dihydroxy bisphenol monomer in the synthesized polyarylate was such that the content of 2,2-bis(4-hydroxyphenyl)propane (BPA) was 97 mol % and the content of allyl bisphenol derivative was 3 mol %. The glass transition temperature and the weight average molecular weight of the synthesized polyarylate were 190° C. and 46.500 g/mol, respectively (Classification 5 in Table 1).
Synthesis of polyarylate having 5 mol % of allyl bisphenol derivative in dihydroxy bisphenol monomer
Polyarylate was synthesized in the same manner as in Example 1, except that the stirring speed during the polymerization was 700 rpm. The composition of the dihydroxy bisphenol monomer in the synthesized polyarylate was such that the content of 2,2-bis(4-hydroxyphenyl)propane (BPA) was 95 mol %, and the content of allyl bisphenol derivative was 5 mol %. The glass transition temperature and the weight average molecular weight of the synthesized polyarylate were 194° C. and 104,000 g/mol, respectively. The NMR spectrum of the synthesized polyarylate is illustrated in
Synthesis of polyarylate introduced with an epoxide group having 5 mol % of allyl bisphenol derivative in dihydroxy bisphenol monomer
To the polyarylate prepared in the same manner as in Example 2. m-CPBA (meta chloro perbenzoic acid) as an epoxidizing agent was added and stirred in methylene chloride for 1 day to introduce an epoxide group to polyarylate. Specifically, to 7.5 g of polyarylate prepared in the same manner as in Example 2, 1.2 g of meta chloro perbenzoic acid (m-CPBA) was mixed to remove air. Then, 300 mL of anhydrous methylene chloride was added and stirred at room temperature for 24 hours. The epoxide group being introduced was confirmed using NMR. After appropriately diluting the solution with methylene chloride, precipitation was performed in methanol. The precipitates were washed with methanol, and then dried. The glass transition temperature and the weight average molecular weight of the synthesized polyarylate were 200° C. and 96,000 g/mol, respectively. The NMR spectrum of the synthesized polyarylate is illustrated in
Synthesis of polyarylate introduced with methoxy-hydroxy group having 5 mol % of allyl bisphenol derivative in dihydroxy bisphenol monomer
To the polyarylate introduced with an epoxide group prepared in the same manner as in Example 3, anhydrous methanol was added in the presence of an acid catalyst (1% sulfuric acid) to introduce a methoxy-hydroxy group.
Specifically, 10 g of the polyarylate introduced with an epoxide group was dissolved in 200 mL of anhydrous THF, then 0.5 mL of sulfuric acid and 3 mL of anhydrous methanol were added thereto and the mixture was stirred at room temperature for 2 hours. The reaction being completed was confirmed using NMR. Here, the solution was diluted with a suitable amount of THF, and then the diluted solution was precipitated in methanol. Thus obtained polyarylate had functional groups of methoxy (OMe) and alcohol (OH). The glass transition temperature and the weight average molecular weight of the synthesized polyarylate were 198° C. and 115,000 g/mol, respectively. The NMR spectrum of the synthesized polyarylate is illustrated in
Synthesis of polyarylate introduced with dihydroxy group having 5 mol % of allyl bisphenol derivative in dihydroxy bisphenol monomer
10 g of the polyarylate introduced with an epoxide group prepared in the same manner as in Example 3 was dissolved in 200 mL of anhydrous THF. Then, 0.5 mL of sulfuric acid and 3 mL of water were added thereto and the mixture was stirred at room temperature for 1 hour for acid hydrolysis to obtain polyarylate having diol as a functional group. The glass transition temperature and the weight average molecular weight of the synthesized polyarylate were 194C and 94,900 g/mol, respectively. The NMR spectrum of the synthesized polyarylate is illustrated in
In addition, in the same manner as in Examples 1 to 5, polyarylates were prepared by varying the composition of divalent phenol, aromatic dicarboxylic acid halide and the allyl bisphenol derivative. The compositions and physical properties of the prepared polyarylates are illustrated in the following Table 1.
DABPA: 2,2-Bis(3-(2-propenyl)-4-hydroxyphenyl)propane
BPA: 2,2-Bis(4-hydroxyphenyl)propane
TPC: Terephthalic acid chloride
IPC: Isophthalic acid chloride
a: Polyarylate having methoxy group (OMe) and hydroxy group (OH)
b: Polyarylate having epoxy group
c: Polyarylate having dihydroxy group
The polyarylate according to the present invention is a novel polyarylate prepared by copolymerizing divalent phenol, aromatic dicarboxylic acid and a third monomer, that is, an allyl bisphenol derivative, wherein by the allyl bisphenol derivative, various functional groups can be introduced to the main chain of the polymer as well as the terminal of a polymer, and the concentrations thereof can be-adjusted. Further, due to the introduced double bonds and functional groups at the main chain of the polymer, it is possible to improve the adhesion force by chemically bonding when coated onto a substrate or a protective layer. Therefore, the polyarylate according to the invention is suitably used as a component for a coating composition or a film.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005-0085213 | Sep 2005 | KR | national |
