Low-molecular weight oxymethylene polymer and composition thereof

• US 6,388,049 B1
• Filed: 02/28/2001
• Issued: 05/14/2002
• Est. Priority Date: 07/01/1999
• Status: Expired due to Fees

• Current Assignee: Asahi Kasei Kabushiki Kaisha
• Original Assignee: Asahi Kasei Kabushiki Kaisha
• Inventors: Ban, Yukihiro, Yokoyama, Hiroshi
• Primary Examiner(s): Truong, Duc
• Application Number:
  US09/786,168
• Time in Patent Office: 440 Days
• Field of Search: 528/425, 528/230, 528/245, 525/398
• US Class Current: 528/425
• CPC Class Codes: C08G 2/10 Polymerisation of cyclic oligomers of formaldehyde
• CPC Class Codes: C08G 2/38 Block or graft polymers prepared by polymerisation of aldehydes or ketones on to macromolecular compounds
• CPC Class Codes: C08L 2666/16 Addition or condensation polymers of aldehydes or ketones according to C08L59/00 - C08L61/00; Derivatives thereof
• CPC Class Codes: C08L 59/00 Compositions of polyacetals; Compositions of derivatives of polyacetals of polyvinyl acetals C08L29/14

Abstract

A low-molecular-weight oxymethylene polymer characterized by having a straight-chain molecular structure, a number-average molecular weight of 1,000 to 8,000 and a molecular weight distribution (Mw/Mn) of 1.0 to 3.0, and containing 0 to 30 mol % of a co-monomer.

Claims

1. A low-molecular-weight oxymethylene polymer having a straight-chain molecular structure, a number-average molecular weight of 1,000 to 8,000 and a molecular weight distribution (Mw/Mn) of 1.0 to 3.0, and containing 0 to 30 mol % of a co-monomer unit.

2. A low-molecular-weight oxymethylene polymer according to claim 1, wherein the content of the co-monomer unit is 0 to 0.8 mol %.

3. A low-molecular-weight oxymethylene polymer according to claim 1, wherein the content of the co-monomer unit and the melting point of the polymer fall in the region defined by DEFG in FIG. 1.

4. A low-molecular-weight oxymethylene polymer according to claim 1, produced by continuous bulk polymerization reaction using as starting materials a monomer or a mixture of a monomer and a co-monomer and a molecular weight modifier in an amount of 0.1 to 1 mole per 1 kg of said monomer or said mixture of a monomer and a co-monomer mixture, and also using as polymerization catalyst a cationic polymerization initiator in an amount of 0.00001 to 0.0001 mole per 1 mole of said starting materials.

5. A polyoxymethylene resin composition comprising (A) 1 to 500 parts by weight of a low-molecular-weight oxymethylene polymer set forth in claim 1, and (B) 100 parts by weight of a high-molecular-weight polyoxymethylene resin having a number-average molecular weight of 15,000 to 1,000,000 and selected from the group consisting of (B-1) oxymethylene homopolymer resin, (B-2) oxymethylene copolymer resin, (B-3) oxymethylene block copolymer resin, and a mixture thereof.

6. A polyoxymethylene resin composition according to claim 5, wherein the content of the low-molecular-weight oxymethylene polymer (A) is 10 to 100 parts by weight.

7. A polyoxymethylene resin composition according to claim 5, wherein the high-molecular-weight polyoxymethylene resin (B) is an oxymethylene copolymer resin (B-2) having a melting point of 167 to 171°

C.

8. A polyoxymethylene-resin-composition according to claim 5, containing 1 to 10,000 ppm of a crystal nucleating agent.

9. A process for continuously producing a polyoxymethylene resin composition set forth in claim 5, said process comprising the steps of producing a crude polymer of the low-molecular-weight oxymethylene polymer (A) and a crude polymer of the high-molecular-weight polyoxymethylene resin (B) simultaneously by the separate polymerizers, by using equipment consisting of at least two continuous bulk polymerizers connected in parallel and an extruder disposed successively thereto, blending 100 parts by weight of said crude polymer of high-molecular-weight polyoxymethylene resin (B) and 1 to 500 parts by weight of said crude polymer of low-molecular-weight oxymethylene polymer (A) while deactivating the polymerization catalyst, and continuously and uniformly melting and mixing said crude polymers while conducting a terminal stabilization treatment on said crude polymers by said extruder.

10. A process for continuously producing a polyoxymethylene resin composition set forth in claim 5, which comprises the steps of polymerizing a monomer or a mixture of a monomer and a co-monomer and a molecular weight modifier with a cationic polymerization initiator as polymerization catalyst, by using one or two or more continuous bulk polymerizers connected in series, and further adding to the obtained polymerization product-said monomer or said mixture of a monomer and a co-monomer and said molecular weight modifier in a state not causing deactivation of said cationic initiator so that the amount of the produced low-molecular-weight oxymethylene polymer will become 1 to 500 parts by weight per 100 parts by weight of the high-molecular-weight polyoxymethylene resin.

11. A process for continuously producing a polyoxymethylene resin composition set forth in claim 5, said process comprising the steps of producing a crude polymer of low-molecular-weight oxymethylene polymer (A) and a crude polymer of high-molecular-weight polyoxymethylene resin (B) simultaneously by the separate polymerizers using formaldehyde and a molecular weight modifier as starting materials and also using an onium salt-based polymerization catalyst, by using a series of equipment consisting of at least two slurry polymerizers connected in series or parallel, a terminal stabilizing device and an extruder provided successively thereto, blending 100 parts by weight of said crude polymer of high-molecular-weight polyoxymethylene resin (B) and 1 to 500 parts by weight of said crude polymer of low-molecular-weight oxymethylene polymer (A) while deactivating and removing the polymerization catalyst, blocking the unstable terminal of the molecule of the produced polymer, and continuously conducting uniform melting and mixing by the extruder.

12. Parts of OA equipment, music, image or information devices, communications apparatus, electrical and electronic devices, toys, sporting goods, furniture, housing equipment or automobiles, obtained by molding a polyoxymethylene resin composition set forth in claim 5.