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  Production method of polymers by using living anionic polymerization methodUSPTO Application #: 20080045677Title: Production method of polymers by using living anionic polymerization method Abstract: An anionic polymerizable monomer is added to a reaction system in which an anion species which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization is present, and then an anion species capable of initiating polymerization is added thereto. It becomes possible to produce high molecular weight polymers and to precisely control the molecular weight thereof even if polymerization inhibiting substances are present in the system or when polymerization inhibiting substances enter from outside. (end of abstract)
Agent: Darby & Darby P.C. - New York, NY, UN Inventors: Eiji Takahashi, Shoji Yamaguchi USPTO Applicaton #: 20080045677 - Class: 526089000 (USPTO) The Patent Description & Claims data below is from USPTO Patent Application 20080045677. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO PRIOR APPLICATION [0001] This is a U.S. National Phase Application under 35 U.S.C. .sctn.371 of International Patent Application No. PCT/JP2005/010485 filed Jun. 8, 2005, and claims the benefit of Japanese Patent Application Nos. 2004-170963, filed Jun. 9, 2004 and 2004-290963, filed Oct. 4, 2004, all of which are incorporated by reference herein. The International Application was published in Japanese on Dec. 22, 2005 as WO 2005/121189 A1 under PCT Article 21(2). TECHNICAL FIELD [0002] The present invention relates to a method for producing polymers by using a living anionic polymerization method, and more specifically, relates to a production method of polymers by using a living anionic polymerization method which make it possible to produce polymers having high molecular weights without performing stringent raw-material purification and also to precisely control the molecular weight of the obtained polymers. BACKGROUND ART [0003] In anionic polymerization systems, since active hydrogen compounds such as water and alcohol, oxygen, or the like become polymerization inhibiting substances, which deactivate the growing terminal anions or initiators, the control of anionic polymerization under the presence of these materials is known to be difficult. [0004] On the other hand, when producing a polymer having a high molecular weight of, for example, several tens of thousands or more by an anionic polymerization method, since the more attempts are made to obtain polymers having high molecular weights, the more the concentration of the growing terminal anion in the polymerization solution reduces, relative effects of polymerization inhibiting substances increase greatly and the growing terminal anion becomes prone to deactivation. For this reason, there has been a problem in that the production of polymers having a desired molecular weight is difficult and yields of targeted polymers are reduced. [0005] In order to solve such problems, a method is proposed where benzylmagnesium bromide, butyllithium, or the like is added to monomers or solvents to be used to react with the polymerization inhibiting substances containing active hydrogen, which are contained in the monomers or the solvents in trace amounts, and the polymerization inhibiting substances are removed from the monomers or the solvents for purification. [0006] In this method, there is a need to add an excessive amount of benzylmagnesium bromide, butyllithium, or the like in order to completely remove the polymerization inhibiting substances. However, since there are also some cases where these reagents function as polymerization inhibitors or polymerization initiators, they must be removed completely from the monomers or solvents before the polymerization. For this reason, there was a practically problem when carrying out anionic polymerization on an industrial scale, since there were some cases where the purification process or the like became complex, and moreover, monomers partially polymerized at the time of purifying the monomers by a distillation method or the like caused a reduction of the purification recovery factor of the monomers. [0007] Moreover, Hsieh et al. reports on the anionic polymerization of styrene or dienes at room temperature by having an ate complex of sec-butyllithium or polystyryl anion and dibutylmagnesium as a polymerization initiator and Sawamoto et al. reports on the styrene bulk polymerization at a polymerization temperature of 120.degree. C. using n-butyllithium/dibutylmagnesium complex. However, even in these examples using dibutylmagnesium, precise control of the molecular weight of a high molecular weight polymer has not been achieved (see Non-patent documents 1 to 4). [0008] [Non-patent document 1] H. L. Hsieh et al., Macromolecules, 1986, 19, 299 [0009] [Non-patent document 2] Seltz, L., Little, G. F., J. Organomet. Chem., 1969, 18, 227 [0010] [Non-patent document 3] A. Deffieux, et al., Macromol. Chem., 1999, 200, 621 [0011] [Non-patent document 4] 7th SPSJ International Polymer conference, 27A13 (1999) DISCLOSURE OF INVENTION Problems to be Solved by the Invention [0012] The present invention was made in view of the actual conditions of the above-mentioned conventional technology and its object is to provide a production method of polymers by using a living anionic polymerization method (hereinafter, "polymers produced by a living anionic polymerization method" is abbreviated to "living anionic polymers") which is capable of producing high molecular weight polymers even if polymerization inhibiting substances are present in the system or when polymerization inhibiting substances have entered from outside, and is also capable of precisely controlling the molecular weight of the obtained anionic polymers. Means for Solving the Problems [0013] The present inventors have intensively studied so as to achieve the above object and found that by adding anionic polymerizable monomers to the polymerization reaction-initiating system where an anion species are present which are capable of initiating polymerization and an anion species which is not capable of initiating polymerization but may react with polymerization inhibiting substances, polymers having a high molecular weight can be produced and precise control of the molecular weight of the obtained anionic polymers becomes possible, and thus the present invention has been completed. [0014] As described above, according to the present invention, production methods of living anionic polymers (1) to (12) described below will be provided. [0015] (1) A production method of living anionic polymers characterized by adding an anionic polymerizable monomer to a reaction system in which an anion species is present which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization (allow polymerization); and adding an anion species capable of initiating polymerization to the reaction system to which the anionic polymerizable monomer is added. [0016] (2) A production method of living anionic polymers characterized by adding an anionic polymerizable monomer to a reaction system in which an anion species is present which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization; and adding an anion species which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization, and an excessive amount of anion species capable of initiating polymerization to the reaction system to which the anionic polymerizable monomer is added. [0017] (3) The production method of living anionic polymers according to (1) or (2) characterized in that the reaction system in which an anion species is present which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization, is a reaction system in which an anion species which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization is added to the reaction system in which an anion species capable of initiating polymerization is present. [0018] (4) The production method of living anionic polymers according to (1) or (2) characterized in that the reaction system in which anion species is present which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization, is a reaction system in which an anion species capable of initiating polymerization is added to the reaction system in which an anion species is present which is incapable of initiating polymerization but may react with polymerization inhibiting substances to convert them into compounds that do not inhibit polymerization. Continue reading... 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