COPOLYMER, METHOD FOR PRODUCING COPOLYMER, AND RESIN COMPOSITION CONTAINING COPOLYMER

Abstract

Provided are a copolymer capable of suppressing coloration even after heating, and a method for producing the copolymer. A copolymer containing a constitutional unit (A) derived from 1,1-dicyanoethylene and a constitutional unit (B) derived from a compound represented by the following general formula (I):

##STR00001##

in which the copolymer includes the following four kinds of triad structures (U-1) to (U-4) composed of the constitutional unit (A) and the constitutional unit (B),

##STR00002##

and a total content of (U-2) and (U-3) in a total amount of the four kinds of triad structures is 5.5 mol % or less.

Claims

1. A copolymer comprising a constitutional unit (A) derived from 1,1-dicyanoethylene and a constitutional unit (B) derived from a compound represented by the following general formula (I), ##STR00008## wherein the copolymer comprises the following four kinds of triad structures (U-1) to (U-4) composed of the constitutional unit (A) and the constitutional unit (B), ##STR00009## and a content of (U-2) and (U-3) in a total amount of the four kinds of triad structures is 5.5 mol % or less, in the general formula (I), R.sup.1 is one or more selected from a hydrogen atom, an alkyl group, a cycloalkyl group, an aryl group, an alkoxy group, and a halogen atom, and R.sup.2 is one or more selected from a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, a halogen atom, and a haloalkyl group.

2. The copolymer according to claim 1, wherein a content of the (U-1) in the total amount of the four kinds of triad structures is 1.8 mol % or less.

3. The copolymer according to claim 1, wherein a content of the constitutional unit (A) in the total amount of the copolymer is 30 to 55 mol %.

4. The copolymer according to claim 1, wherein the compound represented by the general formula (I) is one or more selected from the group consisting of styrene, -methylstyrene, p-methylstyrene, isobutylene, 1-hexene, propylene, and ethylene.

5. A method for producing the copolymer according to claim 1, the method comprising producing the copolymer in the presence of a radical polymerization initiator at a polymerization temperature of 45 C. or lower, wherein a charging amount of the compound represented by the general formula (I) is 0.80 to 3.5 equivalents relative to a charging amount of 1,1-dicyanoethylene.

6. A resin composition comprising the copolymer according to 1.

7. A molded article using the copolymer according to claim 1.

8. A film using the copolymer according to claim 1, wherein a difference between a yellowness index before heating and a yellowness index after heating at 140 C. for 1 hour under normal pressure is 2.5% or less.

9. A conductive film obtained by laminating a conductive layer on the film according to claim 8.

10. A film capacitor comprising the film according to claim 8.

Description

DESCRIPTION OF EMBODIMENTS

[Copolymer]

[0021] The copolymer of the present invention is a copolymer containing a constitutional unit (A) derived from 1,1-dicyanoethylene and a constitutional unit (B) derived from a compound represented by the following general formula (I),

##STR00005##

in which the copolymer includes the following four kinds of triad structures (U-1) to (U-4) composed of the constitutional unit (A) and the constitutional unit (B),

##STR00006##

and a total content of (U-2) and (U-3) in a total amount of the four kinds of triad structures is 5.5 mol % or less,

[0022] in the general formula (I), R.sup.1 is one or more selected from a hydrogen atom, an alkyl group, a cycloalkyl group, an aryl group, an alkoxy group, and a halogen atom, and R.sup.2 is one or more selected from a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, a halogen atom, and a haloalkyl group.

[0023] In the present invention, the triad structure means a structure in which a constitutional unit (A) derived from 1,1-dicyanoethylene and a constitutional unit (B) derived from a compound represented by the general formula (I) are bonded in a total number of three.

[0024] In addition, (A)-(A)-(A), which is one of the four kinds of triad structures, means a triad structure in which three constitutional units (A) derived from 1,1-dicyanoethylene are continuously bonded, and (A)-(A)-(B) means a triad structure in which two constitutional units (A) derived from 1,1-dicyanoethylene are continuously bonded and then a constitutional unit (B) derived from the compound represented by the general formula (I) is bonded, and the other triad structures have the same meaning.

[0025] In the present invention, the amounts of the four kinds of triad structures (U-1) to (U-4) are defined, and the amount of the triad structure (U-1) means the content (mol %) of (A) bonded between two (A)'s in the structure of (A)-(A)-(A) constituting (U-1). Similarly, the content of the triad structure (U-2) means the content (mol %) of (A) bonded between (A) and (B) in the structure of (A)-(A)-(B) constituting (U-2), and the contents of the other triad structures have the same meaning.

[0026] The content of each of the triad structures (U-1) to (U-4) in the present invention can be measured by .sup.13C-NMR, and to be specific, can be measured by the method described in Examples.

[0027] In the present invention, the total content of (U-2) and (U-3) in the total amount of the four kinds of triad structures is 5.5 mol % or less. When the total content of (U-2) and (U-3) is 5.5 mol % or less, it is possible to suppress the amount of an arrangement which causes coloration by heat, specifically an arrangement in which (A) is continuous, to a low level, whereby in a molded article using the copolymer of the present invention, coloration can be suppressed even after heating.

[0028] From the viewpoint of effectively suppressing coloration, the total content of (U-2) and (U-3) in the total amount of the four kinds of triad structures is 5.5 mol % or less, preferably 5.2 mol % or less, preferably 5.0 mol % or less, preferably 4.8 mol % or less, and still more preferably 4.6 mol % or less, and the lower limit value is usually 0.5 mol % or more, but may be less than that, and is preferably 0.1 mol % or more.

[0029] The total content of (U-2) and (U-3) can be adjusted at a relatively low temperature of 50 C. or lower and by controlling the charging amount of the monomers.

[0030] In the present invention, the content of (U-1) in the total amount of the four kinds of triad structures is preferably 1.8 mol % or less. When the content of the (U-1) is equal to or less than the upper limit value, the amount of an arrangement in which (A) is continuous in the copolymer is reduced, and as a result, the coloration after heating of the molded article using the copolymer of the present invention is further suppressed. From the above viewpoint, the content of (U-1) in the total amount of the four kinds of triad structures is preferably 1.7 mol % or less, more preferably 1.5 mol % or less, and still more preferably 0.5 mol % or less.

<Constitutional Unit (A) Derived from 1,1-Dicyanoethylene>

[0031] The copolymer of the present invention contains a constitutional unit (A) derived from 1,1-dicyanoethylene. Since 1,1-dicyanoethylene provides a copolymer having high transparency by radical polymerization, the copolymer of the present invention can be suitably used for a molded article or the like requiring transparency.

[0032] 1,1-Dicyanoethylene can be produced by the production method described in J. Am. Chem. Soc., 1989, 111, 9078 to 9081 and U.S. Pat. No. 2,476,270 A.

<Constitutional Unit (B) Derived from Compound Represented by General Formula (I)>

[0033] The copolymer of the present invention contains a constitutional unit (B) derived from a compound represented by the following general formula (I).

##STR00007##

[0034] In the general formula (I), R.sup.1 is one or more selected from a hydrogen atom, an alkyl group, a cycloalkyl group, an aryl group, an alkoxy group, and a halogen atom, and R.sup.2 is one or more selected from a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, a halogen atom, and a haloalkyl group.

[0035] In the general formula (I), R.sup.1 is one or more selected from a hydrogen atom, an alkyl group, a cycloalkyl group, an aryl group, an alkoxy group, and a halogen atom.

[0036] The alkyl group of R.sup.1 is preferably an alkyl group having 1 to 12 carbon atoms, and examples thereof include a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a n-pentyl group, an isopentyl group, a neopentyl group, a n-hexyl group, a heptyl group, an octyl group, a decyl group, and a dodecyl group.

[0037] The cycloalkyl group of R.sup.1 is preferably a cycloalkyl group having 3 to 12 carbon atoms, and examples thereof include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, and a cyclohexyl group.

[0038] The aryl group of R.sup.1 is preferably an aryl group having 6 to 20 carbon atoms, and examples thereof include a phenyl group, a tolyl group, a xylyl group, and a naphthyl group. The alkoxy group of R.sup.1 is preferably an alkoxy group having 1 to 10 carbon atoms, and examples thereof include a methoxy group, an ethoxy group, a n-propoxy group, an isopropoxy group, a n-butoxy group, an isobutoxy group, a sec-butoxy group, and a tert-butoxy group.

[0039] Examples of the halogen atom of R.sup.1 include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.

[0040] Among these, R.sup.1 is preferably a hydrogen atom and an alkyl group having 1 to 6 carbon atoms, more preferably a hydrogen atom and an alkyl group having 1 to 4 carbon atoms, and still more preferably a hydrogen atom and a methyl group, from the viewpoint of suppressing coloration after heating of a molded article using the copolymer of the present invention.

[0041] In the general formula (I), R.sup.2 is one or more selected from a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, a halogen atom, and a haloalkyl group.

[0042] The alkyl group of R.sup.2 is preferably an alkyl group having 1 to 12 carbon atoms, and examples thereof include a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a sec-butyl group, a tert-butyl group, a n-pentyl group, an isopentyl group, a neopentyl group, and a n-hexyl group.

[0043] The alkenyl group represented by R.sup.2 is preferably an alkenyl group having 2 to 12 carbon atoms, and examples thereof include a vinyl group, an allyl group, a propenyl group, an isopropenyl group, a butenyl group, an isobutenyl group, a pentenyl group, a prenyl group, a hexenyl group (such as a cis-3-hexenyl group), and a cyclohexenyl group.

[0044] The cycloalkyl group of R.sup.2 is preferably a cycloalkyl group having 3 to 12 carbon atoms, and examples thereof include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, and a cyclohexyl group.

[0045] The aryl group of R.sup.2 is preferably an aryl group having 6 to 20 carbon atoms, and examples thereof include a phenyl group, a tolyl group, a xylyl group, and a naphthyl group.

[0046] Examples of the halogen atom of R.sup.2 include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.

[0047] The haloalkyl group of R.sup.2 is preferably a haloalkyl group having 1 to 12 carbon atoms, and more preferably a haloalkyl group having 1 to 6 carbon atoms. Examples of the halogen atom constituting the haloalkyl group include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.

[0048] Among these, R.sup.2 is preferably one selected from the group consisting of a hydrogen atom, an alkyl group, an alkenyl group, and an aryl group, more preferably an alkyl group having 1 to 6 carbon atoms or an aryl group having 6 to 10 carbon atoms, and still more preferably an alkyl group having 1 to 4 carbon atoms or an aryl group having 6 to 10 carbon atoms, from the viewpoint of suppressing coloration after heating of a molded article using the copolymer of the present invention.

[0049] More specifically, the compound represented by the general formula (I) is more preferably one or more selected from the group consisting of styrene, -methylstyrene, p-methylstyrene, isobutylene, 1-hexene, propylene, and ethylene from the viewpoint of suppressing coloration. By using these compounds, discoloration can be more effectively suppressed.

[0050] The compound represented by the general formula (I) is easily available from commercial products, and can also be produced by a known method.

<Content of Each Constitutional Unit in Copolymer>

[0051] The content of the constitutional unit (A) in the copolymer of the present invention is preferably 30 to 55 mol %, more preferably 40 to 53 mol %, and still more preferably 48 to 51 mol %.

[0052] On the other hand, the content of the constitutional unit (B) is preferably 20 to 80 mol %, more preferably 45 to 70 mol %, still more preferably 47 to 60 mol %, even more preferably 49 to 52 mol %, and even more preferably 50 to 51 mol %.

[0053] When the content of each constitutional unit is within the above range, a molded article using the copolymer of the present invention is less likely to be colored even after heating.

[0054] The content of each constitutional unit can be measured by .sup.1H-NMR, and to be specific, can be measured by the method described in Examples.

<Other Constitutional Unit>

[0055] The copolymer of the present invention may contain a constitutional unit derived from a monomer other than the constitutional unit (A) derived from 1,1-dicyanoethylene and the constitutional unit (B) derived from the compound represented by the general formula (I). The other constitutional unit is not particularly limited, and examples thereof include vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate, and butyl acrylate.

[0056] In a case where the copolymer of the present invention contains a constitutional unit derived from a monomer other than the constitutional unit (A) and the constitutional unit (B), the content thereof is preferably 20 mol % or less, more preferably 10 mol % or less, and still more preferably 5 mol % or less in the copolymer.

[Method for Producing Copolymer]

[0057] The method for producing the copolymer of the present invention is not particularly limited, and it is preferable to produce the copolymer by the method for producing the copolymer of the present invention in which the polymerization temperature is 45 C. or lower and the copolymer is produced in the presence of a radical initiator.

[0058] By setting the polymerization temperature to 45 C. or lower, the contents of (U-2) and (U-3) in the total amount of the four kinds of triad structures can be easily adjusted to 5.5 mol % or less. From the viewpoint of adjusting the contents of (U-2) and (U-3), the polymerization temperature is preferably 44 C. or lower, more preferably 43 C. or lower, and still more preferably 40 C. or lower.

[0059] The polymerization temperature is preferably 10 C. or higher, more preferably 20 C. or higher, and still more preferably 30 C. or higher, from the viewpoint of polymerization rate and productivity.

<Radical Polymerization Initiator>

[0060] In the production of the copolymer of the present invention, the copolymer is preferably produced in the presence of a radical polymerization initiator. By using the radical polymerization initiator, it becomes easy to adjust the total content of (U-2) and (U-3) in the total amount of the triad structure.

[0061] Examples of the radical polymerization initiator that can be used in the present invention include azo compounds such as azobisisobutyronitrile, 2,2-azobis(4-methoxy-2,4-dimethylvaleronitrile), 2,2-azobis [2-(2-imidazoline-2-yl) propane], and 2,2-azobis [N-(2-carboxyethyl)-2-methylpropionamidine]hydrate: inorganic peroxides such as sodium persulfate, potassium persulfate, and hydrogen peroxide: organic peroxides such as t-butyl hydroperoxide, cumene hydroperoxide, and p-menthane hydroperoxide; and redox initiators obtained by combining an oxidizing agent and a reducing agent, such as hydrogen peroxide and an iron (II) salt, and a persulfate and sodium hydrogen sulfite. These may be used alone, or two or more kinds thereof may be used in combination.

[0062] In the copolymer of the present invention, by performing radical polymerization at a low temperature as described above, the total content of (U-2) and (U-3) in the total amount of the triad structure is easily adjusted. Therefore, among these radical polymerization initiators, azo compounds such as azobisisobutyronitrile and 2,2-azobis(4-methoxy-2,4-dimethylvaleronitrile), and redox initiators, which are easily used at a low temperature, are preferable.

[0063] The amount of the radical polymerization initiator used is preferably 0.01 to 10 parts by mass, more preferably 0.05 to 5 parts by mass, and still more preferably 0.08 to 3 parts by mass, with respect to 100 parts by mass of all the monomers serving as raw materials of the copolymer.

<Ratio of Charging Amount at the Time of Production of Copolymer>

[0064] In the production of the copolymer of the present invention, the charging amount of the compound represented by the general formula (I) is preferably 0.80 equivalents or more, more preferably 0.85 equivalents or more, and still more preferably 0.90 equivalents or more with respect to the charging amount of 1,1-dicyanoethylene, and is usually preferably 3.5 equivalents or less from the viewpoint of suppressing the production cost. When the charging amount of the compound represented by the general formula (I) with respect to the charging amount of 1,1-dicyanoethylene is equal to or more than the above-described lower limit value, it becomes easy to adjust the total content of (U-2) and (U-3) in the total amount of the triad structure, and as a result, discoloration after heating of a molded article using the copolymer can be suppressed.

[0065] In the production of the copolymer of the present invention, it is preferable that the water content contained in 1,1-dicyanoethylene is small from the viewpoint of suppressing ionic polymerization. The water content contained in 1,1-dicyanoethylene is preferably 10,000 ppm or less, more preferably 1,000 ppm or less, still more preferably 500 ppm or less, even more preferably 200 ppm or less, and even more preferably 100 ppm or less. When the water content contained in 1,1-dicyanoethylene is equal to or less than the above-described upper limit value, it becomes easy to adjust the total content of (U-2) and (U-3) in the total amount of the triad structure, and as a result, discoloration after heating of a molded article using the copolymer can be suppressed.

[0066] The water content contained in 1,1-dicyanoethylene can be measured, for example, by a method in accordance with JIS K 0068:2001.

[Resin Composition]

[0067] The resin composition of the present invention contains the copolymer, and can be suitably used as a raw material for a molded article or the like. As described above, the copolymer of the present invention can suppress coloration even after heating, and thus is particularly suitable as a material for a film or the like.

[0068] The resin composition of the present invention is not particularly limited as long as it contains the copolymer, and may contain a synthetic resin in addition to the copolymer.

[0069] Examples of the other synthetic resin include polyolefin resins such as polyethylene, polypropylene, a copolymer of ethylene and one or more kinds of -olefins having 3 to 20 carbon atoms (for example, propylene, 1-butene, 1-pentene, 1-hexene), an ethylene-propylene-diene copolymer (EPDM), an ethylene-vinyl acetate copolymer, and an ethylene-acrylic acid copolymer, a polyurethane resin, a polyamide resin, a polyester resin, and a polycarbonate resin.

[0070] The resin composition of the present invention may contain, in addition to the copolymer of the present invention and the synthetic resin, other components as necessary.

[0071] Other components may include a solvent, a filler, a thickener, an anti-aging agent, a plasticizer, a flame retardant, a stabilizer, an antioxidant, and the like.

[0072] From the viewpoint of suppressing coloration, the content of the copolymer in the resin composition of the present invention is preferably 0.1% by mass or more, more preferably 20% by mass or more, and still more preferably 50% by mass or more.

[0073] On the other hand, in a case where the resin composition of the present invention contains optional components, that is, the synthetic resin and other components, the total content thereof is preferably 10% by mass or less, and more preferably 3% by mass or less, and is preferably 0.001% by mass or more, with respect to the total amount of the resin composition.

<Method for Producing Resin Composition>

[0074] The method for producing the resin composition is not particularly limited, and the resin composition can be produced by a production method including a mixing step of mixing the copolymer of the present invention and the synthetic resin and other components used as necessary. The method of mixing the respective components is not particularly limited, and the components can be mixed by a known method.

[Molded Article and Film]

[0075] The molded article and the film of the present invention use the copolymer or the resin composition of the present invention. The shape of the molded article is not limited as long as it can be produced using the copolymer or the resin composition of the present invention, and examples thereof include various shapes such as a film, a pellet, a sheet, a plate, a pipe, a tube, a rod-like body, and a granular body.

[0076] The method for producing a molded article is not particularly limited, and the molded article can be molded by various conventionally known molding methods, for example, injection molding, blow molding, press molding, extrusion molding, calendar molding.

[0077] The molded article of the present invention is preferably a film. As described above, since the molded article using the copolymer of the present invention can suppress coloration even after heating, a film having a more excellent appearance can be obtained by processing the copolymer into a film.

[0078] In the film of the present invention, since coloration can be suppressed even after heating, the difference between the yellowness index before heating and the yellowness index after heating at 140 C. for 1 hour under normal pressure is preferably 2.5% or less, more preferably 2.0% or less, still more preferably 1.0% or less, and even more preferably 0.9% or less.

[0079] The yellowness index in the present invention is a yellowness index measured in accordance with JIS Z 8722:2009, and can be specifically measured by a method described in Examples.

[0080] The film of the present invention preferably has a low yellowness index after heating, and the yellowness index after heating at 140 C. for 1 hour under normal pressure is preferably 2.5% or less, more preferably 1.5% or less, still more preferably 1.0% or less, and even more preferably 0.8% or less.

[0081] The thickness of the film of the present invention is not particularly limited, and is preferably 0.001 to 5.0 mm, more preferably 0.005 to 1.5 mm, still more preferably 0.01 to 1.0 mm, even more preferably 0.01 to 0.5 mm, and even more preferably 0.01 to 0.1 mm from the viewpoint of improving the transparency of the film.

[0082] The method for producing the film of the present invention is not particularly limited, and the film can be molded by a conventionally known method. Examples of the molding method include a solution casting method, a melt extrusion method, a calendering method, a compression molding method, and an injection molding method.

[Conductive Film and Film Capacitor]

[0083] The conductive film of the present invention is obtained by laminating a conductive layer on the film, and the film capacitor of the present invention includes the film or the conductive film.

[0084] Since the conductive film of the present invention uses the film of the present invention having excellent relative permittivity, the conductive film exhibits excellent performance as a film capacitor.

[0085] The conductive layer constituting the conductive film is not particularly limited, and generally, it is preferably a layer made of a conductive metal such as aluminum, zinc, gold, platinum, and copper and which is a metal foil or a metal coating film (for example, a vapor-deposited metal coating film), and both of them may be used in combination. Among these, a vapor-deposited metal coating film is preferable from the viewpoint of thinning the conductive layer and increasing the capacity with respect to the volume, from the viewpoint of improving adhesiveness to a dielectric, and from the viewpoint of reducing variation in thickness.

[0086] For the purpose of imparting moisture resistance, the vapor-deposited metal coating film may be formed as a multilayer by further forming a semiconductor aluminum oxide layer on the aluminum layer as described in, for example, JP 2-250306 A.

[0087] The thickness of the vapor-deposited metal coating film is not particularly limited, and is preferably 10 to 200 nm, and more preferably 20 to 100 nm. It is preferable that the thickness of the vapor-deposited metal coating film is within the above range, because it is possible to achieve both the capacity and the strength of the capacitor.

[0088] In a case where a vapor-deposited metal coating film is used as the conductive layer, the method for forming the coating film is not particularly limited, and for example, a vacuum vapor deposition method, a sputtering method, an ion plating method can be adopted, and usually, a vacuum vapor deposition method is preferred.

[0089] Examples of the method for forming the conductive layer include a batch method applied to a molded article, a semi-continuous (semi-continuous) method applied to a long product, and a continuous (air to air) method, and the semi-continuous method, which is the mainstream, is preferable. The semi-continuous metal deposition method is a method in which metal deposition is performed in a vacuum system, and after winding, the vacuum system is returned to an atmospheric system, and the deposited film is taken out.

EXAMPLES

[0090] Hereinafter, the present invention will be described in detail by Examples, but the present invention is not limited to these Examples.

[0091] The water content in 1,1-dicyanoethylene in Examples, Comparative Examples, and Reference Examples was measured by a method in accordance with JIS K 0068:2001.

Example 1

[0092] In a 100-mL four neck flask equipped with a stirring device, a Dimroth condenser, and a thermometer, 2.0 g (0.026 mol, water content: 390 ppm) of 1,1-dicyanoethylene synthesized by the method described in the above-described literature, 2.7 g (0.026 mol) of styrene (manufactured by FUJIFILM Wako Pure Chemical Corporation), 17 mL of toluene (manufactured by FUJIFILM Wako Pure Chemical Corporation), and 18 mg of 2,2-azobis(4-methoxy-2,4-dimethylvaleronitrile) were placed, and were heated and stirred at 40 C. for 4 hours under a nitrogen gas stream to perform radical polymerization.

[0093] After completion of the polymerization, the precipitated copolymer was filtered. Subsequently, washing was performed with toluene and n-hexane (manufactured by FUJIFILM Wako Pure Chemical Corporation) in this order, and then drying was performed overnight at 80 C. under reduced pressure. The yield of the product (copolymer powder) was 4.4 g, and the percentage yield was 95%.

[0094] The obtained copolymer was subjected to NMR spectrum measurement according to a method described later. The results are shown in Table 1.

[0095] The obtained copolymer was dissolved in N,N-dimethylacetamide (manufactured by Tokyo Chemical Industry Co., Ltd.), applied by a solution-casting method using a film applicator (manufactured by Tester Sangyo Co., Ltd.) so as to have a thickness of 50 m, and vacuum-dried at 40 C. and 1 kPa for 7 days to prepare a film before heating. The yellowness index of the obtained film was measured according to a method described later. The results are shown in Table 1.

[0096] The relative permittivity of the obtained film was measured according to a method described later. The results are shown in Table 1.

[0097] As shown in Table 1, the film of the present invention can suppress the yellowness index to a low level and has a high relative permittivity. Such a material having a high relative permittivity is suitable for use in a film capacitor as described in JP 2008-034189 A.

Example 2 and Comparative Examples 1 to 4

[0098] A film was prepared in the same manner as in Example 1 except that the water concentration in 1,1-dicyanoethylene, the polymerization temperature, and the ratio of the charging amount were changed as shown in Tables 1 and 2.

[0099] The spectrum of the obtained copolymer was measured by NMR in the same manner as in Example 1, and the yellowness index of the obtained film was measured. The results are shown in Tables 1 and 2.

Example 3

[0100] In a 300-mL autoclave equipped with a stirring device and a thermometer, 2.0 g (0.026 mol, water content: 390 ppm) of 1,1-dicyanoethylene synthesized by the method described in the above-described literature, 3.6 g (0.064 mol) of isobutylene (manufactured by Tokyo Chemical Industry Co., Ltd.), 6.7 mL of ethyl acetate (manufactured by FUJIFILM Wako Pure Chemical Corporation), and 18 mg of 2,2-azobis(4-methoxy-2,4-dimethylvaleronitrile) were placed, and were heated and stirred at 40 C. for 6 hours under a nitrogen gas stream to perform radical polymerization.

[0101] After completion of the polymerization, the precipitated copolymer was filtered. Subsequently, washing was performed with ethyl acetate and n-hexane (manufactured by FUJIFILM Wako Pure Chemical Corporation) in this order, and then drying was performed overnight at 80 C. under reduced pressure to obtain a product (copolymer powder). The spectrum of the obtained copolymer was measured by NMR according to a method described later, and a film was produced in the same manner as in Example 1 using the obtained copolymer, and the yellowness index was measured. The results are shown in Table 1.

Example 4

[0102] In a 300-mL autoclave equipped with a stirring device and a thermometer, 2.0 g (0.026 mol, water content: 390 ppm) of 1,1-dicyanoethylene synthesized by the method described in the above-described literature, 2.7 g (0.064 mol) of propylene (manufactured by Takachiho Chemical Industrial Co., Ltd.), 8.9 mL of ethyl acetate (manufactured by FUJIFILM Wako Pure Chemical Corporation), and 18 mg of 2,2-azobis(4-methoxy-2,4-dimethylvaleronitrile) were placed, and were heated and stirred at 40 C. for 6 hours under a nitrogen gas stream to perform radical polymerization.

Examples 5 to 8 and Comparative Examples 5 to 8

[0103] A film was prepared in the same manner as in Example 3 except that the water concentration in 1,1-dicyanoethylene, the polymerization temperature, and the ratio of the charging amount were changed as shown in Tables 1 and 2.

[0104] The spectrum of the obtained copolymer was measured by NMR in the same manner as in Example 3, and the yellowness index of the obtained film was measured. The results are shown in Tables 1 and 2.

Example 9 and Comparative Examples 9 and 10

[0105] A film was prepared in the same manner as in Example 4 except that the water concentration in 1,1-dicyanoethylene, the polymerization temperature, and the ratio of the charging amount were changed as shown in Tables 1 and 2.

[0106] The spectrum of the obtained copolymer was measured by NMR in the same manner as in Example 4, and the yellowness index of the obtained film was measured. The results are shown in Tables 1 and 2.

[0107] After completion of the polymerization, the precipitated copolymer was filtered. Subsequently, washing was performed with ethyl acetate and n-hexane (manufactured by FUJIFILM Wako Pure Chemical Corporation) in this order, and then drying was performed overnight at 80 C. under reduced pressure to obtain a product (copolymer powder). The spectrum of the obtained copolymer was measured by NMR according to a method described later, and a film was produced in the same manner as in Example 1 using the obtained copolymer, and the yellowness index was measured. The results are shown in Table 1.

Reference Examples 1 to 5

[0108] With reference to the specification of U.S. Pat. No. 2,615,868 A, a copolymer was produced by setting the water concentration in 1,1-dicyanoethylene, the polymerization temperature, and the ratio of the charging amount as shown in Table 3, and a film was produced in the same manner as in Example 1.

[0109] The spectrum of the obtained copolymer was measured by NMR in the same manner as in Example 1, and the yellowness index of the obtained film was measured. The results are shown in Table 3.

<Measurement Method>

(1) Spectrum Measurement of Copolymer by NMR

[0110] .sup.1H-NMR and .sup.13C-NMR spectra of the product (copolymer powder) were measured under the following conditions using a nuclear magnetic resonance spectrometer (NMR). Using the measurement results, the ratio of each triad structure was obtained in accordance with the method described in NPL 1. The results are shown in Tables 1 to 3.

[.SUP.1.H-NMR Measurement Condition]

[0111] Apparatus: JNM-ECX400 manufactured by JEOL Ltd. [0112] Measurement solvent: Dimethyl Sulfoxide-d6 [0113] Measurement temperature: 65 C. [0114] Chemical shift value standard: Tetramethylsilane

[.SUP.13.C-NMR Measurement Condition]

[0115] Apparatus: JNM-ECX400 manufactured by JEOL Ltd. [0116] Measurement solvent: Dimethyl Sulfoxide-d6 [0117] Measurement temperature: 65 C. [0118] Measurement method: Proton decoupling method [0119] Pulse width: 45 degrees [0120] Inter pulse delay: 10 seconds [0121] Chemical shift value standard: Tetramethylsilane

(2) Measurement of Yellowness Index of Film

[0122] The film obtained in each of Examples, Comparative Examples, and Reference Examples was heated in a clean oven DE-41 (manufactured by Yamato Scientific Co., Ltd.) at 140 C. for 1 hour under normal pressure.

[0123] The yellowness index of the film before being heated and the film after being heated was measured using a haze meter SH7000 (manufactured by Nippon Denshoku Industries Co., Ltd.) in accordance with JIS Z 8722:2009.

[0124] The yellowness index was measured at three positions of each film, and the average value thereof was adopted as the yellowness index. The results are shown in Tables 1 to 3.

(3) Measurement of Relative Permittivity of Film

[0125] Each of the films obtained in Examples, Comparative Examples, and Reference Examples was humidity-controlled at 26 C. and 60% RH, and then an AuPd alloy having a diameter of 30 mm was vapor-deposited on the surface of the film until the surface was electrically connected, and vapor deposition was also performed on the opposite surface to form a conductive layer, thereby obtaining a film capacitor sample.

[0126] The electrostatic capacitance (C) of the sample was measured using an LCR meter (manufactured by Keysight Corporation), and the relative permittivity was calculated from the electrostatic capacitance, the electrode area(S), and the thickness (d) of the film using the equation

C=.sub.0S/d

(.sub.0 is the dielectric constant of vacuum). The results are shown in Tables 1 to 3.

TABLE-US-00001 TABLE 1 Example 1 2 3 4 5 Type of constitutional unit (B) Styrene Styrene Isobutylene Propylene Isobutylene Conditions Polymerization 40 44 40 40 40 temperature ( C.) Ratio of charging 1:1 1:1 1:2.5 1:2.5 1:1.3 amount (equivalent ratio) [(A):(B)] Water content in 1,1-dicyanoethylene 390 390 390 390 100 Molar ratio (A)/(B) in copolymer (*1) 50/50 50/50 49/51 49/51 51/49 Each content in (A)-(A)-(A) 1.0 1.7 0.0 0.0 0.0 four kinds of triad [(U-1)] (mol %) structures (*2) (A)-(A)-(B) 3.7 4.3 1.1 5.3 0.7 (B)-(A)-(A) Total content (mol %) of [(U-2)] and [(U-3)] (B)-(A)-(B) 95.3 94.0 98.9 94.7 99.3 [(U-4)] (mol %) Film thickness (m) 50 50 50 50 50 Evaluation Yellowness index (%) 0.43 0.46 0.80 0.81 0.75 before heating Yellowness index (%) 1.30 1.28 0.88 0.91 0.85 after heating Difference in 0.77 0.81 0.08 0.10 0.10 yellowness index before and after heating (%) Relative permittivity 4.70 4.60 4.80 4.20 4.00 Example 6 7 8 9 Type of constitutional unit (B) Isobutylene Isobutylene Isobutylene Propylene Conditions Polymerization 40 40 40 40 temperature ( C.) Ratio of charging 1:2 1:2.5 1:2.7 1:6 amount (equivalent ratio) [(A):(B)] Water content in 1,1-dicyanoethylene 100 100 100 100 Molar ratio (A)/(B) in copolymer (*1) 50/50 49/51 49/51 49/51 Each content in (A)-(A)-(A) 0.0 0.0 0.0 0.0 four kinds of triad [(U-1)] (mol %) structures (*2) (A)-(A)-(B) 0.5 0.5 0.4 3.4 (B)-(A)-(A) Total content (mol %) of [(U-2)] and [(U-3)] (B)-(A)-(B) 99.5 99.5 99.6 96.6 [(U-4)] (mol %) Film thickness (m) 50 50 50 50 Evaluation Yellowness index (%) 0.70 0.53 0.48 0.71 before heating Yellowness index (%) 0.77 0.58 0.52 0.79 after heating Difference in 0.07 0.05 0.04 0.08 yellowness index before and after heating (%) Relative permittivity 4.50 4.40 4.40 4.00 (*1): Calculated from the results of .sup.1H-NMR measurement (*2): Calculated from the results of .sup.13C-NMR measurement

TABLE-US-00002 TABLE 2 Comparative Example 1 2 3 4 5 Type of constitutional unit (B) Styrene Styrene Styrene Styrene Isobutylene Conditions Polymerization 70 48 40 40 45 temperature ( C.) Ratio of charging 1:1 1:1 1:0.71 1:1 1:10 amount (equivalent ratio) [(A):(B)] Water content in 1,1-dicyanoethylene 390 390 390 15,000 600 Molar ratio (A)/(B) in copolymer (*1) 50/50 50/50 51/49 51/49 50/50 Each content in (A)-(A)-(A) 2.0 1.9 2.2 2.7 0.6 four kinds of triad [(U-1)] (mol %) structures (*2) (A)-(A)-(B) 6.0 5.6 6.2 7.2 5.6 (B)-(A)-(A) Total content (mol %) of [(U-2)] and [(U-3)] (B)-(A)-(B) 92.0 92.5 91.6 90.1 93.8 [(U-4)] (mol %) Film thickness (m) 50 50 50 50 50 Evaluation Yellowness index (%) 0.49 0.47 0.55 0.80 0.80 before heating Yellowness index (%) 3.79 3.17 3.99 5.01 2.80 after heating Difference in yellowness 3.30 2.70 3.44 4.19 2.00 index before and after heating (%) Relative permittivity 4.65 4.50 4.61 4.40 3.80 Comparative Example 6 7 8 9 10 Type of constitutional unit (B) Isobutylene Isobutylene Isobutylene Propylene Propylene Conditions Polymerization 45 45 40 43 43 temperature ( C.) Ratio of charging 1:3.1 1:1.3 1:1.3 1:6 1:1.1 amount (equivalent ratio) [(A):(B)] Water content in 1,1-dicyanoethylene 600 600 600 600 600 Molar ratio (A)/(B) in copolymer (*1) 51/49 53/47 52/48 51/49 52/48 Each content in (A)-(A)-(A) 0.6 0.9 0.6 0.6 0.7 four kinds of triad [(U-1)] (mol %) structures (*2) (A)-(A)-(B) 5.8 6.2 5.7 5.7 6.3 (B)-(A)-(A) Total content (mol %) of [(U-2)] and [(U-3)] (B)-(A)-(B) 93.6 92.9 93.7 93.7 93.0 [(U-4)] (mol %) Film thickness (m) 50 50 50 50 50 Evaluation Yellowness index (%) 0.81 0.87 0.84 0.83 0.90 before heating Yellowness index (%) 3.00 3.54 3.22 2.87 3.05 after heating Difference in 2.19 2.67 2.38 2.04 2.15 yellowness index before and after heating (%) Relative permittivity 4.00 4.00 4.10 3.80 4.00 (*1): Calculated from the results of .sup.1H-NMR measurement (*2): Calculated from the results of .sup.13C-NMR measurement

TABLE-US-00003 TABLE 3 Reference Example 1 2 3 4 5 Type of constitutional unit (B) Styrene Styrene Styrene Styrene Styrene Conditions Polymerization 20 25 48 0 45 temperature ( C.) Ratio of charging 1:3.7 1:0.74 1:0.74 1:5.0 1:0.1 amount (equivalent ratio) [(A):(B)] Water content in 1,1-dicyanoethylene 1500 1500 1500 1500 1500 Molar ratio (A)/(B) in copolymer (*1) 51/49 51/49 51/49 51/49 51/49 Each content in (A)-(A)-(A) 1.9 1.9 2.0 1.8 2.4 four kinds of triad [(U-1)] (mol %) structures (*2) (A)-(A)-(B) 5.7 5.9 6.1 5.6 6.6 (B)-(A)-(A) Total content (mol %) of [(U-2)] and [(U-3)] (B)-(A)-(B) 92.4 92.2 91.9 92.6 91.0 [(U-4)] (mol %) Film thickness (m) 50 50 50 50 50 Evaluation Yellowness index (%) 0.47 0.49 0.49 0.49 0.56 before heating Yellowness index (%) 3.28 3.44 3.57 3.28 4.10 after heating Difference in yellowness 2.81 2.95 3.08 2.79 3.54 index before and after heating (%) Relative permittivity 4.30 4.32 4.45 4.52 4.35 (*1): Calculated from the results of .sup.1H-NMR measurement (*2): Calculated from the results of .sup.13C-NMR measurement

[0127] As is clear from the results in Tables 1 to 3, the copolymer of the present invention can suppress coloration even after heating, and thus can be suitably used for a molded article such as a film.

[0128] As described above, Reference Examples 1 to 5 were conducted in accordance with the specification of U.S. Pat. No. 2,615,868 A, but in the copolymer obtained by the method described in the above-mentioned document, the contents of (U-2) and (U-3) in the total amount of the four kinds of triad structures were not 5.5 mol % or less. Therefore, the films of Reference Examples 1 to 5 produced using the copolymer were colored after beating.