PHOTOIRRADIATION DEVICE, PHOTOREACTION METHOD USING THE SAME, AND METHOD FOR PRODUCING LACTAM

Abstract

Provided are a photoirradiation device equipped with: a first optically transparent container for covering a light-emitting body provided with light-emitting diodes; a liquid phase section provided on the outside thereof and formed from a liquid having a refractive index closer to that of the first optically transparent container than that of a gas forming a gas phase section inside the first optically transparent container; and a second optically transparent container for covering the liquid phase section, a photoreaction method using the photoirradiation device, and a method for producing lactam by using the photoreaction method. The reflection of light between a target liquid and a light-emitting diode light source is suppressed, and a desired photoirradiation can be achieved with a high optical transparency.

Claims

1. A photoirradiation device using light-emitting diodes as a light source, characterized in that a first optically transparent container for covering a light-emitting body provided with said light-emitting diodes is provided, and on the outside thereof, a liquid phase section formed from a liquid having a refractive index closer to that of said first optically transparent container than that of a gas forming a gas phase section inside said first optically transparent container, and a second optically transparent container for covering said liquid phase section are provide.

2. The photoirradiation device according to claim 1, wherein said light emitting diodes are installed such that a center of optical axes of said light emitting diodes is set at 60° or less relatively to a normal line of an inner surface of said first optically transparent container.

3. The photoirradiation device according to claim 1, wherein said liquid forming said liquid phase section is a nonflammable liquid.

4. The photoirradiation device according to claim 1, wherein said liquid forming said liquid phase section is water.

5. The photoirradiation device according to claim 1, wherein said second optically transparent container is disposed at least along an outer circumference of said first optically transparent container.

6. The photoirradiation device according to claim 1, wherein at least one of said first optically transparent container and said second optically transparent container is formed from a material having a refractive index of 1.4 or more.

7. The photoirradiation device according to claim 1, wherein at least one of said first optically transparent container and said second optically transparent container is formed from a glass.

8. The photoirradiation device according to claim 1, wherein said light-emitting body is covered with said gas phase section, and said gas phase section is formed from a gas having an oxygen concentration of 1% or less.

9. The photoirradiation device according to claim 8, wherein said gas phase section is formed from an inert gas.

10. The photoirradiation device according to claim 8, wherein said gas phase section is formed from nitrogen.

11. A photoreaction method characterized by using the photoirradiation device according to claim 1.

12. The photoreaction method according to claim 11, wherein the destination of photoirradiation is a liquid, and the composition of the liquid contains at least a carbon atom.

13. The photoreaction method according to claim 12, wherein said liquid as the destination of photoirradiation is a cycloalkane.

14. The photoreaction method according to claim 13, wherein a cycloalkanone oxime is produced by performing photoirradiation to said cycloalkane and a photo nitrosating agent.

15. The photoreaction method according to claim 14, wherein said cycloalkanone oxime is cyclohexanone oxime or cyclododecanone oxime.

16. The photoreaction method according to claim 14, wherein said photo nitrosating agent is nitrosyl chloride or trichloronitrosomethane.

17. A method for producing a lactam characterized by using a cycloalkanone oxime produced by the photoreaction method according to claim 14.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a schematic vertical sectional view of a photoirradiation device according to an embodiment of the present invention.

[0018] FIG. 2 is an enlarged schematic cross-sectional view of the photoirradiation device shown in FIG. 1.

[0019] FIG. 3 is a schematic partial perspective view of a light-emitting body shown in FIG. 2.

[0020] FIG. 4 is a schematic elevational view of a substrate shown in FIG. 3.

[0021] FIG. 5 is an enlarged cross-sectional view showing an example of the photoirradiation in the photoirradiation device shown in FIG. 1.

[0022] FIG. 6 is a schematic diagram showing an example of refraction of light at an interface between media.

[0023] FIG. 7 is a schematic diagram showing another example of refraction of light at an interface between media.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0024] Hereinafter, embodiments of the present invention will be explained referring to figures.

[0025] In the present invention, the photoirradiation device is a device which has a light-emitting body emitting light and can irradiate light to an object. The object is, for example, a reaction liquid becoming a raw material as a target liquid of photoreaction. FIGS. 1 to 4 show a photoirradiation device according to an embodiment of the present invention, and in particular, show an example in case where light from the photoirradiation device is irradiated to a reaction liquid as a target liquid. In the example shown in FIG. 1 and FIG. 2, the photoirradiation device 1 is inserted in a reaction vessel 2 so as to be used for the photoreaction of the reaction liquid 3 in the reaction vessel 2. The photoirradiation device 1 is provided with a power supply unit 4 at its upper portion and a light-emitting body 6 equipped with a large number of light emitting diodes (hereinafter, also abbreviated as LEDs) 5 (shown in FIG. 2) at its lower portion in the mounting posture shown in FIG. 1, and the upper side of the power supply unit 4 is sealed with a lid 7. The light-emitting body 6 is covered with a first optically transparent container 8, and in this embodiment, the inside of the first optically transparent container 8, that is, the portion between the light-emitting body 6 and the first optically transparent container 8 is formed as a gas phase section 9. A second optically transparent container 10 is provided outside the first optically transparent container 8, and the layer between the first optically transparent container 8 and the second optically transparent container 10 is formed as a liquid phase section 11. This liquid phase section 11 is formed from a liquid closer to the refractive index of the first optically transparent container 8 than gas, and for example, it is formed by filling nonflammable liquid between the first and second optically transparent containers 8 and 10.

[0026] The light emitting diode is a light emitting diode which emits ultraviolet rays, visible light and infrared rays, and as the light emitting diode 5 to be used, a type selected for the wavelength required for the application of the photoirradiation device 1 can be appropriately selected. The shape and size of the light emitting diode 5 is not particularly limited, and it is possible to use a shape and size depending upon the purpose. Although any of bullet type, mounting type, chip type and the like may be used, one capable of radiating heat from the back side of the light emitting diode 5 is preferable because heat removal is easy. Further, one provided with a heat radiation substrate on the back surface of the light emitting diode 5 is desired because a large heat transfer area can be obtained and the cooling performance is improved.

[0027] In the present invention, the light-emitting body means a portion having a surface emitting light in the photoirradiation device. Concretely, for example, a plurality of light emitting diodes 5 are mounted on a planar substrate 12 as shown in FIG. 4, and the planar substrate 12 is attached, for example, to each exterior surface of a structural body 13 whose cross-sectional shape is a star-shaped hexadecagon as shown in FIGS. 2 and 3, whereby it is possible to irradiate light toward the outside.

[0028] In this case, the shape of the light-emitting body 6 is decided by the shape pf the structural body 13 arranged with the above-described planar substrates 12. However, the shape of the light-emitting body 6 is not particularly restricted, and as the cross-sectional shape, except the above-described star shape, a circular shape, a polygonal shape and the like can be employed. Further, by changing the cross-sectional shape of the light-emitting body 6, the area of the light emitting diode placement surface changes, the possible number of mounted light emitting diodes can be increased and decreased, and the shape can be decided depending upon the purpose.

[0029] The first optically transparent container 8 is a container covering the light-emitting body 6 and is provided to protect the light-emitting body 6 from the outside. This first optically transparent container 8 may be formed by using a material transmitting light. If a raw material having transmission wavelength selectivity is used for the optically transparent container, it is possible to suppress transmission of unnecessary wavelength light. As the overall shape of the first optically transparent container 8, for example, a test tube type can be exemplified as shown in FIG. 1, but the shape is not particularly restricted, and cylinder type, box type, spherical type and the like can be selected appropriately depending upon the purpose.

[0030] The second optically transparent container 10 is a container disposed outside the first optically transparent container 8, and may be formed by using a material transmitting light similarly to the first optically transparent container 8. This material of the second optically transparent container 10 may be the same as or different from that of the first optically transparent container 8. As the shape thereof, for example, a test tube type can be exemplified as shown in FIG. 1, but the shape is not particularly restricted, and cylinder type, box type, spherical type and the like can be selected appropriately depending upon the purpose, and further, it may have a similar shape or a different shape to the first optically transparent container 8.

[0031] In the present invention, the liquid phase section formed from a liquid closer to the refractive index of the first optically transparent container than that of the gas forming the gas phase section inside the first optically transparent container means a portion formed from a liquid whose difference in refractive index from the first optically transparent container is smaller than that of the above-described gas, and is, for example, a portion formed by being filled with such a liquid. In this liquid phase section, the liquid may be flowed therethrough at all times or it may be enclosed. As shown in FIGS. 1 and 2, the liquid phase section 11 is interposed between the first optically transparent container 8 and the second optically transparent container 10.

[0032] In case where a liquid, for example, water is flowed through the liquid phase section 11, by lowering the temperature of the flowing water, the refractive index of water can be enhanced and the difference in refractive index from the first optically transparent container can be further reduced. Further, except water, a nonflammable liquid and a liquid having a small difference in refractive index from the first optically transparent container can be used depending upon the purpose. Furthermore, depending upon the purpose, a liquid inert to water may be added and used. It is possible to change the refractive index by the addition.

[0033] In the present invention, by interposing the above-described liquid phase section 11 between the first optically transparent container 8 and the second optically transparent container 10, the energy loss ascribed to reflection in the irradiation route of the light from the light-emitting body 6 is suppressed.

[0034] Using FIG. 6 and FIG. 7, refraction and reflection of light at an interface between media 1 and 2 with refractive indexes n1 and n2 different from each other will be explained. Light produces reflection loss at the interface between the media with different refractive indexes. The surface reflectance of light is represented by the following equation (1), and it is known that the larger the difference in refractive index between the media forming the interface is, the greater the reflection loss is. Where, θ1 indicates an incident angle and θ2 indicates a refractive angle.

Surface reflectance R=0.5×{tan(θ1−θ2)/tan(θ1+θ2)}.sup.2+{sin(θ1−θ2)/sin(θ1+θ2)}.sup.2   (1)

[0035] Namely, in case where there is a media interface having a large difference in refractive index on the optical path, loss ascribed to light reflection increases. Accordingly, in the present invention, by interposing the liquid phase section 11 formed from a liquid having a difference in refractive index as small as possible, in the space between the first optically transparent container 8 and the second optically transparent container 10, the light energy loss ascribed to reflection is reduced.

[0036] For example, an example of an optical path accompanied by refraction and reflection when the photoirradiation is performed by the photoirradiation device 1 of FIG. 1 is shown in FIG. 5. As shown in FIG. 5, the incident light, which is irradiated along the optical axis 21 of the light emitting diodes 5 and is entered at a predetermined incident angle 23 relatively to a normal line 22 of the inner surface of the first optically transparent container 8, passes through the interior of the material of the first optically transparent container 8 after being refracted at the inner surface of the first optically transparent container 8, is entered at an incident angle 25 relatively to a normal line 24 of the interface between the outer surface of the first optically transparent container 8 and the liquid phase section 11, passes through the interior of the liquid phase section 11 after being refracted at the interface, passes through the interior of the material of the second optically transparent container 10 after being refracted at the interface between the liquid phase section 11 and the second optically transparent container 10, and after being refracted at the outer surface of the second optically transparent container 10, it is irradiated to the reaction liquid 3 as a transmitted light 26. In the illustrated example, at the interface between the gas phase section 9 and the first optically transparent container 8, at the interface between the first optically transparent container 8 and the liquid phase section 11, at the interface between the liquid phase section 11 and the second optically transparent container 10 and at the interface between the second optically transparent container 10 and the reaction liquid 3, respectively, the reflected lights 27 are generated, and by forming the liquid phase section 11 with a liquid having a difference in refractive index from the first optically transparent container 8 smaller than that of gas, light energy loss ascribed to reflection can be reduced. In particular, as compared with a case where the liquid phase section 11 is supposed to be formed from a gas, the incident angle of the light passing through the interior of the liquid phase section 11 and entering into the second optically transparent container 10 relative to the normal line of the container surface can be suppressed small, and therefore, at the interface between the first optically transparent container 8 and the liquid phase section 11 and at the interface between the liquid phase section 11 and the second optically transparent container 10, light energy loss ascribed to reflection can be reduced.

[0037] Here, the optical axis 21 of the light emitting diodes 5 means an imaginary center line of a light flux emitted from the light emitting diodes 5 mounted on the aforementioned planar substrate. For example, in case where a plurality of light emitting diodes are equidistantly arranged in a planar substrate and light is irradiated, the optical axis becomes a line extending in the direction perpendicular to the planar substrate from the center of gravity of the planar substrate.

[0038] The incident angle of light into the container surface is determined by the positional relationship between the light emitting surface on which the light emitting diodes 5 are disposed and the container surface, concretely, the angle formed between the light emitting surface and the container surface. Since the angle formed between the light emitting surface and the container surface is determined by the shape of the structural body 13 in which the light emitting diodes 5 are disposed and the shape of the container, the incident angle can be controlled by adjusting the shapes of the structural body 13 and the container.

[0039] According to the aforementioned equation (1), the reflectance of light varies depending on the incident angle, the smaller the incident angle is, the smaller the reflectance is, and the loss of light can be reduced.

[0040] The incident angle into the first optically transparent container 8 is preferably 0° or more and 60° or less, and more preferably 0° or more and 45° or less.

[0041] Namely, it is preferred that the optical axis of the light-emitting diodes 5 is set at 45° or less relatively to the normal line of the inner surface of the first optically transparent container 8. This is to arrange the light emitting diodes 5 so that the angle formed by the center of the optical axis and the normal line of the surface of the optically transparent container 8, that is, the incident angle of light into the surface of the optically transparent container 8, becomes 45° or less.

[0042] Furthermore, it is known that, when light is entered from the side of a high refractive index medium to the side of a low refractive index medium, total reflection, in which all of the incident lights are not transmitted, is caused at a certain incident angle or more. The minimum incident angle causing total reflection is called as a critical angle, and the critical angle is represented by the following equation (2) using the refractive index n1 of the incident side medium and the refractive index n2 of the transmission side medium. Light entered at an incident angle of the critical angle or more is not transmitted but is all reflected at the interface. Therefore, it is important for suppressing the reflection loss to set so that the incident angle does not exceed the critical angle. Here:

Critical angle θc=arcsin(n2/n1)  (2)

[0043] Thus, effectively transmitting the light irradiated from the light-emitting body 6 to the reaction liquid 3 present outside the two optically transparent containers 8 and 10 can be achieved by filling the space between the first optically transparent container 8 and the second optically transparent container 10 with the medium having a refractive index close to that of the optically transparent container and making the incident angle to the container surface small.

[0044] In the present invention, it is preferred to use a liquid which forms the liquid phase section 11 as the above-described medium having a refractive index close to that of the optically transparent container. Where, in the present invention, a nonflammable liquid means a liquid that does not correspond to a dangerous substance specified by the Fire Services Act and is a liquid that transmits light. Concretely, exemplified are ethylene glycol 50% aqueous solution, silicone oil, water and the like.

[0045] The difference in refractive index between the liquid forming the liquid phase section 11 and the first optically transparent container 8 is preferably smaller than the difference in refractive index between the optically transparent container and air, and the liquid forming the liquid phase section 11 may be one in which the refractive index is adjusted by dissolving a soluble substance in water such as one in which sugar or the like is dissolved in water or one an aqueous glycerin solution. Further, since the refractive index varies depending upon temperature, the refractive index may be adjusted by adjusting the temperature.

[0046] Further, by adding a substance which absorbs light having a specific wavelength to the above-described liquid, light of a specific wavelength unnecessary for the reaction may be removed.

[0047] In the present invention, it is preferred that at least one of the first and second optically transparent containers is formed from a material having a refractive index of 1.4 or more. As such a material, any of an organic material typically represented by a resin or an inorganic material typically represented by a glass may be employed. More concretely, acrylic resin, methacrylic resin, polycarbonate, polystyrene, polyvinyl chloride, polyester, borosilicate glass, soda-lime-silica glass, lead glass and the like can be exemplified.

[0048] The refractive index of a nonflammable liquid such as water filled in the liquid phase section is generally smaller than the refractive index of the optically transparent solid. In particular, since a material that reduces the difference in refractive index from the liquid phase section is preferred, for forming the optically transparent container, it is more preferred to use borosilicate glass having a low refractive index among optically transparent solids and having high pressure resistance and chemical stability.

[0049] A material which absorbs light having a specific wavelength may be used for the first and second optically transparent containers. By making the containers absorb the wavelength unnecessary for photoreaction, only the wavelength necessary for photoreaction can be transmitted to the reaction liquid.

[0050] In the present invention, the phrase “the light-emitting body 6 is covered with the gas phase section 9” means a state where the space between the light-emitting body 6 and the first optically transparent container 8 is filled with gas.

[0051] In case where the above-described gas phase section 9 contains oxygen, it causes oxidation deterioration of electronic components such as the light emitting diodes 5. Therefore, in order to lengthen the lifetime of the light-emitting body 6, it is desired that the gas has an oxygen concentration of 2% or less, more preferably 1.5% or less.

[0052] As the gas forming the gas phase section 9, an inert gas can be used, and rare gases such as helium, neon, argon, krypton and xenon can be exemplified, but it is preferred to use nitrogen as an inert gas which can be easily and inexpensively obtained. With respect to this gas phase section 9, the gas may be constantly flown or may be in an enclosed condition.

[0053] In the present invention, the destination of the photoirradiation may be a liquid which contains carbon atoms. Namely, the photoirradiation device according to the present invention can be used as a light source for photoreaction, and at least one destination of the photoirradiation may be a raw material system composed of a liquid. The liquid served as a raw material is not particularly restricted as long as it is a liquid containing carbon atoms, and for example, hydrocarbons such as alkane and cycloalkane can be exemplified.

[0054] In the present invention, although the cycloalkane is not particularly limited in the number of carbon atoms, for example, preferred are cyclopropane, cyclobutane, cyclopentane, cyclohexane, cycloheptane, cyclooctane, cyclononane, cyclodecane, cycloundecane, and cyclododecane. In particular, cyclohexane as a raw material of 8-caprolactam and cyclododecane as a raw material of co-lauryllactam are preferred.

[0055] Using the above-described cycloalkane and photo nitrosating agent, cycloalkanone oxime is obtained by photochemical reaction due to the photo irradiation of light emitting diodes. As the photo nitrosating agent, for example, nitrosyl chloride or a mixed gas of nitrosyl chloride and hydrogen chloride is preferable. Besides, since any of the mixed gas of nitric monoxide and chlorine, the mixed gas of nitric monoxide, chlorine and hydrogen chloride, the mixed gas of nitrose gas and chlorine, etc. acts as nitrosyl chloride in the photoreaction system, it is not limited to these supply forms of the nitrosating agent. Further, trichloronitrosomethane obtained by photochemical reaction of nitrosyl chloride and chloroform may be used as a nitrosating agent. When the photochemical reaction is carried out in the presence of hydrogen chloride, the cycloalkanone oxime becomes its hydrochloride, but it may be in the form of hydrochloride as it is.

[0056] By the above-described photoreaction, it is possible to obtain cycloalkanone oxime which depends upon the carbon number of the cycloalkane. For example, cyclohexanone oxime is obtained by photo nitrosating reaction with nitrosyl chloride using cyclohexane. Further, cyclododecanone oxime is obtained by photo nitrosating reaction with nitrosyl chloride using cyclododecane.

[0057] <Method for Producing Lactam>

[0058] A photochemical reaction is carried out using the photoirradiation device according to the present invention, and a lactam is obtained by Beckmann rearrangement of the obtained cycloalkanone oxime. For example, in the reaction of Beckmann rearrangement of cyclohexanone oxime, ε-caprolactam is obtained as shown by the following reaction formula [Chemical formula 1]. Further, ω-laurolactam is obtained in the reaction of Beckmann rearrangement of cyclododecanone oxime.

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EXAMPLES

[0059] Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example 1, Reference Example 1

[0060] For the light emitting body using light emitting diodes as a light source, borosilicate glass with a refractive index of 1.49 was used for the first optically transparent container, the gas phase section was formed from N.sub.2, and water was placed in the liquid phase section covering the first optically transparent container, and the transmittance of light (optical transparency) from the first optically transparent container to the liquid phase section, in case where the incident angle from the first optically transparent container to the interface between the container outer surface and the liquid phase section was changed, was calculated. As the results are shown in Table 1, high transmittance was obtained. In case where water was placed in the liquid phase section, total reflection occurred at an incident angle of 70 degrees or more (Reference Example 1).

Comparative Example 1, Reference Comparative Example 1

[0061] Transmittance was calculated in the same manner as in Example 1 other than a condition where N.sub.2 was filled in the liquid phase section. The results are shown in Table 1. The transmittance became lower as compared with the case where water was placed in the liquid phase section. In case where N.sub.2 was filled in the liquid phase section, total reflection occurred at an incident angle of 50 degrees or more (Reference Comparative Example 1).

TABLE-US-00001 TABLE 1 Incident side medium Refractive Optical Optically side medium transparency from Incident angle from inside transparent Liquid first optically of container to outer container phase section transparent surface of container Refractive Refractive Reflectance container to liquid (liquid phase section) (°) Material index Material index (—) phase section (—) Remark Example 1 10 borosilicate 1.49 water 1.33 0.00322 0.9968 20 glass 0.00329 0.9967 30 0.00371 0.9963 40 0.00563 0.9944 50 0.01560 0.9844 60 0.12237 0.8776 Reference 70 1.00000 0.0000 total Example 1 reflection 80 1.00000 0.0000 total reflection Comparative 10 N.sub.2 1.00 0.03880 0.9612 Example 1 20 0.04037 0.9596 30 0.05306 0.9469 40 0.21842 0.7816 Reference 50 1.00000 0.0000 total Comparative reflection Example 1 60 1.00000 0.0000 total reflection 70 1.00000 0.0000 total reflection 80 1.00000 0.0000 total reflection

[0062] Further, in case where water is placed in the liquid phase section, the critical angle at which total reflection occurs becomes larger than the case where N.sub.2 is filled, and therefore, it is possible to use light more effectively.

Example 2

[0063] With respect to the light emitting body using light emitting diodes as a light source, N.sub.2 was used for the gas phase section covering the light emitting diodes, and borosilicate glass with a refractive index of 1.49 was used for the first optically transparent container. The incident angle of the light on the optical axis of the light emitting diodes from the gas phase section to the inner surface of the first optically transparent container was set at 10°, and the transmittance of light from the gas phase section to the first optically transparent container was calculated. The results are shown in Table 2.

Examples 3 to 9

[0064] The optical transparency (transmittance of light) was calculated in the same manner as in Example 2 other than a condition where the incident angle was changed from 20° to 80°. The results are shown in Table 2.

TABLE-US-00002 TABLE 2 Refractive Incident side medium Optical side medium Optically transparency from Gas phase transparent gas phase section to Incident angle from gas section container first optically phase section to inner Refractive Refractive Reflectance transparent surface of container (°) Material index Material index (—) container (—) Example 2 10 N.sub.2 1.00 borosilicate 1.49 0.039 0.9613 Example 3 20 glass 0.039 0.9610 Example 4 30 0.040 0.9598 Example 5 40 0.044 0.9556 Example 6 50 0.056 0.9438 Example 7 60 0.088 0.9125 Example 8 70 0.169 0.8308 Example 9 80 0.386 0.6140

[0065] The photoirradiation device according to the present invention is applicable to any field in which efficient photoirradiation is desired, and in particular, it is suitable to a photoreaction method using the photoirradiation device and a method for producing a lactam using the photoreaction method.

EXPLANATION OF SYMBOLS

[0066] 1: photoirradiation device [0067] 2: reaction vessel [0068] 3: reaction liquid [0069] 4: power supply unit [0070] 5: light emitting diode [0071] 6: light-emitting body [0072] 7: lid [0073] 8: first optically transparent container [0074] 9: gas phase section [0075] 10: second optically transparent container [0076] 11: liquid phase section [0077] 12: substrate [0078] 13: structural body [0079] 21: optical axis [0080] 22: normal line of inner surface of first optically transparent container [0081] 23: incident angle to container inner surface [0082] 24: normal line of container outer surface [0083] 25: incident angle to container outer surface [0084] 26: transmitted light [0085] 27: reflected light