Title of Invention

PROCESS FOR PRODUCTION OF POLYESTER PARTICLES, POLYESTER PARTICLES, POLYESTER RESIN PARTICLES, AND PROCESS FOR PRODUCTION THEREOF

Abstract A process for producing polyester particles from a polyester with a low degree of polymerization by a strand cutting method is disclosed. Polyester particles, a process for producing polyester resin particles from the polyester particles by solid phase polycondensation, and polyester resin particles are also disclosed. The process for producing polyester particles involves the steps of:(1) to (3) are sequentially carried out, and the drawing rate ratio of polyester strands represented by the following formula is from 1.5 to 100, polyester particles, a process for producing polyester resin particles which comprises subjecting the particles to solid phase polycondensation, and polyester resin particles: (1) a step of discharging a molten polyester having a melt viscosity of from 0.5 Pas to 50 Pa-s from a die hole into strands, (2) a step of bringing the obtained polyester strands into contact with a liquefied fluid for cooling to lead the strands to a cutter together with the liquefied fluid, and (3) a step of cutting the polyester strands led to the cutter: drawing rate ratio = (linear velocity of strands immediately before cut (v2 (m/s)))/ (linear velocity of molten polyester when discharged from die hole (v1 (m/s))).
Full Text

TECHNICAL FIELD
The present invention relates to a process for
producing polyester particles with a low degree of
polymerization and polyester particles, and further
relates to a process for producing polyester resin
particles by solid phase polycondensation of the
polyester particles and polyester resin particles. More
particularly, it relates to a process of forming a
polyester with a low degree of polymerization to strands
and then cutting the strands, capable of producing
polyester particles stably at a high speed, and polyester
particles which have a substantially cylindroid shape.
Further, it relates to a process for efficiently
producing polyester resin particles with a high degree of
polymerization excellent in processability, which
comprises subjecting the above polyester particles with a
small particle size, having a substantially cylindroid
shape and suitable for solid phase polycondensation at a
high speed, to solid phase polycondensation, and
polyester resin particles.

BACKGROUND ART
A polyester represented by a polyethylene
terephthalate is excellent in mechanical properties,
thermal properties, electrical properties, etc. and is
thereby widely Used for fibers and for molded products
such as films, sheets and bottles for various
applications and its demand is expanding. A polyester to
be used for such applications is usually produced by
subjecting a dicarboxylic acid and/or its ester-forming
derivative and a diol to esterification and/or ester
exchange reaction and then melt polycondensation
reaction, and as the case requires, further to solid
phase polycondensation.
A polyester after the melt polycondensation reaction
is usually granulated to particles with a particle size
of from about 1 mm to about several mm so as to be formed
into a product or to be subjected to solid phase
polycondensation. As a granulation method, usually, a
method (hereinafter sometimes referred to as a "strand
cutting method") of discharging a melt polycondensed polyester from a die plate having a plurality of pores
(die holes) into a gas phase to form the polyester into
strands, and subsequently cutting the strands by a fixed
blade and a rotary blade having a rotation axis
substantially at a right angle to the discharge direction
under cooling with water or after cooling with water, is
excellent in view of production efficiency and is

commonly conducted.
However, when a polyester having a relatively low
intrinsic viscosity after the melt polycondensation
reaction, for example, an intrinsic viscosity of at most
about 0.3 dL/g, is to be granulated in order that the
polyester is used for special purpose or to be subjected
to solid phase polycondensation, the polyester can hardly
be wound in the form of strands since it has a low melt
viscosity, and the strands after cooled are fragile, and
accordingly granulation by the above strand cutting
method has been known to be very difficult. Therefore,
as a method of granulating such a polyester having a low
intrinsic viscosity, for example, Patent Documents 1 and
2 propose granulation method other than the strand
cutting method.
Further, as an improved strand cutting method,
Patent Document 3 discloses a method of extruding a large
number of strands of a molten thermoplastic resin
material from multiple die toward an inclined trough
including a coolant stream to bring the strands into
contact with water in the trough, carrying the strands
downward by the stream to rapidly cool the stands and
then cutting the strands into particles by a strand
cutter. The document discloses a method wherein the
linear velocity of the coolant stream flowing down the
trough is higher than the linear velocity of the strands
extruded from the die, and the edge of strands newly

formed which have passed through the strand cutter
connected to the edge of the tough directly with the
strands are made to pass through an apparatus along a
flow path similar to the flow path of preceding strands.
The above disclosed method is a method excellent for
forming (pelletizing) a thermoplastic resin material as a
common molding material into particles, but by this
method, strands of a polyester low polymer having a very
low melt viscosity will not stably run, and formation
into particles is difficult. Further, particles to be
subjected to solid phase polycondensation are required to
have a small particle size so as to increase the solid
phase polycondensation reaction rate, but with the
technique disclosed, it is further difficult to obtain
particles with a small particle size.
Patent Document 4 discloses a method of stretching a
ribbon, gut or sheet of a polyester with a low degree of
polymerization having an intrinsic viscosity of from 0.32
to 0.40 dL/g between rolls with a draw ratio less than 2
times, followed by cutting. In this method, as shown in
Figs. 1 and 2 of the Patent Document 4, the range of the
proper draw ratio is very narrow at an intrinsic
viscosity of at most 0.35, and this method can not be
employed for practical use.
Further, Patent Document 5 discloses a method of
forming a molten polymer containing a polyester as the
main component to a molding material in the form of

pellets, which comprises cooling molten polymer strands
discharged from an outlet in the air for from 0.10 to
0.50 seconds and then bringing them into contact with
cooling water and solidifying them to form pellets.
However, by the method disclosed in the document,
favorable pellets can not necessarily be obtained from a
polyester having a low melt viscosity.
Further, Patent Document 6 discloses cylindrical
particles made of a polyester having an inherent
viscosity of from about 0.20 to about 0.45 dL/g and their
production method. The requirement of the method
disclosed in the above document is that molten strands
are made to pass in a narrow air gap i.e. an air gap less
than about 4 inch (less than about 0.10 m) before rapidly
cooled by a cooling medium to obtain cylindrical
particles. However, in this method, it is difficult to
stably granulate a low viscosity polyester, and
particularly, it is difficult to efficiently produce
polyester particles with a small particle size having a
substantially cylindroid shape, suitable for solid phase
polycondensation at a high speed in the present
invention, from a low viscosity polyester.
As described above, no specific method of
efficiently forming a polyester with a low degree of
polymerization into particles has been known yet.
Patent Document 1: JP-A-51-066346
Patent Document 2: JP-A-10-512510

Patent Document 3: JP-B-55-016806
Patent Document 4: JP-B-50-024359
Patent Document 5: Japanese Patent No. 2993369
Patent Document 6: WO2004/035284
DISCLOSURE OF THE INVENTION
OBJECTS TO BE ACCOMPLISHED BY THE INVENTION
Under these circumstances, the object of the present
invention is to provide a process for efficiently-
producing polyester particles with a small particle size
from a polyester with a low degree of polymerization and
a low melt viscosity by a strand cutting method, and
polyester particles having a substantially cylindroid
shape. A further object of the present invention is to
provide a process for producing polyester resin particles
with a high degree of polymerization, which comprises the
above polyester particles having a substantially
cylindroid shape to solid phase polycondensation, and
polyester resin particles having a substantially
cylindroid shape.
MEANS TO ACCOMPLISH THE OBJECTS
Namely, the present invention resides in a process
for producing polyester particles, characterized in that
the following steps (1) to (3) are sequentially carried
out, and the drawing rate ratio of polyester strands
represented by the following formula is from 1.5 to 100:

(1) a step of discharging a molten polyester having
a melt viscosity of from 0.5 Pa-s to 50 Pa-s from a die
hole into strands,
(2) a step of bringing the obtained polyester
strands into contact with a liquefied fluid for cooling
to lead the strands to a cutter together with the
liquefied fluid, and
(3) a step of cutting the polyester strands led to
the cutter:
drawing rate ratio = (linear velocity of strands
immediately before cut (v2 (m/s)))/(linear velocity of
molten polyester when discharged from die hole (vl
(m/s))); and polyester particles having a substantially
cylindroid shape.
The present invention further resides in a process
for producing polyester resin particles, which comprises
subjecting the above polyester particles having a
substantially cylindroid shape to solid phase
polycondensation reaction, and polyester resin particles
having a substantially cylindroid shape.
EFFECTS OF THE INVENTION
According to the present invention, a polyester with
a low degree of polymerization can be formed into
particles stably, particularly, polyester particles with
a low degree of polymerization, having a substantially
cylindroid shape and having a small and uniform particle

size, can efficiently be obtained. Further, by using
such particles with a small particle size having a
specific shape, in a solid phase polycondensation
reaction, solid phase polycondensation can be conducted
at a high speed, and accordingly polyester resin
particles with a high degree of polymerization and
excellent in processability, suitable for packaging
materials for e.g. bottles, for industrial fibers, etc.,
can efficiently be obtained.
BEST MODE FOR CARRYING OUT THE INVENTION
Now, the present invention will be described in
detail. However, the following description is a
representative example, and the present invention is by
no means restricted thereto.
The present invention provides a process for
efficiently producing polyester particles from a
polyester having a low melt viscosity by a strand cutting
method, and polyester particles having a substantially
cylindroid shape. Further, it relates to a process for
producing polyester resin particles with a high degree of
polymerization, which comprises subjecting the polyester
particles having a substantially cylindroid shape to
solid phase polycondensation, and polyester resin
particles having a substantially cylindroid shape.
The process for producing polyester particles of the
present invention (hereinafter sometimes referred to as a

particles forming process) is a process for efficiently
producing polyester particles having a low intrinsic
viscosity, particularly polyester particles having a
substantially cylindroid shape from a polyester with a
low degree of polymerization having a low melt viscosity
by a strand cutting method under predetermined operation
conditions.
Namely, the process of the present invention is a
process for producing polyester particles, characterized
in that the following steps (1) to (3) are sequentially
carried out, and the drawing rate ratio of polyester
strands represented by the following formula is from 1.5
to 100:
(1) a step of discharging a molten polyester having
a melt viscosity of from 0.5 Pa-s to 50 Pa-s from a die
hole into strands,
(2) a step of bringing the obtained polyester
strands into contact with a liquefied fluid for cooling
to lead the strands to a cutter together with the
liquefied fluid, and
(3) a step of cutting the polyester strands led to
the cutter:
drawing rate ratio = (linear velocity of strands
immediately before cut (v2 (m/s)))/(linear velocity of
molten polyester when discharged from die hole (vl
(m/s)))
According to the particles forming process of the

present invention, particles having a desired shape can
efficiently be obtained from a polyester with a low
degree of polymerization after the melt polycondensation
reaction, having a melt viscosity at the time of
discharge of from 0.5 Pa-s to 50 Pa-s. Therefore,
achievement of a high degree of polymerization is not
required in the melt polycondensation reaction, and an
expensive equipment to carry out stirring of a liquid
with a high viscosity and reaction in high vacuum in the
melt polycondensation step is unnecessary. Further,
according to the process of the present invention,
particles with a small particle size having a
substantially cylindroid shape can be obtained, and when
such polyester particles with a small particle size are
subjected to solid phase polycondensation, it is possible
to increase the solid phase polycondensation rate.
Therefore, the process is a very useful process capable
of efficiently producing polyester resin particles with a
high degree of polymerization.
The melt viscosity is a complex viscosity of a
polyester to be formed into particles measured at a shear
rate of 10 rad/s by a dynamic viscoelasticity measuring
apparatus (rheometer) at a temperature of a molten
polyester when discharged from a die hole.
Regarding the polyester to be used in the above step
(1) in the particles forming process of the present
invention, the melt viscosity of the polyester when

discharged from a die hole to strands i.e. polyester
strands is from 0.5 Pa-s to 50 Pa-s. The lower limit is
preferably 1.5 Pa-s, more preferably 2.5 Pa-s. The upper
limit is preferably 20 Pa-s, more preferably 10 Pa-s. If
the melt viscosity of the polyester is less than 0.5
Pa-s, the melt viscosity is too low when the polyester is
discharged from the die hole, and no stable strands will
be obtained, and the strands may be broken in some cases.
On the other hand, if it exceeds 50 Pa-s, since the
diameter of the die hole required to obtain polyester
particles with a small particle size is small, the
polyester hardly passes through the die hole, thus
leading to lack of operation stability. Further, to
obtain a polyester having a high melt viscosity, an
expensive equipment to carry out stirring of a liquid
with a high viscosity and reaction in high vacuum will be
required in the above-described melt polycondensation
reaction, such being unfavorable.
The melt viscosity of the polyester particles
obtained by the particles forming process of the present
invention is equal to the melt viscosity of the strands.
In the particles forming process of the present
invention, the drawing rate ratio of strands (hereinafter
represented by r) is the ratio of the linear velocity (v2
(m/s)) of strands immediately before cut to the linear
velocity (vl (m/s)) of the molten polyester when
discharged from the die hole, represented by the

following formula:
r = (v2 (m/s))/(vl (m/s))
wherein vl (m/s) = (discharged weight (kg/s) per unit
time (s: second) per one die hole/density (kg/m3) of
polyester)/(die hole outlet area (m2)), and v2 (m/s) is
the linear velocity of the strands immediately before cut
by a cutter and is usually the same as the linear
velocity of the strands when cut by a cutter, and
accordingly it is calculated in accordance with the
following formula from the number (n) of cogs of a rotary
blade of the cutter, the number of revolutions (R (1/s))
and the length (L (m)) of the cut particles in the
discharge direction:
v2 (m/s) = RnL (m/s).
Further, in a case where a drawing roll to draw the
strands is disposed before the cutter, the v2 (m/s) can
be calculated in accordance with the following formula
from the number of revolutions of the drawing roll as a
component in the direction of the tangent line of the
speed of revolution on the side of the drawing roll:
v2 (m/s) = (diameter (m) of drawing roll) x (number
of revolutions (1/s) of drawing roll) x (pi)
An apparatus having a drawing roll to lead the
strands stably to the cutter disposed particularly before
the cutter is preferably used, and in such a case, the
above method to determine v2 (m/s) from the number of
revolutions of the drawing roll is simple and used

preferably.
The drawing rate ratio r is adjusted so that the
strands together with a liquefied fluid for cooling are
led to the cutter and cut properly. As an adjustment
method, for example, the flow rate of the liquefied fluid
moving together with the strands is changed, and/or the
speed of revolution of the drawing roll which draws the
strands is changed immediately before the strands are cut
by a cutter.
The lower limit of the drawing rate ratio r is 1.5,
preferably 2. If it is less than 1.5, the strands
discharged from the die hole will not stably move
together with the liquefied fluid, the strands may wind
or may be too thick and accordingly the subsequent
cutting by a cutter can not smoothly be carried out,
whereby the particle size will not be uniform, and
irregular deformed particles having a particularly large
particle size may form in some cases. The upper limit of
the drawing rate ratio r is 100, preferably 50, more
preferably 20. If it exceeds 100, the strands may be too
thin and be difficult to be cut by a cutter, or the
strands may easily be broken before they are led to the
cutter in some cases.
In the particles forming process of the present
invention,.as a method of discharging the molten
polyester into strands, the molten polyester is led to a
die head through e.g. an extruder, a gear pump or a

piping connected to a pressurized melt polycondensation
reaction tank and discharged into strands from a single
or a plurality of die holes provided at the tip of the
die head. The hole shape of the die hole may, for
example, be circular, elliptic, polygonal or star, or a
shape of part thereof (e.g. semicircle or semiellipse) or
a shape of combination thereof (e.g. a rectangular shape
with semicircles on both ends). With respect to the size
of the hole of the die hole, the pore diameter is
preferably from 0.7 to 5.0 mm as calculated as the
cfiameter of a circle having the same area as the area of
the hole of the die hole. If it is less than 0.7 mm, the
discharge pressure may be too high, whereby discharge
>5 = —-
tends to be difficult and the strands are likely to be
broken. Further, if it exceeds 5.0 mm, no appropriate
drawing rate ratio r tends to be achieved, and particles
with a small particle size tend to hardly be obtained.
Further, when the molten polyester is discharged
from the die hole into strands, the linear velocity (vl
(m/s)) of the molten polyester discharged from the die
hole is preferably from 0.1 to 3 m/s. If the linear
velocity of the polyester discharged from the die hole is
less than 0.1 m/s, the drawing rate ratio r tends to be
high and the strands tend to be too thin, whereby they
are unlikely to be cut properly by a cutter. If the
linear velocity exceeds 3 m/s, the drawing rate ratio r
tends to be low and the strands tend to be thick, and

particles with a small particle size tend to hardly be
obtained.
Further, the direction of discharge of the molten
polyester when the molten polyester is discharged from
the die hole into strands, is preferably within an angle
formed by the horizontal direction and a direction tilted
downward 70° from the horizontal direction. When the
discharge direction is within this angle, the bending
angle of strands at the point of contact at which the
discharged polyester strands are contacted with the
liquefied fluid is small, and accordingly the strands are
less likely to vibrate, whereby particles can be obtained
stably. The direction of discharge of the molten
polyester is the slope of the tangent line of an arc
drawn by the strands very close to the die plate.
The direction of discharge is preferably within an
angle formed by the horizontal direction and a direction
tilted downward 60°, more preferably an angle formed by
the horizontal direction and a direction tilted downward
50° from the horizontal direction.
In the particles forming process of the present
invention, in the above step (2), the polyester strands
obtained by discharging the molten polyester from the die
hole are brought into contact with a liquefied fluid for
cooling to lead the polyester strands together with the
liquefied fluid to a cutter, and the liquefied fluid is
not particularly limited so long as it is a liquid

capable of cooling the strands discharged in a molten
state and capable of traveling together with the strands.
The liquefied fluid is suitably water, which is safely-
handled, with which a product with little foreign matters
is likely to be obtained, and which is available at a low
cost. The linear velocity of the liquefied fluid is
preferably from about 0.5 to about 10 times, more
preferably from 1 to 2 times the linear velocity v2 of
the strands immediately before cut.
The temperature of the liquefied fluid to be used,
e.g. water, is properly selected depending upon the
temperature at the time of melting the polyester, the
melting point, the softening point or the glass
transition point of the polyester, or the angle of
discharge or thickness of the strands, etc., but is at
least 5°C, preferably at least 25°C, and at most 95°C,
preferably at most 90°C. If it is less than 5°C, the
strands will be cooled too rapidly, whereby vibration may
occur due to shrinkage strain, or the strands may have
void therein, and if it exceeds 95°C, cooling tends to be
insufficient, whereby strands may fuse with one another,
or particles after cut may fuse with one another, such
being unfavorable. Particularly when the polyester is a
polyethylene terephthalate, the lower limit of the
temperature of water is preferably 10°C, more preferably
40°C, and the upper limit is preferably 70°C, more
preferably 65°C.

In the particles forming process of the present
invention, the polyester strands discharged from the die
hole are contacted with the liquefied fluid, and when
they are contacted, the rectilinear distance between the
outlet of the die hole and the point of contact between
the polyester strands and the liquefied fluid (when water
is used as the liquefied fluid, the point will be
referred to as landing point) is preferably from 10 to
500 mm. When the rectilinear distance is within this
range, the equipment is easily disposed and adjusted,
there will be few problems of vibration of the strands
and breakage of the strands, and the polyester will
stably be formed into strands, and thus particles will
stably be obtained.
Particularly, in order to obtain particles with
preferred shape and particle size described hereinafter,
the lower limit of the rectilinear distance between the
outlet of the die hole and the point of contact between
the polyester strands and the liquefied fluid, is
preferably 100 mm, more preferably 13 0 mm, particularly
preferably 150 mm, and the upper limit is 500 mm. When
the rectilinear distance is within this range, the molten
polyester in the form of strands can be sufficiently
elongated before the strands are brought into contact
with the liquefied fluid, whereby fine polyester
particles with an average particle size of at most 2 mm
will be obtained more stably, such being particularly

preferred.
The speed of travel of the liquefied fluid led to
the cutter together with the polyester strands is
determined by e.g. the linear velocity of the strands.
The length of the strands cooling portion (e.g.
water cooling portion) by the liquefied fluid varies
depending upon e.g. the temperature of the discharged
polyester strands and the size of the strands, but is
usually from 0.5 to 10 m. Further, in order to smoothly
lead the strands and the liquefied fluid to a cutter, the
cooling portion preferably inclines at an angle of from
5° to 80°, preferably from 8° to 60°, more preferably from
10° to 45°, whereby the strands will not vibrate and
particles will stably be obtained.
In the above step (3) in the particles forming
process of the present invention, the polyester strands
led to the cutter are cut, and in this step, the
polyester strands should be cooled by the liquefied fluid
to such an extent that they are cuttable.
The polyester to be used for production of small
particles by the particles forming process of the present
invention is not particularly limited so long as it has a
melt viscosity at the time of discharge of from 0.5 Pa-s
to 5 0 Pa-s, but a polyester in a molten state obtained by
subjecting a dicarboxylic acid and/or its ester forming
derivative and a diol to esterification reaction and/or
ester exchange reaction and further conducting melt

polycondensation reaction, is preferably used as it is.
The intrinsic viscosity of the polyester to be
formed into particles in the present invention is equal
to the intrinsic viscosity of the polyester strands
discharged from the die hole in a molten state and is
preferably from 0.2 0 to 0.4 0 dL/g. The lower limit is
more preferably 0.25 dL/g, and the upper limit is more
preferably 0.35 dL/g, particularly preferably 0.32 dl/g.
With a polyester with such a degree of polymerization
that the intrinsic viscosity is less than the lower
limit, the melt viscosity when discharged from the die
hole is too low, whereby stable strands are unlikely to
be obtained. If the intrinsic viscosity exceeds the
upper limit, the polyester is difficult to pass through a
die hole with a small size required to obtain polyester
particles with a small particle size, and expensive
equipment will be required to carry out stirring of a
liquid with a high viscosity and reaction in high vacuum
in the above-described melt polycondensation reaction
step, such being unfavorable.
The polyester to be used for the particles forming
process of the present invention is suitably produced by
subjecting a dicarboxylic acid and/or its ester forming
derivative and a diol to esterification reaction and/or
ester exchange reaction and then to melt polycondensation
reaction using a polycondensation catalyst, but the
method is not particularly limited, and basically a known

method for producing a polyester can be employed. For
example, such a method may be mentioned that a
dicarboxylic acid component such as terephthalic acid and
a diol component such as ethylene glycol or butylene
glycol are put in a slurry preparation tank and stirred
and mixed to prepare a raw material slurry, which is
subjected to esterification reaction in an esterification
reaction tank under normal pressure to elevated pressure
with heating while distilling water or the like caused by
the reaction off, and a polyester low polymer (oligomer)
as the obtained esterification reaction product is
transferred to a polycondensation reaction tank and
subjected to melt polycondensation reaction using a
polycondensation catalyst under reduced pressure with
heating to obtain a polyester.
In a case where the dicarboxylic acid component is
one having a melting point close to the polycondensation
reaction temperature, e.g. an ester forming derivative of
a dicarboxylic acid such as dimethyl terephthalate, it
may not be formed into a slurry with the diol but may be
melted and then subjected.to ester exchange reaction with
a diol.
A method of carrying out the above reaction may be
any of a continuous method, a batch method and a
semibatch method, or a combination thereof. Further,
each of the esterification reaction tank (or an ester
exchange reaction tank) and the melt polycondensation

reaction tank may be single stage or multistage.
The polyester particles obtained by the particles
forming process of the present invention are suitably
used in a process of crystallizing them after granulation
and further conducting solid phase polycondensation.
Thus, the particles forming process of the present
invention is suitably applied to a process for producing
a polyester resin such as a polyethylene terephthalate
resin and/or a polybutylene terephthalate resin by
carrying out such solid phase polycondensation, that is,
a process for producing a polyester resin wherein the
main component of the dicarboxylic acid among the
polyester raw materials is terephthalic acid and/or
dimethyl terephthalate, and the main component of the
diol is ethylene glycol and/or 1,4-butanediol. Here, the
"main component" means that terephthalic acid accounts
for 85 mol% or more of all dicarboxylic acid components
and that ethylene glycol or 1,4-butanediol accounts for
85 mol% or more of all diol components.
In a method for producing the polyester to be used
in the present invention, for the melt polycondensation
reaction, usually a polycondensation catalyst is used.
The polycondensation catalyst to be used is not
particularly limited, and usually a known catalyst as a
polycondensation catalyst for production of a polyester
resin can be used. For example, a germanium compound, an
antimony compound, a titanium compound, a manganese

compound, a zinc compound, an aluminum compound, a
tungsten compound or the like may be used, and among
them, preferred is at least one metal compound selected
from a germanium compound, an antimony compound and a
titanium compound.
The molten polyester in the particles forming
process of the present invention may be one obtained by
once solidifying and then remelting the polyester
obtained by the above melt polycondensation reaction
before used as a material for the particles forming
process of the present invention, or may be the polyester
in a molten state obtained by the melt polycondensation
reaction as it is. The method of solidifying the
polyester obtained by the melt polycondensation reaction
is unfavorable since it requires an operation of
pelletizing the polyester at the solidifying step or an
energy for remelting, and it is preferred to obtain a
polyester in a molten state by the melt polycondensation
reaction and using the obtained polyester as a material
to be subjected to the particles forming process of the
present invention as it is.
The polyester obtained by the melt polycondensation
reaction is preferably supplied to a die head connected
to the melt polycondensation reaction tank via a piping
and discharged from a plurality of die holes provided at
the tip of the die. The discharged polyester strands are
formed into particles by the process of the present

invention. As the case requires, a gear pump or a filter
may be provided in the piping between the melt
polycondensation reaction tank and the die-head.
Of the polyester particles obtainable by the
particles forming process of the present invention, the
average particle size is preferably at least 0.5 mm, more
preferably at least 0.6 mm, particularly preferably at
least 0.65 mm, and preferably at most 2.0 mm, more
preferably at most 1.8 mm, particularly preferably at
most 1.6 mm. Particles obtained by the production
process of the present invention and having an average
particle size within the above range are more preferred,
since the solid phase polycondensation rate when the
polyester particles are subjected to solid phase
polycondensation is high. The size of the particles is
more preferably the lower limit or above, whereby
troubles are less likely to occur in the subsequent steps
or during air power transport. Further, the size of the
particles is more preferably the upper limit or smaller,
whereby troubles such as breakage or formation of dust
will hardly occur at the time of granulation, and the
time for the solid phase polycondensation reaction
required to achieve a desired molecular weight can be
shortened.
The average particle size of the particles is a
value at the cumulative percentage of 50% in a cumulative
distribution curve prepared by the dry sieving method as

stipulated in JIS K0069.
The polyester particles obtained by the particles
forming process of the present invention preferably have
a substantially cylindroid shape. The "substantially
cylindroid shape" includes a cylindroid, quadrangular
prism and an intermediate thereof. The "cylindroid" is a
prism having an elliptic cut surface, and the
"quadrangular prism" is a prism having a rectangular cut
surface. Further, the "intermediate thereof" is a prism
having a cut surface of a shape inscribed in a
rectangular having a long side and a short side equal to
the major axis and the short axis of the cut surface,
e.g. a shape inscribed in a rectangular lacking at least
part of four corners in the arc shape, and in the present
invention, it is expressed as a "a cylindroid
substantially close to a quadrangular prism" or a "a
cylindroid close to a shape having semicircles imparted
to both ends of a quadrangular prism" or the like. The
polyester particles of the present invention having the
above shape are preferred in that the specific surface
area (surface area/volume) of the particles is large,
whereby the solid phase polycondensation rate is
relatively high.
A preferred shape of the polyester particles
obtainable by the particles forming process of the
present invention is a substantial cylindroid having the
size described below. That is, the length is at least

0.5 mm and at most 2.5 mm, more preferably at most 2 mm,
particularly preferably at most 1.5 mm. Further, the cut
surface has a major axis of at least 0.5 mm and at most
2.5 mm, more preferably at most 2 mm, particularly
preferably at most 1.5 mm, and a short axis of at least
0.3 mm and at most 2 mm, more preferably at most 1.5 mm,
particularly preferably at most 1.2 mm.
Preferred polyester particles are ones having an
intrinsic viscosity of from 0.20 to 0.40 dL/g, a length
of from 0.5 to 2.5 mm, having a cut surface with a major
axis and a short axis of from. 0.5 to 2.5 mm and from 0.3
to 2 mm, respectively, and having a substantially
cylindroid shape.
Particularly preferred polyester particles are ones
having a length of from 0.5 to 1.5 mm, having a cut
surface with a major axis and a short axis of from 0.5 to
1.5 mm and from 0.3 to 1.2 mm, respectively, and having a
substantially cylindroid shape. Such a shape is
advantageous in production of a polyester resin, since
the specific surface area of the particles tends to be
large, whereby the solid phase polycondensation rate is
relatively high as compared with cylindrical particles as
disclosed in Patent Document 6.
The polyester particles obtained by the particles
forming process of the present invention are preferably
further subjected to solid phase polycondensation, and
particularly .when polyester resin_ p_a_rti£.les having

crystallinity are desired, the polyester particles are
subjected to a solid phase polycondensation step thereby
to produce polyester resin particles with a higher degree
of polymerization. Polyester resin particles thus
produced are polyester resin particles having more
favorable physical properties in view of moldability,
mechanical and physical properties of a molded product to
be obtained, etc.
The polyester particles of the present invention,
for example, the polyester particles obtained by the
above particles forming process, are subjected to a solid
phase polycondensation step to produce polyester resin
particles, and a specific method of the solid phase
polycondensation is not particularly limited, and various
methods may be employed according to need. As a known
method, a method may be mentioned wherein the polyester
particles are fluidized in an inert gas stream at from
12 0 to 18 0°C for from 0.5 to 12 hours to carry out
crystallization and drying treatment, and then solid
phase polycondensation is continuously carried out in a
moving bed while flowing an inert gas usually at a
temperature of 180°C or above and a temperature lower by
5°C than the melting point of the polyester. The solid
phase polycondensation time is set depending on the
intrinsic viscosity of the aimed polyester resin and is
usually from about 1 to about 50 hours. With respect to
the intrinsic viscosity after the solid phase

polycondensation, the lower limit is usually 0.70 dL/g,
preferably 0.72 dL/g, more preferably 0.74 dL/g, and the
upper limit is usually 1.50 dL/g, preferably 1.45 dL/g,
more preferably 1.40 dL/g. When the intrinsic viscosity
of the polyester resin particles obtained by the
production process of the present invention is within
this range, a molded product obtained from such polyester
resin particles is excellent in mechanical strength and
melt moldability, such being more favorable.
Particularly, in production of a polyester resin by
the solid phase polycondensation in the present
invention, it is preferred to subject polyester particles
having particularly preferred size and shape obtained by
the above-described particles-forming process of the
present invention to solid phase polycondensation. In
such a case, slight shrinkage or the like by
crystallization will occur, but the polyester resin after
the solid phase polycondensation is a polyester resin
having an intrinsic viscosity of at least 0.70 dL/g, in
the form of the most preferred particles having a
substantially cylindroid shape having a length of from
0.5 mm to 1.5 mm and a cut surface with a major axis and
a minor axis of from 0.5 mm to 1.5 mm and from 0.3 mm to
1.2 mm, respectively. The polyester resin having such
size and shape of the present invention is more preferred
in that solid phase polycondensation for production
thereof is carried out in a short time and the melting

time when the polyester resin of the present invention is
subjected to thermoforming is short.
The polyester resin particles to be produced by the
solid phase polycondensation method of the present
invention are excellent in mechanical strength and melt
moldability, and are suitably used for bottles to be
filled with a beverage, by molding a preform by injection
molding or extrusion, followed by orientation blow
molding. Further, the polyester resin particles can be
formed into a bottle also by direct blow molding.
Further, the polyester resin particles can be
suitably used for various applications such as a
packaging material by forming them into a film or a sheet
by injection molding or orientation molding, and can be
suitably used as fibers by extrusion/orientation molding.
EXAMPLES
Now, the present invention will be described in
further detail with reference to Examples, but the
present invention is by no means restricted to the
following Examples.
Methods of evaluating physical properties in the
present invention are as follows.
(Intrinsic viscosity)
About 0.25 g of a sample (polymer) was dissolved in
about 25 mL of a solvent mixer of phenol/1,1,2,2-
tetrachloroethane (weight ratio l/l) at 140°C so that the

concentration became l.OOxlO"2 kg/L. Then, the solution
was cooled to 3 0°C, and the number of seconds during
falling of the sample solution at a concentration of
l.OOxlCT2 kg/L and the solvent alone was measured by an
automatic solution viscometer ("2CH model DJ504"
manufactured by SENTEC Corporation) to calculate the
intrinsic viscosity in accordance with the following
formula:
[n] = [(1 + 4KHrisp)0-5-l]/(200KHC)
wherein nSP = n/n0-l, r| is the number of seconds during
falling of the sample solution, n0 is the number of
seconds during falling of the solvent, C is the polymer
solution concentration (kg/L), and KH is the Huggins
constant, provided that KH = 0.33 was employed.
(Melt viscosity)
A sample was vacuum dried at 12 0°C for 14 hours, and
a test piece with a diameter of 25 mm and a thickness of
2 mm was prepared at a temperature of 280°C by using a
pressing machine ("MINI PRESS" manufactured by Toyo Seiki
Seisaku-sho Ltd.). The sample was stored in a desiccator
immediately before measurement.
As a measuring apparatus, a dynamic viscoelasticity
measuring apparatus ("ARES10 0 model" manufactured by TA
Instruments) was used, and the detector was a full scale
10 g type. As a measuring jig, parallel plates with a
diameter of 25 mm were used, and the plate distance was
1.5 mm. The measuring operation was as follows.

A heating oven was heated to the measurement
temperature, the sample was inserted between parallel
plates and the heating oven was closed, and upon
confirmation of the sample being melted, the upper plate
was let down and closely contacted to the sample, and the
sample was pressed to a plate distance of 1.5 mm.
Then, the heating oven was opened, the sample
spilled from the plates was removed and the heating oven
was closed again, the plate distance was set at 1.50 mm,
and upon confirmation of the temperature being stabilized
at the measurement temperature, measurement was started.
The strain at the time of measurement was 30%. Further,
the time from insertion of the sample to the beginning of
measurement was set to 8 minutes. ,
In such a manner, the complex viscosity at a
temperature of the molten polyester when discharged from
a die hole at a shear rate of 10 rad/s was measured and
regarded as the melt viscosity.
(Average particle size)
Measured in accordance with a dry sieving test
method as stipulated in JIS K0069.
A polyester to be subjected to production of
polyester particles in Examples 1 to 6 and Comparative
Example 1 was produced as follows.
(Production of polyester)
A polyester with a low degree of polymerization to
be subjected to strand cutting was produced by using a

polyester continuous production apparatus equipped with a
slurry preparation tank having a stirrer, an ethylene
glycol charge piping and a terephthalic acid charge
piping; a piping which transfers a slurry to a first
esterification tank; complete mixing type first and
second esterification reaction tanks having a stirrer, a
separation column, a material receiver, a catalyst charge
piping and a reaction product transfer piping; a piping
which transfers an esterification reaction product
(oligomer) to a melt polycondensation reaction tank; a
complete mixing type first melt polycondensation reaction
tank having a stirrer, a separation column, an oligomer
receiver and a catalyst charge piping; plug flow type
second and third melt polycondensation reaction tanks
having a stirrer, a separation column and a polymer
receiver; and a polyester discharge piping. A specific
method was as follows.
(Polyester A: material A)
In the slurry preparation tank, a terephthalic
acid/ethylene glycol (molar ratio 1:1.5) slurry having
orthophosphoric acid added thereto so that the phosphorus
concentration in a polyester to be obtained became 22
wtppm as phosphorous atoms, was prepared. Further, 4 00
parts by weight of bis-(beta-hydroxyethyl)terephthalate
was charged in the first esterification tank and melted
in a nitrogen atmosphere, and in the first tank
maintained at a temperature of 262°C under a pressure of

96 kPaG (hereinafter G represents the relative pressure
to the atmospheric pressure), the above slurry prepared
in the slurry preparation tank was continuously charged
at a rate of 13 5 parts by weight/hour so that the average
retention time as the polyester became. 4.5 hours, to
carry out esterification reaction while distilling formed
water off from the separation column, and the reaction
liquid was continuously transferred to the second
esterification reaction tank.
In the second esterification reaction tank,
esterification reaction was carried out by continuously
adding an ethylene glycol solution of antimony trioxide
(concentration: 1.8 wt% as the antimony atom
concentration) so that the antimony concentration in a
polyester to be obtained became 183 wtppm as antimony
atoms, at a temperature of 2 60°C under a pressure of 5
kPaG for a retention time of 1.5 hours, and the product
was continuously transferred to the complete mixing type
first melt polycondensation reaction tank through the
transfer piping. In the first melt polycondensation
reaction tank, reaction was carried out under a pressure
of 2.5 kPaA (hereinafter A represents the absolute
pressure) of the polycondensation reaction tank at a
temperature of 273°C for a retention time of 1.0 hour,
and the obtained polyester was taken through the
discharge piping in the middle of the transfer piping to
the second melt polycondensation reaction tank and cooled

and solidified.
The intrinsic viscosity of the obtained polyester
was 0.215 dL/g.
The cooled and solidified polyester was made to pass
through two stainless steel rolls having axes of rotation
in parallel with each other, disposed to be close to each
other, having irregularities on the surface and rotating
in different directions four times to compress and
pulverize the polyester to obtain irregular polyester
particles having a particle size within a range of from
0.1 mm to 3.36 mm. The irregular polyester particles
will be referred to as "material A".
(Polyester B: material B)
The reaction up to the first melt polycondensation
reaction tank was carried out in the same manner as in
the above method for producing the material A, and the
obtained polyester was transferred to the second melt
polycondensation reaction tank. In the second melt
polycondensation reaction tank, melt polycondensation
reaction was carried out under a pressure of 2.0 kPaA at
a temperature of 280°C for a retention time of 1.0 hours,
and the obtained polyester was transferred to the third
melt polycondensation reaction tank through the transfer
piping. In the third melt polycondensation reaction
tank, melt polycondensation reaction was carried out
under a pressure of 1.5 kPaA at a temperature of 280°C
for a retention time of 1.2 hours. The obtained

polyester was drawn and led to a die head through the
discharge piping and taken out from the die hole in the
form of strands, which were cooled with water and
solidified and then cut by a cutter to obtain polyester
particles having an intrinsic viscosity of 0.403 dL/g and
an average particle size of 3 mm. The polyester
particles will be referred to as "material B".
(Formation of polyester into particles)
The material A and the material B obtained by the
above methods were put in an inert oven through which
nitrogen flowed, dried at a temperature of 180°C for 3
hours and mixed in a predetermined ratio as identified in
Table 1, and the mixture was supplied to a twin screw
extruder of 45 mm in diameter and discharged from a die
plate at a resin temperature of 2 80°C into strands. The
polyester strands were formed into particles by a strand
cutting method using a pelletizer (P-USG200) manufactured
by Rieter Automatik GmbH. That is, the polyester strands
were transferred to a cutter while bringing it into
contact with water at a predetermined temperature and
cooling it together with water, and on that occasion, the
polyester strands were sandwiched between a pair of
drawing rolls disposed before the cutter and drawn and
then supplied to the cutter and cut by cutter having a
fixed blade and a rotary blade to obtain polyester
particles. The length of the water cooling portion was 2
mm, the slant at the water cooling portion was 20° to the

horizontal direction, and the rotary blade was one having
6 0 cogs.
Operation conditions such as the linear velocity of
the strands being discharged and the drawing rate ratio
in each Example are shown in Table 1.
EXAMPLE 1
Material A was continuously supplied to an extruder
at a rate of 4 8 kg/hour and melted, and discharged from a
die plate with 6 circular die holes of 2 mm in diameter
at a resin temperature of 280°C into strands. The
direction of discharge was at an angle of 45° downward
from the horizontal direction. The linear velocity of
the polyester being discharged is 0.58 m/sec calculated
assuming that the density of the polyester at a resin
temperature of 28 0°C was 1.23 kg/L.
The polyester strands were landed on a cooling zone
of a strand cutter in such a state that the rectilinear
distance between the outlet of the die hole and the point
of contact between the polyester strands and water
(landing point) (hereinafter the linear distance will be
referred to as an "air cooling distance") became 140 mm,
and transferred while being cooled with water at 50°C,
drawn by drawing rolls and supplied to a cutter. The
strand drawing rate was 2.33 m/sec, and the drawing rate
ratio was 4.0. Formation into particles was carried out
by adjusting the ratio of the number of revolutions of
the drawing rolls to the rotary blade of the cutter so

that the length of the particles in the drawing direction
became 1.5 mm.
As a result, polyester particles having a cylindroid
shape substantially close to a quadrangular prism, having
a length of 1.5 mm and a cut surface with a major axis
and a minor axis of 1.5 mm and 0.7 mm, respectively, were
obtained. The average particle size of the particles was
1.5 mm. The amount of irregular particles which did not
pass through a sieve with an opening of 2.8 mm, formed in
the particles forming step, was 3 wt%. Further, the melt
viscosity of the particles at 280°C was 1.7 Pa-s, and the
intrinsic viscosity was 0.205 dL/g. The operation
conditions and the results are shown in Table 1.
EXAMPLE 2
Formation of the polyester into particles was
carried out in the same manner as in Example 1 except
that the operation conditions were changed as identified
in Table 1. As a result, polyester particles having a
cylindroid shape substantially close to a quadrangular
prism, having a length of 1.5 mm and a cut surface with a
major axis and a minor axis of 1.5 mm and 0.8 mm,
respectively, were obtained. The average particle size
of the particles was 1.5 mm. The amount of irregular
particles which did not pass through a sieve with an
opening of 2.8 mm, formed in the particles forming step,
was 3 wt%. The operation conditions and the results are
shown in Table 1.

EXAMPLE 3
Formation of the polyester into particles was
carried out in the same manner as in Example 1 except
that the operation conditions were changed as identified
in Table 1. As a result, polyester particles having a
cylindroid shape substantially close to a quadrangular
prism, having a length of 1.5 mm and a cut surface with a
major axis and a minor axis of 1.4 mm and 0.7 mm,
respectively, were obtained. The average particle size
of the particles was 1.5 mm. The amount of irregular
particles which did not pass through a sieve with an
opening of 2.8 mm, formed in the particles forming step,
was 2 wt%. The operation conditions and the results are
shown in Table 1.
EXAMPLE 4
Formation of the polyester into particles was
carried out in the same manner as in Example 1 except
that the operation conditions were changed as identified
in Table 1. As a result, polyester particles having a
cylindroid shape substantially close to a quadrangular
prism, having a length of 1.5 mm and a cut surface with a
major axis and a minor axis of 1.4 mm and 0.9 mm,
respectively, were obtained. The average particle size
of the particles was 1.5 mm. The amount of irregular
particles which did not pass through a sieve with an
opening of 2.8 mm, formed in the particles forming step,
was 2 wt%. The operation conditions and the results are

shown in Table 1.
EXAMPLE 5
Formation into particles was carried out in the same
manner as in Example 1 except that the die plate was
changed to a die plate with 2 circular die holes of 3 mm
in diameter, that the cooling water temperature was 61°C,
that the number of revolutions of the rotary blade of the
cutter was adjusted so that the length of the particles
in the drawing direction became 1.25 mm, and that the
operation conditions were as identified in Table 1. As a
result, polyester particle having a cylindroid shape
substantially close to a quadrangular prism, having a
length of 1.25 mm and a cut surface with a major axis and
a minor axis of 1.2 mm and 0.8 mm, respectively, were
obtained. The average particle size of the particles was
1.2 mm. The amount of irregular particles which did not
pass through a sieve with an opening of 2.8 mm, formed in
the particles forming step, was 1 wt%. The operation
conditions and the results are shown in Table 1.
COMPARATIVE EXAMPLE 1
Formation of the polyester into particles was
attempted in the same manner as in Example 1 except that
the operation conditions were changed as identified in
Table 1. As a result, the strands wound, a large amount
of irregular particles and uncut strands formed, and
stable granulation could not be carried out. The
operation conditions and the results are shown in Table

1.
EXAMPLE 6
The polyester particles obtained in Example 5 were
put in an inert oven through which nitrogen flowed,
crystallized at a temperature of 180°C for 2 hours and
then subjected to solid phase polycondensation at 230°C
for 12 hours to obtain polyester particles having a high
molecular weight. The particles had a cylindroid shape
substantially close to a quadrangular prism having a
length of 1.2 mm and a cut surface with a major axis and
a minor axis of 1.2 mm and 0.8 mm, respectively, and had
an intrinsic viscosity of 0.845 dL/g.



EXAMPLE 7
Using the polyester continuous production apparatus
used in the above (Production of polyester),
esterification reaction of a dicarboxylic acid and a diol
was carried out and further melt polycondensation
reaction was carried out to obtain a polyester in a
molten state, and the obtained polyester in a molten
state was used for production of particles as it was to
produce polyester particles with a low degree of
polymerization. A specific method was as follows.
In the slurry preparation tank, a terephthalic
acid/ethylene glycol (molar ratio 1:1.5) slurry
containing tetra-n-butyl titanate in an amount of 8 wtppm
as titanium based on a polyester to be obtained, was
prepared. Further, 400 parts by weight of bis-(beta-
hydroxyethyl)terephthalate was charged to the first
esterification tank and melted in a nitrogen atmosphere,
and to the first esterification tank maintained at a
temperature of 262°C under a pressure of 96 kPaG, the
above slurry prepared in the slurry preparation tank was
continuously charged at a rate of 135 parts by
weight/hour so that the average retention time as a
polyester became 4.5 hours to carry out esterification
reaction while distilling formed water off from the
separation column, and the reaction liquid was
continuously transferred to the second esterification
reaction tank.

In the second esterification reaction tank,
esterification reaction was carried out at a temperature
of 260°C under a pressure of 5 kPaG for a retention time
of 1.5 hours, and the reaction product was continuously
transferred to the complete mixing type first melt
polycondensation reaction tank through the transfer
piping.
In the first melt polycondensation reaction tank,
reaction was carried out at a temperature of 270°C under
a pressure of 4.0 kPaA for a retention time of 1.0 hour,
and the reaction product was continuously transferred to
the second melt polycondensation reaction tank through
the transfer piping. In the second melt polycondensation
reaction tank, melt polycondensation reaction was carried
out at a temperature of 270°C under a pressure of 4.0
kPaA for a retention time of 1.0 hour, and the reaction
product was transferred to the third melt
polycondensation reaction tank through the transfer
piping. In the third melt polycondensation reaction
tank, melt polycondensation reaction was carried out at a
temperature of 270°C under a pressure of 4.0 kPaA for a
retention time of 1.2 hours.
The molten polyester thus obtained was led to the
die head through the gear pump and the discharge piping
as it was, discharged from the die hole into strands,
which are cooled with water and formed into particles by
a pelletizer (P-USG100) manufactured by Rieter Automatik

GmbH. The particles forming process was a strand cutting
method, and specifically, the polyester strands were
transferred to the cutter direction together with water
while bringing the polyester strands into contact with
water and cooling them, sandwiched between a pair of
drawing rolls disposed before the cutter and drawn and
supplied to the cutter, and cut by the cutter having a
fixed blade and a rotary blade to obtain polyester
particles. The water cooling length was 2 mm, the slant
at the water cooling portion was 20° to the horizontal
plane, and the rotary blade was one having 6 0 cogs.
The amount of discharge of the molten polyester was
12 6 kg/hour, the temperature was set at 270°C, and the
polyester was discharged from a die plate having 4
circular die holes of 3 mm in the direction of discharge
at an angle of 4 5° downward from the horizontal
direction, into strands. The linear velocity of the
polyester being discharged is 1.01 m/sec calculated
assuming that the density of the polyester at a resin
temperature of 270°C was 1.23 kg/L.
The polyester strands were landed on a cooling zone
(water cooling portion) of the strand cutter in a state
where the air cooling distance became 170 mm, transferred
while cooling with water at 50°C, drawn by drawing rolls
and supplied to the cutter. The strands drawing rate was
3.00 m/sec, and the drawing rate ratio was 3.0.
Formation into particles was carried out by adjusting the

ratio of the number of revolutions of the drawing rolls
to the rotary blade of the cutter so that the length of
the particles in the drawing direction became 1.0 mm.
As a result, polyester particles having a cylindroid
shape substantially close to a shape having semicircles
imparted to both ends of a quadrangular prism, having a
length of 1.0 mm and a cut surface with a major axis and
a minor axis of 1.9 mm and 1.3 mm, respectively, were
obtained. The average particle size of the particles was
1.8 mm. The amount of irregular particles which did not
pass through a sieve with an opening of 2.8 mm formed in
the particles forming step was 0.02 wt%. Further, the
melt viscosity of the particles at 270°C was 9.1 Pa-s,
and the intrinsic viscosity was 0.290 dL/g. The
operation conditions and the results are shown in Table
2.
EXAMPLE 8
Formation of the polyester into particles was
carried out in the same manner as in Example 7 except
that the operation conditions were changed as identified
in Table 2 by changing the amount of discharge of the
molten polyester to 98 kg/hour. As a result, polyester
particles having a cylindroid shape substantially close
to a shape having semicircles imparted to both ends of a
quadrangular prism, having a length of 1.0 mm and a cut
surface with a major axis and a minor axis of 1.6 mm and
1.2 mm, respectively, were obtained. The average

particle size of the particles was 1.5 mm. The amount of
irregular particles which did not pass through a sieve
with an opening of 2.8 mm, formed in the particles
forming step, was 0.01 wt%. The operation conditions and
the results are shown in Table 2.
EXAMPLE 9
Formation of the polyester into particles was
carried out in the same manner as in Example 7 except
that the operation conditions were changed as identified
in Table 2 by changing the amount of discharge of the
molten polyester to 61 kg/hour. As a result, polyester
particles having a cylindroid shape substantially close
to a shape having semicircles imparted to both ends of a
quadrangular prism, having a length of 1.0 mm and a cut
surface with a major axis and a minor axis of 1.3 mm and
0.9 mm, respectively, were obtained. The average
particle size of the particles was 1.3 mm. The amount of
irregular particles which did not pass through a sieve
with an opening of 2.8 mm, formed in the particles
forming step, was 0.01 wt%. The operation conditions and
the results are shown in Table 2.
EXAMPLE 10
Formation of the polyester into particles was
carried out in the same manner as in Example 7 except
that the operation conditions were changed as identified
in Table 2. As a result, polyester particles having a
cylindroid shape substantially close to a shape having

semicircles imparted to both ends of a quadrangular
prism, having a length of 1.0 mm and a cut surface with a
major axis and a minor axis of 2.5 mm and 1.8 mm,
respectively, were obtained. The average particle size
of the particles was 2.2 mm. The amount of irregular
particles which did not pass through a sieve with an
opening of 2.8 mm, formed in the particles forming step,
was 0.03 wt%. The operation conditions and the results
are shown in Table 2.
COMPARATIVE EXAMPLE 2
Formation of the polyester into particles was
attempted in the same manner as in Example 7 except that
the operation conditions were changed as identified in
Table 2. As a result, since strands wound, in addition
to polyester particles having a cylindroid shape
substantially close to a shape having semicircles
imparted to both ends of a quadrangular prism, having a
length of 1.0 mm and a cut surface with a major axis and
a minor axis of 3.1 mm and 1.9 mm, particles cut at a
slant and irregular particles with a length of 10 mm or
longer were obtained. The amount of irregular particles
which did not pass through a sieve with an opening of 2.8
mm was 4 wt%. The operation conditions and the results
are shown in Table 2.
COMPARATIVE EXAMPLE 3
Formation of the polyester into particles was
attempted in the same manner as in Example 7 except that

the direction of discharge of the molten polyester was
changed to an angle (vertical downward) of 90° downward
from the horizontal direction, that the air cooling
distance of the polyester strands was changed to 5 8 mm,
that the temperature of the cooling water was changed to
20°C, that the strands drawing rate was changed to 1.00
m/sec to change the drawing rate ratio to 1.0, that the
length of the particles in the drawing direction was
changed to 3.0 mm, and that the operation conditions were
changed as identified in Table 2. As a result, since
strands wound, in addition to cylindrical polyester
particles having a length of 3.0 mm and a cut surface
with a diameter of 3.0 mm, crushed particles, particles
cut at a slant, and irregular particles having a length
of 10 mm or longer were obtained. The amount of such
irregular particles formed was 10 wt%. Further, most of
the obtained particles had bubbles in their inside,
probably because the cooling water temperature was low
and the strands were thick. The operation conditions and
the results are shown in Table 2.
EXAMPLE 11
Formation of the polyester into particles was
carried out in the same manner as in Example 7 except
that the temperature of the second and third melt
polycondensation reaction tanks was changed to 275°C so
that the temperature of the molten polyester at the time .
of discharge became 275°C, that the die plate was changed

to one having 10 die holes, that the amount of the molten
polyester discharged was changed to 78 kg/hour, and that
the operation conditions were changed as identified in
Table 2. As a result, polyester particles having a
cylindroid shape substantially close to a shape having
semicircles imparted to both ends of a rectangular prism,
having a length of 1.0 mm and a cut surface with a major
axis and a minor axis of 1.0 mm and 0.7 mm, respectively,
were obtained. The average particle size of the
particles was 1.0 mm. The amount of irregular particles
which did not pass through a sieve with an opening of 2.8
mm, formed in the particles forming step, was 0.03 wt%.
The operation conditions and the results are shown in
Table 2.
EXAMPLE 12
The polyester particles obtained in Example 9 were
charged to an inert oven through which nitrogen flowed,
crystallized at a temperature of 180°C for 2 hours and
subsequently subjected to solid phase polycondensation at
23 0°C for 12 hours to obtain polyester particles having a
high molecular weight. The particles had a cylindroid
shape substantially close to a shape having semicircles
imparted to both ends of a quadrangular prism, having a
length of 0.9 mm and a cut surface with a major axis and
a minor axis of 1.3 mm and 0.9 mm, respectively, and had
an intrinsic viscosity of 0.866 dL/g.
COMPARATIVE EXAMPLE 4

Among polyester particles obtained in Comparative
Example 3, particles having a relatively good shape were
selected and charged to an inert oven through which
nitrogen flowed and crystallized at a temperature of
180°C for 2 hours. As a result, most of the particles
burst by the influence of the bubbles in their inside and
became irregular particles. The particles obtained in
Comparative Example 3 were particles unsuitable for solid
phase polycondensation.



INDUSTRIAL APPLICABILITY
The polyester particles obtained by the present
invention are suitable for solid phase polycondensation
at a high rate and are useful as a material of polyester
resin particles. Further, the polyester resin particles
obtained by the present invention are excellent in
mechanical properties, thermal properties, electrical
properties, etc. and are widely used for fibers and for
molded products such as films, sheets and bottles for
various applications.
The entire disclosure of Japanese Patent Application
No. 2005-128890 filed on April 27, 2005 including
specification, claims, drawings and summary is
incorporated herein by reference in its entirety.

WE CLAIM :
1. A process for producing polyester particles, characterized in that the following steps
(1) to (3) are sequentially carried out, and the drawing rate ratio of polyester strands
represented by the following formula is from 1.5 to 100:
(1) a step of discharging a molten polyester having a melt viscosity of from 0.5 Pa's
to 50 Pa-s from a die hole into strands,
(2) a step of bringing the obtained polyester strands into contact with a liquefied
fluid for cooling to lead the strands to a cutter together with the liquefied fluid, and
(3) a step of cutting the polyester strands led to the cutter:
drawing rate ratio = (linear velocity of strands immediately before cut (v2 (m/s)))/
(linear velocity of molten polyester when discharged from die hole (v1 (m/s))),
wherein the pore diameter of the die hole through which the molten polyester is
discharged into polyester strands is from 0.7 to 3.0 mm.
2. The process for producing polyester particles as claimed in claim 1, wherein the
liquefied fluid is water at a temperature of from 5 to 95°C.
3. The process for producing polyester particles as claimed in any one of claims 1 and
2, wherein the linear velocity (vl (m/s)) of the molten polyester when the molten polyester
is discharged from the die hole into strands is from 0.1 to 3 m/sec.
4. The process for producing polyester particles as claimed in any one of claims 1 to 3,
wherein the direction of discharge of the molten polyester when the molten polyester is
discharged from the die hole into strands, is within an angle formed by the horizontal
direction and a direction tilted downward 70° from the horizontal direction.

5. The process for producing polyester particles as claimed in any one of claims 1 to 4,
wherein when the polyester strands discharged from the die hole are brought into contact
with the liquefied fluid, the rectilinear distance between the outlet of the die hole and the
point of contact between the polyester strands and the liquefied fluid is from 10 to 500 mm.
6. The process for producing polyester particles as claimed in any one of claims 1 to 5,
wherein the average particle size of the polyester particles is from 0.5 to 2.0 mm.
7. The process for producing polyester particles according to any one of claims 1 to 6,
wherein the polyester particles have a substantially cylindroid shape.
8. The process for producing polyester particles as claimed in claim 7, wherein the
polyester particles have a substantially cylindroid shape having a length of from 0.5 to 2.5
mm and a cut surface with a major axis and a minor axis of from 0.5 to 2.5 mm and from 0.3
to 2 mm, respectively.
9. The process for producing polyester particles as claimed in any one of claims 1 to 8,
wherein as the molten polyester, a polyester in a molten state obtained by subjecting a
dicarboxylic acid and/or its ester-forming derivative and a diol to esterification reaction and/
or ester exchange reaction and further conducting melt polycondensation reaction, is used as
it is.
10. The process for producing polyester particles as claimed in any one of claims 1 to 9,
wherein the intrinsic viscosity of the polyester to be subjected to the step (1) is from 0.20 to
0.40 dL/g.

11. The process for producing polyester particles as claimed in any one of claims 1 to
10, wherein the polyester is a polyethylene terephthalate and/or a polybutylene
terephthalate.
12. A process for producing polyester resin particles, which comprises subjecting
polyester particles obtained by the process for producing polyester particles as claimed in
any one of claims 1 to 11 to solid phase polycondensation reaction.



ABSTRACT


PROCESS FOR PRODUCTION OF POLYESTER PARTICLES,
POLYESTER PARTICLES, POLYESTER RESIN PARTICLES,
AND PROCESS FOR PRODUCTION THEREOF
A process for producing polyester particles from a polyester with a low degree of
polymerization by a strand cutting method is disclosed. Polyester particles, a process for
producing polyester resin particles from the polyester particles by solid phase
polycondensation, and polyester resin particles are also disclosed. The process for producing
polyester particles involves the steps of:(1) to (3) are sequentially carried out, and the
drawing rate ratio of polyester strands represented by the following formula is from 1.5 to
100, polyester particles, a process for producing polyester resin particles which comprises
subjecting the particles to solid phase polycondensation, and polyester resin particles: (1) a
step of discharging a molten polyester having a melt viscosity of from 0.5 Pas to 50 Pa-s
from a die hole into strands, (2) a step of bringing the obtained polyester strands into contact
with a liquefied fluid for cooling to lead the strands to a cutter together with the liquefied
fluid, and (3) a step of cutting the polyester strands led to the cutter:
drawing rate ratio = (linear velocity of strands immediately before cut (v2 (m/s)))/
(linear velocity of molten polyester when discharged from die hole (v1 (m/s))).

Documents:

03751-kolnp-2007-abstract.pdf

03751-kolnp-2007-claims.pdf

03751-kolnp-2007-correspondence others.pdf

03751-kolnp-2007-description complete.pdf

03751-kolnp-2007-form 1.pdf

03751-kolnp-2007-form 3.pdf

03751-kolnp-2007-form 5.pdf

03751-kolnp-2007-international publication.pdf

03751-kolnp-2007-international search report.pdf

03751-kolnp-2007-pct priority document notification.pdf

03751-kolnp-2007-pct request form.pdf

3751-KOLNP-2007-(01-12-2011)-AMANDED CLAIMS.pdf

3751-KOLNP-2007-(01-12-2011)-AMANDED PAGES OF SPECIFICATION.pdf

3751-KOLNP-2007-(01-12-2011)-CORRESPONDENCE.pdf

3751-KOLNP-2007-(01-12-2011)-FORM-2.pdf

3751-KOLNP-2007-(01-12-2011)-OTHERS.pdf

3751-KOLNP-2007-(01-12-2011)-PA-CERTIFIED COPIES.pdf

3751-KOLNP-2007-(16-07-2013)-CORRESPONDENCE.pdf

3751-KOLNP-2007-(17-08-2012)-ASSIGNMENT.pdf

3751-KOLNP-2007-(17-08-2012)-CORRESPONDENCE.pdf

3751-KOLNP-2007-(17-08-2012)-FORM-1.pdf

3751-KOLNP-2007-(17-08-2012)-FORM-2.pdf

3751-KOLNP-2007-(17-08-2012)-FORM-3.pdf

3751-KOLNP-2007-(17-08-2012)-FORM-5.pdf

3751-KOLNP-2007-(17-08-2012)-FORM-6.pdf

3751-KOLNP-2007-(17-08-2012)-PA.pdf

3751-KOLNP-2007-(29-08-2012)-AMANDED CLAIMS.pdf

3751-KOLNP-2007-(29-08-2012)-EXAMINATION REPORT REPLY RECIEVED.PDF

3751-kolnp-2007-ASSIGNMENT-1.1.pdf

3751-KOLNP-2007-ASSIGNMENT.pdf

3751-kolnp-2007-CANCELLED PAGES.pdf

3751-KOLNP-2007-CORRESPONDENCE OTHERS-1.1.pdf

3751-kolnp-2007-CORRESPONDENCE-1.1.pdf

3751-KOLNP-2007-CORRESPONDENCE.pdf

3751-KOLNP-2007-examination report reply received.pdf

3751-kolnp-2007-EXAMINATION REPORT-1.1.pdf

3751-KOLNP-2007-EXAMINATION REPORT.pdf

3751-KOLNP-2007-FORM 18 1.1.pdf

3751-kolnp-2007-FORM 18-1.2.pdf

3751-kolnp-2007-form 18.pdf

3751-KOLNP-2007-FORM 3 1.2.pdf

3751-KOLNP-2007-FORM 3-1.1.pdf

3751-KOLNP-2007-FORM 3.1.pdf

3751-KOLNP-2007-FORM 5.pdf

3751-kolnp-2007-FORM 6.pdf

3751-kolnp-2007-GPA-1.1.pdf

3751-KOLNP-2007-GPA.pdf

3751-kolnp-2007-GRANTED-ABSTRACT.pdf

3751-kolnp-2007-GRANTED-CLAIMS.pdf

3751-kolnp-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

3751-kolnp-2007-GRANTED-FORM 1.pdf

3751-kolnp-2007-GRANTED-FORM 2.pdf

3751-kolnp-2007-GRANTED-FORM 3.pdf

3751-kolnp-2007-GRANTED-FORM 5.pdf

3751-kolnp-2007-GRANTED-SPECIFICATION-COMPLETE.pdf

3751-kolnp-2007-INTERNATIONAL PUBLICATION-1.1.pdf

3751-KOLNP-2007-INTERNATIONAL PUBLICATION.pdf

3751-kolnp-2007-INTERNATIONAL SEARCH REPORT & OTHERS.pdf

3751-KOLNP-2007-INTERNATIONAL SEARCH REPORT.pdf

3751-KOLNP-2007-OTHERS PCT FORM.pdf

3751-kolnp-2007-OTHERS-1.1.pdf

3751-KOLNP-2007-OTHERS.pdf

3751-KOLNP-2007-PCT REQUEST FORM.pdf

3751-kolnp-2007-REPLY TO EXAMINATION REPORT-1.1.pdf

3751-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf

3751-KOLNP-2007-TRANSLATED COPY OF PRIORITY DOCUMENT.pdf


Patent Number 260296
Indian Patent Application Number 3751/KOLNP/2007
PG Journal Number 17/2014
Publication Date 25-Apr-2014
Grant Date 21-Apr-2014
Date of Filing 03-Oct-2007
Name of Patentee BUHLER AG
Applicant Address GUPFENSTRASSE 5,9240 UZWIL
Inventors:
# Inventor's Name Inventor's Address
1 KIMURA HISASHI C/O MITSUBISHI CHEMICAL CORPORATION, 1, TOHO-CHO,, YOKKAICHI-SHI, MIE 5108530
PCT International Classification Number B29B 9/06,B29B 11/02
PCT International Application Number PCT/JP2006/308868
PCT International Filing date 2006-04-27
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2005-128890 2005-04-27 Japan