JP6901216B2 - 吸水性樹脂粒子及びその製造方法 - Google Patents
吸水性樹脂粒子及びその製造方法 Download PDFInfo
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- JP6901216B2 JP6901216B2 JP2017543628A JP2017543628A JP6901216B2 JP 6901216 B2 JP6901216 B2 JP 6901216B2 JP 2017543628 A JP2017543628 A JP 2017543628A JP 2017543628 A JP2017543628 A JP 2017543628A JP 6901216 B2 JP6901216 B2 JP 6901216B2
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- water
- vinyl monomer
- organic
- absorbent resin
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- 239000011347 resin Substances 0.000 title claims description 90
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- 238000004519 manufacturing process Methods 0.000 title claims description 33
- 239000000178 monomer Substances 0.000 claims description 98
- 229920002554 vinyl polymer Polymers 0.000 claims description 81
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 76
- 125000004432 carbon atom Chemical group C* 0.000 claims description 40
- 239000003431 cross linking reagent Substances 0.000 claims description 33
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- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims description 9
- 229910052787 antimony Inorganic materials 0.000 claims description 8
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 claims description 8
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 7
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- QEAHGOUBRPCBNV-UHFFFAOYSA-N diethyl 2,5-diiodohexanedioate Chemical compound CCOC(=O)C(I)CCC(I)C(=O)OCC QEAHGOUBRPCBNV-UHFFFAOYSA-N 0.000 description 4
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- 235000019345 sodium thiosulphate Nutrition 0.000 description 1
- PDEFQWNXOUGDJR-UHFFFAOYSA-M sodium;2,2-dichloropropanoate Chemical compound [Na+].CC(Cl)(Cl)C([O-])=O PDEFQWNXOUGDJR-UHFFFAOYSA-M 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 150000003440 styrenes Chemical class 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 125000001273 sulfonato group Chemical group [O-]S(*)(=O)=O 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- XSOKHXFFCGXDJZ-UHFFFAOYSA-N telluride(2-) Chemical compound [Te-2] XSOKHXFFCGXDJZ-UHFFFAOYSA-N 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- LENZDBCJOHFCAS-UHFFFAOYSA-N tris Chemical compound OCC(N)(CO)CO LENZDBCJOHFCAS-UHFFFAOYSA-N 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 238000001291 vacuum drying Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
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Description
すなわち、本発明は、水溶性ビニルモノマー(a1)及び/又は加水分解により水溶性ビニルモノマー(a1)となるビニルモノマー(a2)並びに架橋剤(b)を含む単量体組成物を、有機ヨウ素化合物、有機テルル化合物、有機アンチモン化合物及び有機ビスマス化合物からなる群から選ばれる少なくとも1種の有機典型元素化合物の存在下に、重合する工程を有することを特徴とする吸水性樹脂粒子の製造方法;水溶性ビニルモノマー(a1)及び/又は加水分解により水溶性ビニルモノマー(a1)となるビニルモノマー(a2)並びに架橋剤(b)を必須構成単位とする架橋重合体(A)を含む吸水性樹脂粒子であって、ヨウ素、テルル、アンチモン及びビスマスからなる群から選ばれる少なくとも1種の典型元素を、吸水性樹脂粒子の重量を基準として、0.0005〜0.1重量%含有することを特徴とする吸水性樹脂粒子である。
(i)炭素数8〜30の芳香族エチレン性モノマー
スチレン、α−メチルスチレン、ビニルトルエン及びヒドロキシスチレン等のスチレン、並びにビニルナフタレン及びジクロルスチレン等のスチレンのハロゲン置換体等。
(ii)炭素数2〜20の脂肪族エチレン性モノマー
アルケン(エチレン、プロピレン、ブテン、イソブチレン、ペンテン、ヘプテン、ジイソブチレン、オクテン、ドデセン及びオクタデセン等);並びにアルカジエン(ブタジエン及びイソプレン等)等。
(iii)炭素数5〜15の脂環式エチレン性モノマー
モノエチレン性不飽和モノマー(ピネン、リモネン及びインデン等);並びにポリエチレン性ビニルモノマー[シクロペンタジエン、ビシクロペンタジエン及びエチリデンノルボルネン等]等。
これら有機典型元素化合物は単独で使用してもよく、2種以上を併用してもよい。
本明細書中、非付加重合性二重結合(以下、単に非重合性二重結合ともいう)及び非付加重合性三重結合(以下、単に非重合性三重結合ともいう)とは、不飽和結合のうち、付加重合性不飽和結合(それぞれ、付加重合性炭素−炭素二重結合及び付加重合性炭素−炭素三重結合)を除いた結合であり、非付加重合性二重結合及び非付加重合性三重結合としては、カルボニル基に含まれる炭素−酸素二重結合、ニトリル基に含まれる炭素−窒素三重結合、芳香族炭化水素を構成する炭素−炭素二重結合及び複素芳香族化合物を構成する酸素−窒素二重結合並びに炭素−窒素二重結合等が挙げられ、なかでもカルボニル基に含まれる炭素−酸素二重結合、ニトリル基に含まれる炭素−窒素三重結合及び芳香族炭化水素を構成する炭素−炭素二重結合が好ましい。
また、塩としては、アルカリ金属(リチウム、ナトリウム及びカリウム等)塩、アルカリ土類金属(マグネシウム及びカルシウム等)塩及びアンモニウム(NH4)塩等が挙げられる。これらの塩の内、吸収性能等の観点から、アルカリ金属塩及びアンモニウム塩が好ましく、更に好ましいのはアルカリ金属塩、特に好ましいのはナトリウム塩である。
R3で表される炭素数1〜7のn価の飽和炭化水素基のうち、炭素数1〜7の2価の飽和炭化水素基としては、炭素数1〜7の2価の直鎖飽和炭化水素基(メチレン基、エチレン基、プロピレン基、ブチレン基、ペンテン基、ヘキセン基、ヘプテン基等)及び炭素数1〜7の2価の分岐飽和炭化水素基(イソプロピレン基、イソブチレン基、s−ブチレン基、t−ブチレン基、イソペンチレン基、ネオペンチレン基、t−ペンチレン基、1−メチルブチレン基、イソヘキシレン基、s−ヘキシレン基、t−ヘキシレン基、ネオヘキシレン基、イソヘプチレン基等)が挙げられる。
R3で表される炭素数1〜7のn価の飽和炭化水素基のうち、炭素数1〜7の3価の飽和炭化水素基としては、メチン基等が挙げられる。
R3で表される炭素数1〜7のn価の飽和炭化水素基のうち、メチル基、メチレン基、メチン基が好ましく、更に好ましくはメチル基、メチレン基である。
R3が少なくとも1つの非重合性二重結合又は少なくとも1つの非重合性三重結合を有する炭素数2〜12である2価の基である場合、好ましい基としては、ベンゼンジイル基(炭素数6、非重合性炭素−炭素二重結合)、1−メトキシカルボニル−カルボニルオキシエチレンオキシカルボニル基(炭素数6、酸素−酸素二重結合)及びカルボニルオキシエチレンカルボニル基(炭素数4、酸素−酸素二重結合)等が挙げられる。
R3が少なくとも1つの非重合性二重結合又は少なくとも1つの非重合性三重結合を有する炭素数2〜12である3価の基である場合、好ましいものとしては、ベンゼントリイル基(炭素数6、非重合性炭素−炭素二重結合)及び2−カルボニルオキシ−カルボニルオキシプロピレンカルボニル基(炭素数5、酸素−酸素二重結合)等が挙げられる。
水溶液重合を行う場合、有機溶媒の使用量(重量%)は、水の重量を基準として40以下が好ましく、更に好ましくは30以下である。
アルカリは、公知{特許第3205168号公報等}のものが使用できる。これらのうち、吸水性能の観点から、水酸化リチウム、水酸化ナトリウム及び水酸化カリウムが好ましく、さらに好ましくは水酸化ナトリウム及び水酸化カリウム、特に好ましくは水酸化ナトリウムである。中和率は、通液性の観点から、50〜100%が好ましく、更に好ましくは、60〜80%である。
溶媒の使用量は、溶媒の種類により適宜調整できるが、表面架橋前の吸水性樹脂の重量に基づいて、好ましくは1〜10重量%である。また、水に対する溶媒の比率についても任意に調整することができるが、好ましくは重量基準で20〜80重量%、更に好ましくは30〜70重量%である。
他の材料としては繊維状物等が挙げられる。繊維状物と共に用いた場合の吸収体の構造及び製造方法等は、公知のもの(特開2003−225565号公報、特開2006−131767号公報及び特開2005−097569号公報等)と同様である。
吸水性樹脂5gをCMT社製高速振動試料粉砕機を用いて粉砕後、島津社製Briquest Press MP−35を用い、Briquestting Ring(塩化ビニル製、35mm径、5mm厚)にプレスしペレットを作成し、全自動波長分散型蛍光X線分析装置(装置名:Axiosメーカー名:PANalytical社製)を、X線励起条件:電圧50kV,電流40mA、測定室雰囲気:真空とし、定量分析ソフトUniquantを使用した半定量分析法を用いることで原子濃度を決定した。
100mlのビーカーに吸水性樹脂1.000gを入れ、生理食塩水(NaCl濃度0.90%のイオン交換水溶液)を30.00g加え、ビーカーを軽く振り吸水性樹脂が平らになるよう、30分静置することで30倍膨潤の測定試料を作成した。カードメーター(アイテクノエンジニアリング製,品名:カードメーター マックスME−500型)を上昇速度1インチ/7秒、感圧軸8φ、荷重100gの条件で測定し、測定曲線が45度対角線から下がり始める点の破断力を読み取り、3回測定した平均値をゲル強度とした。
目開き63μm(JIS Z8801−1:2006)のナイロン網で作製したティーバッグ(縦20cm、横10cm)に測定試料1.00gを入れ、生理食塩水(食塩濃度0.9%)1,000ml中に無撹拌下、1時間浸漬した後引き上げて、15分間吊るして水切りした。その後、ティーバッグごと、遠心分離器にいれ、150Gで90秒間遠心脱水して余剰の生理食塩水を取り除き、ティーバックを含めた重量(h1)を測定し次式から保水量を求めた。(h2)は、測定試料の無い場合について上記と同様の操作により計測したティーバックの重量である。なお、使用した生理食塩水及び測定雰囲気の温度は25℃±2℃であった。
保水量(g/g)=(h1)−(h2)
目開き63μm(JIS Z8801−1:2006)のナイロン網を底面に貼った円筒型プラスチックチューブ(内径:25mm、高さ:34mm)内に、30メッシュふるいと60メッシュふるいを用いて250〜500μmの範囲にふるい分けした測定試料0.16gを秤量し、円筒型プラスチックチューブを垂直にしてナイロン網上に測定試料がほぼ均一厚さになるように整えた後、この測定試料の上に分銅(重量:310.6g、外径:24.5mm、)を乗せた。この円筒型プラスチックチューブ全体の重量(M1)を計量した後、生理食塩水(食塩濃度0.9%)60mlの入ったシャーレ(直径:12cm)の中に測定試料及び分銅の入った円筒型プラスチックチューブを垂直に立ててナイロン網側を下面にして浸し、60分静置した。60分後に、円筒型プラスチックチューブをシャーレから引き上げ、これを斜めに傾けて底部に付着した水を一箇所に集めて水滴として垂らすことで余分な水を除去した後、測定試料及び分銅の入った円筒型プラスチックチューブ全体の重量(M2)を計量し、次式から加圧下吸収量を求めた。なお、使用した生理食塩水及び測定雰囲気の温度は25℃±2℃であった。
荷重下吸収量(g/g)={(M2)−(M1)}/0.16
図1及び図2で示される器具を用いて以下の操作により測定した。
測定試料0.32gを150ml生理食塩水1(食塩濃度0.9%)に30分間浸漬して膨潤ゲル粒子2を調製する。そして、垂直に立てた円筒3{直径(内径)25.4mm、長さ40cm、底部から60mlの位置及び40mlの位置にそれぞれ目盛り線4及び目盛り線5が設けてある。}の底部に、金網6(目開き106μm、JIS Z8801−1:2006)と、開閉自在のコック7(通液部の内径5mm)とを有する濾過円筒管内に、コック7を閉鎖した状態で、調製した膨潤ゲル粒子2を生理食塩水と共に移した後、この膨潤ゲル粒子2の上に円形金網8(目開き150μm、直径25mm)が金網面に対して垂直に結合する加圧軸9(重さ22g、長さ47cm)を金網と膨潤ゲル粒子とが接触するように載せ、更に加圧軸9におもり10(88.5g)を載せ、1分間静置する。引き続き、コック7を開き、濾過円筒管内の液面が60ml目盛り線4から40ml目盛り線5になるのに要する時間(T1;秒)を計測し、次式よりゲル通液速度(ml/min)を求める。
ゲル通液速度(ml/min)=20ml×60/(T1−T2)
なお、使用する生理食塩水及び測定雰囲気の温度は25℃±2℃で行い、T2は測定試料の無い場合について上記と同様の操作により計測した時間である。
アクリル酸270部、架橋剤としてのペンタエリスリトールトリアリルエーテル(ダイソー製)0.88部、2−ヨード−2−メチルプロピオニトリル(TCI製)0.041部及びイオン交換水712部を混合してモノマー水溶液を調製し、この混合液を断熱重合可能な重合槽に投入した。溶液中に窒素ガスを導入することにより、溶液中の溶存酸素量を0.2ppm以下とし、溶液温度を5℃とした。この重合溶液に、1%過酸化水素水溶液1.1部、2%アスコルビン酸水溶液2.0部及び2%の2,2’−アゾビスアミジノプロパンジハイドロクロライド水溶液13.5部を添加・混合した。重合開始を示す温度上昇が確認されてから約1時間後に80℃でほぼ平衡に達し、更に5時間熟成して含水ゲル状重合体を得た。
この含水ゲル状重合体を、ミートチョッパーを用いて小片に砕断しながら、49%のNaOH水溶液221部を添加し、重合体中のカルボキシル基の約72モル%をナトリウム塩とした。この中和された含水ゲルを、通気熱風乾燥機(井上金属製)を用い、供給風温150℃、風速1.5m/秒の条件下で含水率が4%となるまで通気乾燥した。乾燥体をジューサーミキサー(Oster社製OSTERIZER BLENDER)にて粉砕した後、ふるい分けして、目開き710〜150μmの粒子径範囲に調整して、吸水性樹脂(A1−1)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルの量を0.041部から0.0054部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−2)を得た。平衡時の到達温度は80℃であった。
実施例1において、ペンタエリスリトールトリアリルエーテルの量を0.88部から1.2部に変更し、2−ヨード−2−メチルプロピオニトリルの量を0.041部から0.22部に変更したこと以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−3)を得た。
2,5−ジブロモアジピン酸ジエチル(TCI製)7.2gとよう化ナトリウム(和光純薬製)6.6gをアセトン60mLに溶解し室温で3時間撹拌した。ロータリーエバポレーターでアセトンを除去し、ジエチルエーテルに溶解し、チオ硫酸ナトリウム水溶液で分液洗浄し、ロータリーエバポレーターで溶剤を除去したのち減圧乾燥することで、2,5−ジヨードアジピン酸ジエチルを得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルを2,5−ジヨードアジピン酸ジエチル0.041部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−4)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルをエチル−2−メチル−2−メチルテラニル−プロピネート(WO2004/014848記載の方法により合成)0.041部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−5)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルをエチル−2−メチル−2−ジメチルスチバニル−プロピネート(WO2006/001496記載の方法により合成)0.041部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−6)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルをメチル−2−メチル−2−ジメチルビスタムニル−プロピネート(WO2006/062255記載の方法により合成)0.041部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−7)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルの量を0.015部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−8)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルの量を0.09部に、1%過酸化水素水溶液を0.5部に変更する以外は、実施例1と同様の操作を行い、吸水性樹脂(A1−9)を得た。
吸水性樹脂(A1−1)100部を攪拌(ホソカワミクロン製高速攪拌タービュライザー:回転数2000rpm)しながら、エチレングリコールジグリシジルエーテル0.12部、水1.9部及びプロピレングリコール1.2部及びKlebosol30CAL25(メルク社製)1.0部からなる溶液を添加して混合し、140℃で45分加熱して表面架橋を行い、吸水性樹脂(A2−1)を得た。
吸水性樹脂(A1−1)に代えて、吸水性樹脂(A1−2)〜(A1−9)を使用する以外は実施例10と同様にして、吸水性樹脂(A2−2)〜(A2−9)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルを用いない以外は、実施例1と同様の操作を行い、比較用の吸水性樹脂(R1−1)を得た。
実施例1において、2−ヨード−2−メチルプロピオニトリルの代わりに次亜リン酸ナトリウム(和光純薬製)を0.22部に変更した以外は、実施例1と同様の操作を行い、比較用の吸水性樹脂(R1−2)を得た。
吸水性樹脂(A1−1)に代えて比較用の吸水性樹脂(R1−1)を使用する以外は実施例10と同様にして、比較用の吸水性樹脂(R2−1)を得た。
吸水性樹脂(A1−2)に代えて比較用の吸水性樹脂(R1−1)を使用する以外は実施例1110と同様にして、比較用の吸水性樹脂(R2−2)を得た。
また、得られた吸水性樹脂(A2−1)〜(A2−9)及び比較用の吸水性樹脂(R2−1)〜(R2−2)の保水量、荷重下吸収量、ゲル通液速度の評価結果を表2に示した。
2 含水ゲル粒子
3 円筒
4 底部から60mlの位置の目盛り線
5 底部から40mlの位置の目盛り線
6 金網
7 コック
8 円形金網
9 加圧軸
10 おもり
Claims (4)
- 水溶性ビニルモノマー(a1)及び/又は加水分解により水溶性ビニルモノマー(a1)となるビニルモノマー(a2)並びに架橋剤(b)を含む単量体組成物を、ヨウ素原子が結合する炭素が3級炭素原子である有機ヨウ素化合物、有機アンチモン化合物及び有機ビスマス化合物からなる群から選ばれる少なくとも1種の有機典型元素化合物の存在下に、重合する工程、を有し、前記単量体組成物は、アクリル酸、メタアクリル酸、アクリル酸塩及びメタアクリル酸塩のうち少なくとも1種を水溶性ビニルモノマー(a1)として、水溶性ビニルモノマー(a1)及びビニルモノマー(a2)の合計モルに対して少なくとも75モル%含有するとともに、前記水溶性ビニルモノマー(a1)及び前記ビニルモノマー(a2)の他に、これらと共重合可能なその他のビニルモノマー(a3)を、前記水溶性ビニルモノマー(a1)及び前記ビニルモノマー(a2)の合計モル数に基づいて、0〜5モル%含有することを特徴とする吸水性樹脂粒子の製造方法。
- 有機典型元素化合物が下記一般式(1)で表される請求項1に記載の吸水性樹脂粒子の製造方法。
- 有機ヨウ素化合物、有機アンチモン化合物及び有機ビスマス化合物からなる群から選ばれる少なくとも1種の有機典型元素化合物の重量が、水溶性ビニルモノマー(a1)及び加水分解により水溶性ビニルモノマー(a1)となるビニルモノマー(a2)の合計重量に対し、0.0005〜0.1重量%である請求項1又は2のいずれかに記載の吸水性樹脂粒子の製造方法。
- 架橋重合体(A)を表面架橋する工程を有する請求項1〜3のいずれかに記載の吸水性樹脂粒子の製造方法。
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