JP2005097604A - 粒子状吸水性樹脂組成物の製造方法 - Google Patents
粒子状吸水性樹脂組成物の製造方法 Download PDFInfo
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- JP2005097604A JP2005097604A JP2004256221A JP2004256221A JP2005097604A JP 2005097604 A JP2005097604 A JP 2005097604A JP 2004256221 A JP2004256221 A JP 2004256221A JP 2004256221 A JP2004256221 A JP 2004256221A JP 2005097604 A JP2005097604 A JP 2005097604A
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- Prior art keywords
- water
- absorbent resin
- resin particles
- resin composition
- absorbing resin
- Prior art date
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- 150000002736 metal compounds Chemical class 0.000 description 1
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- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
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- 229960003339 sodium phosphate Drugs 0.000 description 1
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- 229910001220 stainless steel Inorganic materials 0.000 description 1
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- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- 239000005720 sucrose Substances 0.000 description 1
- 125000002153 sulfur containing inorganic group Chemical group 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
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- 230000032258 transport Effects 0.000 description 1
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 1
- YFHICDDUDORKJB-UHFFFAOYSA-N trimethylene carbonate Chemical compound O=C1OCCCO1 YFHICDDUDORKJB-UHFFFAOYSA-N 0.000 description 1
- XHGIFBQQEGRTPB-UHFFFAOYSA-N tris(prop-2-enyl) phosphate Chemical compound C=CCOP(=O)(OCC=C)OCC=C XHGIFBQQEGRTPB-UHFFFAOYSA-N 0.000 description 1
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 1
- ZTWTYVWXUKTLCP-UHFFFAOYSA-N vinylphosphonic acid Chemical compound OP(O)(=O)C=C ZTWTYVWXUKTLCP-UHFFFAOYSA-N 0.000 description 1
- NLVXSWCKKBEXTG-UHFFFAOYSA-N vinylsulfonic acid Chemical compound OS(=O)(=O)C=C NLVXSWCKKBEXTG-UHFFFAOYSA-N 0.000 description 1
- 239000012855 volatile organic compound Substances 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 230000029663 wound healing Effects 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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Abstract
【解決手段】 吸水性樹脂粒子の表面を、架橋剤を用いて架橋して表面処理を行い、その後、吸水性樹脂粒子に種々の機能を付与するための添加物を添加し、凝集物を含む吸水性樹脂粒子を整粒する工程を行う間に、吸水性樹脂粒子と添加物とを混合する工程を行う。
【選択図】 図1
Description
本発明に係る吸水性樹脂粒子は、水膨潤性・水不溶性架橋重合体のことであり、例えば、その前駆体である含水ゲル架橋重合体を解砕することにより製造される。上記含水ゲル架橋重合体は、エチレン性不飽和単量体を微量の架橋剤の存在下で水溶液重合ないし逆相懸濁重合、好ましくは水溶液重合して得ることができる。水膨潤性とは吸水倍率(実施例で規定のCRC)が5g/g以上であることをいう。水不溶性とは吸水性樹脂粒子中の水への可溶性重合体(米国再発行特許RE32649号で規定)が0〜40重量%以下、さらには25重量%以下、特に15重量%以下であることをいう。
上記の方法によって得られた吸水性樹脂粒子は、その表面をさらに表面架橋剤によって二次架橋することで、吸水性樹脂粒子の表面近傍(例えば、粒子表層の厚みの10%以下、特に1%以下)の架橋密度を高めることができる。本発明の方法で得られた吸水性樹脂粒子は、表面架橋剤を用いて処理されることにより、該吸水性樹脂粒子の通液性、吸水速度、加圧下の吸水倍率、及び通液性が一層向上する。
以上のようにして本発明に係る吸水性樹脂粒子が製造される。なお、吸水性樹脂粒子の表面処理を、上記親水性溶媒を用いた方法により行う場合には、表面処理時や表面処理後に加熱して親水性溶媒を蒸発させることが一般的である。これにより吸水性樹脂粒子を乾燥させることができる。ところが、親水性溶媒を蒸発させる際、特に水が蒸発する際には、吸水性樹脂粒子同士が凝集してしまうことがある。これは、蒸発する際に表面に移行した水が吸水性樹脂粒子の可塑剤として作用し、その結果吸水性樹脂粒子同士が凝集し易くなるためと推察される。これら凝集は、脱水反応性架橋剤、特に多価アルコールを使用する場合、および、溶媒として水を主成分に使用する場合に顕著に起こる。本発明はかかる場合、特に表面架橋に多価アルコール水溶液を使用する場合に好適に適用される。
本発明の粒子状吸水性樹脂組成物の製造方法は、表面処理後の吸水性樹脂粒子を整粒、好ましくはさらに一定以上の凝集物(表面架橋での凝集物)を整粒する整粒工程(B)を行う間に、吸水性樹脂粒子に種々の機能を付与するための添加物を添加し、該添加物と吸水性樹脂粒子とを均一に混合させる混合工程(D)を行うものである。これにより、物性を低下させることなく機能が付与された粒子状吸水性樹脂組成物を得ることができる。
上記添加物としては、吸水性樹脂粒子に種々の機能を付与することができるものであって、常温で粉末状のものであることが好ましく、無機粉末、有機粉末、または他の吸水性樹脂粒子等を用いることができる。ただし、添加物として液体の化合物を用いることもできる。また、添加物の溶液ないし分散液を添加してもよく、気体状態で添加してもよい。なお、添加物の水溶性または水不溶性は適宜選択される。
粒子状吸水性樹脂組成物(または吸水性樹脂粒子)0.200g(Wp1)を不織布製の袋(60mm×60mm;材質はEDNA(EUROPEAN DISPOSABLES AND NONWOVENS ASSOCIATION)に準じる)に均一に入れ、ヒートシールした後、23℃の生理食塩水(組成:塩化ナトリウム0.9重量%の水溶液)中に浸漬した。60分後に袋を引き上げ、遠心分離機を用いて250Gで3分間水切りを行った後、袋の重量Wa(g)を測定した。また、同様の操作を粒子状吸水性樹脂組成物を用いないで行い、そのときの袋の重量Wb(g)を測定した。そして、これら重量Wa・Wbから、次式、
無加圧下吸収倍率(g/g)
={(重量Wa(g)−重量Wb(g)−粒子状吸水性樹脂組成物の重量Wp1(g)/粒子状吸水性樹脂組成物の重量Wp1(g))−1
に従って粒子状吸水性樹脂組成物の無加圧下吸収倍率(g/g)を算出した。
まず、粒子状吸水性樹脂組成物(または吸水性樹脂粒子)の加圧下吸収倍率の測定に用いる測定装置について、図2を参照しながら、以下に簡潔に説明する。
加圧下吸収倍率(g/g)
=重量Wc(g)/粒子状吸水性樹脂組成物の重量Wp2(g)
に従って、吸収開始から60分後の加圧下吸収倍率(g/g)を算出した。
0.69質量%生理食塩水流れ誘導性(SFC)は、吸水剤の膨潤時の液透過性を示す値である。SFCの値が大きいほど高い液透過性を有することを示している。本実施例においては、米国特許出願公開US2004-0106745-Aに記載の生理食塩水流れ誘導性(SFC)試験に準じて行った。
2本のシグマ型ブレードを備えたニーダー中、アクリル酸ナトリウム、アクリル酸および水からなるモノマーの濃度が38重量%、中和率が75mol%のモノマー水溶液を調製した。このモノマー水溶液に、内部架橋剤として、ポリエチレングリコールジアクリレート(平均エチレングリコールユニット数:9)を0.03mol%(対モノマー)となるように溶解させた。
実施例1において、冷却後の凝集物を含む吸水性樹脂粒子(ii)を図3に示す整粒機に導入し、吸水性樹脂粒子(ii)の凝集物を整粒した。次いで、850μmの篩いで分級した。篩いを通過しない未通過物は再度整粒機にて整粒した。850μmの篩いを通過した吸水性樹脂粒子(ii)100重量部に対して、実施例1にて用いたシリカ微粒子0.5重量部を複数のパドルを有する高速パドル型攪拌機にて繰り返し連続混合し(回転数1000rpm)、比較粒子状吸水性樹脂組成物(a)を得た。
実施例1において、表面架橋された吸水性樹脂粒子(ii)に添加物シリカ微粒子を加えることなく整粒して、添加物なし比較粒子状吸水性樹脂組成物(b)を得た。比較粒子状吸水性樹脂組成物(b)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は22(g/g)、SFCは2(×10-7cm3s/g)であり、ブロッキング率は90重量%であった。
比較例1において、表面架橋された吸水性樹脂粒子(ii)を整粒することなく添加物シリカ微粒子0.5重量部を加え、比較粒子状吸水性樹脂組成物(c)を得た。得られた比較粒子状吸水性樹脂組成物(c)には、重量平均粒子径が850μm以上の粒子が含まれており異物感があった。
実施例1において、シリカ微粒子に代えてキレート剤であるジエチレンペンタアミン五酢酸の粉末(平均粒径80μm)0.01重量部を混合した他は、実施例1と同様にして本発明の粒子状吸水性樹脂組成物(2)を得た。得られた粒子状吸水性樹脂組成物(2)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は24(g/g)であった。
実施例1において、シリカ微粒子に代えて活性炭の粉末(平均粒径100μm)0.5重量部を混合した他は、実施例1と同様にして本発明の粒子状吸水性樹脂組成物(3)を得た。得られた粒子状吸水性樹脂組成物(3)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は24(g/g)であった。
実施例1において、シリカ微粒子に代えて硫酸アルミ14−18水和物の粉末(平均粒径300μm)0.8重量部を混合した他は、実施例1と同様にして本発明の粒子状吸水性樹脂組成物(4)を得た。得られた粒子状吸水性樹脂組成物(4)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は24(g/g)であった。
実施例1において、シリカ微粒子に代えてセルロースパウダー(商品名:KCフロック、日本製紙株式会社製)1重量部を混合した他は、実施例1と同様にして本発明の粒子状吸水性樹脂組成物(5)を得た。得られた粒子状吸水性樹脂組成物(5)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は24(g/g)であった。
実施例1において、シリカ微粒子に代えてステアリン酸カルシウム(金属石鹸)0.1重量部を混合した他は、実施例1と同様にして本発明の粒子状吸水性樹脂組成物(6)を得た。得られた粒子状吸水性樹脂組成物(6)の無加圧下吸収倍率は36(g/g)、加圧下吸収倍率は22(g/g)であり、ブロッキング率は0重量%であった。
実施例1において、内部架橋剤の使用量を0.10モル%とする以外は実施例1と同様に重合、粉砕および分級を行い吸水性樹脂粒子(iii)を得た。さらに、吸水性樹脂粒子(iii)100重量部を、エチレングリコールジグリシジルエーテル:プロピレングリコール:水=0.03:0.5:2.7からなる表面架橋剤3.23重合部にて表面処理を行って、吸水性樹脂粒子(iv)を得た。表面架橋前の吸水性樹脂粒子(iii)は、上記と同様に重量平均粒子径が850μm以上の粒子は実質ゼロ(0重量%)であったが、冷却後の吸水性樹脂粒子(iv)は、重量平均粒子径が850μmよりも大きい凝集物が約20重量%含まれていた。
実施例1において、得られた粒子状吸水性樹脂組成物(1)をバッチ式の攪拌混合機でさらに20分攪拌して、より均一にシリカ微粒子を混合した粒子状吸水性樹脂組成物(8)を得た。さらに、20分の攪拌工程を追加して均一混合した粒子状吸水性樹脂組成物(8)のCRC/AAPは、粒子状吸水性樹脂組成物(1)のCRC/AAPと同程度であった。しかし、粒子状吸水性樹脂組成物(8)のSFCやブロッキング率は、粒子状吸水性樹脂組成物(1)のSFCやブロッキング率よりも低下し、SFCは12(×10-7cm3s/g)であり、ブロッキング率は10重量%であった。
実施例7において、得られた粒子状吸水性樹脂組成物(7)をバッチ式の攪拌混合機でさらに20分攪拌して、より均一にシリカ凝集微粒子を混合した粒子状吸水性樹脂組成物(9)を得た。さらに、20分の攪拌工程を追加して均一混合した粒子状吸水性樹脂組成物(9)のCRC/AAPは、粒子状吸水性樹脂組成物(7)のCRC/AAPと同程度であった。しかし、粒子状吸水性樹脂組成物(9)のSFCやブロッキング率は、粒子状吸水性樹脂組成物(7)のSFCやブロッキング率よりも低下し、SFCは110(×10-7cm3s/g)であり、ブロッキング率は10重量%であった。
表面架橋されさらに整粒(整粒時間5秒)された吸水性樹脂粒子に対して、さらに無機微粒子(凝集したシリカ微粒子/アエロジル200)を0.5重量%添加して回転攪拌混合したところ、CRCおよびAAPは混合時間によらず実質一定(±0.5g/gの誤差範囲)であったものの、SFCおよびブロッキング率は時間と共に低下することが見出された。SFCは、0.2分で220、1分で190、3分で160、10分で150、30分(比較例4に相当)で110であった。また、ブロッキング率は1重量%(0.2分混合)が、30重量%(30分混合)に低下していた。従来の常識では長時間混合(通常、数10分〜数時間)で均一に添加物が混合され、高物性の粒子状吸水性樹脂組成物が得られると考えられていたが、混合工程(D)および整粒工程(B)を短時間に制御することで、物性(特に無機粉体による通液性や耐ブロッキング性)が向上することが見出された。
Claims (10)
- 吸水性樹脂粒子の表面を、架橋剤を用いて架橋して表面処理する表面処理工程(A)と、表面処理された吸水性樹脂粒子を整粒する整粒工程(B)と、表面処理された吸水性樹脂粒子に添加物を添加する添加工程(C)と、添加物と表面処理された吸水性樹脂粒子とを混合する混合工程(D)とを含む粒子状吸水性樹脂組成物の製造方法であって、
上記整粒工程(B)を行う間に混合工程(D)を行うことを特徴とする粒子状吸水性樹脂組成物の製造方法。 - 吸水性樹脂粒子の表面を、架橋剤を用いて架橋して表面処理する表面処理工程(A)と、表面処理された吸水性樹脂粒子を整粒する整粒工程(B)と、表面処理された吸水性樹脂粒子に添加物を添加する添加工程(C)と、添加物と表面処理された吸水性樹脂粒子とを混合する混合工程(D)とを含む粒子状吸水性樹脂組成物の製造方法であって、
上記整粒工程(B)および混合工程(D)の合計時間が10分以内であることを特徴とする粒子状吸水性樹脂組成物の製造方法。 - 上記表面処理された吸水性樹脂粒子が凝集物または重量平均粒子径が850μm以上の粗大粒子を含むことを特徴とする請求項1または2に記載の粒子状吸水性樹脂組成物の製造方法。
- 上記整粒工程(B)の後に、整粒された吸水性樹脂粒子と整粒されていない吸水性樹脂粒子とに分級する分級工程(E)をさらに含むことを特徴とする請求項1ないし3のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 上記整粒工程(B)の後に、整粒されていない吸水性樹脂粒子を再度整粒することを特徴とする請求項1ないし4のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 上記整粒工程(B)を行う前、または整粒工程(B)を行う間に添加工程(C)を行うことを特徴とする請求項1ないし5のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 上記添加物が無機粉体であることを特徴とする請求項1ないし6のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 粒子状吸水性樹脂組成物の加圧下吸収倍率(AAP)が10g/g以上、または、生理食塩水流れ誘導性(SFC)が10(×10-7cm3s/g)以上であることを特徴とする請求項1ないし7のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 上記架橋剤が脱水エステル反応性架橋剤の水溶液であることを特徴とする請求項1ないし8のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
- 1ラインあたりの生産量が100kg/hr以上であることを特徴とする請求項1ないし9のいずれか1項に記載の粒子状吸水性樹脂組成物の製造方法。
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Also Published As
Publication number | Publication date |
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EP1512712A1 (en) | 2005-03-09 |
DE602004028317D1 (de) | 2010-09-09 |
US20050113252A1 (en) | 2005-05-26 |
EP1512712B2 (en) | 2019-04-24 |
EP1512712B1 (en) | 2010-07-28 |
JP4640923B2 (ja) | 2011-03-02 |
CN1611529A (zh) | 2005-05-04 |
US8309654B2 (en) | 2012-11-13 |
CN100471900C (zh) | 2009-03-25 |
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