JP2006225455A - Manufacturing process of water-absorbing resin having high absorption ratio under high pressure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing process of a water-absorbing resin exhibiting sufficient absorption with a small amount under a heavy load, when used for an absorbent for a sanitary product and the like. <P>SOLUTION: The manufacturing process of the water-absorbing resin comprises polymerizing an ammonium unsaturated carboxylate and other monomers, not less than 0 mol% and less than 5 mol% of a radical polymerizable crosslinking agent and not less than 0 mol% and less than 5 mol% of a carboxylic acid-reactive crosslinking agent, drying and heat-treating the polymer obtained. The heat treatment is carried out under a specific condition so that part of the ammonium carboxylate units in the polymer is heat-decomposed to carboxylic acid units and part of the carboxylic acid-reactive crosslinking agent is crosslinked. <P>COPYRIGHT: (C)2006,JPO&amp;NCIPI

Description

  The present invention relates to a method for producing a water-absorbent resin mainly composed of a polymer obtained by polymerizing an acid group-containing monomer having an ammonium cation as a counter cation. More specifically, it provides a water-absorbing material having a very high water-absorbing capacity under pressure, and a method for producing a water-absorbing resin suitably used in various applications including sanitary materials such as paper diapers, sanitary napkins, incontinence pads, etc. It is about.

  In recent years, a water-absorbing resin that gels by absorbing a large amount of water has been developed as a kind of synthetic polymer, and is widely used in the field of sanitary materials such as disposable diapers and sanitary napkins, agriculture and forestry, and civil engineering. Yes. Examples of such a water-absorbing resin include a crosslinked polyacrylic acid partially neutralized product (see, for example, Patent Document 1), a hydrolyzate of starch-acrylonitrile graft polymer (see, for example, Patent Document 2), and starch-acrylic acid graft weight. Neutralized product of polymer (for example, see Patent Document 3), saponified product of vinyl acetate-acrylic acid ester copolymer (for example, see Patent Document 4), hydrolyzate of acrylonitrile copolymer or acrylamide copolymer (for example, Patent Document) Many are known.

Conventionally, the water-absorbent resin should have a high water absorption capacity and excellent absorption rate when in contact with an aqueous liquid such as body fluid, liquid permeability, gel strength of a swollen gel, and a substrate containing an aqueous liquid. The amount of suction that sucks up water is required. However, the relationship between these characteristics does not necessarily show a positive correlation. For example, the higher the water absorption ratio, the lower the physical properties such as liquid permeability, gel strength, and absorption rate.
Thus, as a method for improving the water absorption properties of such a water absorbent resin in a well-balanced manner, a technique for crosslinking the vicinity of the surface of the water absorbent resin is known, and various methods have been proposed so far.

  For example, a method using a polyhydric alcohol as a crosslinking agent (see, for example, Patent Documents 6 and 7), a method using a polyvalent glycidyl compound, a polyvalent aziridine compound, a polyvalent amine compound, and a polyvalent isocyanate compound (see, for example, Patent Document 8). ), A method using glyoxal (see, for example, Patent Document 9), a method using a polyvalent metal (see, for example, Patent Documents 10 and 11), a method using a silane coupling agent (see, for example, Patent Documents 12, 13, 14), and the like. Are known.

In addition, a method in which a crosslinking agent is uniformly distributed on the surface of the water-absorbent resin during the crosslinking reaction, and an inert inorganic powder is present when adding the crosslinking agent as an attempt to perform uniform surface crosslinking (see, for example, Patent Documents 15 and 16). Also known are a method in which a dihydric alcohol is present (see, for example, Patent Document 17), a method in which water and an ether compound are present (see, for example, Patent Document 18), and a method in which phosphoric acid is present (see, for example, Patent Document 19). Yes.
In addition, as an application example of the above method, there is also known a method (for example, Patent Documents 20 and 21) in which a neutralized monomer having a specific composition is mixed with the above crosslinking agent for the purpose of reducing residual monomer and surface crosslinking is performed while heat treatment. Yes.

  However, although the balance of various physical properties of the water-absorbent resin is improved by these methods, it is still not sufficient, and further higher quality is required. In particular, when considering the necessary characteristics of the water-absorbent resin used in the absorbent article in a sanitary product that has been thinned using a large amount of water-absorbent resin, which is a recent trend, the above-mentioned conventional method still has a sufficient physical property level. It is the current situation that has not yet reached.

  In recent years, the demand for disposable diapers for the elderly has been increasing with the increase in the average lifespan. Compared to infants and diapers for elderly people, the load on the paper diaper is larger, and the amount of excretion per dose is larger. There is a strong demand for a water-absorbing resin having an “excellent water absorption capacity under such a high load”.

JP 55-84304 A Japanese Patent Publication No.49-43395 Japanese Patent Laid-Open No. 51-125468 JP-A-52-14689 Japanese Patent Publication No.53-15959 JP 58-180233 A JP-A 61-16903 JP 59-189103 A JP 52-117393 A JP 51-136588 A JP-A-61-257235 JP-A-61-211305 JP-A 61-252212 JP 61-264006 A JP-A-60-163958 JP 60-255814 A JP-A-1-292004 Japanese Patent Laid-Open No. 2-153903 Japanese National Patent Publication No. 8-508517 JP-A-6-122707 JP-A-6-122708

  Therefore, an object of the present invention is to produce a water absorbent resin having a high water absorption ratio that can exhibit a sufficient water absorption capacity even when used in an absorbent body such as a sanitary article, or a heavier load is applied at the time of mounting. However, an object of the present invention is to provide a method for producing a water-absorbent resin having an excellent water absorption capacity under a high load that can sufficiently exhibit absorption capacity.

As a result of intensive studies to achieve the above object, the present inventors have found that the unsaturated carboxylic acid ammonium salt and other monomers, the radical polymerizable cross-linking agent of 0 mol% or more and less than 5 mol%, In a production method in which a polymer obtained by polymerizing a solution containing 0 mol% or more and less than 5 mol% of an acid-reactive crosslinking agent is subjected to a post-treatment step including a drying step and a heat treatment step, the heat treatment in the heat treatment step It was discovered that the absorption capacity under pressure was improved by carrying out the temperature and heat treatment time under specific conditions, and the present invention was completed.
That is, the present invention includes the following [1] to [4].

[1] Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other single amount Polymerization using a solution containing 0 mol% or more and less than 45 mol% of the product, 0 mol% or more and less than 5 mol% of the radical polymerizable crosslinking agent, and 0 mol% or more and less than 5 mol% of the carboxylic acid reactive crosslinking agent as a raw material solution for polymerization The polymer obtained is subjected to a post-treatment step including a drying step and a heat treatment step, wherein the heat treatment is represented by any one of the following formulas (1) to (5). A method for producing an absorbent resin, characterized in that the method is carried out under the following conditions:
−7.5T + 1245 ≦ t ≦ −6T + 1200 (150 ≦ T <160) (1)
−3.5T + 605 ≦ t ≦ −6T + 1200 (160 ≦ T <170) (2)
−0.5T + 95 ≦ t ≦ −13T + 2390 (170 ≦ T <180) (3)
−0.5T + 95 ≦ t ≦ −2T + 410 (180 ≦ T <190) (4)
0 <t ≦ −1.5T + 315 (190 ≦ T ≦ 200) (5)

[2] Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other single amount Polymerization using a solution containing 0 mol% or more and less than 45 mol% of the product, 0 mol% or more and less than 5 mol% of the radical polymerizable crosslinking agent, and 0 mol% or more and less than 5 mol% of the carboxylic acid reactive crosslinking agent as a raw material solution for polymerization The polymer obtained is subjected to a post-treatment process including a drying process and a heat treatment process, wherein the heat treatment is performed by any one of the following formulas (6) to (10): The method for producing an absorbent resin according to the above [1], which is carried out under the conditions indicated.
−6T + 1020 ≦ t ≦ −15T + 2550 (150 ≦ T <160) (6)
−3T + 540 ≦ t ≦ −3T + 630 (160 ≦ T <170) (7)
−2.4T + 438 ≦ t ≦ −8.8T + 1616 (170 ≦ T <180) (8)
−0.5T + 96 ≦ t ≦ −1.35T + 273.5 (180 ≦ T <190) (9)
−0.1T + 20 ≦ t ≦ −1.35T + 273.5 (190 ≦ T ≦ 200) (10)
[3] Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other single amount Polymerization using a solution containing 0 mol% or more and less than 45 mol% of the product, 0 mol% or more and less than 5 mol% of the radical polymerizable crosslinking agent, and 0 mol% or more and less than 5 mol% of the carboxylic acid reactive crosslinking agent as a raw material solution for polymerization The polymer obtained is subjected to a post-treatment step including a drying step and a heat treatment step, wherein the heat treatment is performed under the conditions shown by the following formula (11) or (12): The method for producing an absorbent resin according to the above [1], wherein the method is carried out below.
−1.2T + 232 ≦ t ≦ −2.8T + 538 (185 ≦ T <190) (11)
−0.6T + 118 ≦ t ≦ −0.8T + 158 (190 ≦ T ≦ 195) (12)

[4] Polymerization raw material solution is (meth) acrylic acid ammonium salt 55 mol% to 100 mol%, (meth) acrylic acid alkali metal salt 0 mol% to less than 45 mol%, (meth) acrylate 0 mol % To less than 45 mol%, other monomers 0 mol% to less than 45 mol%, radical polymerizable crosslinking agent 0 mol% to less than 5 mol%, and carboxylic acid reactive crosslinking agent 0 mol% to less than 5 mol% The method for producing a water-absorbent resin according to any one of [1] to [3] above, wherein
However, the total of unsaturated carboxylic acid ammonium salt, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers is 100 mol%, and the mol% of the radical polymerizable crosslinking agent and the carboxylic acid reactive crosslinking agent is It is an outer ratio with respect to 100 mol% defined above.
Moreover, in said numerical formula (1)-(12), T is heat processing temperature [degreeC], t is heat processing time [min]. )

  The water-absorbent resin obtained by the production method of the present invention is characterized by excellent water absorption performance under load and excellent water absorption performance under no load depending on the setting of heat treatment conditions.

The present invention will be described in more detail below.
In the present invention, a polymerization method using a solution containing an unsaturated carboxylic acid ammonium salt and other monomers, a crosslinking agent, etc. as a raw material for polymerization, followed by a drying process and a heat treatment process, In the heat treatment step, it is essential to carry out under specific heat treatment conditions.

That is, unsaturated ammonium carboxylate 55 mol% or more and 100 mol% or less, unsaturated carboxylic acid alkali metal salt 0 mol% or more and less than 45 mol%, unsaturated carboxylic acid 0 mol% or more and less than 45 mol%, other monomers Obtained by polymerizing a raw material solution for polymerization containing 0 mol% or more and less than 45 mol%, radical polymerizable crosslinking agent 0 mol% or more and less than 5 mol%, and carboxylic acid reactive crosslinking agent 0 mol% or more and less than 5 mol%. The polymer product is subjected to a post-treatment step including a drying step and a heat treatment step, wherein in the heat treatment step, a part of the ammonium carboxylate unit in the polymer is thermally decomposed to obtain a carboxylic acid unit. In addition, a part of the carboxylic acid-reactive cross-linking agent is not cross-linked, and is not cross-linked and cured only in the vicinity of the surface. While exhibiting a high absorption capacity under, also succeeded in producing a resin exhibiting a relatively high absorbency under no pressure conditions.
Hereinafter, each of the unsaturated carboxylic acid ammonium salt, the other monomer, the crosslinking agent, and the like, which are raw materials for polymerization, will be described.

(Description of unsaturated carboxylic acid ammonium salt)
The unsaturated carboxylic acid ammonium salt of the present invention refers to a compound having both an unsaturated bond and a carboxylic acid ammonium group. This may contain many unsaturated bonds and ammonium carboxylate groups. The unsaturated bond means a bond containing a double bond (ethylene bond) or a triple bond (acetylene bond) in a bond between carbon atoms. Typical examples of such unsaturated carboxylic acids that form ammonium salts include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, crotonic acid, and cinnamic acid. Of these ammonium salts of unsaturated carboxylic acids, ammonium acrylate and ammonium methacrylate are preferred from the viewpoints of polymerizability and polymer absorbability.

  The amount of unsaturated ammonium carboxylate used is the total molar amount of radical polymerizable monomer (this is the amount of each of unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers). Is 100 mol%, and is contained in the polymerization raw material liquid in the range of 55 to 100 mol%. In order to improve the absorption capacity of the absorbent resin produced from the raw material liquid for polymerization, it is preferable that the content of mol% of the unsaturated ammonium carboxylate is high, and it is preferably in the range of 80 to 100 mol%. More preferably, it is 90 to 100%.

This unsaturated ammonium carboxylate may partially contain an unsaturated carboxylic acid amide. An unsaturated amide refers to a compound containing both an unsaturated bond and a functional group represented by the general formula R—CONH ₂ (R is an alkyl group, an aryl group, etc.) in the molecule. Examples of such compounds include Cinnamamide, acrylamide, and methacrylamide, and acrylamide and methacrylamide are preferable, and acrylamide is particularly preferable.

(Description of production method of unsaturated ammonium carboxylate)
The unsaturated ammonium carboxylate in the present invention may be produced by any production method. For example, (a) a method of subjecting an unsaturated nitrile and / or unsaturated amide to a hydrolysis reaction by a microorganism, and (b) a method of neutralizing an unsaturated carboxylic acid with ammonia can be raised.
Hereinafter, the methods (a) and (b) will be described.

(A) Microbial hydrolysis method An unsaturated nitrile subjected to a hydrolysis reaction by a microorganism refers to a compound containing both an unsaturated bond and a cyan group in the molecule. It may contain many unsaturated bonds and cyan groups. The unsaturated bond means a bond containing a double bond (ethylene bond) or a triple bond (acetylene bond) in a bond between carbon atoms. Examples of such compounds include acrylonitrile, methacrylonitrile, crotonnitrile, cinnamate nitrile and the like. Of these, acrylonitrile and methacrylonitrile are preferable, and acrylonitrile is particularly preferable.

The unsaturated amide used for the hydrolysis reaction by microorganisms is a compound containing both an unsaturated bond and a functional group represented by the general formula R-CONH ₂ (where R is an alkyl group, aryl group, etc.) in the molecule. I mean. Examples of such compounds include Cinnamamide, acrylamide, and methacrylamide, and acrylamide and methacrylamide are preferable, and acrylamide is particularly preferable.

  There are no particular limitations on the hydrolysis conditions of unsaturated nitrile and / or unsaturated amide by microorganisms, but microorganisms capable of producing an aqueous solution of unsaturated ammonium carboxylate having a concentration of 20% by weight or more are preferable. As such a microorganism, it is preferable to use at least one selected from the group consisting of Acinetobacter, Alkagenes, Corynebacterium, Rhodococcus, and Gordona. Among the above-mentioned microorganisms, microorganisms belonging to the genus Acinetobacter are preferable, and among them, the microorganism is Acinetobacter sp. AK226 strain (Mikken Kenki No. 8271) or Acinetobacter sp. Most preferred. In addition, the microbiological properties of Acinetobacter sp. AK226 strain (Microtechnological Bacteria No. 8271) and Acinetobacter sp. AK227 strain (Microtechnological Bacteria No. 8272) are as shown in JP-B 63-2596 It is.

Since the unsaturated ammonium carboxylate aqueous solution produced by the hydrolysis method using this microorganism has a very small amount of impurities such as dimers and / or hydrates of unsaturated carboxylic acid, the production method is a preferable method. .
Specific examples of the impurities include, in the case of acrylic acid, β-acryloyloxypropionic acid which is a dimer of acrylic acid, β-hydroxypropionic acid which is a hydrate of acrylic acid, and salts thereof. Can be mentioned.

(B) Method for neutralizing unsaturated carboxylic acid with ammonia As the unsaturated carboxylic acid used in the method for neutralizing unsaturated carboxylic acid with ammonia, the same unsaturated carboxylic acid as described above is used.
This unsaturated carboxylic acid may be produced by any method. When such an unsaturated carboxylic acid contains a large amount of impurities, it is preferable to produce them to reduce the impurities.

The impurity here refers to a compound that can be decomposed to become a monomer component. For example, in the case of acrylic acid, such as hydrated unsaturated bonds and oligomers, β-hydroxypropionic acid and β-acryloyloxypropionic acid can be used.
The purification method may be any method as long as the amount of impurities can be reduced to a predetermined amount or less, and the means is not particularly limited. As the method, for example, distillation may be carried out as described in JP-A-6-56931. The amount of impurities is preferably reduced to 1000 ppm or less, more preferably 500 ppm or less, further preferably 300 ppm or less, and most preferably 100 ppm or less. If the amount of impurities is large, the resulting water-absorbent resin has a large amount of residual monomer, and the residual monomer increases in the subsequent manufacturing process. Further, various physical properties of the polymer may be insufficient, which is not preferable.

  The neutralization method is not particularly limited. Ammonia water may be used, or ammonia gas may be used. As described in JP-A-6-56931 and JP-B-7-49449, neutralization is performed under the condition that the neutralization rate of acrylic acid exceeds 100 mol% at least for a period of time during the neutralization step. Also good. In the neutralization step, the temperature is preferably maintained at 0 to 50 ° C. by cooling. An excessively high temperature is not preferable because β-hydroxypropionic acid and oligomers are produced.

(Unsaturated carboxylic acid alkali metal salt)
The unsaturated carboxylic acid alkali metal salt in the present invention refers to a compound having both an unsaturated bond and a carboxylic acid alkali metal group. This may contain many unsaturated bonds and alkali metal carboxylate groups. The unsaturated bond means a bond containing a double bond (ethylene bond) or a triple bond (acetylene bond) in a bond between carbon atoms. Representative examples of such unsaturated carboxylic acids that form alkali metal salts include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, crotonic acid, and cinnamic acid. Among these alkali metal salts of unsaturated carboxylic acids, alkali metal acrylates and alkali metal methacrylates are preferred from the viewpoints of polymerizability and polymer absorbability. Further, as the alkali metal, lithium is preferable for improving the absorption capacity of the produced resin, and sodium is preferable from the viewpoint of safety when used as a sanitary material.

  The amount of unsaturated carboxylic acid alkali metal salt used is the total amount of radically polymerizable monomers (this includes unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers, respectively). Is included in the polymerization raw material liquid in the range of 0 to 45 mol%. In order to improve the absorptivity of the absorbent resin produced from the raw material liquid for polymerization, the content of the unsaturated carboxylic acid alkali metal salt is preferably as low as possible, and may be in the range of 0 to 20 mol%. preferable. More preferably, it is 0 to 10%.

(Unsaturated carboxylic acid)
The unsaturated carboxylic acid in the present invention refers to a compound having both an unsaturated bond and a carboxylic acid group. This may contain a large number of unsaturated bonds and carboxylic acid groups. The unsaturated bond means a bond containing a double bond (ethylene bond) or a triple bond (acetylene bond) in a bond between carbon atoms. Typical examples of such unsaturated carboxylic acids include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, crotonic acid, cinnamic acid, and the like. Among these unsaturated carboxylic acids, acrylic acid and methacrylic acid are preferable from the viewpoints of polymerizability and polymer absorbability.

  The amount of unsaturated carboxylic acid used is the total molar amount of radical polymerizable monomers (this is the molar amount of each of unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers). Is included in the raw material liquid for polymerization in the range of 0 to 45 mol%. In order to improve the absorptivity of the absorbent resin produced from the raw material liquid for polymerization, the content of the unsaturated carboxylic acid alkali metal salt is preferably as low as possible, and may be in the range of 0 to 20 mol%. preferable. More preferably, it is 0 to 10%.

(Other monomers)
Other monomers in the present invention are mainly monofunctional unsaturated monomers, such as (meth) acrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, crotonic acid, vinyl sulfonic acid, Acid group-containing hydrophilic monofunctional typified by styrenesulfonic acid, 2- (meth) acrylamido-2-methylpropanesulfonic acid, 2- (meth) acryloylethanesulfonic acid, 2- (meth) acryloylpropanesulfonic acid, etc. Unsaturated monomers and salts thereof, acrylamide, methacrylamide, N-ethyl (meth) acrylamide, Nn-propyl (meth) acrylamide, N-isopropyl (meth) acrylamide, N, N-dimethyl (meth) acrylamide Amido group-containing hydrophilic monofunctional unsaturated monomer represented by 2-hydroxyethyl ( TA) acrylate, 2-hydroxypropyl (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, esterified hydrophilic unsaturated monomer represented by polyethylene glycol mono (meth) acrylate, vinylpyridine, N- Vinylpyrrolidone, N-acryloylpiperidine, N-acryloylpyrrolidine, N, N-dimethylaminoethyl (meth) acrylate, N, N-diethylaminoethyl (meth) acrylate, N, N-dimethylaminopropyl (meth) acrylate, N, N atom-containing hydrophilic monofunctional unsaturated monomers represented by N-dimethylaminoethyl (meth) acrylamide and quaternary salts thereof, styrene, vinyl chloride, butadiene, isobutene, ethylene, propylene, alkyl (meth) Acry It can be mentioned hydrophobic monofunctional unsaturated monomers over bets, etc..

  Among these, (meth) acrylic acid (salt), 2- (meth) acryloylethanesulfonic acid (salt), 2- (meth) acrylamido-2-methylpropanesulfonic acid (salt), methoxypolyethylene glycol (meth) acrylate, N, N-dimethylaminoethyl (meth) acrylate and (meth) acrylamide are preferred.

  The content of these monomers in the raw material solution for polymerization is the total molar amount of radical polymerizable monomers (this includes unsaturated carboxylic acid ammonium, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other single monomers. The sum of the molar amounts of each of the monomers is in the range of 0 to 45 mol%, where 100 mol%. Since these are used for the modification of the absorbent resin according to various purposes, the optimum use amount varies depending on the purpose, but in order to suppress the decrease in the absorption capacity of the absorbent resin, it is a small amount. Is preferable, the range of 0 to 20 mol% is preferable, and the range of 0 to 5 mol% is more preferable.

(Radical polymerizable crosslinking agent)
In the present invention, it is desirable to introduce a crosslinked structure in the interior by using a radical polymerizable crosslinking agent in addition to the monofunctional unsaturated monomer in the polymerization. The radical polymerizable crosslinking agent may be a compound having a plurality of polymerizable unsaturated groups and / or reactive groups in one molecule. It is preferable to use a highly hydrophilic compound as the internal cross-linking agent because the water absorption performance of the resin is improved. In the case where the monofunctional unsaturated monomer is a self-crosslinking compound, an internal cross-linked structure can be formed without using a radical polymerizable cross-linking agent.

  Examples of the radical polymerizable crosslinking agent include N, N-methylenebis (meth) acrylamide, (poly) ethylene glycol di (meth) acrylate, (poly) propylene glycol di (meth) acrylate, and trimethylolpropane tri (meth) acrylate. , Trimethylolpropane di (meth) acrylate, glycerin (meth) acrylate, glycerin acrylate methacrylate, ethylene oxide modified trimethylolpropane tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, triary Multiple in one molecule typified by lucyanurate, triallyl isocyanurate, triallyl phosphate, triallylamine, poly (meth) allyloxyalkane Compounds having an unsaturated bond, (poly) ethylene glycol diglycidyl ether, a compound having a plurality of epoxy groups in one molecule represented by glycerol diglycidyl ether, and glycidyl (meth) acrylate. These radical polymerizable crosslinking agents may be used alone or in combination of two or more.

The amount of radical polymerizable crosslinking agent used is the total molar amount of radical polymerizable monomer (this is the molar amount of each of unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers. The total amount)) is 100 mol%, the outer percentage is 0-5 mol%, preferably 0.005-3 mol%, more preferably 0.01-1.5 mol%, Most preferably, it is 0.01-0.09 mol%.
The use of the radical polymerizable crosslinking agent can be changed according to the amount of the carboxylic acid reactive crosslinking agent used. That is, when a relatively large amount of the carboxylic acid reactive crosslinking agent is used, the crosslinked product can be maintained even if the radical polymerizable crosslinking agent is small (including 0 mol%), and a small amount of carboxylic acid reactive crosslinking agent (0 In the case where only a small amount (including mol%) is used, it is necessary to use a relatively large amount of a radically polymerizable crosslinking agent. If the amount of the radical polymerizable crosslinking agent is small, the soluble content of the polymer is remarkably increased. If the amount of the radical polymerizable crosslinking agent is large, the gel becomes hard and the water absorption performance is remarkably lowered.

(Carboxylic acid reactive crosslinking agent)
Examples of the compound containing two or more functional groups capable of reacting with a carboxyl group in the present invention (hereinafter also referred to as “carboxylic acid-reactive crosslinking agent”) include ethylene glycol diglycidyl ether, trimethylolpropane triglycidyl ether, ) Glyceryl ether compounds such as glycerin polyglycidyl ether, diglycerin polyglycidyl ether, propylene glycol diglycidyl ether; (poly) glycerin, (poly) ethylene glycol, (poly) propylene glycol, 1,3-propanediol, polyoxyethylene Glycol, triethylene glycol, tetraethylene glycol, 1,6-hexanediol, trimethylolpropane, diethanolamine, triethanolamine, polyoxypropylene, oxyethylene Various polyhydric alcohols represented by polyoxypropylene block copolymer, pentaerythritol, sorbitol, etc .; polyhydric amines such as ethylenediamine, diethylenediamine, polyethyleneimine, hexamethylenediamine; 2,2-bishydroxymethylbutanol- Multivalent aziridine compounds represented by tris (3- (1-aziridinyl) propionate), 1,3-dioxolan-2-one, 4-methyl-1,3-dioxolan-2-one, 4,6-dimethyl Various alkylene carbonate compounds typified by -1,3-dioxolan-2-one, etc., various polyhydric aldehyde compounds typified by glyoxal, polyvalent oxazoline compounds typified by 2,4-tolylene diisocyanate, typified by epichlorohydrin Haloepoki Compounds; zinc, calcium, magnesium, etc. multivalent ions like typified by aluminum.

Among such carboxylic acid reactive cross-linking agents, it is preferable to use one or more selected from the group consisting of polyhydric alcohols, polyhydric glycidyl compounds, polyhydric amines, and alkylene carbonates.
The content of the carboxylic acid-reactive crosslinking agent in the polymerization raw material solution is the total molar amount of the radical polymerizable monomer (this includes unsaturated carboxylic acid ammonium, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other The sum of the respective molar amounts of the monomers) is 100 mol%, and the outer percentage is 0 mol% or more and less than 5 mol%.

The amount of the carboxylic acid reactive crosslinking agent used can be changed according to the amount of the radical polymerizable crosslinking agent used. That is, when a relatively large amount of the radical polymerizable crosslinking agent is used, a crosslinked product can be maintained even if the amount of the carboxylic acid reactive crosslinking agent is small (including 0 mol%), and a small amount of the radical polymerizable crosslinking agent (0 mol). When used, it is necessary to use a relatively large amount of carboxylic acid reactive crosslinking agent.
A preferred amount of the carboxylic acid reactive crosslinking agent is 0.1 to 3 mol%, more preferably 0.5 to 2 mol%. When the amount of the carboxylic acid reactive crosslinking agent is too small, the soluble content of the polymer is remarkably increased, and when the amount of the carboxylic acid reactive crosslinking agent is too large, the gel becomes too hard and the absorption performance is lowered.
Moreover, you may superpose | polymerize by adding a foaming agent, a chain transfer agent, surfactant, a chelating agent, etc. other than the said monofunctional unsaturated monomer and an internal crosslinking agent as needed.

(Description of radical initiator and reducing agent)
As an initiator used for the radical polymerization reaction of the present invention, the radical reaction can be usually started by mixing a peroxide and a reducing agent.
As the peroxide, any peroxide can be used, but it is preferable to use a peroxide having high hydrophilicity. For example, hydroperoxides, peroxides, and the like are suitable. Used as. Hydroperoxides refer to compounds represented by the general formula ROOH (R is hydrogen, an alkyl group, other organic and / or inorganic atomic groups). Examples of such compounds include hydrogen peroxide, methyl hydroperoxide, allyl hydroperoxide, benzyl hydroperoxide, cumene hydroperoxide, tert-butyl hydroperoxide, and the like. Typical examples of peracid salts include persulfates such as potassium persulfate, ammonium persulfate, and sodium persulfate.
These peroxides may be used alone or in combination of two or more.

Of these peroxides, it is preferable to use hydroperoxide. By using hydroperoxide as an initiator, the initiator end of the main chain becomes an OH group and can react with a carboxyl group in another main chain, so that it has an apparently high molecular weight, so the water absorption capacity is increased. It is done. Of course, a radical polymerization initiator other than hydroperoxide may be used in combination.
Among hydroperoxides, it is preferable to use hydrogen peroxide.

  The amount of peroxide used is the total molar amount of radical polymerizable monomers (this is the molar amount of each of unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers). Is 100 mol%, the outer percentage is preferably 0.001 to 2 mol%, more preferably 0.01 to 0.5 mol%. If the amount of the initiator is too small, too few radicals are generated and a large amount of unreacted monomer remains. On the other hand, if the amount of the initiator is too large, impurities after polymerization increase, which is not preferable.

  The reducing agent used for the initiation of polymerization of the present invention may be originally contained in the monomer raw material for polymerization or may be added at the time of polymerization. A reducing agent refers to a substance that can cause reduction. Examples of such reducing components include hydrogen and relatively unstable hydrogen compounds such as hydrogen sulfide, lower oxides such as carbon monoxide, sulfite, and bisulfite, or salts of lower oxides, sodium sulfide, and the like. Highly electropositive metals such as sulfur compounds, alkali metals, magnesium, calcium, aluminum, zinc, or their low atoms such as amalgam, iron (II), tin (II), titanium (III), chromium (II) There are organic compounds such as metal salts, aldehydes, saccharides, formic acid and the like in a valence state that are susceptible to oxidation reaction. Other examples include sodium thiosulfate, hydrazine hydrate, ascorbic acid, erythorbic acid, longalit and the like. These reducing agents may be used alone or in combination of two or more.

  Among these, metals with high electrical positivity and metals with low valence state, alkali metal sulfites, alkali metal bisulfites, ammonium sulfites, ammonium bisulfites, ascorbic acid, erythorbic acid, Rongalite, etc. Is mentioned as a preferred reducing agent. The most preferred reducing agent is Rongalite, and there is a feature that the amount of residual monomer in the polymer is further reduced when Rongalite and a metal having a large electropositive property are used in combination.

  The amount of these reducing agents used is the total molar amount of the radical polymerizable monomer (this is the molar amount of each of unsaturated ammonium carboxylate, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers). The total amount is preferably 0.000001 to 12% by weight, more preferably 0.00001 to 6% by weight, more preferably 0.0001 to 1.2% by weight. It is.

(Polymerization reaction)
There are no particular restrictions on the polymerization method of the radically polymerizable unsaturated monomer, but known methods such as solution polymerization and reverse phase suspension polymerization are preferably used. The type of the reactor is not particularly limited, and may be either batch type or continuous type. The polymerization initiation method is not particularly limited, but polymerization with a radical polymerization initiator, polymerization by irradiation with radiation, electron beam, or ultraviolet polymerization with a photosensitizer can also be performed.
The polymerization start temperature can be 0-70 degreeC. The concentration of the radical polymerizable monomer in the radical polymerizable monomer solution is preferably 10 to 70%, and most preferably 30 to 50% from the viewpoint of economy and ease of reaction control.

  It is preferable to perform a deoxygenation operation in the radical polymerizable monomer solution in advance before the start of polymerization. As a specific method, there is a method of removing dissolved oxygen by bubbling with an inert gas for a sufficient time. In addition, it is preferable that the atmosphere in the reactor is replaced with an inert gas such as nitrogen or helium. The inside of the reactor may be any of reduced pressure, normal pressure, and increased pressure. The polymerization initiation temperature is usually preferably in the range of 0 to 70 ° C. More preferably, it is the range of 10-40 degreeC. If the starting temperature is too high, polymerization by heat occurs before the initiator is added, which is not preferable. On the other hand, if the starting temperature is too low, it takes too much time to start the reaction, which is not preferable. The temperature in the reactor during the reaction may depend on the outcome, and the temperature may be controlled by cooling or heating from the outside. The temperature rising rate and the maximum temperature during the polymerization are not particularly problematic, and there is no problem even if the maximum temperature exceeds 100 ° C. The maximum temperature during polymerization is usually 20 to 140 ° C, preferably 40 ° C to 120 ° C.

  The concentration of the monomer solution is preferably 10 to 70%, and most preferably 30 to 50%. If the concentration is too high, the reaction tends to run away, which is not preferable. If the concentration is too low, it takes too much time for the reaction, and the subsequent post-treatment process is also burdened, which is not preferable. The polymerization time is preferably set in the vicinity of the time when heat generation from the reaction solution stops. Since post-processes such as a drying process and a heat treatment process exist as post-processes after the polymerization, the polymerization may be terminated before the heat generation from the reaction solution stops. Moreover, you may heat for several hours after completion | finish of heat_generation | fever.

(Drying process)
When the polymer obtained after the polymerization is a hydrogel, drying may be performed. Although this drying method is not particularly limited, for example, azeotropic dehydration, fluidized drying, hot air drying, vacuum drying and the like are preferably used, and hot air drying and vacuum drying are particularly preferable. The moisture content is 30% by weight or less, preferably 10% by weight or less. Drying may be performed with any form of hydrogel, but it is preferable to dry after coarsely crushing to increase the surface area. The drying temperature is preferably in the range of 70 ° C to 180 ° C, particularly preferably 100 to 140 ° C.

  The particle size of the polymer after drying is adjusted by operations such as pulverization and classification as required. The shape may be various shapes such as spherical, scaly, irregularly crushed, and granular, but the weight average particle size is 10 to 3000 μm, preferably 40 to 2000 μm, more preferably 50 to 1500 μm, Still more preferably, it is 100-850 micrometers, and the most preferable 300-700 micrometers. If the particle size is too small, it becomes fine powder, and it becomes easy to scatter. Further, the amount of ammonia that volatilizes during heating increases, resulting in a decrease in water absorption performance, which is not preferable. When the particle size is too large, there are problems such as a decrease in water absorption rate and unevenness of the water absorbent resin in the absorbent article.

(Heat treatment conditions)
The heat treatment of the present invention is performed under conditions that satisfy the following mathematical formulas (1) to (5),
−7.5T + 1245 ≦ t ≦ −6T + 1200 (150 ≦ T <160) (1)
−3.5T + 605 ≦ t ≦ −6T + 1200 (160 ≦ T <170) (2)
−0.5T + 95 ≦ t ≦ −13T + 2390 (170 ≦ T <180) (3)
−0.5T + 95 ≦ t ≦ −2T + 410 (180 ≦ T <190) (4)
0 <t ≦ −1.5T + 315 (190 ≦ T ≦ 200) (5)

Preferably, it is performed under the conditions satisfying the following mathematical formulas (6) to (10),
−6T + 1020 ≦ t ≦ −15T + 2550 (150 ≦ T <160) (6)
−3T + 540 ≦ t ≦ −3T + 630 (160 ≦ T <170) (7)
−2.4T + 438 ≦ t ≦ −8.8T + 1616 (170 ≦ T <18 (8)
−0.5T + 96 ≦ t ≦ −1.35T + 273.5 (180 ≦ T <190 (9)
−0.1T + 20 ≦ t ≦ −1.35T + 273.5 (190 ≦ T ≦ 200) (10)

More preferably, it is performed under the conditions satisfying the following mathematical formulas (11) and (12).
−1.2T + 232 ≦ t ≦ −2.8T + 538 (185 ≦ T <190) (11)
−0.6T + 118 ≦ t ≦ −0.8T + 158 (190 ≦ T ≦ 195) (12)
(However, in the above formulas (1) to (12), T [° C.] is the heat treatment temperature, and t [min] is the heat treatment time.)

  The gas replacement time T (min) in the heat treatment apparatus is a value obtained by dividing the volume V (L) in the heat treatment apparatus by the gas flow velocity v (L / min), and this is preferably shorter. Specifically, it is preferably 60 minutes or less. When the amount of particles staying in the container is increased, it is preferable that the amount is further shortened. More preferably, it is 5 or less. Shortening to 3 minutes or less is most preferable, and there is almost no effect of shortening further.

  The gas flow rate (L / min · g) per particle weight is a value obtained by dividing the gas flow rate v (L / min) by the amount of particles W (g) in the heat treatment apparatus, and it is preferable that the gas flow rate is larger. Specifically, it is 0.001 L / min · g or more. In the case where a relatively large amount of particles are retained in a relatively small heat treatment, it is preferably 0.01 L / min · g or more. More preferably, it is 0.1 L / min · g or more, and most preferably 1 L / min · g or more.

  Through the heat treatment step, ammonia is released from some ammonium carboxylate units in the polymer, and a water-absorbing resin containing carboxylic acid units is obtained. Examples of the water-absorbing resin thus obtained include 9 to 100 mol% of an ammonium carboxylate unit, 0 to 90 mol% of a carboxylic acid metal salt unit, 1 to 50 mol% of a carboxylic acid unit, and other simple units. It is preferable that a functional unsaturated monomer unit is 0-50 mol%. More preferably, the ammonium carboxylate unit is 15 to 90 mol%, the carboxylic acid metal salt unit is 0 to 80 mol%, the carboxylic acid unit is 5 to 45 mol%, and other monofunctional unsaturated monomer units. Is 0 to 40 mol%, more preferably 20 to 80 mol% of ammonium carboxylate units, 0 to 70 mol% of carboxylic acid metal salt units, 10 to 40 mol% of carboxylic acid units, and other than these The monofunctional unsaturated monomer unit is 0 to 30 mol%.

  For the above heat treatment, a normal dryer or a heating furnace can be used. For example, a groove type mixer / dryer, a rotary dryer, a disk dryer, a fluidized bed dryer, an airflow dryer, an infrared dryer, etc. Can be mentioned.

(Use of surface cross-linking agent)
A surface cross-linking agent may be added to the polymer before the heat treatment step. For this, a known method is used, and examples thereof include a method of directly adding a surface cross-linking agent to a dried polymer product and a method of adding a surface cross-linking agent by dispersing the dried polymer product in a solvent. When the former method is used, an inorganic compound such as silicon oxide fine powder or a surfactant may coexist for the addition of a uniform surface cross-linking agent.
Of course, as a particularly preferred crosslinking method, a predetermined amount of a carboxylic acid-reactive crosslinking agent and a radically polymerizable crosslinking agent are added to the monomer of the present invention for polymerization. It is preferable to carry out a heat treatment after carrying out the crosslinking reaction of the carboxylic acid reactive crosslinking agent.

  Examples of the compound used as the surface crosslinking agent include glycidyl ether compounds such as ethylene glycol diglycidyl ether, trimethylolpropane triglycidyl ether, (poly) glycerin polyglycidyl ether, diglycerin polyglycidyl ether, and propylene glycol diglycidyl ether; Polyhydric alcohols such as (poly) glycerin, (poly) ethylene glycol, propylene glycol, 1,3-propanediol, polyoxyethylene glycol, triethylene glycol, tetraethylene glycol, diethanolamine, triethanolamine; ethylenediamine, diethylenediamine Polyamines such as polyethyleneimine and hexamethylenediamine; zinc, calcium, magnesium, aluminum Such as any multivalent ions, and the like.

  The surface crosslinking agent can be used in an amount of 0.01% to 20% by weight, based on the weight of the polymer, and one or two or more can be used. When the addition amount of the surface cross-linking agent exceeds 20% by weight, it is not preferable because appropriate cross-linking curing cannot be obtained and the water absorption ratio is lowered.

(Other additives)
In the water-absorbing resin thus obtained, if necessary, deodorants, fragrances, various inorganic powders, foaming agents, pigments, dyes, antibacterial agents, hydrophilic short fibers, plasticizers, adhesives, surfactants, Fertilizers, oxidizing agents, reducing agents, chelating agents, antioxidants, heat stabilizers, UV absorbers, light stabilizers, water, salts, etc. may be added.

Examples of the inorganic powder include fine particles of various inorganic compounds that are inert to water and hydrophilic organic solvents, fine particles of clay mineral, and the like. In particular, the inorganic powder preferably has an appropriate affinity for water and is insoluble or hardly soluble in water, such as metal oxides such as silicon dioxide and titanium oxide, natural zeolite, synthetic zeolite, etc. Silicic acid (salt), kaolin, talc, clay, bentonite and the like.
The usage-amount of the said inorganic powder is 0.001-10 weight part normally with respect to 100 weight part of water absorbing resin, Preferably it is 0.01-5 weight part. There is no restriction | limiting in particular in the mixing method of water absorbing resin and inorganic powder, It carries out by the dry blend method, the wet mixing method, etc.

(Classification)
In the present invention, the particle diameter of the water absorbent resin is finally adjusted by operations such as pulverization and classification as required. The shape may be various shapes such as a spherical shape, a scale shape, an irregular crushed shape, and a granular shape, but the weight average particle size is 10 to 3000 μm. In order to improve the absorption rate per 1 g of particles, the range of 40 to 2000 μm is preferable, more preferably 50 to 1500 μm, still more preferably 100 to 850 μm, and most preferably 300 to 700 μm.

In order to increase the saturation swelling amount per 1 g of particles, the weight average particle diameter of the particles is in the range of 100 to 3000 μm, and more preferably in the range of 400 to 2000 μm.
Since the absorbent resin containing an ammonium salt releases ammonia gas by heat treatment, particles having a relatively small particle diameter have a high heat treatment temperature, and when the heat treatment time is long, the ammonium salt content per gram of the particles is high. Particles with a relatively large particle size may be preferred because they can be significantly reduced and the absorption capacity can be reduced.

(Usage of water-absorbing resin)
The absorbent article which sandwiched between the top sheet and the back sheet the absorbent layer containing the water-absorbent resin obtained on the basis of the production method of the present invention and the absorbent mainly composed of hydrophilic fibers can be obtained. Specific examples of such absorbent articles include various sanitary materials such as paper diapers, sanitary napkins, and incontinence pads.

  EXAMPLES Hereinafter, although an Example demonstrates this invention, the scope of the present invention is not limited only to these Examples. In addition, the various physical properties described in the examples indicate values measured by the following test methods.

(1) Non-pressurized water absorption ratio A cylinder made of acrylic resin having an inner diameter of 25 mm, an outer diameter of 35 mm, and a height of 30 mm, in a special container in which the bottom portion of the cylinder is closed with nylon 400 mesh, is made into a water-absorbing resin. 16 g was uniformly charged on the bottom mesh, and the dedicated container was gently immersed in 60 g of a 0.9 wt% sodium chloride aqueous solution in an SUS petri dish having an inner diameter of 120 mm and a height of 28 mm. After 1 hour, pull up the dedicated container, wipe off the moisture on the side of the dedicated container, drain the water by allowing the moisture on the bottom of the dedicated container to stand on a predetermined filter paper for 3 seconds, measure the weight of the dedicated container, and use the following formula The water absorption capacity under pressure was calculated in (13).

(2) Water absorption capacity under pressure 0.16 g of water-absorbing resin in a special container made of acrylic resin with an inner diameter of 25 mm, an outer diameter of 35 mm, and a height of 30 mm, the bottom of which is sealed with nylon 400 mesh Is placed uniformly on the bottom mesh, and a cylindrical weight with a predetermined weight (278.33) having an outer diameter of 24.5 mm is slowly fitted from above, so that 0.8 psi can be applied vertically downward. The conditions under pressure were set, and the dedicated container was gently immersed in 60 g of a 0.9 wt% sodium chloride aqueous solution contained in an SUS petri dish having an inner diameter of 120 mm and a height of 28 mm. After 1 hour, pull up the dedicated container, wipe off the moisture on the side of the dedicated container, drain the water by allowing the moisture on the bottom of the dedicated container to stand on the filter paper for 3 seconds, and then measure the weight of the dedicated container together with the weight. The water absorption capacity under pressure was calculated by the formula (14).

[Example 1]
A 40% by weight ammonium acrylate aqueous solution (pH = 7.0) was prepared under cooling with ice using a special grade reagent acrylic acid and 28% by weight ammonia water and distilled water. In order to remove the polymerization inhibitor present in the 40 wt% ammonium acrylate aqueous solution, the 40 wt% ammonium acrylate aqueous solution was treated with activated carbon to obtain a polymerization inhibitor free 40 wt% ammonium acrylate aqueous solution.

  100 g of the 40 wt% ammonium acrylate aqueous solution, 0.06 mol% of N, N′-methylenebisacrylamide and 1 part by weight of glycerin were charged into a 500 ml separable flask, deaerated by bubbling with nitrogen gas for 30 minutes, and then stirred with a stirrer. While at a temperature of 35 ° C., 0.001 mol% of L-ascorbic acid and 0.07 mol% of ammonium persulfate were added. After about 1 to 2 minutes, an increase in internal temperature was observed, and polymerization was started. Immediately before the progress of the polymerization, the viscosity of the liquid increased and stirring with the stirrer became impossible. Stirring was stopped, and the bubbling nitrogen gas was switched to gas phase substitution to continue the polymerization. Eventually, when the polymerization peak temperature reached 95 ° C. and the internal temperature began to drop, the separable flask was immersed in a water bath, and aging at 70 ° C. was performed for 2 hours.

  The water-containing gel polymer thus obtained was taken out and subdivided into about 5 mm, then dried at 100 ° C. under nitrogen flow for 2 hours, and the resulting dried product was crushed with a commercially available crusher. After carrying out drying at 100 ° C. for 2 hours under a nitrogen flow, the obtained dried product was pulverized and classified into a range of 106 to 850 μm using a sieve to obtain a water absorbent resin before surface crosslinking.

  2 g of the water-absorbing resin before surface cross-linking was placed on a 10 × 14 cm petri dish and subjected to heat treatment (surface cross-linking treatment) under a nitrogen flow at 150 ° C. for 0.5 to 700 min. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Example 2]
2 g of the pre-surface-crosslinked water-absorbing resin obtained by the same method as in Example 1 was placed on a 10 × 14 cm petri dish made of aluminum and heated under a nitrogen flow at 160 ° C. for 0.5 to 700 min (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Example 3]
2 g of the pre-surface-crosslinked water-absorbing resin obtained by the same method as in Example 1 was placed on a 10 × 14 cm aluminum petri dish and heated under conditions of 170 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Example 4]
2 g of the pre-surface-crosslinked water-absorbing resin obtained in the same manner as in Example 1 was placed on a 10 × 14 cm aluminum petri dish and heated under conditions of 180 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Example 5]
2 g of the water-absorbing resin before surface cross-linking obtained by the same method as in Example 1 was placed on a 10 × 14 cm aluminum petri dish and heated under conditions of 190 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Example 6]
2 g of the pre-surface-crosslinked water-absorbing resin obtained by the same method as in Example 1 was placed on a 10 × 14 cm petri dish made of aluminum and heated under conditions of 200 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Comparative Example 1]
2 g of the pre-surface-crosslinked water-absorbing resin obtained in the same manner as in Example 1 was placed on a 10 × 14 cm aluminum petri dish and heated under conditions of 140 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

[Comparative Example 2]
2 g of the pre-crosslinked water-absorbing resin obtained in the same manner as in Example 1 was placed on a 10 × 14 cm aluminum petri dish and heated under conditions of 210 ° C. and 0.5 to 700 min under nitrogen flow (surface Crosslinking treatment) was performed. The water absorption capacity under no pressure and the water absorption capacity under pressure were measured with respect to the obtained water-absorbing resin after heat treatment. Table 1 shows the results of the absorption capacity without load, and Table 2 shows the results of the absorption capacity under pressure.

  From the result of Table 1, the area | region which becomes water absorption performance 40 [g / g] or more under non-pressurization, the area | region which becomes 45 [g / g] or more, the area | region which becomes 50 [g / g] or more, 55 [g / g] The above regions are shown in FIG.

  From the results of Table 2, the region where the water absorption performance under pressure is 20 [g / g] or more is shown in FIG. 2, the region where 25 [g / g] or more is shown in FIG. 3, and the region where 27 [g / g] or more is obtained. Are shown in FIG.

  The method for producing the water-absorbing resin of the present invention is a method for producing a water-absorbing resin having a high water-absorbing magnification that can exhibit a sufficient water-absorbing capacity even when used in an absorbent body such as a sanitary product, or depending on when it is mounted. It can be suitably used in the field of manufacturing a water-absorbent resin having an excellent water absorption capacity under a high load that can sufficiently exhibit absorption capacity even when a heavy load is applied.

It is a figure which shows the relationship between the heat processing temperature and heat processing time which exhibit specific non-pressurized water absorption performance regarding the heat processing conditions with respect to the water absorbing resin of this invention. It is a figure which shows the relationship between the heat processing temperature which exhibits the water absorption performance under pressure 20 [g / g] or more regarding heat processing conditions with respect to the water absorbing resin of this invention, and heat processing time. It is a figure which shows the relationship between the heat processing temperature which exhibits the water absorption performance under pressure 25 [g / g] or more regarding the heat processing conditions with respect to the water absorbing resin of this invention, and heat processing time. It is a figure which shows the relationship between the heat processing temperature and heat processing time which exhibit the water absorption performance under pressure 27 [g / g] or more regarding the heat processing conditions with respect to the water absorbing resin of this invention.

Claims (4)

Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other monomer 0 mol % And less than 45 mol%, a radical polymerizable crosslinker 0 mol% to less than 5 mol%, and a carboxylic acid reactive crosslinker containing 0 mol% to less than 5 mol% as a raw material solution for polymerization. A method for producing a water-absorbent resin, wherein the polymer obtained is subjected to a post-treatment step including a drying step and a heat treatment step, wherein the heat treatment is performed under any of the following formulas (1) to (5): The manufacturing method of the absorptive resin characterized by the above-mentioned.
−7.5T + 1245 ≦ t ≦ −6T + 1200 (150 ≦ T <160) (1)
−3.5T + 605 ≦ t ≦ −6T + 1200 (160 ≦ T <170) (2)
−0.5T + 95 ≦ t ≦ −13T + 2390 (170 ≦ T <180) (3)
−0.5T + 95 ≦ t ≦ −2T + 410 (180 ≦ T <190) (4)
0 <t ≦ −1.5T + 315 (190 ≦ T ≦ 200) (5)
(However, the total amount of unsaturated carboxylic acid ammonium salt, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers is 100 mol%, and the radical polymerizable crosslinking agent and carboxylic acid reactive crosslinking agent mol%. Is an outer ratio with respect to 100 mol% defined above, and in the above formulas (1) to (5), T is a heat treatment temperature [° C.] and t is a heat treatment time [min]. Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other monomer 0 mol % To less than 45 mol%, a radical polymerizable crosslinking agent in an amount of from 0 mol% to less than 5 mol%, and a carboxylic acid reactive crosslinking agent in an amount of from 0 mol% to less than 5 mol% are used as polymerization raw material solutions. A method for producing a water-absorbent resin, wherein the polymer obtained is subjected to a post-treatment step including a drying step and a heat treatment step, wherein the heat treatment is performed under any of the following formulas (6) to (10): The manufacturing method of the absorptive resin characterized by performing below.
−6T + 1020 ≦ t ≦ −15T + 2550 (150 ≦ T <160) (6)
−3T + 540 ≦ t ≦ −3T + 630 (160 ≦ T <170) (7)
−2.4T + 438 ≦ t ≦ −8.8T + 1616 (170 ≦ T <180) (8)
−0.5T + 96 ≦ t ≦ −1.35T + 273.5 (180 ≦ T <190) (9)
−0.1T + 20 ≦ t ≦ −1.35T + 273.5 (190 ≦ T ≦ 200) (10)
(However, the total amount of unsaturated carboxylic acid ammonium salt, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers is 100 mol%, and the radical polymerizable crosslinking agent and carboxylic acid reactive crosslinking agent mol%. Is an outer percentage with respect to 100 mol% defined above, and in the above formulas (6) to (10), T is a heat treatment temperature [° C.] and t is a heat treatment time [min]. Unsaturated carboxylic acid ammonium salt 55 mol% to 100 mol%, unsaturated carboxylic acid alkali metal salt 0 mol% to less than 45 mol%, unsaturated carboxylic acid 0 mol% to less than 45 mol%, other monomer 0 mol % To less than 45 mol%, a radical polymerizable crosslinking agent in an amount of from 0 mol% to less than 5 mol%, and a carboxylic acid reactive crosslinking agent in an amount of from 0 mol% to less than 5 mol% are used as polymerization raw material solutions. The polymer obtained is subjected to a post-treatment process including a drying process and a heat treatment process, wherein the heat treatment is performed under the conditions represented by the following formula (11) or (12): The manufacturing method of the absorbent resin characterized by the above-mentioned.
−1.2T + 232 ≦ t ≦ −2.8T + 538 (185 ≦ T <190) (11)
−0.6T + 118 ≦ t ≦ −0.8T + 158 (190 ≦ T ≦ 195) (12)
(However, the total amount of unsaturated carboxylic acid ammonium salt, unsaturated carboxylic acid alkali metal salt, unsaturated carboxylic acid and other monomers is 100 mol%, and the radical polymerizable crosslinking agent and carboxylic acid reactive crosslinking agent mol%. Is an outer ratio with respect to 100 mol% defined above, and in the above formulas (11) and (12), T is the heat treatment temperature [° C.] and t is the heat treatment time [min].   The raw material solution for polymerization is 55 mol% or more and 100 mol% or less of (meth) acrylic acid ammonium salt, 0 to 45 mol% of (meth) acrylic acid alkali metal salt, and 0 to 45 mol% of (meth) acrylate. Solution containing less than mol%, other monomer 0 mol% or more and less than 45 mol%, radical polymerizable crosslinking agent 0 mol% or more and less than 5 mol%, and carboxylic acid reactive crosslinking agent 0 mol% or more and less than 5 mol% The method for producing a water-absorbent resin according to claim 1, wherein

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