JP2021017552A - Acrylic rubber bale excellent in storage stability and water resistance - Google Patents

Abstract

To provide an acrylic rubber bale excellent in storage stability and water resistance, a method for producing the same, a rubber mixture containing acrylic rubber bale, and a crosslinked product of the rubber.SOLUTION: The acrylic rubber bale according to the present invention comprises an acrylic rubber having a reactive group and a weight average molecular weight (Mw) of 100,000 to 5,000,000, and in which the ash content is 0.8 wt.% or less and the phosphorous amount in the ash is 10 wt.% or more, and the specific gravity is 0.8 or more.SELECTED DRAWING: None

Description

The present invention relates to an acrylic rubber bale, a method for producing the same, a rubber mixture and a rubber crosslinked product. More specifically, the present invention relates to an acrylic rubber bale having excellent storage stability and water resistance, a method for producing the same, and a rubber obtained by mixing the acrylic rubber bale. The present invention relates to a mixture and a rubber cross-linked product obtained by cross-linking the mixture.

Acrylic rubber is a polymer containing acrylic acid ester as a main component, and is generally known as rubber having excellent heat resistance, oil resistance, and ozone resistance, and is widely used in automobile-related fields and the like.

Such acrylic rubber is usually emulsion-polymerized with the monomer components constituting the acrylic rubber, brought into contact with the obtained emulsion polymerization solution and a coagulant, and the obtained hydrous crumb is dried and then veiled and commercialized. To.

For example, Patent Document 1 (Japanese Unexamined Patent Publication No. 2006-328239) describes a step of obtaining a crumb slurry containing a crumb-like rubber polymer by bringing a polymer latex into contact with a coagulating liquid, and a stirring power of 1 kW / m3 or more. A step of crushing the crumb-shaped rubber polymer contained in the crumb slurry with a mixer having a stirring / crushing function, and dehydration of removing water from the crumb slurry in which the crumb-shaped rubber polymer is crushed to obtain a crumb-shaped rubber polymer. A method for producing a rubber polymer comprising a step and a step of heating and drying the moisture-removed crumb-like rubber polymer is disclosed, and the dried crumb is introduced into a baler in the form of flakes, compressed and veiled. It is stated that it will be polymerized. Further, it is described that it is preferable to adjust the maximum width of the crumb to about 3 to 20 mm for crushing with a mixer having a stirring / crushing function. As the rubber polymer used here, an unsaturated nitrile-conjugated diene copolymer latex obtained by emulsification polymerization is specifically shown, and ethyl acrylate / n-butyl acrylate copolymer and ethyl acrylate / It has been shown that it can be applied to a copolymer composed only of an acrylate such as an n-butyl acrylate / 2-methoxyethyl acrylate copolymer. However, acrylic rubber composed only of acrylate has a problem that it is inferior in crosslinked rubber characteristics such as heat resistance and compression set resistance.

Examples of acrylic rubber having a reactive group having excellent heat resistance and compression resistance permanent strain characteristics are described in Patent Document 2 (International Publication No. 2018/116828) as ethyl acrylate, n-butyl acrylate and fumaric acid. Acrylic rubber latex obtained by emulsifying a monomer component composed of mono-n-butyl with sodium lauryl sulfate as an emulsifier, polyethylene glycol monostearate and water, and emulsion polymerization in the presence of a polymerization initiator until the polymerization conversion rate reaches 95%. Was added to an aqueous solution of magnesium sulfate and a polymer flocculant dimethylamine-ammonia-epichlorohydrin polycondensate, and then stirred at 85 ° C. to generate a crumb slurry, and then the crumb slurry was added to 1 A method of recovering a crumb-shaped acrylic rubber by passing the entire amount through a 100-mesh wire net after washing with water to capture only the solid content is disclosed. According to this method, it is described that the obtained hydrous crumb is dehydrated by centrifugation or the like, dried at 50 to 120 ° C. by a band dryer or the like, introduced into a baler, compressed and veiled. There is. However, this method has problems such as a large number of semi-solidified hydrous crumbs generated in the coagulation reaction and a large amount of adhering to the coagulation tank, and the coagulant and emulsifier cannot be sufficiently removed by washing. Even if it was veiled with a baler, there was a problem that it was inferior in water resistance and storage stability.

Japanese Unexamined Patent Publication No. 2006-328239 International Publication No. 2018/116828 Pamphlet

The present invention has been made in view of such circumstances, and provides an acrylic rubber veil having excellent storage stability and water resistance, a method for producing the same, a rubber mixture containing the acrylic rubber veil, and a crosslinked rubber product thereof. With the goal.

As a result of diligent research in view of the above problems, the present inventors have found that an acrylic rubber veil having a reactive group and having a specific molecular weight, ash content, specific component amount in ash content and specific gravity has improved storage stability and water resistance. Found to be excellent.

The present inventors also carry out emulsion polymerization of a monomer component containing a reactive group-containing monomer, wash the hydrous crumb produced by the coagulation reaction, and then dry it to a specific hydrous content with a specific screw type extruder. It has been found that an acrylic rubber bale having excellent storage stability and water resistance can be produced by extruding it as a dry rubber and bale the extruded dry rubber.

The present inventors further improve the strength characteristics and storage stability by converting the dried rubber extruded by the screw type extruder into a sheet-shaped dry rubber and laminating the extruded sheet-shaped dry rubber to form a veil. We have found that an excellent acrylic rubber veil can be produced.

The present inventors have also found that the water resistance and storage stability are remarkably improved by providing a dehydration step of squeezing out water from the water-containing crumb washed in the washing step before the drying step.
The present inventors have completed the present invention based on these findings.

Thus, according to the present invention, the acrylic rubber has a reactive group and has a weight average molecular weight (Mw) of 100,000 to 5,000,000, has an ash content of 0.8% by weight or less, and has a phosphorus content in the ash content. Acrylic rubber veil having a ratio of 10% by weight or more and a specific gravity of 0.8 or more is provided.

In the acrylic rubber veil of the present invention, the total amount of phosphorus and magnesium in the ash content is preferably 30% by weight or more in the ash content.

According to the present invention, a monomer component containing a (meth) acrylic acid ester and a reactive group-containing monomer is emulsified with water and a phosphoric acid-based emulsifier, emulsion-polymerized in the presence of a polymerization catalyst, and emulsion polymerization. A screw-type extrusion of an emulsion polymerization step of obtaining a liquid, a coagulation step of bringing the obtained emulsion polymerization liquid into contact with a coagulating liquid to generate a hydrous crumb, a cleaning step of washing the produced hydrous crumb, and the washed hydrous crumb. Provided is a method for producing an acrylic rubber bale, which comprises a drying step of extruding a dry rubber by drying it to a water content of less than 1% by weight using a machine and a bale step of laminating and bale the extruded dry rubber.

Further, in the method for producing an acrylic rubber veil of the present invention, it is preferable that the coagulating liquid is a magnesium salt aqueous solution.

Further, in the method for producing an acrylic rubber veil of the present invention, it is preferable to further provide a dehydration step of squeezing out water from the washed hydrous crumb.

Further, in the method for producing an acrylic rubber bale of the present invention, it is preferable that the extruded dry rubber is a sheet-shaped dry rubber and the bale is formed by laminating the sheet-shaped dry rubber.

According to the present invention, a rubber mixture obtained by mixing a filler and a cross-linking agent with the acrylic rubber veil is provided.

According to the present invention, a rubber crosslinked product obtained by cross-linking the rubber mixture is further provided.

According to the present invention, an acrylic rubber bale having excellent storage stability and water resistance, a method for producing the same, a rubber mixture obtained by mixing the acrylic rubber bale, and a rubber crosslinked product obtained by cross-linking the acrylic rubber bale are provided.

It is a figure which shows typically an example of the acrylic rubber manufacturing system used for manufacturing the acrylic rubber veil which concerns on one Embodiment of this invention. It is a figure which shows the structure of the screw type extruder of FIG. It is a figure which shows the structure of the transport type cooling apparatus used as the cooling apparatus of FIG.

The acrylic rubber veil of the present invention is composed of acrylic rubber having a reactive group and a weight average molecular weight (Mw) of 100,000 to 5,000,000, and has an ash content of 0.8% by weight or less and phosphorus in the ash content. It is characterized in that the ratio of the amount is 10% by weight or more and the specific gravity is 0.8 or more.

<Monomer component>
The acrylic rubber veil of the present invention is made of acrylic rubber having a reactive group.

The reactive group is appropriately selected depending on the intended use without any particular limitation, but preferably at least one functional group selected from the group consisting of a carboxyl group, an epoxy group and a halogen group, more preferably a carboxyl group. It is suitable because the cross-linking property of the acrylic rubber veil can be highly improved when it is a group. Further, as the reactive group, when it is an ionic reactive group such as a carboxyl group or an epoxy group, the water resistance can be particularly improved, which is preferable. As the acrylic rubber having such a reactive group, a reactive group may be imparted to the acrylic rubber by a post-reaction, but a copolymer of a reactive group-containing monomer is preferable.

The acrylic rubber constituting the acrylic rubber sheet of the present invention preferably contains (meth) acrylic acid ester, and is selected from the group consisting of (meth) acrylic acid alkyl ester and (meth) acrylic acid alkoxyalkyl ester. It preferably contains at least one (meth) acrylic acid ester.

Specific examples of the acrylic rubber having a preferable reactive group include at least one (meth) acrylic acid ester selected from the group consisting of (meth) acrylic acid alkyl ester and (meth) acrylic acid alkoxyalkyl ester, and a reactive group. Examples thereof include those composed of a contained monomer and other monomers copolymerizable as required.

The (meth) acrylic acid alkyl ester is not particularly limited, but usually has a (meth) acrylic acid alkyl ester having an alkyl group having 1 to 12 carbon atoms, preferably an alkyl having 1 to 8 carbon atoms (meth). ) Acrylic acid alkyl ester, more preferably a (meth) acrylic acid alkyl ester having an alkyl group having 2 to 6 carbon atoms.

Specific examples of the (meth) acrylic acid alkyl ester include methyl (meth) acrylic acid, ethyl (meth) acrylic acid, n-propyl (meth) acrylic acid, isopropyl (meth) acrylic acid, and n- (meth) acrylic acid. Butyl, isobutyl (meth) acrylate, n-hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate and the like, ethyl (meth) acrylate, (meth) acrylate n-butyl is preferable, and ethyl acrylate and n-butyl acrylate are more preferable.

The (meth) alkoxyalkyl ester is not particularly limited, but usually has 2 to 12 alkoxyalkyl groups (meth) acrylic acid alkoxyalkyl ester, preferably 2 to 8 alkoxyalkyl groups (meth). ) Acrylic acid alkoxyalkyl ester, more preferably a (meth) acrylic acid alkoxy ester having an alkoxyalkyl group having 2 to 6 carbon atoms.

Specific examples of the (meth) acrylate alkoxyalkyl ester include methoxymethyl (meth) acrylate, methoxyethyl (meth) acrylate, methoxypropyl (meth) acrylate, methoxybutyl (meth) acrylate, and (meth) acrylic. Examples thereof include ethoxymethyl acid, ethoxyethyl (meth) acrylate, propoxyethyl (meth) acrylate, butoxyethyl (meth) acrylate and the like. Among these, methoxyethyl (meth) acrylate, ethoxyethyl (meth) acrylate and the like are preferable, and methoxyethyl acrylate and ethoxyethyl acrylate are more preferable.

At least one (meth) acrylic acid ester selected from the group consisting of these (meth) acrylic acid alkyl esters and (meth) acrylic acid alkoxyalkyl esters may be used alone or in combination of two or more, and acrylic. The proportion in the rubber is usually 50% by weight or more, preferably 70 to 99.9% by weight, more preferably 80 to 99.5% by weight, and most preferably 87 to 99% by weight. If the amount of (meth) acrylic acid ester in the monomer component is excessively small, the weather resistance, heat resistance, and oil resistance of the obtained acrylic rubber may decrease, which is not preferable.

The reactive group-containing monomer is appropriately selected according to the purpose of use without any particular limitation, but is a single amount having at least one functional group selected from the group consisting of a carboxyl group, an epoxy group and a halogen group. The body is preferable, a monomer having an ionic reactive group such as a carboxyl group and an epoxy group is more preferable, and a monomer having a carboxyl group is particularly preferable.

The monomer having a carboxyl group is not particularly limited, but an ethylenically unsaturated carboxylic acid can be preferably used. Examples of the ethylenically unsaturated carboxylic acid include ethylenically unsaturated monocarboxylic acid, ethylenically unsaturated dicarboxylic acid, and ethylenically unsaturated dicarboxylic acid monoester, and among these, ethylenically unsaturated dicarboxylic acid monoester. It is preferable that the ester can further enhance the compression resistance permanent strain property when the acrylic rubber is used as a rubber crosslinked product.

The ethylenically unsaturated monocarboxylic acid is not particularly limited, but an ethylenically unsaturated monocarboxylic acid having 3 to 12 carbon atoms is preferable, and for example, acrylic acid, methacrylic acid, α-ethylacrylic acid, crotonic acid, etc. Examples thereof include crotonic acid.

The ethylenically unsaturated dicarboxylic acid is not particularly limited, but an ethylenically unsaturated dicarboxylic acid having 4 to 12 carbon atoms is preferable, and for example, butenedioic acid such as fumaric acid and maleic acid, itaconic acid, citraconic acid, and chloro. Maleic acid and the like can be mentioned. The ethylenically unsaturated dicarboxylic acid includes those existing as an anhydride.

The ethylenically unsaturated dicarboxylic acid monoester is not particularly limited, but is usually an ethylenically unsaturated dicarboxylic acid having 4 to 12 carbon atoms and an alkyl monoester having 1 to 12 carbon atoms, preferably 4 to 6 carbon atoms. Ethylene unsaturated dicarboxylic acid and an alkyl monoester having 2 to 8 carbon atoms, more preferably an alkyl monoester having 2 to 6 carbon atoms of buthenic acid having 4 carbon atoms.

Specific examples of the ethylenically unsaturated dicarboxylic acid monoester include monomethyl fumarate, monoethyl fumarate, mono n-butyl fumarate, monomethyl maleate, monoethyl maleate, mono n-butyl maleate, monocyclopentyl fumarate, and fumarate. Butendionic acid monoalkyl esters such as monocyclohexyl acid, monocyclohexenyl fumarate, monocyclopentyl maleate, and monocyclohexyl maleate; Examples thereof include monoalkyl esters; among these, mono n-butyl fumarate and mono n-butyl maleate are preferable, and mono n-butyl fumarate is particularly preferable.

Examples of the monomer having an epoxy group include an epoxy group-containing (meth) acrylic acid ester such as glycidyl (meth) acrylate; an epoxy group-containing vinyl ether such as allyl glycidyl ether and vinyl glycidyl ether; and the like.

Examples of the monomer having a halogen group include unsaturated alcohol esters of halogen-containing saturated carboxylic acids, (meth) acrylic acid haloalkyl esters, (meth) acrylic acid haloacyloxyalkyl esters, and (meth) acrylic acids (haloacetylcarbamoyl). Oxy) alkyl esters, halogen-containing unsaturated ethers, halogen-containing unsaturated ketones, halomethyl group-containing aromatic vinyl compounds, halogen-containing unsaturated amides, haloacetyl group-containing unsaturated monomers and the like can be mentioned.

Examples of the unsaturated alcohol ester of the halogen-containing saturated carboxylic acid include vinyl chloroacetate, vinyl 2-chloropropionate, and allyl chloroacetate. Examples of the (meth) acrylic acid haloalkyl ester include chloromethyl (meth) acrylic acid, 1-chloroethyl (meth) acrylic acid, 2-chloroethyl (meth) acrylic acid, and 1,2-dichloroethyl (meth) acrylic acid. Examples thereof include 2-chloropropyl (meth) acrylic acid, 3-chloropropyl (meth) acrylic acid, and 2,3-dichloropropyl (meth) acrylic acid. Examples of the (meth) acrylic acid haloacyloxyalkyl ester include (meth) acrylic acid 2- (chloroacetoxy) ethyl, (meth) acrylic acid 2- (chloroacetoxy) propyl, and (meth) acrylic acid 3- (chloroacetoxy). ) Propyl, 3- (hydroxychloroacetoxy) propyl (meth) acrylate and the like. Examples of the (meth) acrylic acid (haloacetylcarbamoyloxy) alkyl ester include (meth) acrylic acid 2- (chloroacetylcarbamoyloxy) ethyl and (meth) acrylic acid 3- (chloroacetylcarbamoyloxy) propyl. Be done. Examples of the halogen-containing unsaturated ether include chloromethyl vinyl ether, 2-chloroethyl vinyl ether, 3-chloropropyl vinyl ether, 2-chloroethyl allyl ether, 3-chloropropyl allyl ether and the like. Examples of the halogen-containing unsaturated ketone include 2-chloroethyl vinyl ketone, 3-chloropropyl vinyl ketone, 2-chloroethyl allyl ketone and the like. Examples of the halomethyl group-containing aromatic vinyl compound include p-chloromethylstyrene, m-chloromethylstyrene, o-chloromethylstyrene, and p-chloromethyl-α-methylstyrene. Examples of the halogen-containing unsaturated amide include N-chloromethyl (meth) acrylamide. Examples of the haloacetyl group-containing unsaturated monomer include 3- (hydroxychloroacetoxy) propylallyl ether and p-vinylbenzylchloroacetic acid ester.

Each of these reactive group-containing monomers is used alone or in combination of two or more, and the proportion in the acrylic rubber is usually 0.01 to 20% by weight, preferably 0.1 to 10% by weight. , More preferably 0.5 to 5% by weight, most preferably 1 to 3% by weight.

The other monomer used as needed is not particularly limited as long as it can be copolymerized with the above-mentioned monomer. For example, aromatic vinyl, ethylenically unsaturated nitrile, acrylamide-based monomer, and the like. Olefin-based monomers and the like. Examples of aromatic vinyl include styrene, α-methylstyrene, divinylbenzene and the like. Examples of the ethylenically unsaturated nitrile include acrylonitrile and methacrylonitrile. Examples of the acrylamide-based monomer include acrylamide and methacrylamide. Examples of other olefin-based monomers include ethylene, propylene, vinyl chloride, vinylidene chloride, vinyl acetate, ethyl vinyl ether, and butyl vinyl ether.

These other monomers are used alone or in combination of two or more, and the proportion in the acrylic rubber is usually 0 to 30% by weight, preferably 0 to 20% by weight, more preferably 0. It is in the range of ~ 15 parts by weight, most preferably 0 to 10 parts by weight.

<Acrylic rubber>
The acrylic rubber constituting the acrylic rubber veil of the present invention is characterized by having a reactive group.

The content of the reactive group may be appropriately selected according to the purpose of use, but is usually 0.001 to 5% by weight, preferably 0.01 to 3% by weight, based on the weight ratio of the reactive group itself. Workability, strength properties, compression set resistance, oil resistance, cold resistance, water resistance, etc. are preferably in the range of 0.05 to 1% by weight, particularly preferably 0.1 to 0.5% by weight. The characteristics are highly balanced and suitable.

Specific examples of the acrylic rubber constituting the acrylic rubber veil of the present invention include at least one (meth) acrylic acid ester selected from the group consisting of (meth) acrylic acid alkyl ester and (meth) acrylic acid alkoxyalkyl ester. It consists of a reactive group-containing monomer and, if necessary, other copolymerizable monomers, and the proportions in each acrylic rubber are (meth) acrylic acid alkyl ester and (meth) acrylic acid alkoxyalkyl ester. The binding unit derived from at least one (meth) acrylic acid ester selected from the group consisting of is usually 50% by weight or more, preferably 70 to 99.9% by weight, more preferably 80 to 99.5% by weight, particularly. It is preferably in the range of 87 to 99% by weight, and the bonding unit derived from the reactive group-containing monomer is usually 0.01 to 20% by weight, preferably 0.1 to 10% by weight, and more preferably 0.5. It is in the range of ~ 5% by weight, particularly preferably 1 to 3% by weight, and the binding unit derived from other monomers is usually 0 to 30% by weight, preferably 0 to 20% by weight, and more preferably 0 to 15% by weight. It is in the range of% by weight, particularly preferably 0 to 10% by weight. By setting the bonding unit derived from these monomers of acrylic rubber in this range, the object of the present invention can be highly achieved, and when the acrylic rubber veil is used as a crosslinked product, water resistance and compression resistance permanent strain characteristics are remarkably improved. It is improved and suitable.

The weight average molecular weight (Mw) of the acrylic rubber constituting the acrylic rubber veil of the present invention is an absolute molecular weight measured by GPC-MALS, which is 100,000 to 5,000,000, preferably 1,100,000 to 3. , 500,000, more preferably in the range of 1,200,000 to 2,500,000, the processability, strength characteristics, and compression resistance permanent strain characteristics of the acrylic rubber bale during mixing are highly balanced and suitable. Is.

The ratio (Mz / Mw) of the z average molecular weight (Mz) and the weight average molecular weight (Mw) of the acrylic rubber constituting the acrylic rubber veil of the present invention is not particularly limited, but is measured by GPC-MALS. The processability and strength characteristics of the acrylic rubber veil are highly balanced and preserved when the absolute molecular weight distribution is usually in the range of 1.3 or more, preferably 1.4 to 5, more preferably 1.5 to 2. It is suitable because it can alleviate changes in physical properties over time.

The ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) of the acrylic rubber constituting the acrylic rubber veil of the present invention is not particularly limited, but is absolutely measured by GPC-MALS. When the molecular weight distribution is usually in the range of 1.1 to 8, preferably 1.2 to 7, and more preferably 1.4 to 6, the processability, strength characteristics, and compression resistance permanent strain characteristics of the acrylic rubber bale are high. It is well-balanced and suitable.

The glass transition temperature (Tg) of the acrylic rubber constituting the acrylic rubber veil of the present invention is not particularly limited, but is usually 20 ° C. or lower, preferably 10 ° C. or lower, and more preferably 0 ° C. or lower. The lower limit of the glass transition temperature (Tg) of acrylic rubber is not particularly limited, but is usually −80 ° C. or higher, preferably −60 ° C. or higher, and more preferably −40 ° C. or higher. By setting the glass transition temperature to the lower limit or higher, the oil resistance and heat resistance can be improved, and by setting the glass transition temperature to the upper limit or lower, the cold resistance and workability can be improved.

The content of acrylic rubber in the acrylic rubber veil of the present invention is appropriately selected depending on the intended use, but is usually 95% by weight or more, preferably 97% by weight or more, and more preferably 98% by weight or more.

<Acrylic rubber veil>
The acrylic rubber veil of the present invention is made of the acrylic rubber, and is characterized in that the amount of ash, the amount of ash component, and the specific gravity are specific.

The size of the acrylic rubber veil of the present invention is not particularly limited, but the width is usually in the range of 100 to 800 mm, preferably 200 to 500 mm, more preferably 250 to 450 mm, and the length is usually 300 to 1200 mm. The height is usually in the range of 400 to 1000 mm, more preferably 500 to 800 mm, and the height is usually in the range of 50 to 500 mm, preferably 100 to 300 mm, more preferably 150 to 250 mm.

The ash content of the acrylic rubber veil of the present invention is. Although not particularly limited, 0.8% by weight or less, preferably 0.5% by weight or less, more preferably 0.4% by weight, particularly preferably 0.3% by weight or less, most preferably 0.2% by weight. When it is less than% by weight, it is excellent in storage stability and water resistance and is suitable.

The lower limit of the ash content of the acrylic rubber veil of the present invention is not particularly limited, but is usually 0.0001% by weight or more, preferably 0.0005% by weight or more, and more preferably 0.001% by weight or more. Particularly preferably, when it is 0.005% by weight or more, and most preferably 0.01% by weight or more, metal adhesion is suppressed and workability is excellent.

The content of at least one element selected from the group consisting of sodium, sulfur, calcium, magnesium and phosphorus in the ash content of the acrylic rubber veil of the present invention is not particularly limited, but is usually a ratio to the total ash content. When it is at least 30% by weight, preferably 50% by weight or more, more preferably 70% by weight or more, and particularly preferably 80% by weight or more, storage stability and water resistance are highly excellent and suitable.

The total amount of sodium and sulfur in the ash content of the acrylic rubber veil of the present invention is not particularly limited, but is usually 30% by weight or more, preferably 50% by weight or more, more preferably 70% by weight, as a ratio to the total ash content. % Or more, particularly preferably 80% by weight or more, the storage stability and water resistance are highly excellent and suitable.

The ratio of sodium to sulfur ([Na] / [S]) in the ash content of the acrylic rubber veil of the present invention is 0.4 to 2.5, preferably 0.6 to 2, preferably 0 by weight. When it is in the range of .8 to 1.7, more preferably 1 to 1.5, the water resistance is highly excellent and suitable.

The amount of phosphorus in the ash content of the acrylic rubber veil of the present invention is not particularly limited, but is usually 10% by weight or more, preferably 20 to 70% by weight, more preferably 30 to 65% by weight, as a ratio to the total ash content. Water resistance and storage stability are excellent and suitable when the weight is in the range of 40% by weight, particularly preferably 40 to 60% by weight.

The total amount of magnesium and phosphorus in the ash content of the acrylic rubber veil of the present invention is not particularly limited, but is usually 30% by weight or more, preferably 50% by weight or more, more preferably 70% by weight or more, as a ratio to the total ash content. When it is by weight or more, particularly preferably 80% by weight or more, storage stability and water resistance are highly excellent and suitable.

The ratio of magnesium to phosphorus ([Mg] / [P]) in the ash content of the acrylic rubber veil of the present invention is a weight ratio and is not particularly limited, but is usually 0.4 to 2.5, preferably 0. .4 to 1.3, more preferably 0.4 to 1, particularly preferably 0.45 to 0.75, most preferably 0.

The specific gravity of the acrylic rubber veil of the present invention is not particularly limited, but is 0.8 or more, preferably 0.8 to 1.4, more preferably 0.9 to 1.3, and particularly preferably 0. When it is in the range of 95 to 1.25, most preferably 1.0 to 1.2, the storage stability is highly excellent and suitable. When the specific gravity of the acrylic rubber bale is small, it indicates that the amount of air entrained in the acrylic rubber bale is large, and it greatly affects the storage stability including oxidative deterioration.

The gel amount of the acrylic rubber veil of the present invention is not particularly limited, but is an insoluble content of methyl ethyl ketone, and is usually 50% by weight or less, preferably 30% by weight or less, more preferably 20% by weight or less, particularly. When it is preferably 10% by weight or less, most preferably 5% by weight or less, the workability is highly improved and is preferable. The amount of gel, which is the insoluble matter of methyl ethyl ketone in the acrylic rubber veil of the present invention, has different characteristics depending on the solvent used, and does not particularly correlate with the amount of THF (tetrahydrofuran) insoluble gel.

The water content of the acrylic rubber veil of the present invention is not particularly limited, but the vulcanization property is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less. It is optimized and has excellent properties such as heat resistance and water resistance, and is suitable.

The pH of the acrylic rubber veil of the present invention is not particularly limited, but is usually 6 or less, preferably 2 to 6, more preferably 2.5 to 5.5, and particularly preferably 3 to 5. The storage stability is highly improved and is suitable.

The complex viscosity ([η] 60 ° C.) of the acrylic rubber veil of the present invention at 60 ° C. is not particularly limited, but is usually 15,000 Pa · s or less, preferably 2,000 to 10,000 Pa · s. , More preferably 2,500 to 7,000 Pa · s, and most preferably 2,700 to 5,500 Pa · s, which is excellent in processability, oil resistance and shape retention.

The complex viscosity ([η] 100 ° C.) of the acrylic rubber veil of the present invention at 100 ° C. is not particularly limited, but is usually 1,500 to 6,000 Pa · s, preferably 2,000 to 5, It is excellent in processability, oil resistance, and shape retention when it is in the range of 000 Pa · s, more preferably 2,500 to 4,000 Pa · s, and most preferably 2,500 to 3,500 Pa · s. ..

The ratio of the complex viscosity ([η] 100 ° C.) of the acrylic rubber veil of the present invention at 100 ° C. to the complex viscosity ([η] 60 ° C.) at 60 ° C. ([η] 100 ° C./[η] 60 ° C.) Is not particularly limited, but is usually in the range of 0.5 or more, preferably 0.5 to 0.98, more preferably 0.6 to 0.95, and most preferably 0.75 to 0.93. In addition, workability, oil resistance, and shape retention are highly balanced and suitable.

The Mooney viscosity (ML1 + 4,100 ° C.) of the acrylic rubber veil of the present invention is not particularly limited, but is usually processed when it is in the range of 10 to 150, preferably 20 to 100, and more preferably 25 to 70. It is suitable because its properties and strength characteristics are highly balanced.

<Manufacturing method of acrylic rubber veil>
In the acrylic rubber veil, a monomer component containing a (meth) acrylic acid ester and a reactive group-containing monomer is emulsionized with water and a phosphoric acid-based emulsifier, and the polymerization conversion rate is 90% by weight in the presence of a polymerization catalyst. The emulsion polymerization step of emulsion polymerization to obtain an emulsion polymerization solution and
A coagulation step of bringing the obtained emulsion polymerization solution into contact with the coagulation solution to form a hydrous crumb,
A cleaning process to clean the generated hydrous crumbs,
A dehydration / drying / molding process in which the washed water-containing crumb is dried to a water content of less than 1% by weight using a screw extruder and the dried rubber is extruded.
A veiling process to veil the extruded dry rubber,
It can be easily manufactured by a manufacturing method including.

(Emulsion polymerization process)
In the emulsion polymerization step in the method for producing an acrylic rubber veil of the present invention, a monomer component containing a (meth) acrylic acid ester and a reactive group-containing monomer is emulsionized with water and an emulsifier and polymerized in the presence of a polymerization catalyst. This is a step of obtaining an emulsion polymerization solution by emulsion polymerization to a conversion rate of 90% by weight or more.

The monomer component used is the same as that described in the monomer component, and the amount used may be appropriately selected so as to have the monomer composition of the acrylic rubber constituting the acrylic rubber veil. Often, the amount is usually the same as the monomer composition of the acrylic rubber constituting the acrylic rubber veil.

The phosphoric acid-based emulsifier used is not particularly limited as long as it is usually used in the emulsion polymerization reaction. For example, an alkyloxypolyoxyalkylene phosphoric acid ester or a salt thereof or an alkylphenyloxypolyoxyalkylene is used. A phosphoric acid ester or a salt thereof can be preferably used.

Examples of the alkyloxypolyoxyalkylene phosphate or its salt include an alkyloxypolyoxyethylene phosphate or a salt thereof, an alkyloxypolyoxypropylene phosphate or a salt thereof, and among these, alkyloxypoly Oxyethylene phosphate or a salt thereof is preferable, and alkyloxypolyoxyethylene phosphate is particularly preferable.

Examples of the alkyloxypolyoxyethylene phosphate or a salt thereof include octyloxydioxyethylene phosphate, octyloxytrioxyethylene phosphate, octyloxytetraoxyethylene phosphate, and decyloxytetraoxyethylene phosphate. Estel, dodecyloxytetraoxyethylene phosphate, tridecyloxytetraoxyethylene phosphate, tetradecyloxytetraoxyethylene phosphate, hexadecyloxytetraoxyethylene phosphate, octadecyloxytetraoxyethylene phosphate, Octyloxypentaoxyethylene Phosphate, Decyloxypentaoxyethylene Phosphate, Dodecyloxypentaoxyethylene Phosphate, Tridecyloxypentaoxyethylene Phosphate, Tetradecyloxypentaoxyethylene Phosphate, Hexadecyloxy Pentaoxyethylene Phosphate, Octadecyloxypentaoxyethylene Phosphate, Octyloxyhexaoxyethylene Phosphate, Decyloxyhexaoxyethylene Phosphate, Dodecyloxyhexaoxyethylene Phosphate, Tridecyloxyhexaoxyethylene Phosphate Acid ester, tetradecyloxyhexaoxyethylene phosphoric acid ester, hexadecyloxyhexaoxyethylene phosphoric acid ester, octadecyloxyhexaoxyethylene phosphoric acid ester, octyloxyoctaoxyethylene phosphoric acid ester, decyloxyoctaoxyethylene phosphoric acid ester, Dodecyloxyoctaoxyethylene phosphoric acid ester, tridecyloxyoctaoxyethylene phosphate ester, tetradecyloxyoctaoxyethylene phosphate ester, hexadecyloxyoctaoxyethylene phosphate ester, octadecyloxyoctaoxyethylene phosphate ester, etc. Examples thereof include those metal salts, preferably those metal salts, more preferably those alkali metal salts, and most preferably their sodium salts.

The alkyloxypolyoxypropylene phosphate or its salt is not particularly limited, but for example, octyloxydioxypropylene phosphate, octyloxytrioxypropylene phosphate, octyloxytetraoxypropylene phosphate, etc. Decyloxytetraoxypropylene phosphate ester, dodecyloxytetraoxypropylene phosphate ester, tridecyloxytetraoxypropylene phosphate ester, tetradecyloxytetraoxypropylene phosphate ester, hexadecyloxytetraoxypropylene phosphate ester, octadecyloxy Tetraoxypropylene Phosphate, Octyloxypentaoxypropylene Phosphate, Decyloxypentaoxypropylene Phosphate, Dodecyloxypentaoxypropylene Phosphate, Tridecyloxypentaoxypropylene Phosphate, Tetradecyloxypentaoxypropylene Phosylate, Hexadecyloxypentaoxypropylene Phosphate, Octadecyloxypentaoxypropylene Phosphate, Octyloxyhexaoxypropylene Phosphate, Decyloxyhexaoxypropylene Phosphate, Dodecyloxyhexaoxypropylene Phosphate, Tridecyloxyhexaoxypropylene phosphate ester, tetradecyloxyhexaoxypropylene phosphate ester, hexadecyloxyhexaoxypropylene phosphate ester, octadecyloxyhexaoxypropylene phosphate ester, octyloxyoctoxypropylene phosphate ester, decyloxy Octaoxypropylene Phosphate, Dodecyloxyoctaoxypropylene Phosphate, Tridecyloxyoctaoxyethylene Phosphate, Tetradecyloxyoctaoxypropylene Phosphate, Hexadecyloxyoctaoxypropylene Phosphate, Octadecyloxyoctaoxy Examples thereof include propylene phosphate and the like, and metal salts thereof, preferably those metal salts, more preferably those alkali metal salts, and most preferably their sodium salts.

Examples of the alkylphenyloxypolyoxyalkylene phosphate or its salt include alkylphenyloxypolyoxyethylene phosphate or its salt, alkylphenyloxypolyoxypropylene phosphate or its salt, and the like. Alkylphenyloxypolyoxyethylene phosphate salts are preferred.

Examples of the alkylphenyloxypolyoxyethylene phosphate or its salt include methyloxyoxytetraoxyethylene phosphate, ethylphenyloxytetraoxyethylene phosphate, butylphenyloxytetraoxyethylene phosphate, and hexylphenyloxy. Tetraoxyethylene Phosphate, Nonylphenyloxytetraoxyethylene Phosphate, Dodecylphenyloxytetraoxyethylene Phosphate, Octadecyloxytetraoxyethylene Phosphate, Methylphenyloxypentaoxyethylene Phosphate, Ethylphenyloxypenta Oxyethylene Phosphate, Butylphenyloxypentaoxyethylene Phosphate, Hexylphenyloxypentaoxyethylene Phosphate, Nonylphenyloxypentaoxyethylene Phosphate, Dodecylphenyloxypentaoxyethylene Phosphate, Methylphenyloxyhexa Oxyethylene Phosphate, Ethylphenyloxyhexaoxyethylene Phosphate, Butylphenyloxyhexaoxyethylene Phosphate, Hexylphenyloxyhexaoxyethylene Phosphate, Nonylphenyloxyhexaoxyethylene Phosphate, Dodecylphenyloxyhexa Oxyethylene Phosphate, Methylphenyloxyhexaoxyethylene Phosphate, Ethylphenyloxyoctaoxyethylene Phosphate, Butylphenyloxyoctaoxyethylene Phosphate, Hexylphenyloxyoctaoxyethylene Phosphate, Nonylphenyloxyocta Examples thereof include oxyethylene phosphate, dodecylphenyloxyoctaoxyethylene phosphate and the like, and their metal salts, preferably with their metal salts, more preferably with their alkali metal salts, most preferably with their sodium salts. is there.

The alkylphenyloxypolyoxypropylene phosphate or its salt is not particularly limited, but for example, methylphenyloxytetraoxypropylene phosphate, ethylphenyloxytetraoxypropylene phosphate, and butylphenyloxytetraoxypropylene. Phosylate, Hexylphenyloxytetraoxypropylene Phosphate, Nonylphenyloxytetraoxypropylene Phosphate, Dodecylphenyloxytetraoxypropylene Phosphate, Methylphenyloxypentaoxypropylene Phosphate, Ethylphenyloxypentaoxypropylene Phosphate, Butylphenyloxypentaoxypropylene Phosphate, Hexylphenyloxypentaoxypropylene Phosphate, Nonylphenyloxypentaoxypropylene Phosphate, Dodecylphenyloxypentaoxypropylene Phosphate, Methylphenyloxyhexaoxypropylene Phosylate, Ethylphenyloxyhexaoxypropylene Phosphate, Butylphenyloxyhexaoxypropylene Phosphate, Hexylphenyloxyhexaoxypropylene Phosphate, Nonylphenyloxyhexaoxypropylene Phosphate, Dodecylphenyloxyhexaoxypropylene Phosphate, Methylphenyloxyoctaoxypropylene Phosphate, Ethylphenyloxyoctaoxypropylene Phosphate, Butylphenyloxyoctaoxypropylene Phosphate, Hexylphenyloxyoctaoxyethylene Phosphate, Nonylphenyloxyoctaoxypropylene Examples thereof include phosphoric acid esters, dodecylphenyloxyoctaoxypropylene phosphate esters, and metal salts thereof, preferably those metal salts, more preferably their alkali metal salts, and most preferably their sodium salts.

As a method of mixing the monomer component, water and emulsifier, a conventional method may be followed, and examples thereof include a method of stirring the monomer, emulsifier and water using a stirrer such as a homogenizer or a disk turbine. .. The amount of water used is usually in the range of 10 to 750 parts by weight, preferably 50 to 500 parts by weight, and more preferably 100 to 400 parts by weight with respect to 100 parts by weight of the monomer component.

The polymerization catalyst used is not particularly limited as long as it is usually used in emulsion polymerization, and for example, a redox catalyst composed of a radical generator and a reducing agent can be used.

Examples of the radical generator include peroxides and azo compounds, and peroxides are preferable. As the peroxide, an inorganic peroxide or an organic peroxide is used.

Examples of the inorganic peroxide include sodium persulfate, potassium persulfate, hydrogen peroxide, ammonium persulfate and the like. Among these, potassium persulfate, hydrogen peroxide and ammonium persulfate are preferable, and potassium persulfate is particularly preferable. preferable.

The organic peroxide is not particularly limited as long as it is a known organic peroxide used in emulsion polymerization. For example, 2,2-di (4,5-di- (t-butylperoxy) cyclohexyl) propane. , 1-di- (t-hexyl peroxy) cyclohexane, 1,1-di- (t-butyl peroxy) cyclohexane, 4,4-di- (t-butyl peroxy) n-butyl valerate, 2, 2-Di- (t-butylperoxy) butane, t-butylhydroperoxide, cumenehydroperoxide, diisopropylbenzenehydroperoxide, paramentanhydroperoxide, benzoyl peroxide, 1,1,3,3-tetraethyl Butylhydroperoxide, t-butylcumyl peroxide, di-t-butyl peroxide, di-t-hexyl peroxide, di (2-t-butylperoxyisopropyl) benzene, dicumyl peroxide, diisobutyryl peroxide , Di (3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, disuccinic acid peroxide, dibenzoyl peroxide, di (3-methylbenzoyl) peroxide, benzoyl (3-methylbenzoyl) peroxide , Diisobutyryl peroxydicarbonate, di-n-propyl peroxydicarbonate, di (2-ethylhexyl) peroxydicarbonate, di-sec-butylperoxydicarbonate, 1,1,3,3-tetramethylbutyl Peroxyneodecanate, t-hexylperoxypivarate, t-butylperoxyneodecanate, t-hexylperoxypivarate, t-butylperoxypivarate, 2,5-dimethyl-2,5-di (2-Ethylhexanoylperoxy) hexane, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanate, t-hexylperoxy-2-ethylhexanate, t-butylperoxy-3 , 5,5-trimethylhexanate, t-hexulperoxyisopropyl monocarbonate, t-butylperoxyisopropyl monocarbonate, t-buylperoxy-2-ethylhexyl monocarbonate, 2,5-dimethyl-2,5 -Di (benzoylperoxy) hexane, t-butylperoxyacetate, t-hexylperoxybenzoate, t-butylperoxybenzoate, 2,5-dimethyl-2,5-di ( Examples thereof include t-butylperoxy) hexane, and among these, diisopropylbenzene hydroperoxide, cumene hydroperoxide, paramentan hydroperoxide, benzoyl peroxide and the like are preferable.

Examples of the azo compound include azobisisobutyronitrile, 4,4'-azobis (4-cyanovaleric acid), 2,2'-azobis [2- (2-imidazolin-2-yl) propane, 2,2. '-Azobis (Propane-2-carboamidine), 2,2'-Azobis [N- (2-carboxyethyl) -2-methylpropaneamide], 2,2'-Azobis {2- [1- (2- (2-) Hydroxyethyl) -2-imidazolin-2-yl] propane}, 2,2'-azobis (1-imino-1-pyrrolidino-2-methylpropane) and 2,2'-azobis {2-methyl-N- [ 1,1-bis (hydroxymethyl) -2-hydroxyethyl] propanamide} and the like.

Each of these radical generators can be used alone or in combination of two or more, and the amount used is usually 0.0001 to 5 parts by weight, preferably 0.0001 to 5 parts by weight, based on 100 parts by weight of the monomer component. It is in the range of 0.0005 to 1 part by weight, more preferably 0.001 to 0.5 part by weight.

As the reducing agent, any one used in the redox catalyst of emulsion polymerization can be used without particular limitation, but in the present invention, it is particularly preferable to use at least two kinds of reducing agents. As the at least two types of reducing agents, for example, a combination of a metal ion compound in a reduced state and another reducing agent is suitable.

The metal ion compound in the reduced state is not particularly limited, and examples thereof include ferrous sulfate, sodium hexamethylenediamine tetraacetate, and cuprous naphthenate, and among these, ferrous sulfate is preferable. Each of these reduced metal ion compounds can be used alone or in combination of two or more, and the amount used is usually 0.000001 to 0. With respect to 100 parts by weight of the monomer component. It is in the range of 01 parts by weight, preferably 0.00001 to 0.001 parts by weight, and more preferably 0.00005 to 0.0005 parts by weight.

The reducing agent other than the metal ion compound in the reduced state is not particularly limited, but is, for example, ascorbic acid such as ascorbic acid, sodium ascorbate, potassium ascorbate or a salt thereof; erythorbic acid, sodium erythorbicate, erythorbin. Elysorbic acid such as potassium acid or a salt thereof; sulphinate such as sodium hydroxymethane sulfite; sodium sulfite, potassium sulfite, sodium hydrogen sulfite, aldehyde sodium bisulfite, potassium hydrogen sulfite sulfite; sodium pyrosulfite, potassium pyrosulfite Pyro sulfites such as sodium bisulfite and potassium hydrogen pyrosulfite; thiosulfates such as sodium thiosulfite and potassium thiosulfite; of sodium bisulfite, sodium bisulfite, potassium bisulfite, sodium hydrogen phosphite, potassium hydrogen phosphite Pyrophosphoric acid or a salt thereof; pyroaphosphate or a salt thereof such as pyrophosphate, sodium pyrophosphate, potassium pyrophosphate, sodium bisulfite, potassium hydrogenpyrophosphate and the like; sodium formaldehyde sulfoxylate and the like. Among these, alcorbic acid or a salt thereof, sodium formaldehyde sulfoxylate and the like are preferable, and ascorbic acid or a salt thereof is particularly preferable.

The reducing agents other than the metal ion compounds in the reduced state can be used alone or in combination of two or more, and the amount used is usually 0.001 with respect to 100 parts by weight of the monomer component. It is in the range of ~ 1 part by weight, preferably 0.005 to 0.5 parts by weight, and more preferably 0.01 to 0.3 parts by weight.

A preferred combination of the reducing metal ion compound and the other reducing agent is ferrous sulfate and ascorbic acid or a salt thereof and / or sodium formaldehyde sulfoxylate, more preferably ferrous sulfate and ascorbate. And / or sodium formaldehyde sulfoxylate, most preferably a combination of ferrous sulfate and alcorbate. At this time, the amount of ferrous sulfate used is usually 0.000001 to 0.01 parts by weight, preferably 0.00001 to 0.001 parts by weight, more preferably 0.00001 parts by weight, based on 100 parts by weight of the monomer component. In the range of 0.00005 to 0.0005 parts by weight, the amount of ascorbic acid or a salt thereof and / or sodium formaldehyde sulfoxylate used is usually 0.001 to 1 part by weight with respect to 100 parts by weight of the monomer component. It is preferably in the range of 0.005 to 0.5 parts by weight, more preferably 0.01 to 0.3 parts by weight.

The amount of water used in the emulsion polymerization reaction may be only the one used at the time of emulsification of the monomer component, but is usually 10 to 1000 parts by weight, preferably 50 parts by weight, based on 100 parts by weight of the monomer component used for polymerization. It is adjusted to be in the range of ~ 500 parts by weight, more preferably 80 to 400 parts by weight, and most preferably 100 to 300 parts by weight.

The emulsion polymerization reaction may be carried out according to a conventional method, and may be a batch type, a semi-batch type or a continuous type. The polymerization temperature and the polymerization time are not particularly limited and can be appropriately selected from the type of polymerization initiator used and the like. The polymerization temperature is usually in the range of 0 to 100 ° C., preferably 5 to 80 ° C., more preferably 10 to 50 ° C., and the polymerization time is usually 0.5 to 100 hours, preferably 1 to 10 hours.

The polymerization conversion rate of the emulsion polymerization reaction is not particularly limited, but is excellent in the strength characteristics of the acrylic rubber bale produced when it is usually 80% by weight or more, preferably 90% by weight or more, and more preferably 95% by weight or more. Moreover, there is no monomeric odor and it is suitable. A polymerization inhibitor may be used to terminate the polymerization.

(Coagulation process)
The coagulation step in the method for producing an acrylic rubber sheet of the present invention is characterized in that the obtained emulsion polymerization solution is added to a stirring coagulation solution (coagulant-containing aqueous solution) to generate a hydrous crumb.

The solid content concentration of the emulsion polymerization solution used in the coagulation step is not particularly limited, but is usually adjusted to the range of 5 to 50% by weight, preferably 10 to 45% by weight, and more preferably 20 to 40% by weight. To.

The coagulant used is not particularly limited, but a metal salt is usually used. Examples of the metal salt include alkali metals, Group 2 metal salts of the Periodic Table, and other metal salts, preferably alkali metal salts, Group 2 metal salts of the Periodic Table, and more preferably Group 2 metals of the Periodic Table. A salt, particularly preferably a magnesium salt.

Examples of the alkali metal salt include sodium salts such as sodium chloride, sodium nitrate and sodium sulfate; potassium salts such as potassium chloride, potassium nitrate and potassium sulfate; and lithium salts such as lithium chloride, lithium nitrate and lithium sulfate. Among these, sodium salts are preferable, and sodium chloride and sodium sulfate are particularly preferable.

Examples of the Group 2 metal salt of the periodic table include magnesium chloride, calcium chloride, magnesium nitrate, calcium nitrate, magnesium sulfate, calcium sulfate and the like, preferably calcium chloride, magnesium sulfate, and more preferably magnesium sulfate.

Other metal salts include, for example, zinc chloride, titanium chloride, manganese chloride, iron chloride, cobalt chloride, nickel chloride, aluminum chloride, tin chloride, zinc nitrate, titanium nitrate, manganese nitrate, iron nitrate, cobalt nitrate, nickel nitrate. , Aluminum nitrate, tin nitrate, zinc sulfate, titanium sulfate, manganese sulfate, iron sulfate, cobalt sulfate, nickel sulfate, aluminum sulfate, tin sulfate and the like.

Each of these coagulants can be used alone or in combination of two or more, and the amount used is usually 0.01 to 100 parts by weight, preferably 0, with respect to 100 parts by weight of the monomer component. It is in the range of 1 to 50 parts by weight, more preferably 1 to 30 parts by weight. When the coagulant is in this range, the acrylic rubber can be sufficiently solidified, and the compression-resistant permanent strain resistance and water resistance when the acrylic rubber veil is crosslinked can be highly improved, which is preferable.

The coagulant concentration of the coagulant is usually in the range of 0.1 to 20% by weight, preferably 0.5 to 15% by weight, more preferably 1 to 10% by weight, and particularly preferably 1.5 to 5. It is suitable because the particle size of the produced hydrous crumb can be uniformly focused in a specific region.

The temperature of the coagulating liquid is not particularly limited, but is preferably 40 ° C. or higher, preferably 40 to 90 ° C., more preferably 50 to 80 ° C., to form a uniform water-containing crumb.

The stirring speed (rotation speed) of the coagulated liquid being stirred is, that is, the rotation speed of the stirring blade of the stirring device, and is not particularly limited, but is usually 100 rpm or more, preferably 200 to 1000 rpm, and more preferably 300 to 900 rpm. , Especially preferably in the range of 400 to 800 rpm. It is preferable that the rotation speed is a rotation speed in which the mixture is vigorously agitated to some extent so that the water-containing crumb particle size to be generated can be made small and uniform. The formation of and can be suppressed, and the solidification reaction can be more easily controlled by setting the content to the upper limit or less.

The peripheral speed of the coagulated liquid being agitated, that is, the speed of the outer circumference of the stirring blade of the agitating device is not particularly limited, but the water-containing crumb particle size generated by being vigorously agitated to a certain degree is smaller and It can be made uniform and is preferable, usually 0.5 m / s or more, preferably 1 m / s or more, more preferably 1.5 m / s or more, particularly preferably 2 m / s or more, and most preferably 2.5 m / s or more. On the other hand, the upper limit of the peripheral speed is not particularly limited, but usually solidifies when it is 50 m / s or less, preferably 30 m / s or less, more preferably 25 m / s or less, and most preferably 20 m / s or less. It is suitable because the reaction can be easily controlled.

It is produced by setting the above conditions of the coagulation reaction in the coagulation step (contact method, solid content concentration of emulsion polymerization solution, concentration and temperature of coagulation solution, rotation speed and peripheral speed of coagulation solution during stirring, etc.) within a specific range. The shape and crumb diameter of the hydrous crumb are uniform and focused, and the removal of emulsifiers and coagulants during washing and dehydration is remarkably improved, which is suitable.

(Washing process)
The cleaning step in the method for producing an acrylic rubber veil of the present invention is a step of cleaning the produced hydrous crumb with water.

The cleaning method is not particularly limited and may follow a conventional method. For example, the produced hydrous crumb can be mixed with a large amount of water.

The amount of water used is not particularly limited, but the amount per washing with water is usually 50 parts by weight or more, preferably 50 to 15,000 parts by weight, based on 100 parts by weight of the monomer component. The amount of ash in the acrylic rubber can be effectively reduced, preferably in the range of 100 to 10,000 parts by weight, particularly preferably in the range of 150 to 5,000 parts by weight.

The temperature of the water to be washed with water is not particularly limited, but it is preferable to use warm water, usually 40 ° C. or higher, preferably 40 to 100 ° C., more preferably 50 to 90 ° C., and most preferably 60 to 80 ° C. It is suitable because the cleaning efficiency can be significantly increased at ℃.

By setting the temperature of the washing water to the above lower limit or higher, the emulsifier and the coagulant are released from the water-containing crumb, and the washing efficiency is further improved.

The washing time is not particularly limited, but is usually in the range of 1 to 120 minutes, preferably 2 to 60 minutes, and more preferably 3 to 30 minutes.

The number of washings is not particularly limited, and is usually 1 to 10 times, preferably a plurality of times, and more preferably 2 to 3 times. From the viewpoint of reducing the residual amount of the coagulant in the finally obtained acrylic rubber, it is desirable that the number of times of washing with water is large, but the shape and diameter of the water-containing crumb should be specified and / or By setting the cleaning temperature within the above range, the number of cleanings can be significantly reduced.

(Dehydration process)
In the method for producing an acrylic rubber veil of the present invention, a dehydration step of squeezing out water from the water-containing crumb after washing is provided before the drying step to reduce the amount of ash composed of emulsifiers and coagulants that could not be removed in the washing step. It is suitable because it can be reduced to significantly improve the water resistance of the acrylic rubber bale and improve the storage stability and workability.

The dehydrator is not particularly limited and may follow a conventional method. Examples thereof include a centrifuge, a squeezer, and a screw type extruder. In particular, the screw type extruder has a high water content of a water-containing crumb. It is suitable because it can be lowered to. Adhesive acrylic rubber adheres to the wall surface and slits in a centrifuge and can usually be dehydrated only to about 45 to 55% by weight, and water is forcibly squeezed out like a screw type extruder. A mechanism is suitable.

The water content of the hydrous crumb after dehydration is not particularly limited, but is usually 1 to 50% by weight, preferably 1 to 40% by weight, more preferably 10 to 40% by weight, and more preferably 15 to 35% by weight. The range. By setting the water content after dehydration to be equal to or higher than the lower limit, the dehydration time can be shortened and deterioration of acrylic rubber can be suppressed, and by setting it to be lower than the upper limit, the amount of ash can be sufficiently reduced.

(Drying process)
The drying step in the method for producing an acrylic rubber veil of the present invention is a step of using a screw type extruder to dry the hydrous crumb after the cleaning and preferably dehydration, and extrude the dried rubber having a moisture content of less than 1% by weight. ..

The temperature of the hydrous crumb charged into the screw type extruder is not particularly limited, but is usually 40 ° C. or higher, preferably 40 to 100 ° C., more preferably 50 to 90 ° C., particularly preferably 55 to 85 ° C., most preferably. When the temperature is in the range of 60 to 80 ° C, the water-containing crumb, which has a large specific heat of 1.5 to 2.5 KJ / kg · K and is difficult to raise the temperature like the acrylic rubber of the present invention, is surely dried in the screw type extruder. Can be preferred. In particular, in the present invention, the hydrous crumb is dried in a screw type extruder to a state in which it is substantially free of water (moisture content after dehydration below) and melt-kneaded, so that the polymerization of emulsion polymerization is particularly carried out during production. It is important because it eliminates the gel content that increases rapidly when the conversion rate is increased.

The drying temperature of the screw type extruder may be appropriately selected, but when it is usually in the range of 100 to 250 ° C., preferably 110 to 200 ° C., more preferably 120 to 180 ° C., the acrylic rubber is burnt or deteriorated. It is suitable because it can be dried efficiently and the amount of gel of the acrylic rubber veil can be reduced.
The shape of the dried rubber is not particularly limited, and examples thereof include a crumb shape, a powder shape, a rod shape, and a sheet shape. Among these, when the dry rubber is made into a sheet shape, air is not entrained (the specific gravity is large). ) It is suitable because it can be made into an acrylic rubber veil with excellent storage stability.

The water content of the dried rubber is less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less.

(Veiling process)
The bale step in the method for producing an acrylic rubber veil of the present invention is a step of bale the obtained dry rubber having a water content of less than 1% by weight.

The bale of the dried rubber may be made according to a conventional method. For example, the dried rubber can be put in a baler and compressed for production. The pressure to be compressed is appropriately selected according to the intended use, but is usually in the range of 0.1 to 15 MPa, preferably 0.5 to 10 MPa, and more preferably 1 to 5 MPa. The compression time is not particularly limited, but is usually in the range of 1 to 60 seconds, preferably 5 to 30 seconds, and more preferably 10 to 20 seconds.

In the present invention, it is also possible to prepare a sheet-shaped dry rubber and laminate it to form a veil. Veiling by laminating sheets is suitable because it is easy to manufacture, and a bale with few bubbles (large specific gravity) can be formed, and it is excellent in storage stability, processability and handleability.

(Dehydration / drying process and bale process using screw type extruder)
In the present invention, it is preferable to perform the dehydration step and the drying step by using a dehydration barrel having a dehydration slit, a drying barrel for drying under reduced pressure, and a screw type extruder provided with a die at the tip. After that, it is preferable to carry out the bale step, and the embodiment is shown below.

Draining process In the method for producing an acrylic rubber bale of the present invention, it is necessary to provide a draining step for separating free water from the water-containing crumb after cleaning with a drainer before shifting from the washing step to the dehydration / drying step. It is suitable for raising.

As the drainer, a known one can be used without particular limitation, and examples thereof include a wire mesh, a screen, an electric sieve, and the like, preferably a wire mesh and a screen.

The opening of the drainer is not particularly limited, but when it is usually in the range of 0.01 to 5 mm, preferably 0.1 to 1 mm, and more preferably 0.2 to 0.6 mm, the water content crumb loss is small. Moreover, draining can be done efficiently, which is suitable.

The water content of the water-containing crumb after draining, that is, the water content of the water-containing crumb added to the dehydration / drying / molding step is not particularly limited, but is usually 50 to 80% by weight, preferably 50 to 70% by weight. , More preferably in the range of 50-60% by weight.

The temperature of the water-containing crumb after draining, that is, the temperature of the water-containing crumb put into the dehydration / drying / molding step is not particularly limited, but is usually 40 ° C. or higher, preferably 40 to 95 ° C., more preferably 50 ° C. It is in the range of ~ 90 ° C., particularly preferably 55 to 85 ° C., most preferably 60 to 80 ° C.

Dehydration of the dehydration barrel part Dehydration of the dry water-containing crumb is performed in a dehydration barrel having a dehydration slit. The opening of the dehydration slit may be appropriately selected according to the conditions of use, but when it is usually in the range of 0.1 to 1 mm, preferably 0.2 to 0.6 mm, the loss of the water-containing crumb is small. Moreover, the hydrous crumb can be efficiently dehydrated, which is suitable.

The number of dehydration barrels in the screw extruder is not particularly limited, but usually a plurality, preferably 2 to 10, more preferably 3 to 6, is used to dehydrate the adhesive acrylic rubber. It is suitable for efficient operation.

There are two ways to remove water from the water-containing crumb in the dehydration barrel: one that removes water from the dehydration slit in liquid form (drainage) and one that removes water in the form of vapor (exhaust vapor). In the present invention, the drainage is dehydrated. Exhaust steam is defined as dry and distinguished.

When using a screw type extruder equipped with a plurality of dehydration barrels, it is preferable to combine drainage and exhaust steam because drainage (dehydration) of the adhesive acrylic rubber and reduction of water content can be efficiently performed. The selection of the drainage type dehydration barrel or the exhaust steam type dehydration barrel of the screw type extruder equipped with three or more dehydration barrels may be appropriately performed according to the purpose of use, but the amount of ash in the acrylic rubber usually produced is small. In this case, the number of drainage barrels is increased. For example, when there are three dehydration barrels, two drainage barrels are selected, and when there are four dehydration barrels, three drainage barrels are appropriately selected.

The set temperature of the dehydration barrel is appropriately selected depending on the type of acrylic rubber, ash content, water content, operating conditions, etc., but is usually 60 to 150 ° C., preferably 70 to 140 ° C., more preferably 80 to 130 ° C. The range. The set temperature of the dehydration barrel for dehydrating in the drained state is usually 60 ° C. to 120 ° C., preferably 70 to 110 ° C., and more preferably 80 to 100 ° C. The set temperature of the dehydration barrel that dries in the exhausted steam state is usually in the range of 100 to 150 ° C., preferably 105 to 140 ° C., and more preferably 110 to 130 ° C.

The water content after dehydration of the drainage type that squeezes water from the water-containing crumb is not particularly limited, but is usually 1 to 45% by weight, preferably 1 to 40% by weight, more preferably 5 to 35% by weight, and particularly preferably. Is preferably 10 to 35% by weight because the productivity and the distribution removal efficiency are highly balanced.

When dehydration of adhesive acrylic rubber is performed using a centrifuge or the like, the acrylic rubber adheres to the dehydration slit portion and can hardly be dehydrated (water content is up to about 45 to 55% by weight), but in the present invention. By using a screw type extruder that has a dehydration slit and is forcibly squeezed with a screw, the water content can be reduced to this extent.

In the dehydration of the water-containing crumb when the drain type dehydration barrel and the exhaust steam type dehydration barrel are provided, the water content in the drain type dehydration barrel portion is usually 5 to 45% by weight, preferably 10 to 40% by weight, more preferably 15 to. The water content in the exhaust steam type dehydration barrel portion is usually 1 to 30% by weight, preferably 3 to 20% by weight, and more preferably 5 to 15% by weight.

By setting the water content after dehydration to be equal to or higher than the lower limit, the dehydration time can be shortened and deterioration of acrylic rubber can be suppressed, and by setting it to be lower than the upper limit, the amount of ash can be sufficiently reduced.

Drying the Dry Barrel The hydrous crumb that has been dehydrated and dried in the dehydration barrel is further dried in the dry barrel under reduced pressure.

The degree of decompression of the drying barrel may be appropriately selected, but it is preferable that the hydrous crumb can be efficiently dried when it is usually 1 to 50 kPa, preferably 2 to 30 kPa, and more preferably 3 to 20 kPa.

The set temperature of the drying barrel may be appropriately selected, but when it is usually in the range of 100 to 250 ° C., preferably 110 to 200 ° C., more preferably 120 to 180 ° C., there is no discoloration or deterioration of the acrylic rubber. It is suitable because it can be dried efficiently and the amount of acrylic rubber gel can be reduced.

The number of drying barrels in the screw type extruder is not particularly limited, but is usually a plurality, preferably 2 to 10 barrels, and more preferably 3 to 8 barrels. When a plurality of dry barrels are provided, the degree of decompression may be an approximate degree of decompression for all the dry barrels, or may be changed. When there are multiple drying barrels, the set temperature may be an approximate temperature for all the drying barrels or may be changed, but it is closer to the discharge part (closer to the die) than the temperature of the introduction part (closer to the dehydration barrel). It is preferable to raise the temperature of (1) because the drying efficiency can be increased.

The water content of the dried rubber after drying is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less.

Acrylic rubber shape (die part)
The acrylic rubber dehydrated and dried by the screw portion of the dehydration barrel and the drying barrel is sent to the screwless rectifying die portion. A breaker plate or wire mesh may or may not be provided between the screw portion and the die portion.

Acrylic rubber to be extruded can be obtained in various shapes such as granular, columnar, round bar, and sheet depending on the nozzle shape of the die. By making the die shape substantially rectangular and forming it into a sheet, air is entrained. It is suitable because a dry rubber having a small amount of water and a large specific gravity and excellent storage stability can be obtained.

The resin pressure in the die portion is not particularly limited, but when it is usually in the range of 0.1 to 10 MPa, preferably 0.5 to 5 MPa, more preferably 1 to 3 MPa, there is little air entrainment and the productivity is excellent. Suitable.

Screw-type extruder and operating conditions The screw length (L) of the screw-type extruder used may be appropriately selected according to the purpose of use, but is usually 3000 to 15000 mm, preferably 4000 to 10000 mm, and more preferably 4500. The range is ~ 8000 mm.

The screw diameter (D) of the screw type extruder used may be appropriately selected depending on the intended use, but is usually in the range of 50 to 250 mm, preferably 100 to 200 mm, and more preferably 120 to 160 mm.

The ratio (L / D) of the screw length (L) to the screw diameter (D) of the screw type extruder used is not particularly limited, but is usually 10 to 100, preferably 20 to 80. When it is preferably in the range of 30 to 60, particularly preferably 40 to 50, the water content can be reduced to less than 1% by weight without causing a decrease in the molecular weight or burning of the dried rubber.

The rotation speed (N) of the screw type extruder used may be appropriately selected according to various conditions, but is usually 10 to 1000 rpm, preferably 50 to 750 rpm, more preferably 100 to 500 rpm, and most preferably 120. At ~ 300 rpm, the water content and gel amount of acrylic rubber can be efficiently reduced, which is preferable.

The extrusion amount (Q) of the screw type extruder used is not particularly limited, but is usually 100 to 1,500 kg / hr, preferably 300 to 1200 kg / hr, more preferably 400 to 1000 kg / hr, and most preferably 500. It is in the range of ~ 800 kg / hr.

The ratio (Q / N) of the extrusion amount (Q) to the rotation speed (N) of the screw type extruder used is not particularly limited, but is usually 2 to 10, preferably 3 to 8, more preferably. Is in the range of 4-6.

The shape of the dried rubber extruded from the dry rubber screw type extruder is not particularly limited, and examples thereof include a crumb shape, a powder shape, a rod shape, a sheet shape, and the sheet shape is particularly preferable.

The temperature of the dry rubber extruded from the screw type extruder is not particularly limited, but is usually in the range of 100 to 200 ° C., preferably 110 to 180 ° C., and more preferably 120 to 160 ° C.

The water content of the dry rubber extruded from the screw type extruder is less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less.

Bale-making step The bale-making step after the dehydration and drying steps by the screw type extruder is a step of bale-forming the extruded dried rubber. The bale of the dried rubber may be made according to a conventional method. For example, the dried rubber can be put in a baler and compressed for production. The compression pressure of the baler may be appropriately selected depending on the intended use, but is usually in the range of 0.1 to 15 MPa, preferably 0.5 to 10 MPa, and more preferably 1 to 5 MPa. The compression temperature is not particularly limited, but is usually in the range of 10 to 80 ° C, preferably 20 to 60 ° C, and more preferably 30 to 60 ° C. The compression time may be appropriately selected depending on the intended use, but is usually in the range of 1 to 100 seconds, preferably 2 to 50 seconds, and more preferably 5 to 25 seconds.

In the present invention, the sheet-shaped dried rubber can be extruded from the screw type extruder in the dehydration and drying steps, cut if necessary, and laminated to form a veil. Veiling by laminating sheet-shaped dry rubber is suitable because it is easy to manufacture, and a bale with few bubbles (large specific gravity) can be formed, and it has excellent storage stability. The following shows a mode in which the sheet-shaped dry rubber is extruded from the screw type extruder, and then the sheets are laminated and veiled.

The thickness of the sheet-shaped dry rubber extruded from the screw type extruder is not particularly limited, but is usually in the range of 1 to 40 mm, preferably 2 to 35 mm, more preferably 3 to 30 mm, and most preferably 5 to 25 mm. It is suitable because it has excellent workability and productivity at some time. In particular, since the thermal conductivity of the sheet-shaped dry rubber is as low as 0.15 to 0.35 W / mK, the thickness of the sheet-shaped dry rubber is usually 1 to 30 mm when the cooling efficiency is increased and the productivity is remarkably improved. The range is preferably 2 to 25 mm, more preferably 3 to 15 mm, and particularly preferably 4 to 12 mm.

The width of the sheet-shaped dry rubber extruded from the screw type extruder is appropriately selected depending on the intended use, but is usually in the range of 300 to 1200 mm, preferably 400 to 1000 mm, and more preferably 500 to 800 mm.

The temperature of the sheet-shaped dry rubber extruded from the screw type extruder is not particularly limited, but is usually in the range of 100 to 200 ° C., preferably 110 to 180 ° C., and more preferably 120 to 160 ° C.

The complex viscosity ([η] 100 ° C.) of the sheet-shaped dry rubber extruded from the screw type extruder at 100 ° C. is not particularly limited, but is usually 1,500 to 6,000 Pa · s, preferably 2. Extrudability and shape retention as a sheet when it is in the range of 5,000 to 5,000 Pa · s, more preferably 2,500 to 4,000 Pa · s, and most preferably 2,500 to 3,500 Pa · s. Is highly balanced and suitable. That is, when it is set to the lower limit or more, the extrudability can be improved, and when it is set to the upper limit or less, the shape of the sheet-shaped dried rubber can be suppressed from collapsing or breaking.

In the present invention, the sheet-shaped dry rubber extruded from the screw type extruder is suitable because it is laminated after cutting and veiled because the amount of air involved is small and the storage stability is excellent. The cutting of the sheet-shaped dry rubber is not particularly limited, but since the acrylic rubber of the acrylic rubber veil of the present invention has strong adhesiveness, the sheet-shaped dry rubber is used for continuous cutting without entraining air. It is preferable to cool it down.

The cutting temperature of the sheet-shaped dry rubber is not particularly limited, but when it is usually 60 ° C. or lower, preferably 55 ° C. or lower, more preferably 50 ° C. or lower, the cutability and productivity are highly balanced and preferable. Is.

The complex viscosity ([η] 60 ° C.) of the sheet-shaped dry rubber at 60 ° C. is not particularly limited, but is usually 15,000 Pa · s or less, preferably 2,000 to 10,000 Pa · s. When it is preferably in the range of 2,500 to 7,000 Pa · s, most preferably 2,700 to 5,500 Pa · s, it is preferable that it can be cut continuously without entraining air.

The ratio of the complex viscosity at 100 ° C. ([η] 100 ° C.) to the complex viscosity at 60 ° C. ([η] 60 ° C.) ([η] 100 ° C./[η] 60 ° C.) of the sheet-shaped dry rubber is Although there is no particular limitation, air is usually in the range of 0.5 or more, preferably 0.5 to 0.98, more preferably 0.6 to 0.95, and most preferably 0.75 to 0.93. It is suitable because it has low entanglement and has a high balance between cutting and productivity.

The method for cooling the sheet-shaped dry rubber is not particularly limited and may be left at room temperature. However, since the thermal conductivity of the sheet-shaped dry rubber is very small, 0.15 to 0.35 W / mK, it is blown or blown. Forced cooling such as an air cooling method under cooling, a water spraying method in which water is sprayed, or an immersion method in which water is immersed is preferable in order to increase productivity, and an air cooling method in which air is blown or cooled is particularly preferable.

In the air-cooled method of sheet-shaped dry rubber, for example, the sheet-shaped dry rubber can be extruded from a screw-type extruder onto a conveyor such as a belt conveyor, and can be conveyed and cooled while blowing cold air. The temperature of the cold air is not particularly limited, but is usually in the range of 0 to 25 ° C, preferably 5 to 25 ° C, and more preferably 10 to 20 ° C. The length to be cooled is not particularly limited, but is usually in the range of 5 to 500 m, preferably 10 to 200 m, and more preferably 20 to 100 m. The cooling rate of the sheet-shaped dry rubber is not particularly limited, but it is particularly easy to cut when it is usually 50 ° C./hr or more, more preferably 100 ° C./hr or more, and more preferably 150 ° C./hr or more. It is suitable.

The cutting length of the sheet-shaped dry rubber is not particularly limited and may be appropriately selected according to the size of the acrylic rubber bale to be manufactured, but is usually 100 to 800 mm, preferably 200 to 500 mm, more preferably 250 to 450 mm. Is the range of.

The sheet-shaped dry rubber after cutting is laminated and integrated into a veil. The laminating temperature of the sheet-shaped dry rubber is not particularly limited, but is preferably 30 ° C. or higher, preferably 35 ° C. or higher, more preferably 40 ° C. or higher, because air entrained during laminating can escape. The number of laminated layers may be appropriately selected according to the size or weight of the acrylic rubber veil.

The acrylic rubber veil of the present invention thus obtained has excellent operability and storage stability as compared with crumb-shaped acrylic rubber, and the acrylic rubber veil can be used as it is or cut into a required amount and put into a mixer such as a vanbury or roll. Can be used.

<Rubber mixture>
The rubber mixture of the present invention is characterized in that the acrylic rubber veil is mixed with a filler and a cross-linking agent.

The filler is not particularly limited, and examples thereof include a reinforcing filler and a non-reinforcing filler, and a reinforcing filler is preferable.

Examples of the reinforcing filler include carbon black such as furnace black, acetylene black, thermal black, channel black, and graphite; silica such as wet silica, dry silica, and colloidal silica; and the like. Examples of the non-reinforcing filler include quartz powder, silica soil, zinc oxide, basic magnesium carbonate, active calcium carbonate, magnesium silicate, aluminum silicate, titanium dioxide, talc, aluminum sulfate, calcium sulfate, barium sulfate and the like. be able to.

Each of these fillers can be used alone or in combination of two or more, and the blending amount thereof is appropriately selected within a range that does not impair the effect of the present invention, with respect to 100 parts by weight of the acrylic rubber veil. It is usually in the range of 1 to 200 parts by weight, preferably 10 to 150 parts by weight, and more preferably 20 to 100 parts by weight.

The cross-linking agent may be appropriately selected according to the type and application of the reactive group contained in the acrylic rubber constituting the acrylic rubber bale, but is not particularly limited as long as it can cross-link the acrylic rubber bale. , For example, polyvalent amine compounds such as diamine compounds, and carbonates thereof; sulfur compounds; sulfur donors; triazinethiol compounds; polyvalent epoxy compounds; ammonium organic carboxylates; organic peroxides; polyvalent carboxylic acids; Conventionally known cross-linking agents such as a secondary onium salt; an imidazole compound; an isocyanuric acid compound; an organic peroxide; and a triazine compound; can be used. Among these, polyvalent amine compounds, ammonium carboxylates, metal dithiocarbamic acid salts and triazinethiol compounds are preferable, hexamethylenediamine carbamate, 2,2'-bis [4- (4-aminophenoxy) phenyl] propane, and benzoate. Ammonium acid, 2,4,6-trimercapto-1,3,5-triazine is particularly preferred.

When the acrylic rubber veil to be used is composed of a carboxyl group-containing acrylic rubber, it is preferable to use a polyvalent amine compound and a carbonate thereof as a cross-linking agent. Examples of the polyvalent amine compound include aliphatic polyvalent amine compounds such as hexamethylenediamine, hexamethylenediamine carbamate, and N, N'-dicinnamylidene-1,6-hexanediamine; 4,4'-methylenedianiline, p. -Phenylenediamine, m-Phenylenediamine, 4,4'-diaminodiphenyl ether, 3,4'-diaminodiphenyl ether, 4,4'-(m-Phenylenediisopropyridene) dianiline, 4,4'-(p-phenylenedi) Isopropylidene) dianiline, 2,2'-bis [4- (4-aminophenoxy) phenyl] propane, 4,4'-diaminobenzanilide, 4,4'-bis (4-aminophenoxy) biphenyl, m-xyli Aromatic polyvalent amine compounds such as rangeamine, p-xylylenediamine, 1,3,5-benzenetriamine; and the like. Among these, hexamethylenediamine carbamate, 2,2'-bis [4- (4-aminophenoxy) phenyl] propane and the like are preferable.

When the acrylic rubber veil to be used is composed of an epoxy group-containing acrylic rubber, the cross-linking agent is an aliphatic polyvalent amine compound such as hexamethylenediamine or hexamethylenediamine carbamate, and a carbonate thereof; 4,4'-methylene. Aromatic polyvalent amine compounds such as dianiline; ammonium carboxylic acid salts such as ammonium benzoate and ammonium adipate; metal dithiocarbamic acid salts such as zinc dimethyldithiocarbamate; polyvalent carboxylic acids such as tetradecanodic acid; cetyltrimethylammonium bromide Tertiary onium salts such as; imidazole compounds such as 2-methylimidazole; isocyanuric acid compounds such as ammonium isocyanurate; among these, ammonium carboxylic acid salt and metal dithiocarbamate salt are preferable, and ammonium benzoate is preferable. Is more preferable.

When the acrylic rubber veil to be used is composed of a halogen atom-containing acrylic rubber, it is preferable to use sulfur, a sulfur donor, or a triazine thiol compound as a cross-linking agent. Examples of the sulfur donor include dipentamethylene thiuram hexasulfide and triethyl thiuram disulfide. Examples of the triazine compound include 6-trimercapto-s-triazine, 2-anilino-4,6-dithiol-s-triazine, 1-dibutylamino-3,5-dimercaptotriazine, 2-dibutylamino-4, 6-Dithiol-s-Triazine, 1-Phenylamino-3,5-Dimercaptotriazine, 2,4,6-Trimercapto-1,3,5-Triazine, 1-Hexylamino-3,5-Dimercaptotriazine Among these, 2,4,6-trimercapto-1,3,5-triazine is preferable.

Each of these cross-linking agents can be used alone or in combination of two or more, and the blending amount thereof is usually 0.001 to 20 parts by weight, preferably 0.1 parts by weight, based on 100 parts by weight of the acrylic rubber veil. It is 10 parts by weight, more preferably 0.1 to 5 parts by weight. By setting the blending amount of the cross-linking agent within this range, it is possible to make the mechanical strength of the rubber cross-linked product excellent while making the rubber elasticity sufficient, which is preferable.

In the rubber mixture of the present invention, other rubber components other than the acrylic rubber veil can be used, if necessary.

Other rubber components used as needed are not particularly limited, for example, natural rubber, polybutadiene rubber, polyisoprene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, silicon rubber, fluororubber, olefin-based. Examples thereof include elastomers, styrene-based elastomers, vinyl chloride-based elastomers, polyester-based elastomers, polyamide-based elastomers, polyurethane-based elastomers, and polysiloxane-based elastomers. The shape of the other rubber components is not particularly limited, and may be, for example, a crumb shape, a sheet shape, a veil shape, or the like.

These other rubber components can be used alone or in combination of two or more. The amount of these other rubber components used is appropriately selected within a range that does not impair the effects of the present invention.

The rubber mixture of the present invention can be blended with an anti-aging agent, if necessary. The anti-aging agent is not particularly limited, but is 2,6-di-t-butyl-4-methylphenol, 2,6-di-t-butylphenol, butylhydroxyanisole, 2,6-di-t-butyl-. α-Dimethylamino-p-cresol, octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate, styrenated phenol, 2,2'-methylene-bis (6-α-methyl-) Benzyl-p-cresol), 4,4'-methylenebis (2,6-di-t-butylfunol), 2,2'-methylene-bis (4-methyl-6-t-butylphenol), 2,4-bis [(Octylthio) Methyl] -6-methylphenol, 2,2'-thiobis- (4-methyl-6-t-butylphenol), 4,4'-thiobis- (6-t-butyl-o-cresol), Other phenolic antioxidants such as 2,6-di-t-butyl-4- (4,6-bis (octylthio) -1,3,5-triazine-2-ylamino) phenol; tris (nonylphenyl) Phenolic acid ester anti-aging agents such as phosphite, diphenylisodecylphosphite, tetraphenyldipropylene glycol diphosphite; sulfur ester anti-aging agents such as dilauryl thiodipropionate; phenyl-α-naphthylamine, phenyl-β- Naftylamine, p- (p-toluenesulfonylamide) -diphenylamine, 4,4'-(α, α-dimethylbenzyl) diphenylamine, N, N-diphenyl-p-phenylenediamine, N-isopropyl-N'-phenyl-p -Amine-based antioxidants such as phenylenediamine, butylaldehyde-aniline condensate; imidazole-based antioxidants such as 2-mercaptobenzimidazole; 6-ethoxy-2,2,4-trimethyl-1,2-dihydroquinolin, etc. Kinolin-based anti-aging agents; hydroquinone-based anti-aging agents such as 2,5-di- (t-amyl) hydroquinone; and the like. Of these, amine-based anti-aging agents are particularly preferable.

These anti-aging agents can be used alone or in combination of two or more, and the blending amount thereof is 0.01 to 15 parts by weight, preferably 0.% by weight, based on 100 parts by weight of the acrylic rubber veil. It is in the range of 1 to 10 parts by weight, more preferably 1 to 5 parts by weight.

The rubber mixture of the present invention contains the acrylic rubber veil of the present invention, a filler, a cross-linking agent and, if necessary, other rubber components and an anti-aging agent, and is usually used in the art as necessary. Optional blending of other additives such as cross-linking aids, cross-linking accelerators, cross-linking retarders, silane coupling agents, plasticizers, processing aids, rubbers, pigments, colorants, antistatic agents, foaming agents, etc. it can. These other compounding agents can be used alone or in combination of two or more, and the compounding amount thereof is appropriately selected within a range that does not impair the effects of the present invention.

<Manufacturing method of rubber mixture>
The method for producing the rubber mixture is not limited to each, and examples thereof include a method of mixing the acrylic rubber veil of the present invention with the filler, the cross-linking agent, and the other compounding agent which can be contained if necessary. Any means conventionally used in the field of rubber processing, such as an open roll, a Banbury mixer, and various kneaders, can be used for mixing. That is, using these mixers, the acrylic rubber veil can be mixed by directly mixing the filler, the cross-linking agent and the like, preferably by directly kneading.

In that case, the acrylic rubber bale may be used as it is or after being divided (cut or the like).

The mixing procedure of each component is not particularly limited, but for example, after sufficiently mixing the components that are difficult to react or decompose with heat, the reaction or decomposition occurs with a cross-linking agent that is a component that easily reacts or decomposes with heat. Two-step mixing is preferred, in which the mixture is mixed in a short time at no temperature. Specifically, it is preferable to mix the acrylic rubber veil and the filler in the first step and then mix the cross-linking agent in the second step. Other rubber components and anti-aging agents are usually mixed in the first stage, the cross-linking accelerator may be selected in the second stage, and other compounding agents may be appropriately selected.

The Mooney viscosity (ML1 + 4,100 ° C.; compound Mooney) of the rubber mixture of the present invention thus obtained is not particularly limited, but is usually in the range of 10 to 150, preferably 20 to 100, and more preferably 25 to 80. Is.

<Rubber crosslinked product>
The rubber crosslinked product of the present invention is obtained by cross-linking the above rubber mixture.

The rubber crosslinked product of the present invention is formed by using the rubber mixture of the present invention with a molding machine corresponding to a desired shape, for example, an extruder, an injection molding machine, a compressor, a roll, or the like, and is crosslinked by heating. It can be produced by carrying out a reaction and fixing the shape as a rubber crosslinked product. In this case, cross-linking may be performed after molding in advance, or cross-linking may be performed at the same time as molding. The molding temperature is usually 10 to 200 ° C, preferably 25 to 150 ° C. The cross-linking temperature is usually 100 to 250 ° C., preferably 130 to 220 ° C., more preferably 150 to 200 ° C., and the cross-linking time is usually 0.1 minutes to 10 hours, preferably 1 minute to 5 hours. As the heating method, a method used for cross-linking rubber such as press heating, steam heating, oven heating, and hot air heating may be appropriately selected.

The rubber crosslinked product of the present invention may be further heated for secondary cross-linking depending on the shape and size of the rubber cross-linked product. The secondary cross-linking varies depending on the heating method, cross-linking temperature, shape and the like, but is preferably carried out for 1 to 48 hours. The heating method and heating temperature may be appropriately selected.

The rubber crosslinked product of the present invention is a sealing material such as an O-ring, packing, diaphragm, oil seal, shaft seal, bearing sheath, mechanical seal, well head seal, seal for electric / electronic equipment, seal for air compression equipment, and the like. A unit cell equipped with a rocker cover gasket attached to the connecting portion between the cylinder block and the cylinder head, an oil pan gasket attached to the connecting portion between the oil pan and the cylinder head or the transmission case, a positive electrode, an electrolyte plate and a negative electrode. Various gaskets such as gaskets for fuel cell separators and gaskets for top covers of hard disk drives mounted between a pair of sandwiched housings; cushioning material, vibration isolator; wire coating material; industrial belts; tubes and hoses; sheets It is preferably used as;

The rubber cross-linked product of the present invention is also used as an extruded molded product and a molded cross-linked product used in automobile applications, for example, fuel oil for fuel tanks such as fuel hoses, filler neck hoses, bent hoses, paper hoses, and oil hoses. It is suitably used for various hoses such as air hoses such as system hoses, turbo air hoses and mission control hoses, radiator hoses, heater hoses, brake hoses and air conditioner hoses.

<Device configuration used for manufacturing acrylic rubber veils>
Next, an apparatus configuration used for manufacturing an acrylic rubber veil according to an embodiment of the present invention will be described. FIG. 1 is a diagram schematically showing an example of an acrylic rubber manufacturing system having an apparatus configuration used for manufacturing an acrylic rubber veil according to an embodiment of the present invention. For the production of the acrylic rubber according to the present invention, for example, the acrylic rubber production system 1 shown in FIG. 1 can be used.

The acrylic rubber manufacturing system 1 shown in FIG. 1 is composed of an emulsion polymerization reactor (not shown), a coagulation device 3, a cleaning device 4, a drainer 43, a screw type extruder 5, a cooling device 6, and a bale device 7. ..

The emulsion polymerization reactor is configured to perform the treatment related to the emulsion polymerization step described above. Although not shown in FIG. 1, this emulsion polymerization reactor includes, for example, a polymerization reaction tank, a temperature control unit for controlling the reaction temperature, a motor, and a stirring device including a stirring blade. In the emulsion polymerization reactor, water and a phosphate-based emulsifier are mixed with a monomer component for forming acrylic rubber, emulsified while being appropriately stirred with a stirrer, and emulsion-polymerized in the presence of a polymerization catalyst. An emulsion polymerization solution can be obtained. The emulsion polymerization reactor may be a batch type, a semi-batch type, or a continuous type, and may be any of a tank type reactor and a tube type reactor.

The coagulation device 3 shown in FIG. 1 is configured to perform the process related to the coagulation step described above. As schematically shown in FIG. 1, the coagulation device 3 includes, for example, a stirring tank 30, a heating unit 31 for heating the inside of the stirring tank 30, and a temperature control unit (not shown) for controlling the temperature inside the stirring tank 30. It has a stirring device 34 including a motor 32 and a stirring blade 33, and a drive control unit (not shown) that controls the rotation speed and rotation speed of the stirring blade 33. In the coagulation apparatus 3, a hydrous crumb can be produced by bringing the emulsion polymerization solution obtained by the emulsion polymerization reactor into contact with the coagulation solution as a coagulant and coagulating it.

In the coagulation device 3, for example, a method of adding the emulsion polymerization solution to the stirring magnesium salt aqueous solution is adopted for the contact between the emulsion polymerization solution and the coagulation solution. That is, a water-containing crumb is generated by filling the stirring tank 30 of the coagulation device 3 with a coagulation liquid and adding and contacting the emulsion polymerization liquid with the coagulation liquid to coagulate the emulsion polymerization liquid.

The heating unit 31 of the coagulation device 3 is configured to heat the coagulation liquid filled in the stirring tank 30. Further, the temperature control unit of the coagulation device 3 controls the temperature inside the stirring tank 30 by controlling the heating operation by the heating unit 31 while monitoring the temperature inside the stirring tank 30 measured by the thermometer. It is configured. The temperature of the coagulating liquid in the stirring tank 30 is controlled by the temperature control unit so as to be usually in the range of 40 ° C. or higher, preferably 40 to 90 ° C., and more preferably 50 to 80 ° C.

The stirring device 34 of the coagulating device 3 is configured to stir the coagulating liquid filled in the stirring tank 30. Specifically, the stirring device 34 includes a motor 32 that generates rotational power and a stirring blade 33 that extends in a direction perpendicular to the rotation axis of the motor 32. The stirring blade 33 can flow the coagulating liquid by rotating around the rotation axis by the rotational power of the motor 32 in the coagulating liquid filled in the stirring tank 30. The shape and size of the stirring blade 33, the number of installations, and the like are not particularly limited.

The drive control unit of the solidifying device 3 is configured to control the rotational drive of the motor 32 of the stirring device 34 to set the rotation speed and the rotation speed of the stirring blade 33 of the stirring device 34 to predetermined values. The rotation of the stirring blade 33 is controlled by the drive control unit so that the stirring number of the coagulating liquid is, for example, usually 100 rpm or more, preferably 200 to 1000 rpm, more preferably 300 to 900 rpm, and particularly preferably 400 to 800 rpm. Will be done. The peripheral speed of the coagulant is usually 0.5 m / s or more, preferably 1 m / s or more, more preferably 1.5 m / s or more, particularly preferably 2 m / s or more, and most preferably 2.5 m / s or more. The rotation of the stirring blade 33 is controlled by the drive control unit. Further, the drive control unit agitates the coagulant so that the upper limit of the peripheral speed is usually 50 m / s or less, preferably 30 m / s or less, more preferably 25 m / s or less, and most preferably 20 m / s or less. The rotation of the wing 33 is controlled.

The cleaning device 4 shown in FIG. 1 is configured to perform the processing related to the cleaning step described above. As schematically shown in FIG. 1, the cleaning device 4 includes, for example, a cleaning tank 40, a heating unit 41 that heats the inside of the cleaning tank 40, and a temperature control unit (not shown) that controls the temperature inside the cleaning tank 40. Have. In the cleaning device 4, the amount of ash in the finally obtained acrylic rubber veil can be effectively reduced by mixing the water-containing crumb generated by the coagulation device 3 with a large amount of water and cleaning.

The heating unit 41 of the cleaning device 4 is configured to heat the inside of the cleaning tank 40. Further, the temperature control unit of the cleaning device 4 controls the temperature inside the cleaning tank 40 by controlling the heating operation by the heating unit 41 while monitoring the temperature inside the cleaning tank 40 measured by the thermometer. It is configured. As described above, the temperature of the washing water in the washing tank 40 is usually controlled to be in the range of 40 ° C. or higher, preferably 40 to 100 ° C., more preferably 50 to 90 ° C., and most preferably 60 to 80 ° C. To.

The water-containing crumb washed by the washing device 4 is supplied to the screw type extruder 5 that performs the dehydration step and the drying step. At this time, it is preferable that the water-containing crumb after cleaning is supplied to the screw type extruder 5 through a drainer 43 capable of separating free water. For the drainer 43, for example, a wire mesh, a screen, an electric sieve, or the like can be used.

Further, when the water-containing crumb after cleaning is supplied to the screw type extruder 5, the temperature of the water-containing crumb is preferably 40 ° C. or higher, more preferably 60 ° C. or higher. For example, by setting the temperature of the water used for washing in the washing device 4 to 60 ° C. or higher (for example, 70 ° C.), the temperature of the water-containing crumb when supplied to the screw type extruder 5 is maintained at 60 ° C. or higher. The temperature of the hydrous crumb may be 40 ° C. or higher, preferably 60 ° C. or higher when it is conveyed from the cleaning device 4 to the screw type extruder 5. As a result, the dehydration step and the drying step, which are the subsequent steps, can be effectively performed, and the water content of the finally obtained dried rubber can be significantly reduced.

The screw type extruder 5 shown in FIG. 1 is configured to perform the processes related to the above-mentioned dehydration step and drying step. Although the screw type extruder 5 is shown as a suitable example in FIG. 1, a centrifuge, a squeezer, or the like may be used as the dehydrator for performing the treatment related to the dehydration step. A hot air dryer, a vacuum dryer, an expander dryer, a kneader type dryer, or the like may be used as the dryer.

The screw type extruder 5 is configured to mold the dried rubber obtained through the dehydration step and the drying step into a predetermined shape and discharge it. Specifically, the screw type extruder 5 has a dehydration barrel portion 53 having a function as a dehydrator for dehydrating the hydrous crumb washed by the cleaning device 4, and a drying machine having a function as a dryer for drying the hydrous crumb. A barrel portion 54 is provided, and a die 59 having a molding function for forming a water-containing crumb is provided on the downstream side of the screw type extruder 5.

Hereinafter, the configuration of the screw type extruder 5 will be described with reference to FIG. FIG. 2 shows a configuration of a specific example suitable for the screw type extruder 5 shown in FIG. With this screw type extruder 5, the above-mentioned dehydration / drying step can be suitably performed.

The screw type extruder 5 shown in FIG. 2 is a biaxial screw type extruder / dryer provided with a pair of screws (not shown) in the barrel unit 51. The screw type extruder 5 has a drive unit 50 that rotationally drives a pair of screws in the barrel unit 51. The drive unit 50 is attached to the upstream end (left end in FIG. 2) of the barrel unit 51. Further, the screw type extruder 5 has a die 59 at the downstream end (right end in FIG. 2) of the barrel unit 51.

The barrel unit 51 has a supply barrel portion 52, a dehydration barrel portion 53, and a dry barrel portion 54 from the upstream side to the downstream side (from the left side to the right side in FIG. 2).

The supply barrel portion 52 is composed of two supply barrels, that is, a first supply barrel 52a and a second supply barrel 52b.

Further, the dehydration barrel portion 53 is composed of three dehydration barrels, that is, a first dehydration barrel 53a, a second dehydration barrel 53b, and a third dehydration barrel 53c.

Further, the drying barrel portion 54 includes eight drying barrels, that is, a first drying barrel 54a, a second drying barrel 54b, a third drying barrel 54c, a fourth drying barrel 54d, and a fifth drying barrel 54e. , A sixth dry barrel 54f, a seventh dry barrel 54g, and an eighth dry barrel 54h.

As described above, the barrel unit 51 is configured by connecting the 13 divided barrels 52a to 52b, 53a to 53c, 54a to 54h from the upstream side to the downstream side.

Further, the screw type extruder 5 individually heats the barrels 52a to 52b, 53a to 53c, 54a to 54h, and determines the water content crumbs in the barrels 52a to 52b, 53a to 53c, 54a to 54h, respectively. It has a heating means (not shown) for heating to a temperature. The heating means includes a number corresponding to each barrel 52a to 52b, 53a to 53c, 54a to 54h. As such a heating means, for example, a configuration is adopted in which high-temperature steam is supplied from the steam supply means to the steam distribution jackets formed in the barrels 52a to 52b, 53a to 53c, 54a to 54h. It is not limited to this. Further, the screw type extruder 5 has a temperature control means (not shown) that controls a set temperature of each heating means corresponding to each barrel 52a to 52b, 53a to 53c, 54a to 54h.

The number of supply barrels, dehydration barrels, and drying barrels that constitute each barrel portion 52, 53, 54 in the barrel unit 51 is not limited to the mode shown in FIG. 2, and the acrylic rubber to be dried is used. The number can be set according to the water content of the water-containing crumb.

For example, the number of supply barrels installed in the supply barrel portion 52 is, for example, 1 to 3. The number of dehydration barrels installed in the dehydration barrel portion 53 is preferably, for example, 2 to 10, and more preferably 3 to 6, because dehydration of the water-containing crumb of the adhesive acrylic rubber can be efficiently performed. Further, the number of dry barrels installed in the dry barrel portion 54 is preferably, for example, 2 to 10, and more preferably 3 to 8.

The pair of screws in the barrel unit 51 are rotationally driven by a driving means such as a motor housed in the driving unit 50. The pair of screws extend from the upstream side to the downstream side in the barrel unit 51, and by being rotationally driven, the water-containing crumbs supplied to the supply barrel portion 52 can be conveyed to the downstream side while being mixed. It has become like. The pair of screws is preferably a biaxial meshing type in which the peaks and valleys are meshed with each other, whereby the dehydration efficiency and the drying efficiency of the hydrous crumb can be improved.

Further, the rotation direction of the pair of screws may be the same direction or different directions, but from the viewpoint of self-cleaning performance, a type that rotates in the same direction is preferable. The screw shape of the pair of screws is not particularly limited as long as it is a shape required for each of the barrel portions 52, 53, 54, and is not particularly limited.

The supply barrel portion 52 is a region for supplying the water-containing crumb into the barrel unit 51. The first supply barrel 52a of the supply barrel portion 52 has a feed port 55 for supplying a water-containing crumb in the barrel unit 51.

The dehydration barrel portion 53 is a region for separating and discharging a liquid (serum water) containing a coagulant or the like from the hydrous crumb.

The first to third dehydration barrels 53a to 53c constituting the dehydration barrel portion 53 have dehydration slits 56a, 56b, and 56c for discharging the water content of the hydrous crumb to the outside, respectively. A plurality of the dehydration slits 56a, 56b, 56c are formed in the dehydration barrels 53a to 53c, respectively.

The slit widths, that is, the openings of the dehydration slits 56a, 56b, and 56c may be appropriately selected according to the usage conditions, and are usually 0.01 to 5 mm, so that the water-containing crumbs are less damaged and the water-containing crumbs have little loss. From the viewpoint of efficient dehydration, it is preferably 0.1 to 1 mm, and more preferably 0.2 to 0.6 mm.

There are two ways to remove water from the water-containing crumbs in each of the dehydration barrels 53a to 53c of the dehydration barrel portion 53: a liquid removal from the dehydration slits 56a, 56b, 56c, and a vapor removal. .. In the dehydration barrel portion 53 of the present embodiment, the case where water is removed in liquid form is defined as wastewater, and the case where water is removed in vapor form is defined as exhaust steam.

The dehydration barrel portion 53 is suitable because the water content of the adhesive acrylic rubber can be efficiently reduced by combining drainage and exhaust steam. In the dehydration barrel portion 53, which of the first to third dehydration barrels 53a to 53c is used for drainage or exhaust steam may be appropriately set according to the purpose of use, but is usually manufactured. When reducing the amount of ash in the acrylic rubber, it is advisable to increase the number of dehydration barrels for draining. In that case, for example, as shown in FIG. 2, drainage is performed in the first and second dehydration barrels 53a and 53b on the upstream side, and steam is discharged in the third dehydration barrel 53c on the downstream side. Further, for example, when the dehydration barrel portion 53 has four dehydration barrels, for example, drainage may be performed by three dehydration barrels on the upstream side, and steam may be exhausted by one dehydration barrel on the downstream side. On the other hand, when reducing the water content, it is preferable to increase the number of dehydration barrels for exhausting steam.

As described in the above-mentioned dehydration / drying step, the set temperature of the dehydration barrel portion 53 is usually in the range of 60 to 150 ° C., preferably 70 to 140 ° C., more preferably 80 to 130 ° C., and is dehydrated in the drained state. The set temperature of the dehydration barrel to be dehydrated is usually 60 ° C. to 120 ° C., preferably 70 to 110 ° C., more preferably 80 to 100 ° C., and the set temperature of the dehydration barrel to be dehydrated in the exhausted steam state is usually 100 to 150 ° C. The temperature is preferably in the range of 105 to 140 ° C, more preferably 110 to 130 ° C.

The drying barrel portion 54 is a region for drying the hydrous crumb after dehydration under reduced pressure. Of the first to eighth dry barrels 54a to 54h constituting the dry barrel portion 54, the second dry barrel 54b, the fourth dry barrel 54d, the sixth dry barrel 54f, and the eighth dry barrel 54h are It has vent ports 58a, 58b, 58c, and 58d for degassing, respectively. Vent pipes (not shown) are connected to the vent ports 58a, 58b, 58c, and 58d, respectively.

Vacuum pumps (not shown) are connected to the ends of the vent pipes, and the operation of the vacuum pumps reduces the pressure inside the drying barrel portion 54 to a predetermined pressure. The screw type extruder 5 has a pressure control means (not shown) that controls the operation of these vacuum pumps to control the degree of decompression in the drying barrel portion 54.

The degree of decompression in the dry barrel portion 54 may be appropriately selected, but as described above, it is usually set to 1 to 50 kPa, preferably 2 to 30 kPa, and more preferably 3 to 20 kPa.

The set temperature in the drying barrel portion 54 may be appropriately selected, but as described above, it is usually set to 100 to 250 ° C., preferably 110 to 200 ° C., and more preferably 120 to 180 ° C.

In each of the dry barrels 54a to 54h constituting the dry barrel portion 54, the set temperatures in all the dry barrels 54a to 54h may be approximated or different, but on the upstream side (dehydrated barrel portion). It is preferable to set the temperature on the downstream side (die 59 side) to a higher temperature than the temperature on the downstream side (53 side) because the drying efficiency is improved.

The die 59 is a mold arranged at the downstream end of the barrel unit 51, and has a discharge port having a predetermined nozzle shape. The acrylic rubber dried by the drying barrel portion 54 is extruded into a shape corresponding to a predetermined nozzle shape by passing through the discharge port of the die 59. The acrylic rubber that passes through the die 59 is formed into various shapes such as granular, columnar, round bar, and sheet depending on the nozzle shape of the die 59. For example, by making the discharge port of the die 59 substantially rectangular, the acrylic rubber can be extruded into a sheet shape. A breaker plate or wire mesh may or may not be provided between the screw and the die 59.

According to the screw type extruder 5 according to the present embodiment, the water-containing crumb of the raw material acrylic rubber is extruded into a sheet-shaped dry rubber as follows.

The water-containing crumb of acrylic rubber obtained through the cleaning step is supplied from the feed port 55 to the supply barrel portion 52. The water-containing crumb supplied to the supply barrel portion 52 is sent from the supply barrel portion 52 to the dehydration barrel portion 53 by the rotation of the pair of screws in the barrel unit 51. In the dehydration barrel portion 53, as described above, the water contained in the water-containing crumb is drained and exhausted from the dehydration slits 56a, 56b, 56c provided in the first to third dehydration barrels 53a to 53c, respectively. , The hydrous crumb is dehydrated.

The water-containing crumb dehydrated by the dehydration barrel portion 53 is sent to the dry barrel portion 54 by the rotation of a pair of screws in the barrel unit 51. The hydrous crumb sent to the dry barrel portion 54 is plasticized and mixed to form a melt, which generates heat and is carried to the downstream side while raising the temperature. Then, the water contained in the melt of the acrylic rubber is vaporized, and the water (steam) is discharged to the outside through vent pipes (not shown) connected to the vent ports 58a, 58b, 58c, and 58d, respectively.

By passing through the dry barrel portion 54 as described above, the hydrous crumb is dried and becomes a melt of acrylic rubber, and the acrylic rubber is supplied to the die 59 by the rotation of a pair of screws in the barrel unit 51 to form a sheet. It is extruded from the die 59 as a dry rubber.

Here, an example of the operating conditions of the screw type extruder 5 according to the present embodiment will be given.

The rotation speed (N) of the pair of screws in the barrel unit 51 may be appropriately selected according to various conditions, and is usually 10 to 1000 rpm, and the water content and gel amount of the acrylic rubber veil can be efficiently reduced. From the point of view, it is preferably 50 to 750 rpm, more preferably 100 to 500 rpm, and most preferably 120 to 300 rpm.

The extrusion amount (Q) of acrylic rubber is not particularly limited, but is usually 100 to 1500 kg / hr, preferably 300 to 1200 kg / hr, more preferably 400 to 1000 kg / hr, and 500 to 800 kg / hr. hr is most preferred.

The ratio (Q / N) of the extrusion amount (Q) of the acrylic rubber to the rotation speed (N) of the screw is not particularly limited, but is usually 1 to 20, preferably 2 to 10, and more preferably. It is 3 to 8, and 4 to 6 is particularly preferable.

The cooling device 6 shown in FIG. 1 is configured to cool the dried rubber obtained through the dehydration step by the dehydrator and the drying step by the dryer. As the cooling method by the cooling device 6, various methods including an air cooling method by blowing air or cooling, a watering method of spraying water, a dipping method of immersing in water, and the like can be adopted. Further, the dried rubber may be cooled by leaving it at room temperature.

As described above, the dried rubber discharged from the screw type extruder 5 is extruded into various shapes such as granular, columnar, round bar, and sheet according to the nozzle shape of the die 59. Hereinafter, as an example of the cooling device 6, the transport type cooling device 60 for cooling the sheet-shaped dry rubber 10 formed into a sheet shape will be described with reference to FIG.

FIG. 3 shows the configuration of a transport type cooling device 60 suitable as the cooling device 6 shown in FIG. The transport type cooling device 60 shown in FIG. 3 is configured to cool the sheet-shaped dry rubber 10 discharged from the discharge port of the die 59 of the screw type extruder 5 by an air cooling method while transporting the sheet-shaped dry rubber 10. By using this transport type cooling device 60, the sheet-shaped dry rubber discharged from the screw type extruder 5 can be suitably cooled.

The transport type cooling device 60 shown in FIG. 3 is used, for example, directly connected to the die 59 of the screw type extruder 5 shown in FIG. 2 or installed in the vicinity of the die 59.

The transport-type cooling device 60 sends cold air to the conveyor 61 that conveys the sheet-shaped dry rubber 10 discharged from the die 59 of the screw-type extruder 5 in the direction of arrow A in FIG. 3 and the sheet-shaped dry rubber 10 on the conveyor 61. It has a cooling means 65 for spraying.

The conveyor 61 has rollers 62 and 63, and a conveyor belt 64 that is wound around the rollers 62 and 63 and on which the sheet-shaped dry rubber 10 is placed. The conveyor 61 is configured to continuously convey the sheet-shaped dry rubber 10 discharged from the die 59 of the screw type extruder 5 to the downstream side (right side in FIG. 3) on the conveyor belt 64.

The cooling means 65 is not particularly limited, but has, for example, a structure capable of blowing the cooling air sent from the cooling air generating means (not shown) onto the surface of the sheet-shaped dry rubber 10 on the conveyor belt 64. And so on.

The length (length of the portion where the cooling air can be blown) L1 of the conveyor 61 and the cooling means 65 of the transport type cooling device 60 is not particularly limited, but is, for example, 10 to 100 m, preferably 20 to 50 m. .. Further, the transport speed of the sheet-shaped dry rubber 10 in the transport-type cooling device 60 is the length L1 of the conveyor 61 and the cooling means 65, the discharge speed of the sheet-shaped dry rubber 10 discharged from the die 59 of the screw type extruder 5. It may be appropriately adjusted according to the target cooling rate, cooling time, etc., but is, for example, 10 to 100 m / hr, more preferably 15 to 70 m / hr.

According to the transport type cooling device 60 shown in FIG. 3, the sheet-shaped dry rubber 10 discharged from the die 59 of the screw type extruder 5 is conveyed by the conveyor 61, and the sheet-shaped dry rubber 10 is transported from the cooling means 65. The sheet-shaped dry rubber 10 is cooled by blowing cooling air.

The transport type cooling device 60 is not particularly limited to a configuration including one conveyor 61 and one cooling means 65 as shown in FIG. 3, and two or more conveyors 61 and two or more corresponding conveyors 61. It may be configured to include the cooling means 65 of the above. In that case, the total length of each of the two or more conveyors 61 and the cooling means 65 may be within the above range.

The bale device 7 shown in FIG. 1 is configured to extrude from a screw type extruder 5 and further process a dry rubber cooled by the cooling device 6 to produce a bale which is a block. As described above, the screw type extruder 5 can extrude the dried rubber into various shapes such as granular, columnar, round bar, and sheet, and the bale device 7 has various shapes as described above. It is configured to veil dry rubber molded into a shape. The weight and shape of the acrylic rubber bale produced by the bale-forming device 7 are not particularly limited, but for example, an acrylic rubber bale having a substantially rectangular parallelepiped shape of about 20 kg is produced.

The bale device 7 may include, for example, a baler, and may manufacture an acrylic rubber bale by compressing the cooled dry rubber with the baler.

Further, when the sheet-shaped dry rubber 10 is manufactured by the screw type extruder 5, an acrylic rubber veil in which the sheet-shaped dry rubber 10 is laminated may be manufactured. For example, the bale-forming device 7 arranged on the downstream side of the transport-type cooling device 60 shown in FIG. 3 may be provided with a cutting mechanism for cutting the sheet-shaped dry rubber 10. Specifically, the cutting mechanism of the bale device 7 continuously cuts the cooled sheet-shaped dry rubber 10 at predetermined intervals and processes it into a cut sheet-shaped dry rubber 16 having a predetermined size. It is configured as follows. By laminating a plurality of cut sheet-shaped dry rubbers 16 cut to a predetermined size by a cutting mechanism, an acrylic rubber veil in which the cut-sheet-shaped dry rubbers 16 are laminated can be manufactured.

When producing an acrylic rubber veil on which the cut sheet-shaped dry rubber 16 is laminated, it is preferable to laminate the cut sheet-shaped dry rubber 16 at 40 ° C. or higher, for example. By laminating the cut sheet-shaped dry rubber 16 at 40 ° C. or higher, good air release is realized by further cooling and compression by its own weight.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. In addition, "part", "%" and "ratio" in each example are weight-based unless otherwise specified.

Various physical properties were evaluated according to the following methods.

[Monomer composition]
Regarding the monomer composition in acrylic rubber, the monomer composition of each monomer unit in acrylic rubber was confirmed by 1 H-NMR, and the activity of the reactive group remained in the acrylic rubber and each group thereof. The reactive group content was confirmed by the following test method.

The content ratio of each monomer unit in the acrylic rubber was calculated from the amount used in the polymerization reaction of each monomer and the polymerization conversion rate. Specifically, since the polymerization reaction was an emulsion polymerization reaction and the polymerization conversion rate was approximately 100% in which none of the unreacted monomers could be confirmed, the content ratio of each monomer unit was set to a single amount. It was the same as the amount used by the body.

[Reactive group content]
The content of the reactive group of the acrylic rubber was measured in the acrylic rubber veil by the following method.
(1) The amount of carboxyl groups was calculated by dissolving an acrylic rubber veil in acetone and performing potentiometric titration with a potassium hydroxide solution.
(2) The amount of epoxy group was calculated by dissolving an acrylic rubber veil in methyl ethyl ketone, adding a specified amount of hydrochloric acid to the mixture to react with the epoxy group, and titrating the remaining amount of hydrochloric acid with potassium hydroxide.
(3) The amount of chlorine was calculated by completely burning an acrylic rubber veil in a combustion flask, absorbing the generated chlorine in water, and titrating with silver nitrate.

[Ash content]
The amount of ash (%) contained in the acrylic rubber veil was measured according to the JIS K6228 A method.

[Amount of ash component]
The amount of each component (ppm) in the acrylic rubber veil ash content was measured by XRF using ZSX Primus (manufactured by Rigaku) by pressing the collected ash content onto a Φ20 mm titration filter paper in the difference in the above ash content measurement.

[Gel amount]
The gel amount (%) of the acrylic rubber veil was the amount of the insoluble matter in methyl ethyl ketone, and was determined by the following method.

About 0.2 g of acrylic rubber veil is weighed (Xg), immersed in 100 ml methyl ethyl ketone, left at room temperature for 24 hours, and then dissolved in a filtrate obtained by filtering out the insoluble matter in methyl ethyl ketone using an 80 mesh wire mesh, that is, methyl ethyl ketone. The dry solid content (Yg) obtained by evaporating and solidifying the filtrate in which only the rubber component was dissolved was weighed and calculated by the following formula.
Gel amount (%) = 100 × (XY) / X

[specific gravity]
The specific gravity of the acrylic rubber veil was measured according to the method A of JIS K6268 crosslinked rubber-density measurement.

[Glass transition temperature (Tg)]
The glass transition temperature (Tg) of acrylic rubber was measured using a differential scanning calorimeter (DSC, product name "X-DSC7000", manufactured by Hitachi High-Tech Science Co., Ltd.).

[PH]
The pH of the acrylic rubber veil was measured with a pH electrode after confirming that 6 g (± 0.05 g) of the acrylic rubber veil was dissolved in 100 g of tetrahydrofuran, and 2.0 ml of distilled water was added to completely dissolve the acrylic rubber veil.

[Water content]
The water content (%) of the acrylic rubber veil was measured according to the JIS K6230-1: Oven A (volatile content measurement) method.

[Molecular weight and molecular weight distribution]
The weight average molecular weight (Mw) and molecular weight distribution (Mw / Mn and Mz / Mw) of the acrylic rubber are as follows: dimethylformamide as a solvent, lithium chloride at a concentration of 0.05 mol / L, and 37% concentrated hydrochloric acid at a concentration of 0.01%, respectively. It is an absolute molecular weight and an absolute molecular weight distribution measured by the GPC-MALS method using the added solution. Specifically, a multi-angle laser light scattering photometric meter (MALS) and a differential refractometer (RI) are incorporated into a GPC (Gel Permeation Chromatography) device, and the light scattering intensity and refraction of the molecular chain solution size-sorted by the GPC device are incorporated. The molecular weight of the solute and its content were sequentially calculated and obtained by measuring the rate difference with the elution time. The measurement conditions and measurement method by the GPC device are as follows.
Column: 2 TSKgel α-M (φ7.8 mm x 30 cm, manufactured by Tosoh Corporation)
Temperature: Column 40 ° C
Flow velocity: 0.8 ml / mm
Sample preparation: 5 ml of solvent was added to 10 mg of sample, and the mixture was gently stirred at room temperature (dissolution was visually observed). Then, filtration was performed using a 0.5 μm filter.
Injection volume: 0.200 ml

[Complex viscosity]
The complex viscosity η of the acrylic rubber bale is subjected to temperature dispersion (40 to 120 ° C.) at a strain of 473% and 1 Hz using a dynamic viscoelasticity measuring device “Rubber Process Analyzer RPA-2000” (manufactured by Alpha Technology). The measurement was performed to determine the complex viscoelasticity η at each temperature. Here, among the above-mentioned dynamic viscoelasticities, the dynamic viscoelasticity at 60 ° C. is defined as the complex viscoelasticity η (60 ° C.), and the dynamic viscoelasticity at 100 ° C. is defined as the complex viscoelasticity η (100 ° C.) The values of ° C.) / η (60 ° C.) and η (60 ° C.) / η (100 ° C.) were calculated.

[Moony Viscosity (ML1 + 4,100 ° C)]
The Mooney viscosity (ML1 + 4,100 ° C.) of the acrylic rubber veil was measured according to the uncrosslinked rubber physical test method of JIS K6300.

[Storing stability evaluation]
For the storage stability of the rubber sample, the rubber sample was placed in a constant temperature and humidity chamber (SH-222 manufactured by ESPEC) at 45 ° C. × 80% RH, and the rubber sample before and after the test for 7 days was used as a Mooney scorch of the rubber mixture. The minimum viscosity (Vm) was measured at 125 ° C. using an L rotor according to JIS K6300-1: 2013, and the rate of change after the test loss was calculated. The Vm change rate was evaluated by an index with the change rate of Comparative Example 2 as 100 (the smaller the index, the better the storage stability).

[Water resistance evaluation]
The water resistance of the rubber sample is determined by immersing the crosslinked product of the rubber sample in distilled water at a temperature of 85 ° C. for 100 hours in accordance with JIS K6258 for a dipping test, and calculating the volume change rate before and after dipping according to the following formula. It was evaluated by an index with 2 as 100 (the smaller the index, the better the water resistance).
Volume change rate before and after immersion (%) = ((volume of test piece after immersion-volume of test piece before immersion) / volume of test piece before immersion) × 100

[Evaluation of normal physical properties]
The normal physical properties of the rubber sample were evaluated according to the following criteria by measuring the breaking strength, 100% tensile stress and breaking elongation of the crosslinked rubber sample of the rubber sample according to JIS K6251.
(1) The breaking strength was evaluated as ⊚ for 10 MPa or more and × for less than 10 MPa.
(2) For 100% tensile stress, 5 MPa or more was evaluated as ⊚, and less than 5 MPa was evaluated as x.
(3) The elongation at break was evaluated as ⊚ for 150% or more and x for less than 150%.

[Example 1]
In a mixing container equipped with a homomixer, 46 parts of pure water, 28 parts of ethyl acrylate, 38 parts of n-butyl acrylate, 27 parts of methoxyethyl acrylate, 5 parts of acrylonitrile and 2 parts of allyl glycidyl ether, and nonylphenyl as an emulsifier. 1.8 parts of oxyhexaoxyethylene phosphate sodium salt was charged and stirred to obtain a monomeric emulsion.

Next, 170 parts of pure water and 3 parts of the monomer emulsion obtained above were put into a polymerization reaction tank equipped with a thermometer and a stirrer, and cooled to 12 ° C. under a nitrogen stream. Next, the rest of the monomer emulsion, 0.00033 parts of ferrous sulfate, 0.264 parts of sodium ascorbate, and 0.22 parts of potassium persulfate were continuously added dropwise to the polymerization reaction tank over 3 hours. did. After that, the reaction was continued while the temperature in the polymerization reaction was kept at 23 ° C., it was confirmed that the polymerization conversion rate reached approximately 100%, and hydroquinone as a polymerization terminator was added to stop the polymerization reaction. An emulsion polymerization solution was obtained.

Emulsion polymerization obtained in a 2% magnesium sulfate aqueous solution (coagulant) heated to 80 ° C. and vigorously stirred (600 rpm: peripheral speed 3.1 m / s) in a coagulation tank equipped with a thermometer and a stirrer. The liquid was heated to 80 ° C. and continuously added to solidify the polymer and filtered off to obtain a hydrous crumb.

Next, 194 parts of warm water (70 ° C.) was added to the coagulation tank and stirred for 15 minutes, then the water was discharged, and 194 parts of warm water (70 ° C.) was added again and stirred for 15 minutes. Cleaning was performed. The washed hydrous crumb was supplied to a screw type extruder, dehydrated and dried, and a sheet-shaped dry rubber having a width of 300 mm and a thickness of 10 mm was extruded. Next, the sheet-shaped dry rubber was cooled at a cooling rate of 200 ° C./hr using a transport-type cooling device directly connected to the screw type extruder.

The screw type extruder used in the first embodiment has one supply barrel, three dehydration barrels (first to third dehydration barrels), and five drying barrels (first to fifth drying barrels). It is configured. The first and second dehydration barrels are designed to drain water, and the third dehydration barrel is designed to drain steam. The operating conditions of the screw type extruder are as follows.

Moisture content:
Moisture content of the hydrous crumb after drainage in the second dehydration barrel: 20%
Moisture content of the hydrous crumb after steam exhaust in the third dehydration barrel: 10%
Rubber temperature:
-The temperature of the hydrous crumb supplied to the first supply barrel: 65 ° C.
・ Temperature of rubber discharged from screw type extruder: 140 ℃
Set temperature of each barrel:
-First dehydration barrel: 90 ° C
-Second dehydration barrel: 100 ° C
-Third dehydration barrel: 120 ° C
-First drying barrel: 120 ° C
-Second drying barrel: 130 ° C
-Third drying barrel: 140 ° C
・ Fourth drying barrel: 160 ° C
・ Fifth drying barrel: 180 ° C
Operating conditions:
-Screw diameter (D) in the barrel unit: 132 mm
-Overall length (L) of the screw in the barrel unit: 4620 mm
・ L / D: 35
・ Screw rotation speed in the barrel unit: 135 rpm
-Rubber extrusion amount from die: 700 kg / hr
・ Die resin pressure: 2MPa

The extruded sheet-shaped dry rubber was cooled to 50 ° C., cut with a cutter, and laminated to 20 parts (20 kg) before the temperature fell below 40 ° C. to obtain an acrylic rubber veil (A). .. Reactive group content, ash content, ash component content, specific gravity, gel amount, pH, glass transition temperature (Tg), water content, molecular weight, molecular weight distribution, complex viscosity and Moony of the obtained acrylic rubber veil (A) The viscosities (ML1 + 4,100 ° C.) were measured and the results are shown in Table 2.

Next, using a Bunbury mixer, 100 parts of the acrylic rubber veil (A) and the compounding agent A of "formulation 1" shown in Table 1 were added and mixed at 50 ° C. for 5 minutes.

Next, the obtained mixture was transferred to a roll at 50 ° C., and the compounding agent B of "Formulation 1" shown in Table 1 was mixed to obtain a rubber mixture. The Mooney Scorch minimum viscosity (Vm) of the rubber mixture thus prepared using the obtained rubber mixture and the acrylic rubber veil (A) after the storage stability test was measured, and the rate of change is shown in Table 2.

The obtained rubber mixture was placed in a mold having a length of 15 cm, a width of 15 cm, and a depth of 0.2 cm, and was first crosslinked by pressing at 180 ° C. for 10 minutes while pressurizing at a press pressure of 10 MPa, and then obtained. The primary crosslinked product was further heated in a gear oven at 180 ° C. for 2 hours for secondary cross-linking to obtain a sheet-shaped rubber crosslinked product. Then, a 3 cm × 2 cm × 0.2 cm test piece was cut out from the obtained sheet-shaped rubber crosslinked product, and the water resistance and normal physical characteristics were evaluated, and the results are shown in Table 2.

[Example 2]
The monomer component was 42.2 parts of ethyl acrylate, 35 parts of n-butyl acrylate, 20 parts of methoxyethyl acrylate, 1.5 parts of acrylonitrile and 1.3 parts of vinyl chloroacetate, and the emulsifier was tridecyloxyhexa. Acrylic rubber veil (B) was obtained in the same manner as in Example 1 except that the sodium salt was changed to oxyethylene phosphate sodium salt, and each characteristic (changed to "formulation 2") was evaluated. The results are shown in Table 2.

[Example 3]
The temperature of the first dehydration barrel of the screw type extruder is changed to 100 ° C., and the temperature of the second dehydration barrel is changed to 120 ° C. so that drainage is performed only by the first dehydration barrel, and in the first dehydration barrel. Acrylic rubber barrels (C) were obtained and each characteristic was evaluated in the same manner as in Example 1 except that the water content of the water-containing crumb after drainage was changed to 30%. The results are shown in Table 2.

[Example 4]
The temperature of the first dehydration barrel of the screw type extruder is changed to 100 ° C., and the temperature of the second dehydration barrel is changed to 120 ° C. so that drainage is performed only by the first dehydration barrel, and in the first dehydration barrel. Acrylic rubber barrels (D) were obtained and each characteristic was evaluated in the same manner as in Example 2 except that the water content of the water-containing crumb after drainage was changed to 30%. The results are shown in Table 2.

[Example 5]
After performing the washing step in the same manner as in Example 1, the washed crumbs were dried with a hot air dryer at 160 ° C. to obtain a crumb-shaped dried rubber having a water content of 0.4% by weight. 20 parts (20 kg) of the obtained crumb-shaped dry rubber was filled in a 300 × 650 × 300 mm baler and compacted at a pressure of 3 MPa for 30 seconds to obtain an acrylic rubber veil (E). Each characteristic of the obtained acrylic rubber bale (E) was evaluated, and the results are shown in Table 2.

[Example 6]
After performing the washing step in the same manner as in Example 2, the washed crumbs were dried with a hot air dryer at 160 ° C. to obtain a crumb-shaped dried rubber having a water content of 0.4% by weight. 20 parts (20 kg) of the obtained crumb-shaped dry rubber was filled in a 300 × 650 × 300 mm baler and compacted at a pressure of 3 MPa for 30 seconds to obtain an acrylic rubber veil (F). Each characteristic of the obtained acrylic rubber bale (F) was evaluated, and the results are shown in Table 2.

[Example 7]
In the coagulation step, an acrylic rubber bale (G) was obtained in the same manner as in Example 6 except that the stirring speed of the 2% magnesium sulfate aqueous solution (coagulation liquid) was changed to 100 rpm and the peripheral speed was changed to 0.5 m / s. It was evaluated and shown in Table 2.

[Example 8]
In the coagulation step, an acrylic rubber veil (G) was obtained in the same manner as in Example 7 except that the coagulation liquid was changed to a 0.7% magnesium sulfate aqueous solution, and each characteristic was evaluated and shown in Table 2.

[Comparative Example 1]
In the coagulation reaction of the coagulation step, a 0.7% magnesium sulfate aqueous solution was continuously added to the emulsion polymerization solution obtained by emulsion polymerization to generate a hydrous crumb, and it was not veiled by a baler after hot air drying. A crumb-shaped acrylic rubber (I) was obtained in the same manner as in Example 8 except for the above. Each property of the crumb-shaped acrylic rubber (I) was evaluated, and the results are shown in Table 2.

[Comparative Example 2]
In a mixing container equipped with a homomixer, 46 parts of pure water, 42.2 parts of ethyl acrylate, 35 parts of n-butyl acrylate, 20 parts of methoxyethyl acrylate, 1.5 parts of acrylonitrile, 1.3 parts of vinyl chloroacetate As an emulsifier, 0.709 parts of sodium lauryl sulfate and 1.82 parts of polyoxyethylene dodecyl ether (molecular weight 1500) were charged and stirred to obtain a monomer emulsion.

Next, 170 parts of pure water and 3 parts of the monomer emulsion obtained above were put into a polymerization reaction tank equipped with a thermometer and a stirrer, and cooled to 12 ° C. under a nitrogen stream. Next, the rest of the monomer emulsion, 0.00033 parts of ferrous sulfate, 0.264 parts of sodium ascorbate, and 0.22 parts of potassium persulfate were continuously added dropwise to the polymerization reaction tank over 3 hours. did. After that, the reaction was continued while the temperature in the polymerization reaction was kept at 23 ° C., it was confirmed that the polymerization conversion rate reached approximately 100%, and hydroquinone as a polymerization terminator was added to stop the polymerization reaction. An emulsion polymerization solution was obtained.

Next, after heating the emulsion polymerization solution to 80 ° C., a 0.7% sodium sulfate aqueous solution (coagulant solution) was continuously added to the emulsion polymerization solution (rotation speed 100 rpm, peripheral speed 0.5 m / s). The polymer was coagulated and filtered off to give a hydrous crumb. To 100 parts of the obtained water-containing crumb, 194 parts of industrial water was added, and after stirring at 25 ° C. for 5 minutes, the water-containing crumb for discharging water from the coagulation tank was washed four times, and then a sulfuric acid aqueous solution having a pH of 3 was washed. After adding 194 parts and stirring at 25 ° C. for 5 minutes, water is discharged from the coagulation tank to perform acid cleaning once, then 194 parts of pure water is added and pure water cleaning is performed once, and then 160. It was dried with a hot air dryer at ° C. to obtain a crumb-shaped acrylic rubber (J) having a water content of 0.4% by weight. Each characteristic of the obtained crumb-shaped acrylic rubber (J) was evaluated and shown in Table 2.

From Table 2, it is composed of acrylic rubber having a reactive group and a weight average molecular weight (Mw) of 100,000 to 5,000,000, the ash content is 0.8% by weight or less, and the phosphorus content in the ash content is 10% by weight. It can be seen that the acrylic rubber veils (A) to (H) having a% or more and a specific gravity of 0.8 or more are excellent in storage stability and water resistance (Examples 1 to 8).

Regarding the storage stability, the rate of change in the minimum viscosity (Vm) of the Mooney scorch before and after putting it in the constant temperature and humidity chamber of 45 ° C. × 80% RH is evaluated. In the present invention, the acrylic rubber veils (A) to (H) are evaluated. Is superior to the crumb-shaped acrylic rubbers (I) to (J) (comparison between Examples 1 to 8 and Comparative Examples 1 and 2). Among the acrylic rubber veils (A) to (H), the storage stability is divided into the overwhelmingly excellent acrylic rubber (A) to (D) and the greatly excellent acrylic rubber veils (E) to (H). (Comparison between Examples 1 to 4 and Examples 5 to 8), all relationships including comparative examples (Acrylic rubber bale (A) to (D) >> Acrylic rubber bale (E) to (H) >> It can be seen that the crumb-shaped acrylic rubbers (I) to (J)) correlate with the specific gravity of the rubber properties (Examples 1 to 8 and Comparative Examples 1 to 2). The specific gravity is related to the amount of air entrained, and the acrylic rubber veils (A) to (D), which have an overwhelmingly large specific gravity, are preserved against oxidative deterioration, etc., because they contain almost no air. It seems that the stability is remarkably excellent.

Regarding water resistance, it can be seen that the amount of ash remaining in the crumb-shaped acrylic rubber is much higher when phosphoric acid-based emulsification is used than when sulfuric acid-based emulsifier is used (comparison with Comparative Examples 1 and 2). However, by adding the emulsion obtained from the method of adding the coagulant to the emulsion polymer obtained by emulsion polymerization of the coagulation method (Comparative Example 1) to the coagulated solution that has been stirred, the same cleaning method remains. It can be seen that the ash content is significantly reduced and the water resistance is improved (comparison between Comparative Example 1 and Example 8). Furthermore, the coagulant concentration of the coagulant being stirred should be changed to 2%, the rotation speed should be changed to 600 rpm, the peripheral speed should be changed to 3.1 m / s, which is a certain degree of vigorous stirring, and the water-containing crumb. It can be seen that the ash content is remarkably reduced and the water resistance is improved by performing dehydration by squeezing out water from the body (Examples 1 to 8).

Regarding water resistance, it can be seen that the acrylic rubber veil of the present invention has significantly improved water resistance even though it is not so different from the ash content of crumb-shaped acrylic rubber using a sulfuric acid-based emulsifier. .. This is a product using a phosphoric acid-based emulsifier, particularly a product using a combination of a metal salt of Group 2 of the periodic table as a coagulant, and more preferably a divalent phosphoric acid-based emulsifier as an emulsifier and a magnesium salt as a coagulant. Although the amount of ash remaining when using is not small (difficult to remove by washing), it does not affect the water resistance, and therefore the acrylic rubber veils (A) to (H) of the present invention have no effect. It seems that it exhibits remarkably excellent water resistance (comparison between Examples 1 to 8 and Comparative Example 2).

Regarding water resistance, further, acrylic rubber veils (A), (C) and (E) having an ionic reactive group such as an epoxy group as a reactive group are acrylic rubber veils (B) having a chlorine atom. It can be seen that it is superior to D) and (F) (Examples 1 to 6).

From Table 2, further, the reactive group weight, specific gravity, gel weight, glass transition temperature (Tg), pH, water content, weight average molecular weight (Mw), z average molecular weight (Mz) and weight average molecular weight (Mw) Ratio (Mz / Mw), ratio of weight average molecular weight (Mw) to number average molecular weight (Mn) (Mw / Mn), complex viscosity η (100 ° C) at 100 ° C, complex viscosity η (60 ° C) at 60 ° C Acrylic rubber veils (A) to (H) having a specific range of complex viscosity ratios (η100 ° C./η60 ° C.) and Mooney viscosity (1 + 4,100 ° C.) at 100 ° C. and 60 ° C. are storage stability. It can be seen that the water resistance is excellent and the strength characteristics (normal physical properties) are also excellent (Examples 1 to 8).

1 Acrylic rubber manufacturing system 3 Coagulation equipment 4 Cleaning equipment 5 Screw type extruder 6 Cooling equipment 7 Veiling equipment

In the acrylic rubber veil of the present invention, it is preferable that phosphorus and magnesium are contained in the ash content, and the total amount of phosphorus and magnesium in the ash content is 30% by weight or more in the ash content.

[Molecular weight and molecular weight distribution]
Regarding the weight average molecular weight (Mw) and molecular weight distribution ( Mz / Mw) of the acrylic rubber, lithium chloride was added to dimethylformamide at a concentration of 0.05 mol / L and 37% concentrated hydrochloric acid was added at a concentration of 0.01%, respectively. It is an absolute molecular weight and an absolute molecular weight distribution measured by the GPC-MALS method using a solution. Specifically, a multi-angle laser light scattering photometric meter (MALS) and a differential refractometer (RI) are incorporated into a GPC (Gel Permeation Chromatography) device, and the light scattering intensity and refraction of the molecular chain solution size-sorted by the GPC device are incorporated. The molecular weight of the solute and its content were sequentially calculated and obtained by measuring the rate difference with the elution time. The measurement conditions and measurement method by the GPC device are as follows.
Column: 2 TSKgel α-M (φ7.8 mm x 30 cm, manufactured by Tosoh Corporation)
Temperature: Column 40 ° C
Flow velocity: 0.8 ml / mm
Sample preparation: 5 ml of solvent was added to 10 mg of sample, and the mixture was gently stirred at room temperature (dissolution was visually observed). Then, filtration was performed using a 0.5 μm filter.
Injection volume: 0.200 ml

From Table 2, further, the reactive group weight, specific gravity, gel weight, glass transition temperature (Tg), pH, water content, weight average molecular weight (Mw), z average molecular weight (Mz) and weight average molecular weight (Mw) Ratio (Mz / Mw ), complex viscosity at 100 ° C. η (100 ° C.), complex viscosity at 60 ° C. η (60 ° C.), ratio of complex viscosity at 100 ° C. and 60 ° C. (η100 ° C./η60 ° C.) and It can be seen that the acrylic rubber veils (A) to (H) having a Mooney viscosity (1 + 4,100 ° C.) in a specific range are excellent in storage stability and water resistance, and also in strength characteristics (normal physical properties) (normal physical properties). Examples 1-8).

Claims (8)

It is made of acrylic rubber having a reactive group and a weight average molecular weight (Mw) of 100,000 to 5,000,000, and has an ash content of 0.8% by weight or less and a phosphorus content in the ash content of 10% by weight or more. Acrylic rubber veil with a specific gravity of 0.8 or more. The acrylic rubber veil according to claim 1, wherein the total amount of phosphorus and magnesium in the ash content is 30% by weight or more in the ash content. An emulsion polymerization step in which a monomer component containing a (meth) acrylic acid ester and a reactive group-containing monomer is emulsified with water and a phosphoric acid-based emulsifier and emulsion-polymerized in the presence of a polymerization catalyst to obtain an emulsion polymerization solution.
A coagulation step of bringing the obtained emulsion polymerization solution into contact with the coagulation solution to form a hydrous crumb,
A cleaning process to clean the generated hydrous crumbs,
A drying process in which the washed hydrous crumb is dried to a moisture content of less than 1% by weight using a screw type extruder and the dried rubber is extruded.
The method for producing an acrylic rubber veil according to claim 1, further comprising a veiling step of laminating extruded dried rubber to form a veil. The method for producing an acrylic rubber veil according to claim 3, wherein the coagulating liquid is an aqueous magnesium salt solution. The method for producing an acrylic rubber veil according to claim 3 or 4, further comprising a dehydration step of squeezing out water from the washed hydrous crumb. The method for producing an acrylic rubber bale according to any one of claims 3 to 5, wherein the dried rubber to be extruded is a sheet-shaped dry rubber, and the bale is formed by laminating the sheet-shaped dry rubber. A rubber mixture obtained by mixing a filler and a cross-linking agent with the acrylic rubber veil according to claim 1 or 2. A rubber crosslinked product obtained by cross-linking the rubber mixture according to claim 7.