JP2021105121A - Acryl rubber having excellent heat resistance and water resistance - Google Patents

Abstract

To provide an acryl rubber having excellent heat resistance and water resistance and a method for producing the same.SOLUTION: An acryl rubber contains an acrylate derived-bond unit 10-98.9 wt.%, a methacrylate derived-bond unit 1-50 wt.%, a reactive group-containing monomer derived-bond unit 0.1-10 wt.% and other monomer derived-bond units 0-30 wt.%, with the total ash content of 1 wt.% or less, and the total amount of magnesium and phosphorus in the total ash content being 60 wt.% or more relative to the total ash content, and a Mooney viscosity of 10-150. The acryl rubber is excellent in both heat resistance and water resistance.SELECTED DRAWING: None

Description

The present invention relates to acrylic rubber and its manufacturing method, acrylic rubber molded body, rubber composition and crosslinked rubber, and more specifically, acrylic rubber having excellent heat resistance and water resistance and its manufacturing method, and the acrylic rubber being molded. The present invention relates to a molded product, a crosslinkable rubber composition containing the acrylic rubber, and a crosslinked rubber product obtained by crosslinking the same.

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.

As such an acrylic rubber, for example, Patent Document 1 (International Publication No. 2018/101146 pamphlet) describes a structural unit derived from an acrylic acid ester having an alkyl group having 1 to 8 carbon atoms and / or 2 to 8 carbon atoms. 45 to 89.5% by weight of the structural unit derived from the acrylic acid ester having an alkoxyalkyl group, 10 to 50% by weight of the structural unit derived from the alkyl methacrylate having an alkyl group having 3 to 16 carbon atoms, A highly heat-resistant acrylic copolymer containing 0.5 to 5% by weight of a structural unit derived from a crosslinkable monomer is disclosed, and specifically, ethyl acrylate, n-butyl acrylate, and n-butyl methacrylate are disclosed. , Monomer composed of monoethyl fumarate, water, polyoxyalkylene alkyl ether phosphate ester as an emulsifier, sodium ascorbate and potassium persulfate were added, and the emulsion polymerization reaction was started at normal pressure and normal temperature to carry out polymerization. The reaction was continued until the conversion rate reached 95%, and the emulsion polymerization solution obtained by adding hydroquinone to stop the polymerization was coagulated with an aqueous sodium sulfate solution to form a hydrous crumb, and then the produced hydrocramm was washed with water and dried. It is described that an acrylic rubber having a Mooney viscosity of 38 is produced. However, in this method, the obtained acrylic rubber has a problem of being inferior in water resistance.

International Publication No. 2018/10146 Pamphlet

The present invention has been made in view of the actual conditions of the prior art, and is an acrylic rubber excellent in both heat resistance and water resistance, a method for producing the same, an acrylic rubber molded body obtained by molding the acrylic rubber, and the acrylic rubber. It is an object of the present invention to provide a rubber composition containing the above and a rubber crosslinked product obtained by cross-linking the rubber composition.

As a result of diligent research in view of the above problems, the present inventors have made up a structural unit having a specific composition containing a methacrylic acid ester, the amount of ash contained in the rubber is within a specific range, and magnesium and phosphorus are contained in the ash. It has been found that acrylic rubber containing a specific amount and having a Mooney viscosity (ML1 + 4,100 ° C.) in a specific range is remarkably excellent in heat resistance and water resistance.

The present inventors can also easily perform an emulsion polymerization solution obtained by emulsifying a specific monomer component with a specific phosphoric acid emulsifier and then emulsion polymerization by coagulating with a specific coagulant, washing and drying. It was found that an acrylic rubber having excellent heat resistance and water resistance can be obtained.

The present inventors also add an emulsion polymerization solution to a coagulating solution in which the coagulation reaction is vigorously agitated, squeeze out water before drying the washed hydrous crumb, or dehydrate and dry the hydrous crumb. It was found that acrylic rubber having an excellent water resistance with a further reduced amount of ash can be produced by carrying out the above with a screw type extruder.

The present inventors have further found that by making the acrylic rubber into a sheet shape or a veil shape, it is excellent in heat resistance and water resistance, and also excellent in other properties such as operability, processability, and storage stability. ..

The present inventors have completed the present invention based on these findings.

Thus, according to the present invention, the binding unit (A) derived from acrylic acid ester (A) 10 to 98.9% by weight, the binding unit (B) derived from methacrylic acid ester (B) 1 to 50% by weight, derived from the reactive group-containing monomer. (C) 0.1 to 10% by weight and other monomer-derived binding unit (D) 0 to 30% by weight, the total ash content is 1% by weight or less, and magnesium in the total ash content. Acrylic rubbers having a total amount of and phosphorus in an amount of 60% by weight or more based on the total amount of ash and a Mooney viscosity (ML1 + 4,100 ° C.) in the range of 10 to 150 are provided.

In the acrylic rubber of the present invention, the bonding unit (A) derived from an acrylic acid ester is a bonding unit derived from at least one acrylic acid ester selected from the group consisting of an acrylic acid alkyl ester and an acrylic acid alkoxyalkyl ester. preferable.

In the acrylic rubber of the present invention, the amount of gel is preferably 50% by weight or less.

In the acrylic rubber of the present invention, the weight average molecular weight (Mw) is preferably 1,000,000 or more.

According to the present invention, the acrylic acid ester (a), the methacrylate ester (b), the reactive group-containing monomer (c), and other monomers (d) that can be copolymerized as needed. An emulsion polymerization step of emulsion-polymerizing a monomer component composed of the above with water and a phosphoric acid-based emulsifier and then emulsion-polymerizing in the presence of a polymerization catalyst to obtain an emulsion polymerization solution, and the obtained emulsion polymerization solution and a magnesium salt aqueous solution. Provided is a method for producing acrylic rubber, which comprises a coagulation step of contacting to generate a hydrous crumb, a cleaning step of washing the produced hydrous crumb, and a drying step of drying the washed hydrous crumb.

In the method for producing acrylic rubber of the present invention, it is preferable to add the emulsion polymerization solution to the stirring magnesium aqueous solution for the contact between the emulsion polymerization solution and the magnesium aqueous solution.

In the method for producing acrylic rubber of the present invention, it is preferable to provide a dehydration step for squeezing water from the hydrous crumb between the washing step and the drying step.

In the method for producing acrylic rubber of the present invention, it is preferable that the hydrous crumb is dehydrated and dried by a screw extruder.

According to the present invention, a sheet-shaped or veil-shaped acrylic rubber molded product made of the acrylic rubber is provided.

In the acrylic rubber molded product of the present invention, the specific gravity is preferably 0.8 or more.

According to the present invention, there is also provided a rubber composition containing the above-mentioned rubber component containing acrylic rubber, a filler and a cross-linking agent.

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

According to the present invention, an acrylic rubber excellent in both heat resistance and water resistance and an efficient manufacturing method thereof, an acrylic rubber molded body obtained by molding the acrylic rubber, a rubber composition containing the acrylic rubber and the like. A rubber crosslinked product obtained by cross-linking the above is provided.

It is a figure which shows typically an example of the acrylic rubber manufacturing system 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 of the present invention is derived from an acrylic acid ester-derived binding unit (A) 10 to 98.9% by weight, a methacrylate ester-derived binding unit (B) 1 to 50% by weight, and a reactive group-containing monomer. Bonding unit (C) 0.1 to 10% by weight and binding unit (D) derived from other monomers (D) 0 to 30% by weight, total ash content is 1% by weight or less, and magnesium in total ash The total amount of phosphorus is 60% by weight or more as a ratio to the total amount of ash, and the monomer (ML1 + 4,100 ° C.) is in the range of 10 to 150.

<Monomer component>
The bonding unit (A) constituting the acrylic rubber of the present invention is a bonding unit derived from the acrylic acid ester (a), and preferably at least one selected from the group consisting of an acrylic acid alkyl ester and an acrylic acid alkoxy alkyl ester. A binding unit derived from the seed acrylic acid ester.

The acrylic acid alkyl ester is not particularly limited, and examples thereof include an acrylic acid alkyl ester having an alkyl group having 1 to 12 carbon atoms, and preferably an acrylic acid alkyl ester having an alkyl group having 1 to 8 carbon atoms. , More preferably an acrylic acid alkyl ester having an alkyl group having 2 to 6 carbon atoms.

Specific examples of the acrylic acid alkyl ester include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, n-hexyl acrylate, and 2-ethylhexyl acrylate. Cyclohexyl acrylate and the like can be mentioned, with methyl acrylate, ethyl acrylate, isopropyl acrylate and n-butyl acrylate being preferred, and ethyl acrylate and n-butyl acrylate being more preferred.

The acrylic acid alkoxyalkyl ester is not particularly limited, and examples thereof include an acrylic acid alkoxyalkyl ester having an alkoxyalkyl group having 2 to 12 carbon atoms, and preferably an alkoxyalkyl group having 2 to 8 carbon atoms. Acrylic acid alkoxyalkyl ester having, more preferably an acrylic acid alkoxy ester having an alkoxyalkyl group having 2 to 6 carbon atoms.

Specific examples of the acrylate alkoxyalkyl ester include methoxymethyl acrylate, methoxyethyl acrylate, methoxypropyl acrylate, methoxybutyl acrylate, ethoxymethyl acrylate, ethoxyethyl acrylate, propoxyethyl acrylate, butoxyethyl acrylate. And so on. Among these, methoxyethyl acrylate, ethoxyethyl acrylate, ethoxymethyl acrylate, methoxymethyl acrylate and the like are preferable, and methoxyethyl acrylate and ethoxyethyl acrylate are more preferable.

The bonding unit (A) derived from these acrylic acid esters can be used alone or in combination of two or more, and the bonding amount in the acrylic rubber is 10 to 98.9% by weight, preferably 32 to 97. It is in the range of 7% by weight, more preferably 50 to 96.5% by weight, and particularly preferably 62 to 94% by weight. If the amount of the bonding unit (A) in the acrylic rubber is excessively small, the weather resistance, heat resistance, and oil resistance may be deteriorated, and if it is excessively large, the strength characteristics and the compression set resistance may be deteriorated. Yes, not preferable.

The binding unit (B) constituting the acrylic rubber of the present invention is a binding unit derived from the methacrylic acid ester (b).

The methacrylic acid ester (b) is not particularly limited, and for example, at least one methacrylic acid ester selected from the group consisting of an alkyl methacrylate ester and an alkyl methacrylate ester can be mentioned as a preferable example, and particularly methacrylic acid. Alkyl esters are preferred.

Examples of the methacrylic acid alkyl ester include a methacrylic acid alkyl ester having an alkyl group having 1 to 14 carbon atoms, preferably an alkyl methacrylic acid ester having an alkyl group having 2 to 8 carbon atoms, and more preferably carbon. It is a methacrylic acid alkyl ester having an alkyl group of several 2 to 6.

Specific examples of the alkyl methacrylate are methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, n-hexyl methacrylate, 2-ethylhexyl methacrylate, and the like. Cyclohexyl methacrylate, octyl methacrylate, dodecyl methacrylate, isotridecyl methacrylate and the like can be mentioned, preferably ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, hexyl methacrylate, octyl methacrylate, more preferably ethyl methacrylate. , N-Butyl methacrylate.

Examples of the methacrylate alkoxyalkyl ester include a methacrylate alkoxyalkyl ester having an alkoxyalkyl group having 2 to 14 carbon atoms, and preferably a methacrylate alkoxyalkyl alkyl ester having an alkoxyalkyl group having 2 to 8 carbon atoms. , More preferably, a methacrylate alkoxyalkyl ester having an alkoxyalkyl group having 2 to 6 carbon atoms.

Specific examples of the methacrylic acid alkoxyalkyl ester include methoxymethyl methacrylate, methoxyethyl methacrylate, methoxypropyl methacrylate, methoxybutyl methacrylate, ethoxymethyl methacrylate, ethoxyethyl methacrylate, propoxyethyl methacrylate, butoxyethyl methacrylate. And so on. Among these, methoxyethyl methacrylate, ethoxyethyl methacrylate, ethoxymethyl methacrylate, ethoxyethyl methacrylate and the like are preferable, and methoxyethyl methacrylate is more preferable.

The binding unit (B) derived from these methacrylic acid esters can be used alone or in combination of two or more, and the binding amount in the acrylic rubber is 1 to 50% by weight, preferably 2 to 40% by weight. It is more preferably in the range of 3 to 30% by weight, particularly preferably in the range of 5 to 25% by weight.

The binding unit (C) constituting the acrylic rubber of the present invention is a binding unit derived from the reactive group-containing monomer (c).

The reactive group-containing monomer (c) is not particularly limited, and examples thereof include a monomer having at least one functional group selected from the group consisting of a carboxyl group, an epoxy group and a halogen group. It is preferably a monomer having a carboxyl group, a monomer having an epoxy group, and particularly preferably a monomer having a carboxyl group.

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. Among these, ethylenically unsaturated dicarboxylic acid monoester However, it is preferable because the compression-resistant permanent strain characteristics of the obtained acrylic rubber can be further enhanced.

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, ethylacrylic acid, crotonic acid, and cinnamic acid. Acrylic acid and the like can be mentioned.

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 anhydrides.

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 buthendioic 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. Monocyclohexyl acid, monocyclohexenyl fumarate, monocyclopentyl maleate, monoalkyl maleate such as monocyclohexyl maleate; monomethyl itaconate, monoethyl itaconate, monon-butyl itaconate, monocyclohexyl itaconate and other itaconic acids Examples thereof include monoalkyl esters; preferably mono-n-butyl fumarate, mono n-butyl maleate, and particularly preferably mono n-butyl fumarate.

Examples of the monomer having an epoxy group include an epoxy group-containing (meth) acrylic acid ester such as glycidyl (meth) acrylate; and an epoxy group-containing vinyl ether such as allyl glycidyl ether and vinyl glycidyl ether. In addition, "(meth) acrylic acid" here is used as a generic term for acrylic acid and / or methacrylic acid, and the same applies hereinafter.

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.

The binding unit (C) derived from these reactive group-containing monomers can be used alone or in combination of two or more, and the binding amount in the acrylic rubber is 0.1 to 10% by weight, preferably 0.1 to 10% by weight. It is in the range of 0.3 to 8% by weight, more preferably 0.5 to 5% by weight, and particularly preferably 1 to 3% by weight.

The bonding unit (D) constituting the acrylic rubber of the present invention is a bonding unit derived from another monomer (d) that is copolymerized as needed.

The other monomer (d) is not particularly limited as long as it is other than the above-mentioned monomers (a), (b) and (c) and can be copolymerized with them. For example, aromatic vinyl and ethylene Examples thereof include sex-unsaturated nitriles, acrylamide-based monomers, and other olefin-based monomers. 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.

The binding unit (D) derived from these other monomers can be used alone or in combination of two or more, and the binding amount in the acrylic rubber is 0 to 30% by weight, preferably 0 to 20% by weight. %, More preferably 0 to 15% by weight, and particularly preferably 0 to 10% by weight. Therefore, some of the acrylic rubbers of the present invention do not contain the binding unit (D) derived from other monomers or contain them within the above range, and in the former case, the other monomers as described above ( d) is not used.

<Acrylic rubber>
The acrylic rubber of the present invention has a binding unit (A) derived from the acrylic acid ester, a binding unit (B) derived from a methacrylate ester, a binding unit (C) derived from a reactive group-containing monomer, and if necessary. It is composed of a binding unit (D) derived from other monomers, and the proportion of each binding unit (A) is 10 to 98.9% by weight, preferably 32 to 97.7% by weight, and more preferably 50 to 50 to 9% by weight. It is in the range of 96.5% by weight, particularly preferably 62 to 94% by weight, and the binding unit (B) is 1 to 50% by weight, preferably 2 to 40% by weight, more preferably 3 to 30% by weight, particularly. It is preferably in the range of 5 to 25% by weight, and the binding unit (C) is 0.1 to 10% by weight, preferably 0.3 to 8% by weight, more preferably 0.5 to 5% by weight, and particularly preferably. Is in the range of 1 to 3% by weight, and the binding unit (D) is 0 to 30% by weight, preferably 0 to 20% by weight, more preferably 0 to 15% by weight, and particularly preferably 0 to 10% by weight. The range. That is, the acrylic rubber of the present invention is a copolymer containing each of the above-mentioned bonding units in the above-mentioned specific weight ratio and containing the total of each bonding unit so as to be 100% by weight, and each single unit in the acrylic rubber. When a crosslinked product of acrylic rubber is used when the polymer bonding unit is in this range, heat resistance, water resistance and compression resistance permanent strain characteristics can be highly balanced, which is preferable.

The content of the reactive group of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected from the ratio of the binding units derived from the above-mentioned reactive group-containing monomer, and is based on the weight ratio of the reactive group itself. Workability is usually in the range of 0.001 to 5% by weight, preferably 0.01 to 3% by weight, more preferably 0.05 to 1% by weight, and particularly preferably 0.1 to 0.5% by weight. It is suitable because it has a high balance of properties such as strength characteristics, compression set resistance, oil resistance, cold resistance, and water resistance.

The total ash content in the acrylic rubber of the present invention is 1% by weight or less, preferably 0.5% by weight or less, more preferably 0.3% by weight or less, particularly preferably 0.2% by weight or less, and most preferably 0. When it is .15% by weight or less and the total ash content is in this range, the water resistance as acrylic rubber is remarkably excellent and suitable.

The lower limit of the total ash content in the acrylic rubber 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. Especially, when it is 0.005% by weight or more, most preferably 0.01% by weight or more, the metal adhesion of the acrylic rubber is reduced and the workability is excellent, which is preferable.

Therefore, the total ash content in which the water resistance and the metal adhesion resistance of the acrylic rubber of the present invention are highly balanced is usually 0.0001 to 1% by weight, preferably 0.0005 to 0.5% by weight, and more. It is preferably in the range of 0.001 to 0.3% by weight, particularly preferably 0.005 to 0.2% by weight, and most preferably 0.01 to 0.15% by weight.

When the total amount of magnesium and phosphorus in the ash content of the acrylic rubber of the present invention accounts for 60% by weight or more, preferably 70% by weight or more, more preferably 80% by weight or more of the total ash content, the water resistance of the acrylic rubber Is highly suitable because it is highly excellent.

The ratio of magnesium to phosphorus ([Mg] / [P]) in the ash content of the acrylic rubber of the present invention is not particularly limited, but is usually 0.4 to 2.5, preferably 0.45 by weight. When the range is ~ 1.2, more preferably 0.5 to 0.7, the water resistance of the acrylic rubber is highly excellent, which is preferable.

Here, the ash content in the acrylic rubber is mainly derived from the emulsifier used when emulsifying the monomer component and emulsion polymerization and the coagulant used when coagulating the emulsion polymerization solution. The contents of magnesium and phosphorus in the ash vary not only with the conditions of the emulsion polymerization step and the solidification step, but also with the conditions of each subsequent step.

The amount of gel of the acrylic rubber 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 15% by weight or less, and particularly preferably 10% by weight. % Or less, most preferably 5% by weight or less, the processability of the acrylic rubber is highly improved and is preferable.

The glass transition temperature (Tg) of the acrylic rubber of the present invention is not particularly limited, and is usually 20 ° C. or lower, preferably 10 ° C. or lower, and more preferably 0 ° C.

The pH of the acrylic rubber of the present invention is not particularly limited, but is usually 7 or less, preferably 6 or less, more preferably 2 to 6, particularly preferably 2.5 to 5.5, and most preferably 3 to 5. The range is good, and when it is in this range, the storage stability is highly improved and is suitable.

When the water content of the acrylic rubber of the present invention is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less, the scorch characteristics can be optimized and it is preferable.

The Mooney viscosity (ML1 + 4,100 ° C.) of the acrylic rubber of the present invention is in the range of 10 to 150, preferably 20 to 100, and more preferably 25 to 80.

The weight average molecular weight (Mw) of the acrylic rubber of the present invention is an absolute molecular weight measured by GPC-MALS and is not particularly limited, but is usually 100,000 to 5,000,000, preferably 500,000 to 4 , Million, more preferably 700,000 to 3,000,000, most preferably 1,000,000 to 2,500,000 when the acrylic rubber is mixed with processability and strength characteristics. It is suitable because the compression resistance permanent strain characteristics are highly balanced.

The ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) of the acrylic rubber of the present invention is not particularly limited, but is usually 1 in the absolute molecular weight distribution measured by GPC-MALS. When the range is 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 acrylic rubber are highly balanced, which is preferable. be.

<Acrylic rubber manufacturing method>
The method for producing the acrylic rubber is not particularly limited, but for example, the acrylic acid ester (a), the methacrylate ester (b), the reactive group-containing monomer (c), and if necessary, the copolymer. An emulsion polymerization step of emulsion-polymerizing a monomer component composed of other polymerizable monomer (d) with water and a phosphoric acid-based emulsifier and then emulsion polymerization 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 a magnesium salt aqueous solution to form a hydrous crumb, and
A cleaning process to clean the generated hydrous crumb,
A drying process to dry the washed hydrous crumb,
It can be easily manufactured by a manufacturing method including.

Hereinafter, embodiments of each of the above steps will be described.

(Emulsion polymerization process)
The emulsion polymerization step in the method for producing acrylic rubber of the present invention includes an acrylic acid ester (a), a methacrylic acid ester (b), a reactive group-containing monomer (c), and other copolymerizable if necessary. A monomer component composed of the monomer (d) is emulsionized with water and a phosphoric acid-based emulsifier, and then emulsion-polymerized in the presence of a polymerization catalyst to obtain an emulsion polymerization solution.

The monomer components (a) to (d) used in the emulsion polymerization step of acrylic rubber are examples of the monomer components corresponding to the acrylic rubber bonding units (A) to (D) described above and a preferable range. It is the same. The amount of the monomer component used is also as described above, and in the emulsion polymerization step, each monomer may be appropriately selected so as to have the above composition of the acrylic rubber of the present invention.

As the phosphoric acid-based emulsifier used as an emulsifier in the emulsion polymerization step, a phosphoric acid ester salt is usually used, although not particularly limited, as long as it can be used as an emulsifier in the emulsion polymerization reaction. As the phosphoric acid ester salt, a divalent phosphoric acid ester metal salt is preferably used, and among them, a divalent phosphoric acid ester sodium salt is particularly preferable.

Specific examples of suitable divalent phosphoric acid ester salts include alkyloxypolyoxyalkylene phosphates, alkylphenyloxypolyoxyalkylene phosphates, and the like, and among these, these metal salts are preferable. Alkali metal salts are more preferred, and these sodium salts are most preferred.

Examples of the alkyloxypolyoxyalkylene phosphoric acid ester salt include alkyloxypolyoxyethylene phosphoric acid ester salts and alkyloxypolyoxypropylene phosphoric acid ester salts. Among these, alkyloxypolyoxyethylene phosphoric acid is used. Ester salts are preferred.

Specific examples of the alkyloxypolyoxyethylene phosphate salt include octyloxydioxyethylene phosphate, octyloxytrioxyethylene phosphate, octyloxytetraoxyethylene phosphate, and decyloxytetraoxyethylene phosphate. , Dodecyloxytetraoxyethylene Phosphate, Tridecyloxytetraoxyethylene Phosphate, Tetradecyloxytetraoxyethylene Phosphate, Hexadecyloxytetraoxyethylene Phosphate, Octadecyloxytetraoxyethylene Phosphate, Octyl Oxypentaoxyethylene Phosphate, Decyloxypentaoxyethylene Phosphate, Dodecyloxypentaoxyethylene Phosphate, Tridecyloxypentaoxyethylene Phosphate, Tetradecyloxypentaoxyethylene Phosphate, Hexadecyloxypenta Oxyethylene Phosphate, Octadecyloxypentaoxyethylene Phosphate, Octyloxyhexaoxyethylene Phosphate, Decyloxyhexaoxyethylene Phosphate, Dodecyloxyhexaoxyethylene Phosphate, Tridecyloxyhexaoxyethylene Phosphate Estel, Tetradecyloxyhexaoxyethylene Phosphate, Hexadecyloxyhexaoxyethylene Phosphate, Octadecyloxyhexaoxyethylene Phosphate, Octyloxyoctaoxyethylene Phosphate, Decyloxyoctaoxyethylene Phosphate, Dodecyl Metal salts such as oxyoctaoxyethylene phosphoric acid ester, tridecyloxyoctaoxyethylene phosphoric acid ester, tetradecyloxyoctaoxyethylene phosphoric acid ester, hexadecyloxyoctaoxyethylene phosphoric acid ester, octadecyloxyoctaoxyethylene phosphoric acid ester, etc. Among these, alkali metal salts thereof, particularly sodium salts, are preferable.

Specific examples of the alkyloxypolyoxypropylene phosphate ester include octyloxydioxypropylene phosphate, octyloxytrioxypropylene phosphate, octyloxytetraoxypropylene phosphate, and decyloxytetraoxypropylene phosphate. , Dodecyloxytetraoxypropylene phosphate, tridecyloxytetraoxypropylene phosphate, tetradecyloxytetraoxypropylene phosphate, hexadecyloxytetraoxypropylene phosphate, octadecyloxytetraoxypropylene phosphate, octyl Oxypentaoxypropylene Phosphate, Decyloxypentaoxypropylene Phosphate, Dodecyloxypentaoxypropylene Phosphate, Tridecyloxypentaoxypropylene Phosphate, Tetradecyloxypentaoxypropylene Phosphate, Hexadecyloxypenta Oxypropylene Phosphate, Octadecyloxypentaoxypropylene Phosphate, Octyloxyhexaoxypropylene Phosphate, Decyloxyhexaoxypropylene Phosphate, Dodecyloxyhexaoxypropylene Phosphate, Tridecyloxyhexaoxypropylene Phosphate Estel, Tetradecyloxyhexaoxypropylene Phosphate, Hexadecyloxyhexaoxypropylene Phosphate, Octadecyloxyhexaoxypropylene Phosphate, Octyloxyoctaoxypropylene Phosphate, Decyloxyoctaoxypropylene Phosphate, Dodecyl Oxyoctaoxypropylene Phosphate, Tridecyloxyoctaoxyethylene Phosphate, Tetradecyloxyoctaoxypropylene Phosphate, Hexadecyloxyoctaoxypropylene Phosphate, Octadecyloxyoctaoxypropylene Phosphate and their metals Examples thereof include salts, and among these, alkali metal salts thereof, particularly sodium salts, are preferable.

Specific examples of the alkylphenyloxypolyoxyalkylene phosphate ester include alkylphenyloxypolyoxyethylene phosphate and alkylphenyloxypolyoxypropylene phosphate, among which alkylphenyloxypoly is used. Oxyethylene phosphate salts are preferred.

Specific examples of the alkylphenyloxypolyoxyethylene phosphate salt include methyloxyoxytetraoxyethylene phosphate, ethylphenyloxytetraoxyethylene phosphate, butylphenyloxytetraoxyethylene phosphate, and hexylphenyloxytetra. Oxyethylene Phosphate, Nonylphenyloxytetraoxyethylene Phosphate, Dodecylphenyloxytetraoxyethylene Phosphate, Octadecyloxytetraoxyethylene Phosphate, Methylphenyloxypentaoxyethylene Phosphate, Ethylphenyloxypentaoxy Ethylene Phosphate, Butylphenyloxypentaoxyethylene Phosphate, Hexylphenyloxypentaoxyethylene Phosphate, Nonylphenyloxypentaoxyethylene Phosphate, Dodecylphenyloxypentaoxyethylene Phosphate, Methylphenyloxyhexaoxy Ethylene Phosphate, Ethylphenyloxyhexaoxyethylene Phosphate, Butylphenyloxyhexaoxyethylene Phosphate, Hexylphenyloxyhexaoxyethylene Phosphate, Nonylphenyloxyhexaoxyethylene Phosphate, Dodecylphenyloxyhexaoxy Ethylene Phosphate, Methylphenyloxyhexaoxyethylene Phosphate, Ethylphenyloxyoctaoxyethylene Phosphate, Butylphenyloxyoctaoxyethylene Phosphate, Hexylphenyloxyoctaoxyethylene Phosphate, Nonylphenyloxyoctaoxy Examples thereof include metal salts such as ethylene phosphoric acid ester and dodecylphenyloxyoctaoxyethylene phosphoric acid ester, and among these, alkali metal salts thereof, particularly sodium salt, are preferable.

Specific examples of the alkylphenyloxypolyoxypropylene phosphate ester include methylphenyloxytetraoxypropylene phosphate ester, ethylphenyloxytetraoxypropylene phosphate ester, butylphenyloxytetraoxypropylene phosphate ester, and hexylphenyloxytetralate. Oxypropylene Phosphate, Nonylphenyloxytetraoxypropylene Phosphate, Dodecylphenyloxytetraoxypropylene Phosphate, Methylphenyloxypentaoxypropylene Phosphate, Ethylphenyloxypentaoxypropylene Phosphate, Butylphenyloxypenta Oxypropylene Phosphate, Hexylphenyloxypentaoxypropylene Phosphate, Nonylphenyloxypentaoxypropylene Phosphate, Dodecylphenyloxypentaoxypropylene Phosphate, Methylphenyloxyhexaoxypropylene Phosphate, Ethylphenyloxyhexa Oxypropylene Phosphate, Butylphenyloxyhexaoxypropylene Phosphate, Hexylphenyloxyhexaoxypropylene Phosphate, Nonylphenyloxyhexaoxypropylene Phosphate, Dodecylphenyloxyhexaoxypropylene Phosphate, Methylphenyloxyocta Oxypropylene Phosphate, Ethylphenyloxyoctaoxypropylene Phosphate, Butylphenyloxyoctaoxypropylene Phosphate, Hexylphenyloxyoctaoxyethylene Phosphate, Nonylphenyloxyoctaoxypropylene Phosphate, Dodecylphenyloxyocta Examples thereof include metal salts such as oxypropylene phosphate, and among these, alkali metal salts thereof, particularly sodium salts, are preferable.

Examples of the phosphoric acid-based emulsifier other than the above divalent phosphoric acid ester salt include monovalent phosphoric acid ester salts such as di (alkyloxypolyoxyalkylene) phosphoric acid ester sodium salt.

These phosphoric acid-based emulsifiers can be used alone or in combination of two or more, and the amount used is usually 0.01 to 10 parts by weight, preferably 0, based on 100 parts by weight of the monomer component. It is in the range of 1 to 5 parts by weight, more preferably 1 to 3 parts by weight.

In the method of the present invention, the above-mentioned phosphoric acid-based emulsifier and other emulsifiers may be used in combination as the emulsifier. Examples of other emulsifiers that can be used in combination with the above-mentioned phosphoric acid-based emulsifier include other anionic emulsifiers, cationic emulsifiers, nonionic emulsifiers and the like, and are preferably nonionic emulsifiers.

Other anionic emulsifiers include, for example, salts of fatty acids such as myristic acid, palmitic acid, oleic acid, linolenic acid; alkylbenzene sulfonates such as sodium dodecylbenzene sulfonate; sulfate esters such as sodium lauryl sulfate, alkyl sulfosuccinates. Examples include acid salts. Among these anionic emulsifiers, sulfate ester salts are preferable.

Examples of the cationic emulsifier include alkyltrimethylammonium chloride, dialkylammonium chloride, and benzylammonium chloride.

Examples of the nonionic emulsifier include polyoxyalkylene fatty acid esters such as polyoxyethylene stearic acid ester; polyoxyalkylene alkyl ethers such as polyoxyethylene dodecyl ether; polyoxyalkylene alkyl phenol ethers such as polyoxyethylene nonylphenyl ether; and poly. Examples thereof include oxyethylene sorbitan alkyl ester, and polyoxyalkylene alkyl ether and polyoxyalkylene alkyl phenol ether are preferable, and polyoxyethylene alkyl ether and polyoxyethylene alkyl phenol ether are more preferable.

The above-mentioned other emulsifiers can be used alone or in combination of two or more, and the amount used may be appropriately selected as long as the effects of the present invention are not impaired. When other emulsifiers are used, the amount thereof is preferably small, and is usually 0.01 to 10 parts by weight, preferably 0.1 to 5 parts by weight, more preferably with respect to 100 parts by weight of the monomer component. Is in the range of 1 to 3 parts by weight.

The method of mixing the monomer component, water and emulsifier (mixing method) may follow a conventional method. For example, a method of stirring the monomer, emulsifier and water using a stirrer such as a homogenizer or a disk turbine. And so on. The amount of water used is usually 1 to 1,000 parts by weight, preferably 5 to 500 parts by weight, more preferably 4 to 300 parts by weight, and particularly preferably 3 to 150 parts by weight, based on 100 parts by weight of the monomer component. Parts, most preferably in the range of 20-80 parts by weight.

The polymerization catalyst to be 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 preferable. Especially preferable.

The organic peroxide is not particularly limited as long as it is used in emulsification polymerization such as acrylic rubber. 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 -Tetraethylbutylhydroperoxide, t-butylcumyl peroxide, di-t-butyl peroxide, di-t-hexyl peroxide, di (2-t-butylperoxyisopropyl) benzene, dicumyl peroxide, diisobutyri Luperoxide, di (3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, disuccinate 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-tetra Methylbutylperoxyneodecanate, 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-hexyl peroxyisopropyl 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- Examples thereof include 2,5-di (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-carbamomidin), 2,2'-azobis [N- (2-carboxyethyl) -2-methylpropaneamide], 2,2'-azobis {2- [1- (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 can be mentioned.

These radical generators can be used individually or in combination of two or more, and the amount used is usually 0.0001 to 5 parts by weight, preferably 0.% by weight, based on 100 parts by weight of the monomer component. It is in the range of 0005 to 1 part by weight, more preferably 0.001 to 0.5 part by weight.

The reducing agent can be used without limitation as long as it is used in the redox catalyst of emulsion polymerization, 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. 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, erythorbic acid. Elysorbic acid such as potassium or a salt thereof; sulphinate such as sodium hydroxymethane sulfite; sodium sulfite, potassium sulfite, sodium hydrogen sulfite, aldehyde sodium hydrogen sulfite, potassium hydrogen sulfite sulfite; sodium pyrosulfite, potassium pyrosulfite, Pyro sulfites such as sodium pyrosulfite and potassium hydrogen pyrosulfite; thiosulfates such as sodium thiosulfite and potassium thiosulfite; subphosphates, sodium bisulfite, potassium bisulfite, sodium hydrogen phosphite, potassium hydrogen phosphite Phosphoric acid or a salt thereof; pyrophosylic acid such as pyrophosphate, sodium pyrophosphate, potassium pyrophosphate, sodium hydrogenpyrophosphate, potassium hydrogenpyrophosphate or a salt thereof; sodium formaldehyde sulfoxylate and the like can be mentioned. 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 0.1 parts by weight.

A preferable combination of the metal ion compound in the reduced state and the other reducing agent is a combination of ferrous sulfate and ascorbic acid or a salt thereof and / or sodium formaldehyde sulfoxylate, and more preferably ferrous sulfate. A combination of ascorbate and / or sodium formaldehyde sulfoxylate, most preferably a combination of ferrous sulfate and alcorbate. The amount of ferrous sulfate used at this time is usually 0.000001 to 0.01 parts by weight, preferably 0.00001 to 0.001 parts by weight, and more preferably 0, based on 100 parts by weight of the monomer component. In the range of 0.0005 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, preferably 0.001 to 1 part by weight, based on 100 parts by weight of both components. It is in the range of 0.005 to 0.5 parts by weight, more preferably 0.01 to 0.1 parts by weight.

The amount of water used in the emulsion polymerization reaction may be only the amount used at the time of emulsioning the monomer component, but is usually 10 to 1,000 parts by weight, preferably 10 to 1,000 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 50 to 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 method may be 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 usually 80% by weight or more, preferably 90% by weight or more, more preferably 95% by weight or more, and the acrylic rubber produced at this time has strength characteristics. It is excellent and has no monomeric odor and is suitable. A polymerization inhibitor may be used to terminate the polymerization.

(Coagulation process)
The coagulation step in the method for producing acrylic rubber of the present invention is a step of producing a hydrous crumb by bringing the emulsion polymerization solution obtained in the above emulsion polymerization step into contact with a magnesium salt aqueous solution.

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. NS.

The magnesium salt used as a coagulant is not particularly limited, and examples thereof include inorganic magnesium salts such as magnesium chloride, magnesium nitrate and magnesium sulfate, and organic magnesium salts such as magnesium formate and magnesium acetate. Of these, an inorganic magnesium salt is preferable, and magnesium sulfate is particularly preferable.

Each of these magnesium salts 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 0.1 by weight, based on 100 parts by weight of the monomer component. It is in the range of ~ 50 parts by weight, more preferably 1 to 30 parts by weight. When the magnesium salt 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 is crosslinked can be highly improved, which is preferable. In the present invention, a coagulant other than the magnesium salt may be used in combination as long as the effects of the present invention are not impaired.

The magnesium salt concentration of the aqueous magnesium salt solution used is usually in the range of 0.1 to 20% by weight, preferably 0.5 to 10% by weight, more preferably 1 to 5% by weight. It is suitable because the particle size can be uniformly focused on a specific region.

The temperature of the magnesium salt aqueous solution used is not particularly limited, but is preferably 40 ° C. or higher, preferably 40 to 90 ° C., more preferably 50 to 80 ° C., to produce a uniform hydrous crumb. ..

In the method for producing acrylic rubber of the present invention, the contact between the emulsion polymerization solution and the magnesium salt aqueous solution in the coagulation step is a method of adding the emulsion polymerization solution to the stirring magnesium salt aqueous solution, and the emulsion polymerization solution is a magnesium salted solution. There is a method of adding it to the inside, but when it is a method of adding the emulsion polymerization solution to the stirring magnesium salt aqueous solution, it suppresses the formation of maximum and fine hydrous crumbs and improves the cleaning efficiency of emulsifiers and coagulants. It is suitable because it can be significantly improved.

The stirring speed (stirring speed) of the agitated magnesium salt aqueous solution is represented by the rotation speed per minute (specifically, the rotation speed of the stirring blade) of the stirring device provided in the coagulation tank, and is emulsion polymerization. The number of revolutions is usually 100 rpm or more, preferably 200, because it is preferable that the water-containing crumb particle size generated is small and uniform when the liquid is added to the coagulation tank with a certain degree of vigorous stirring. It is in the range of ~ 1,000 rpm, more preferably 300 to 900 rpm, particularly preferably 350 to 850 rpm, and most preferably 400 to 800 rpm. If the stirring speed (rotation speed) of the magnesium salt aqueous solution is excessively low, a large crumb particle size and a small crumb particle size will be produced, and if it is excessively high, it will be difficult to control the coagulation reaction. Is also not preferable.

The peripheral speed of the magnesium salt aqueous solution being stirred is represented by the speed of the outer periphery of the stirring blade of the stirring device. As described above, the magnesium salt aqueous solution is generated when the magnesium salt aqueous solution is stirred violently to a certain extent. The water-containing crumb particle size can be made small and uniform, which is preferable. Therefore, the peripheral speed of the magnesium salt aqueous solution in the coagulation tank is preferably at least 0.5 m / s or more. The cleaning step when the peripheral speed is 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, particularly 2.5 m / s or more. It is suitable because it can produce a hydrous crumb having a crumb shape and a crumb diameter that is excellent in removing coagulants and emulsifiers in the dehydration step.

The upper limit of the peripheral speed of the agitated magnesium salt aqueous solution is not particularly limited, but is usually 30 m / s or less, preferably 25 m / s or less, more preferably 20 m / s or less, and particularly preferably 15 m / s or less. When the pressure is high, the solidification reaction can be easily controlled, which is preferable.

The acrylic rubber production method of the present invention is produced by appropriately selecting the above conditions for the solidification reaction (contact method, solid content concentration of emulsion polymerization solution, concentration of magnesium salt aqueous solution, temperature, rotation speed, peripheral speed, etc.). The shape and clam diameter of the water-containing crumb are uniform and focused, and the efficiency of removing emulsifiers and coagulants in the water-containing crumb in the washing step and the dehydration step is remarkably improved, which is suitable.

By adjusting the particle size (size) and particle size distribution of the hydrous crumb produced during the production of acrylic rubber to a specific range in this way, the efficiency of removing emulsifiers and coagulants in the hydrous crumb during washing and dehydration is greatly improved. can.

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

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 added for washing is not particularly limited, but the amount per washing with water is usually 50 parts by weight or more, preferably 50 to 15, with respect to 100 parts by weight of the monomer component charged by emulsion polymerization. When it is in the range of 000 parts by weight, more preferably 100 to 10,000 parts by weight, and further preferably 500 to 5,000 parts by weight, the amount of ash in the acrylic rubber can be effectively reduced, which is preferable. be.

The temperature of the water used is not particularly limited, but it is preferable to use warm water, which is usually 40 ° C. or higher, preferably 40 to 100 ° C., more preferably 50 to 90 ° C., and particularly 60 to 80 ° C. It is optimal because it can significantly improve the cleaning efficiency. By setting the temperature of the hot water used to be equal to or higher than the above lower limit, the emulsifier and coagulant are released from the hydrous crumb to further improve the cleaning efficiency.

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 (washing with water) in the washing step is also not particularly limited, and is usually 1 to 10 times, preferably 1 to 5 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 washings with water is large, but as described above, the shape of the water-containing crumb and the diameter of the water-containing crumb are set within a specific range. By setting the cleaning temperature within the above range, the number of washings with water can be significantly reduced.

(Dehydration process)
In the method for producing acrylic rubber of the present invention, it is preferable to provide a dehydration step of squeezing out water before moving from the washed water-containing crumb to a drying step because the ash content in the acrylic rubber can be significantly reduced. In particular, the ash content produced by using a phosphoric acid-based emulsifier as an emulsifier and a magnesium salt as a coagulant can be significantly reduced by providing a dehydration step, which is preferable.

The means for dehydrating the water-containing crumb is not particularly limited and may follow a conventional method. For example, a dehydrator such as a centrifuge, a squeezer, or a screw type extruder can be used to discharge water from the water-containing crumb. Among these dehydrators, the acrylic rubber of the present invention has strong adhesiveness and can only be dehydrated to a water content of about 45 to 50% by weight with a centrifuge or the like, so a squeezer or screw type that forcibly squeezes water from the water content crumb. An extruder is preferable, and among these, a screw type extruder is most preferable.

The emulsifier or coagulant when the water content of the hydrous crumb after dehydration is 1 to 50% by weight, preferably 3 to 40% by weight, more preferably 5 to 35% by weight, and most preferably 10 to 35% by weight. It is suitable because the removal of the emulsifier is remarkably improved and the drying in the drying step is efficient.

(Drying process)
The drying step in the method for producing acrylic rubber of the present invention is a step of drying the water-containing crumb after washing, preferably the dehydrated water-containing crumb after washing, to obtain acrylic rubber.

The method for drying the water-containing crumb may be according to a conventional method, and for example, it can be dried using a dryer such as a hot air dryer, a vacuum dryer, an expander dryer, a kneader type dryer, or a screw type extruder. The drying temperature of the hydrous crumb is not particularly limited, but is usually in the range of 80 to 250 ° C, preferably 100 to 200 ° C, and more preferably 120 to 180 ° C.

The water content of the acrylic 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.

(Dehydration / drying process by screw type extruder)
In the method for producing acrylic rubber of the present invention, the above dehydration step and drying step are provided with a screw type extruder, particularly a dehydration barrel having a dehydration slit, a drying barrel for drying under reduced pressure, and a die at the tip. It is preferable to continuously perform the process using a screw type extruder, which can significantly reduce the ash content and water content in the acrylic rubber. Specific embodiments thereof are shown below, but this does not limit the scope of the present invention.

Dehydration / drying in the dehydration barrel The dehydration of the hydrous crumb is performed in a dehydration barrel having a dehydration slit provided in the screw type extruder. The opening of the dehydration slit may be appropriately selected according to the conditions of use, but 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. In addition, it is suitable because the loss of the hydrous crumb is small and the hydrous crumb can be efficiently dehydrated.

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 steam (exhaust vapor). Exhaust steam is defined as pre-drying to distinguish it.

When using a screw type extruder equipped with multiple dehydration barrels, it is possible to efficiently dehydrate the adhesive acrylic rubber and reduce the water content by combining drainage (dehydration) and exhaust steam (pre-drying). Suitable. In a screw type extruder provided with three or more dehydration barrels, the selection of whether to use a drainage type dehydration barrel or a steam exhaust type dehydration barrel for each dehydration barrel may be appropriately performed according to the purpose of use of the acrylic rubber. To reduce the amount of ash in normally produced rubber, increase the number of drainage barrels. For example, if there are three dehydration barrels, use two drainage barrels, and if there are four dehydration barrels, use three drainage barrels. Select as appropriate, such as individual.

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 that dehydrates in the drained state is usually 60 to 120 ° C., preferably 70 to 110 ° C., and more preferably 80 to 100 ° C. The set temperature of the dehydration barrel for which pre-drying is performed 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 of the water-containing crumb after dehydration, that is, the water content after passing through the drainage barrel is not particularly limited, but is usually 1 to 50% by weight, preferably 3 to 40% by weight, more preferably 5 to 35% by weight, most. It is preferable that the emulsifier and the coagulant can be efficiently removed when the content is preferably 10 to 35% by weight. When the screw type extruder is used to efficiently remove emulsifiers and coagulants and reduce the water content, the water content after dehydration is 5 to 40% by weight, preferably 10 to 40% by weight, more preferably 15 to 35%. It is in the range of% by weight.

When dehydration of the adhesive acrylic rubber having a crosslinkable group with the above specific composition is carried out using a centrifuge or the like, the acrylic rubber adheres to the dehydration slit portion and can hardly be dehydrated (water content is about 45 to about 45 to). In the present invention, by using a screw type extruder having a dehydration slit and a dehydration barrel forcibly squeezed by a screw, the water content can be efficiently reduced to less than that. Therefore, it is particularly suitable.

The water content of the water-containing crumb that has been pre-dried in the exhaust steam type dehydration barrel after the dehydration is usually 1 to 30% by weight, preferably 3 to 20% by weight, and more preferably 5 to 15% by weight.

Drying in a Dry Barrel The hydrous crumb that has been dehydrated and dried in the dehydration barrel is further dried in a dry barrel under reduced pressure provided on the downstream side (extruder side) in the same screw type extruder.

The degree of decompression inside 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 extruder is not particularly limited, but is usually a plurality, preferably 2 to 10 barrels, more preferably 3 to 8 barrels. When there are a plurality of dry barrels, the degree of decompression may be an approximate degree of decompression for all the dry barrels, or may be changed. When having a plurality of 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 acrylic rubber crumb after drying in the dry barrel portion is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less. In the present invention, particularly in a screw type extruder, when the water content of the acrylic rubber reaches this value (a state in which almost all water is removed) and melt extrusion is performed, the gel amount of the acrylic rubber is reduced and the acrylic rubber is in the form of a sheet. Even when acrylic rubber is molded and extruded, it is suitable because it can reduce entrained air bubbles and increase the specific gravity.

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 a screwless rectifying die portion provided near the tip portion of the screw type extruder. A breaker plate or wire mesh may or may not be provided between the screw portion and the die portion.

The acrylic rubber extruded from the die portion of the screw type extruder has various shapes such as granular, pellet-shaped, columnar, round bar-shaped, and sheet-shaped depending on the nozzle shape of the die.

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, air entrainment is small (the specific gravity is large). Moreover, it is suitable because it is excellent in productivity.

Operating conditions of the screw type extruder The screw length (L) of the screw type extruder used may be appropriately selected according to the purpose of use, but is usually 3,000 to 15,000 mm, preferably 4,000 to. It is in the range of 10,000 mm, more preferably 4,500 to 8,000 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, or more. It is preferable that the water content is less than 1% by weight without lowering the molecular weight or burning of the dried rubber when it is in the range of 30 to 60.

The rotation speed (N) of the screw type extruder used may be appropriately selected according to various conditions, but is usually 10 to 1,000 rpm, preferably 50 to 750 rpm, more preferably 100 to 500 rpm, and most preferably. Is suitable because the water content and gel amount of acrylic rubber can be efficiently reduced when the speed is 120 to 300 rpm.

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 1,200 kg / hr, and more preferably 400 to 1, It is in the range of 000 kg / hr, most preferably 500 to 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 1 to 20, preferably 2 to 10, and more preferably. Is preferably in the range of 3 to 8, particularly preferably 4 to 6, because the adhesive acrylic rubber can be efficiently dehydrated, dried, and molded.

As described above, according to the method for producing acrylic rubber of the present invention, the above-mentioned bond unit (A) derived from acrylic acid ester (A) 10 to 98.9% by weight and the bond (B) derived from alkyl methacrylate ester by weight 1 to 50% by weight. %, Bonding unit (C) 0.1 to 10% by weight derived from a reactive group-containing monomer, and binding unit (D) 0 to 30% by weight derived from other monomers, and the total ash content is Acrylic rubber having 1% by weight or less, the total amount of magnesium and phosphorus in the ash content being 60% by weight or more with respect to the total ash content, and the Mooney viscosity (ML1 + 4,100 ° C.) in the range of 10 to 150. It can be manufactured efficiently.

<Acrylic rubber molded body>
(Sheet-shaped or veil-shaped acrylic rubber molded product)
The acrylic rubber molded product of the present invention is characterized by being made of the acrylic rubber and having a sheet shape or a veil shape.

The specific gravity of the sheet-shaped or bale-shaped acrylic rubber molded product of the present invention is not particularly limited, but is usually 0.7 or more, preferably 0.8 or more, more preferably 0.9 or more, and particularly preferably 0. 95 or more, most preferably 1.0 or more, particularly 0.7 to 1.5, preferably 0.8 to 1.4, more preferably 0.9 to 1.3, particularly preferably 0.95 to When it is 1.25, most preferably in the range of 1.0 to 1.2, the storage stability is highly excellent and suitable.

The pH of the sheet-shaped or veil-shaped acrylic rubber molded product of the present invention is not particularly limited, but is usually 7 or less, preferably 6 or less, more preferably 2 to 6, and particularly preferably 2.5 to 5.5. , Most preferably in the range of 3 to 5, the storage stability is highly improved and is preferable.

The complex viscosity ([η] 60 ° C.) of the sheet-shaped or veil-shaped acrylic rubber molded product of the present invention at 60 ° C. is not particularly limited, but is usually 15,000 Pa · s or less, preferably 2, Excellent workability, oil resistance and shape retention when in the range of 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. Suitable.

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

The ratio ([η] 100 ° C.) of the complex viscosity ([η] 100 ° C.) at 100 ° C. to the complex viscosity ([η] 60 ° C.) at 60 ° C. of the sheet-shaped or veil-shaped acrylic rubber molded product of the present invention. / [Η] 60 ° C.) is not particularly limited, but is usually 0.5 or more, preferably 0.6 to 0.98, more preferably 0.7 to 0.96, and particularly preferably 0.8 to 0. When 95, most preferably 0.83 to 0.93, workability, oil resistance, and shape retention are highly balanced and preferable.

The characteristic values of the ash content of the sheet-shaped or veil-shaped acrylic rubber molded product of the present invention, the total amount and ratio of magnesium and phosphorus in the ash content, the gel amount, the water content, and the Mooney viscosity (ML1 + 4,100 ° C.) are the acrylic. It is the same as each characteristic value of rubber.

The thickness of the sheet-shaped acrylic rubber molded product of the present invention is appropriately selected depending on the intended use, but is usually 1 mm to 45 mm, preferably 2 to 40 mm, more preferably 3 to 25 mm, and particularly preferably 3 to 20 mm. The range. In particular, the thickness in the case of producing a low-priced acrylic rubber sheet with significantly improved productivity is usually in the range of 1 to 15 mm, preferably 2 to 10 mm, and more preferably 3 to 8 mm.

The width of the sheet-shaped acrylic rubber molded product of the present invention is appropriately selected depending on the intended use, but is usually in the range of 300 to 1,200 mm, preferably 400 to 1,000 mm, and more preferably 500 to 800 mm. Sometimes, it is particularly excellent in handleability and suitable. The length of the sheet-shaped acrylic rubber molded product of the present invention is not particularly limited, but is usually in the range of 300 to 1,200 mm, preferably 400 to 1,000 mm, and more preferably 500 to 800 mm. In particular, it is excellent in handleability and suitable.

The size of the veil-shaped acrylic rubber molded product of the present invention is not particularly limited, but the width is usually 100 to 800 mm, preferably 200 to 500 mm, and more preferably 250 to 450 mm in length. Usually 300 to 1,200 mm, preferably 400 to 1,000 mm, more preferably 500 to 800 mm, height usually more than 50 mm and less than 500 mm, preferably 100 to 300 mm, more preferably 150 to 250 mm. be.

(Manufacturing method of sheet-shaped acrylic rubber molded product)
The method for producing the sheet-shaped acrylic rubber molded product is not particularly limited, but for example, a screw including a dehydration barrel having the dehydration slit, a drying barrel to be dried under reduced pressure, and a die at the tip. When manufacturing acrylic rubber using a mold extruder, it can be easily manufactured by making the shape of the die substantially rectangular and continuously extruding it.

Acrylic rubber extruded from the die part of a screw type extruder is suitable because it is possible to obtain dry rubber with less air entrainment and excellent storage stability by making the die shape substantially rectangular and extruding it into a sheet shape. be.

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, air entrainment is small (the specific gravity is large). Moreover, it is suitable because it is excellent in productivity.

The sheet-shaped acrylic rubber molded product extruded from the screw-type extruder can increase the specific gravity without entraining air at this time, and the storage stability of the obtained sheet-shaped acrylic rubber molded product is highly improved and is suitable. The sheet-shaped acrylic rubber molded product extruded from the screw-type extruder is cooled and then cut to a predetermined size as needed to obtain a sheet-shaped acrylic rubber molded product.

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

The width of the sheet-shaped acrylic rubber molded product extruded from the screw type extruder is appropriately selected according to the purpose of use, but the width is usually 300 to 1,200 mm, preferably 400 to 1,000 mm, and more preferably 500 to 500. The range is 800 mm.

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

The water content of the sheet-shaped acrylic rubber molded product 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.

The complex viscosity ([η] 100 ° C.) of the sheet-shaped acrylic rubber molded product extruded from the screw type extruder at 100 ° C. is not particularly limited, but is usually 1,500 to 6,000 Pa · s, preferably 1,500 to 6,000 Pa · s. Extrudability as a sheet and sheet when is in the range of 2,000 to 5,000 Pa · s, more preferably 2,500 to 4,000 Pa · s, and most preferably 2,500 to 3,500 Pa · s. The shape of the product is highly balanced and suitable. By setting the value of the complex viscosity ([η] 100 ° C.) at 100 ° C. to the lower limit or higher, the extrudability can be improved, and by setting the value to the upper limit or lower, the shape of the sheet-shaped acrylic rubber molded product can be improved. Collapse and breakage can be suppressed.

The cooling method of the sheet-shaped acrylic rubber molded body is not particularly limited and may be left at room temperature, but since the heat conductivity of the sheet-shaped acrylic rubber molded body is very small, 0.1 to 0.4, Forced cooling such as an air-cooling method under blowing or cooling, a watering method for spraying water, or a dipping method for immersing in water is preferable in order to increase productivity, and an air-cooling method under blowing or cooling is particularly preferable.

In the air-cooling method of the sheet-shaped acrylic rubber molded product, for example, the sheet-shaped acrylic rubber molded product can be extruded from a screw-type extruder onto a conveyor such as a belt conveyor, transported 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 30 ° 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 acrylic rubber molded product is not particularly limited, but the cutting is usually performed at 50 ° C./hr or more, more preferably 100 ° C./hr or more, and more preferably 150 ° C./hr or more. It is particularly easy and suitable.

The temperature at which the sheet-shaped acrylic rubber molded product is cut is not particularly limited, but when it is usually 60 ° C. or lower, preferably 55 ° C. or lower, and more preferably 50 ° C. or lower, the cutability and productivity are high. It is well-balanced and suitable.

The complex viscosity ([η] 60 ° C.) of the sheet-shaped acrylic rubber molded product 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, the cutting can be performed continuously without entraining air.

Further, the ratio of the complex viscosity ([η] 100 ° C.) at 100 ° C. to the complex viscosity ([η] 60 ° C.) at 60 ° C. of the sheet-shaped acrylic rubber molded product ([η] 100 ° C./[η] 60 ° C.) is not particularly limited, but is usually 0.5 or more, preferably 0.6 to 0.98, more preferably 0.75 to 0.95, particularly preferably 0.8 to 0.94, most preferably. Preferably, when it is in the range of 0.83 to 0.93, the air entrainment property is low, and cutting and productivity are highly balanced and preferable.

The cutting length of the sheet-shaped acrylic rubber molded product is not particularly limited and may be appropriately selected depending on the intended use of the rubber sheet, but is usually 100 to 800 mm, preferably 200 to 500 mm, and more preferably 250 to 450 mm. Is the range of.

The sheet-shaped acrylic rubber molded product of the present invention thus obtained is superior in operability and storage stability as compared with crumb-shaped acrylic rubber, and can be used as it is or by laminating a plurality of sheets to form a veil.

(Manufacturing method of veil-shaped acrylic rubber molded product)
The method for producing the bale-shaped acrylic rubber molded product of the present invention is not particularly limited, but for example, a method of laminating a plurality of the above-mentioned sheet-shaped acrylic rubber molded products and a method of bale-forming a crumb-shaped acrylic rubber with a veiler. However, it is preferable because the storage stability of the veil-shaped acrylic rubber molded product produced by laminating a plurality of sheet-shaped acrylic rubber molded products can be highly improved. A plurality of sheet-shaped acrylic rubber molded products can be laminated by cooling the sheet-shaped acrylic rubber molded product extruded from the screw type extruder, cutting the molded product, and laminating and integrating the plurality of sheet-shaped acrylic rubber molded products.

The laminating temperature of the sheet-shaped acrylic rubber molded product 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 be released. be. The number of layers is appropriately selected according to the size or weight of the bale-shaped acrylic rubber molded product.

The veil-shaped acrylic rubber molded product thus obtained is superior in operability and storage stability to the crumb-shaped acrylic rubber, and the bale-shaped acrylic rubber molded product can be used as it is or by cutting the required amount into a kneader for vanbury, roll, etc. It can be used by throwing it into.

<Rubber composition>
The rubber composition of the present invention is suitable because it contains the rubber component containing the acrylic rubber of the present invention, a filler, and a cross-linking agent, so that heat resistance and water resistance are highly balanced.

As the rubber component to be the main component, the acrylic rubber of the present invention may be used alone, or the acrylic rubber of the present invention and other rubber components may be used in combination, if necessary. The shape of the acrylic rubber of the present invention to be used may be appropriately selected depending on the purpose of use, the type of mixer used, and the like, and a sheet-shaped or veil-shaped acrylic rubber molded product can be used. The content of the acrylic rubber of the present invention in the rubber component may be selected according to the purpose of use, for example, usually 10% by weight or more, preferably 30% by weight or more, more preferably 50% by weight or more, particularly preferably. Is 70% by weight or more.

The other rubber components to be combined with the acrylic rubber of the present invention are not particularly limited, and are, for example, natural rubber, polybutadiene rubber, polyisoprene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, silicon rubber, fluororubber, and olefin type. Examples thereof include elastomers, styrene-based elastomers, vinyl chloride-based elastomers, polyester-based elastomers, polyamide-based elastomers, polyurethane-based elastomers, and polysiloxane-based elastomers.

These other rubber components can be used alone or in combination of two or more. The shape of these other rubber components may be any of veil-like, sheet-like, and powder-like. The content of other rubber components in the entire rubber component is appropriately selected within a range that does not impair the effects of the present invention, and is, for example, usually 90% by weight or less, preferably 70% by weight or less, more preferably 50% by weight or less, particularly. It is preferably 30% by weight or less.

The filler contained in the rubber composition 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 blacks such as furnace black, acetylene black, thermal black, channel black and graphite; silicas 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.

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 effects of the present invention, and is usually used with respect to 100 parts by weight of the rubber component. The range is 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 contained in the rubber composition is not particularly limited, but is, for example, a polyvalent amine compound such as a diamine compound and a carbonate thereof; a sulfur compound; a sulfur donor; a triazine thiol compound; a polyvalent epoxy compound; an organic carboxyl. Conventionally known cross-linking agents such as ammonium acid salt; organic peroxide; polyvalent carboxylic acid; quaternary onium salt; imidazole compound; isocyanuric acid compound; organic peroxide; triazine compound; can be used. Among these, a polyvalent amine compound and a triazine compound are preferable, and a polyvalent amine compound is particularly preferable.

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-Phenylenediisopropylidene) 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. These multivalent amine compounds are particularly preferably used in combination with a carboxyl group-containing acrylic rubber.

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 And so on. These triazine compounds are particularly preferably used in combination with a halogen group-containing acrylic rubber.

These cross-linking agents can be used individually or in combination of two or more, and the blending amount thereof is usually 0.001 to 20 parts by weight, preferably 0.1 to 10 parts by weight, based on 100 parts by weight of the rubber component. Parts, 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.

As the rubber composition, an anti-aging agent can be blended if necessary. The type of anti-aging agent is not particularly limited, but for example, 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-butylphenol), 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-) Other phenolic antioxidants such as cresol), 2,6-di-t-butyl-4- (4,6-bis (octylthio) -1,3,5-triazine-2-ylamino) phenol; tris (tris ( Nonylphenyl) Phosphite, diphenylisodecylphosphite, tetraphenyldipropylene glycol / diphosphite and other phosphite-based anti-aging agents; sulfur ester-based antiaging agents such as dilauryl thiodipropionate; -Β-naphthylamine, p- (p-toluenesulfonylamide) -diphenylamine, 4,4'-(α, α-dimethylbenzyl) diphenylamine, N, N-diphenyl-p-phenylenediamine, N-isopropyl-N'- Amine-based antioxidants such as phenyl-p-phenylenediamine, butylaldehyde-aniline condensates; imidazole-based antioxidants such as 2-mercaptobenzimidazole; 6-ethoxy-2,2,4-trimethyl-1,2- Kinolin-based anti-aging agents such as dihydroquinoline; 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 individually or in combination of two or more, and the blending amount thereof is 0.01 to 15 parts by weight, preferably 0.1 to 1 part by weight, based on 100 parts by weight of the rubber component. It is in the range of 10 parts by weight, more preferably 1 to 5 parts by weight.

The rubber composition of the present invention contains the rubber component containing the acrylic rubber of the present invention, a filler and a cross-linking agent as essential components, and if necessary, an anti-aging agent, and further, if necessary, in the art. Other commonly used additives such as cross-linking aids, cross-linking accelerators, cross-linking retarders, silane coupling agents, plasticizers, processing aids, rubbers, pigments, colorants, antioxidants, foaming agents, etc. Can be arbitrarily blended. 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.

Examples of the method for producing the rubber composition include a method of mixing the rubber component containing acrylic rubber of the present invention, a filler, a cross-linking agent, and an antiaging agent and other compounding agents which can be contained as needed. , Any means used in the conventional rubber processing field, for example, an open roll, a Banbury mixer, various kneaders and the like can be used. The mixing procedure of each component may be carried out by the usual procedure performed in the field of rubber processing. For example, after sufficiently mixing the components that are difficult to react or decompose with heat, the components that easily react or decompose with heat are used. It is preferable to mix a certain cross-linking agent or the like at a temperature at which reaction or decomposition does not occur in a short time.

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

The rubber crosslinked product is formed by using the above rubber composition with a molding machine corresponding to a desired shape, for example, an extruder, an injection molding machine, a compressor or a roll, and then heating to carry out a cross-linking reaction to obtain rubber. It can be manufactured by fixing the shape as a 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.

Depending on the shape, size, etc., the rubber crosslinked product may be further heated for secondary cross-linking. 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 crosslinked rubber product using the acrylic rubber of the present invention has excellent heat resistance and water resistance while maintaining basic characteristics as a rubber such as tensile strength, elongation, and hardness.

The rubber crosslinked product using the acrylic rubber of the present invention utilizes the above characteristics, for example, for O-rings, packings, diaphragms, oil seals, shaft seals, bearing seals, mechanical seals, well head seals, and electrical / electronic equipment. Sealing materials such as seals and seals for air compression equipment; rocker cover gaskets attached to the connection between the cylinder block and the cylinder head, oil pan gaskets attached to the connection between the oil pan and the cylinder head or the transmission case, positive electrode Various gaskets such as fuel cell separator gaskets and hard disk drive top cover gaskets mounted between a pair of housings that sandwich a unit cell with an electrolyte plate and a negative electrode; cushioning material, vibration isolator; wire coating material; industry Suitable for belts; tubes / hoses; sheets; etc.

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

<Device configuration used for manufacturing acrylic rubber>
Next, an apparatus configuration used for manufacturing acrylic rubber 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 acrylic rubber 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 phosphoric acid-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 liquid and coagulating it.

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

The heating unit 31 of the coagulation device 3 is configured to heat the magnesium salt aqueous solution 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 magnesium salt aqueous solution 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 coagulation device 3 is configured to stir the magnesium salt aqueous solution 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 magnesium salt aqueous solution by rotating around the rotation axis by the rotational power of the motor 32 in the magnesium salt aqueous solution 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 stirring blade 33 is operated by the drive control unit so that the stirring number of the magnesium salt aqueous solution is usually in the range of 100 rpm or more, preferably 200 to 1,000 rpm, more preferably 300 to 900 rpm, and particularly preferably 400 to 800 rpm. Rotation is controlled. The peripheral speed of the magnesium salt aqueous solution 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 so as to be. Further, the drive control unit sets the upper limit of the peripheral speed of the magnesium salt aqueous solution to be 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 stirring blade 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 obtained acrylic rubber 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. NS.

The water-containing crumb washed by the washing device 4 is supplied to the screw type extruder 5 (see FIG. 2) 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 transferred 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 is configured to perform the processes related to the above-mentioned dehydration step and drying step. Although the screw type extruder 5 is shown here as a preferable example, a centrifuge, a squeezer, or the like may be used as the dehydrator for performing the treatment related to the dehydration step, and the drying for performing the treatment related to the drying step may be used. A hot air dryer, a vacuum dryer, an expander dryer, a kneader type dryer, or the like may be used as the machine.

The screw type extruder 5 is configured to form the dried rubber obtained through the dehydration step and the drying step into a predetermined shape and discharge the rubber. 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 dryer 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 twin-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. Further, 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. The number of drying barrels installed in the drying 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 conditions of use, and are usually 0.01 to 5 mm, so that the loss of the water-containing crumb is small and the water-containing crumb is dehydrated. It is preferably 0.1 to 1 mm, and more preferably 0.2 to 0.6 mm from the viewpoint of being able to efficiently perform.

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 water. 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, it is conceivable that, for example, drainage is performed by three dehydration barrels on the upstream side and steam is 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. It is preferably in the range of 105 to 140 ° C, more preferably 110 to 130 ° C.

The drying barrel portion 54 is a region where the dehydrated hydrous crumb is dried under reduced pressure. Of the first to eighth drying barrels 54a to 54h constituting the drying barrel portion 54, the second drying barrel 54b, the fourth drying barrel 54d, the sixth drying barrel 54f, and the eighth drying 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 these 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. In the present invention, the shape of the acrylic rubber passing through the die 59 can be extruded into a sheet shape by making the nozzle shape of the die 59 substantially rectangular. 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 plastically 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 of.

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 1,000 rpm, and the water content and gel amount of the acrylic rubber are 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 1,500 kg / hr, preferably 300 to 1,200 kg / hr, and more preferably 400 to 1,000 kg / hr. There is, and 500 to 800 kg / hr is the most preferable.

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 water spraying 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.

Hereinafter, as an example of the cooling device 6, the transport type cooling device 60 for cooling the sheet-shaped acrylic rubber molded body 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 acrylic rubber molded body 10 discharged from the discharge port of the die 59 of the screw-type extruder 5 by an air-cooling method while transporting it. By using this transfer type cooling device 60, the sheet-shaped acrylic rubber molded product 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 includes a conveyor 61 that conveys the sheet-shaped acrylic rubber molded body 10 discharged from the die 59 of the screw-type extruder 5 in the direction of arrow A in FIG. 3, and a sheet-shaped acrylic rubber molded body on the conveyor 61. The 10 has a cooling means 65 for blowing cold air.

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 acrylic rubber molded body 10 is placed. The conveyor 61 is configured to continuously convey the sheet-shaped acrylic rubber molded body 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 is configured such that, for example, the cooling air sent from the cooling air generating means (not shown) can be blown onto the surface of the sheet-shaped acrylic rubber molded body 10 on the conveyor belt 64. Examples include those that have.

The length L1 of the conveyor 61 and the cooling means 65 of the transport type cooling device 60 (the length of the portion where the cooling air can be blown) 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 acrylic rubber molded body 10 in the transport-type cooling device 60 is the length L1 of the conveyor 61 and the cooling means 65, and the sheet-shaped acrylic rubber molded body 10 discharged from the die 59 of the screw type extruder 5. It may be appropriately adjusted according to the discharge rate, the target cooling rate, the 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 acrylic rubber molded body 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 cooled by the cooling means. By blowing cooling air from 65, the sheet-shaped acrylic rubber molded body 10 is cooled.

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. The weight and shape of the bale-shaped acrylic rubber molded product produced by the bale-forming device 7 are not particularly limited, but for example, a veil-shaped acrylic rubber molded product having a substantially rectangular parallelepiped shape of about 20 kg is produced.

Further, the sheet-shaped acrylic rubber molded product 10 produced by the screw type extruder 5 may be laminated to produce a veil-shaped acrylic rubber molded product. 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 acrylic rubber molded body 10. Specifically, the cutting mechanism of the bale device 7 is, for example, a cut sheet-shaped acrylic rubber molded body having a predetermined size by continuously cutting the cooled sheet-shaped acrylic rubber molded body 10 at predetermined intervals. It is configured to be processed into 16. By laminating a plurality of cut sheet-shaped acrylic rubber molded bodies 16 cut to a predetermined size by a cutting mechanism, a veil-shaped acrylic rubber molded body in which the cut sheet-shaped acrylic rubber molded bodies 16 are laminated can be manufactured. ..

When producing a bale-shaped acrylic rubber molded body in which the cut sheet-shaped acrylic rubber molded body 16 is laminated, it is preferable to laminate the cut sheet-shaped acrylic rubber molded body 16 at, for example, 40 ° C. or higher. By laminating the cut sheet-shaped acrylic rubber molded product 16 at 40 ° C. or higher, good air bleeding 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. Unless otherwise specified, "parts", "%" and "ratio" in each example are based on weight. Various characteristics (including 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 acrylic rubber and each reaction thereof. The sex group content was confirmed by the following 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 in the rubber was The amount used for each monomer was the same.

[Reactive group content]
The amount of carboxyl groups, which are reactive groups in acrylic rubber, was calculated by dissolving a rubber sample (acrylic rubber or acrylic rubber molded product) in acetone and performing potentiometric titration with a potassium hydroxide solution.

[Ash content]
The ash content (%) of the rubber sample was measured according to the JIS K6228 A method.

[Amount of ash component]
The amount of each component (ppm) in the ash content of the rubber sample was measured by XRF using ZSX Primus (manufactured by Rigaku) by pressing the ash content collected at the time of the above ash content measurement onto a titration filter paper having a diameter of 20 mm.

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

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

[Molecular weight]
The weight average molecular weight (Mw) of the rubber sample was determined by the GPC-MALS method using a solution in which lithium chloride was added at a concentration of 0.05 mol / L and 37% concentrated hydrochloric acid was added at a concentration of 0.01% to dimethylformamide as a solvent. Absolute molecular weight to be measured. 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

[Glass transition temperature (Tg)]
The glass transition temperature (Tg) of the rubber sample 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 rubber sample was measured with a pH electrode after dissolving 6 g (± 0.05 g) of the rubber sample in 100 g of tetrahydrofuran, adding 2.0 ml of distilled water and confirming that the sample was completely dissolved.

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

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

[Water resistance evaluation]
The water resistance of the rubber sample was 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. Comparative Example 1 was evaluated with an index of 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 workability]
Regarding the processability of the rubber sample, the rubber sample was put into a Banbury mixer heated to 50 ° C., kneaded for 1 minute, and then the compounding agent A containing the rubber mixture shown in Table 1 was added to obtain the rubber mixture in the first stage. The time required for integration to show the maximum torque value, that is, BIT (Black Incorporation Time) was measured and evaluated with an index of Comparative Example 1 as 100 (the smaller the index, the better the workability).

[Storage stability evaluation]
For the storage stability of the rubber sample, the rubber mixture of the rubber sample was put into a constant temperature and humidity chamber of 45 ° C. × 80% RH for 7 days, and the rubber sample before and after the test was used as the rubber mixture in a rubber vulcanization tester (moving dialeometer MDR; Perform a cross-linking test at 180 ° C. for 10 minutes using (manufactured by Alpha Technology) to calculate the rate of change in cross-linking density, which is the difference (MH-ML) between the maximum torque (MH) and the minimum torque (ML), and compare them. Evaluation was performed using an index of Example 1 as 100 (the smaller the index, the better the storage stability).

[Heat resistance evaluation]
To evaluate the heat resistance of the rubber sample, a heating test was performed in which the crosslinked product of the rubber sample was allowed to stand at 175 ° C. for 250 hours, and the tensile strength of the crosslinked rubber sample before and after the test was measured according to JIS K6251 and the hardness was measured according to JIS K6253. , Changes in cutting elongation and changes in hardness were evaluated according to the following criteria.
The change in cutting elongation was evaluated as "⊚" when the rate of change in breaking elongation was 20% or less, and as "x" when the rate of change in breaking elongation exceeded 20%. The change in hardness was evaluated as “⊚” when the rate of change in hardness was 20 points or less, and as “x” when the rate of change in hardness exceeded 20 points.

[Example 1]
In a mixing container equipped with a homomixer, 46 parts of pure water, 63.25 parts of ethyl acrylate as a monomer component, 17 parts of n-butyl acrylate, 7 parts of methoxyethyl acrylate, 11 parts of butyl methacrylate and fumaric acid 1.75 parts of monoethyl and 1.8 parts of octyloxydioxyethylene phosphate sodium salt as an emulsifier were charged and stirred to obtain a monomeric emulsion.

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 balance 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. .. After that, the reaction was continued while the temperature in the polymerization reaction tank 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 carry out the polymerization reaction. It was stopped to obtain an emulsion polymerization solution.

Next, in a coagulation tank equipped with a thermometer and a stirrer, a 2% magnesium sulfate aqueous solution (coagulation) that was vigorously stirred at a stirrer blade rotation speed of 600 rpm (peripheral speed 3.1 m / s) and heated to 80 ° C. The obtained emulsion polymer solution was heated to 80 ° C. and continuously added to coagulate the polymer in 350 parts (coagulation solution using magnesium sulfate as an agent) to coagulate the solidified acrylic rubber crumb. A solidified slurry containing water was obtained. Moisture was discharged from the solidified layer while filtering the crumbs from the obtained slurry to obtain a hydrous crumb.

194 parts of warm water (70 ° C.) was added to the coagulation tank in which the filtered hydrous crumbs remained, and the mixture was stirred for 15 minutes to wash the hydrous crumbs, and then water was discharged, and 194 parts of warm water (70 ° C.) was discharged again. Was added and stirred for 15 minutes to wash the hydrous crumbs (total number of washings was 2). The washed hydrous crumb (clam temperature 65 ° C.) was supplied to a screw type extruder, dehydrated, dried and molded to extrude a sheet-shaped dried rubber (sheet-shaped acrylic rubber molded body) having a width of 300 mm and a thickness of 10 mm. Next, the sheet-shaped dry rubber was cooled at a cooling temperature of 200 ° C./hr by 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 dehydration barrel drains water, and the second and third dehydration barrels drain steam. The operating conditions of the screw type extruder are as follows.

Moisture content ・ Moisture content of the water content crumb after drainage in the first dehydration barrel: 20%
Moisture content of the hydrous crumb after steam exhaust in the third dehydration barrel: 10%
Rubber temperature ・ Temperature of the hydrous crumb supplied to the supply barrel: 65 ° C
・ Temperature of rubber discharged from screw type extruder: 140 ℃
Set temperature of each barrel:
-First dehydration barrel: 100 ° C
-Second dehydration barrel: 120 ° 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): 132 mm
-Overall length (L) of the screw: 4620 mm
・ L / D: 35
・ Screw rotation speed: 135 rpm
-Rubber extrusion amount from die: 700 kg / hr
-Resin pressure on the die: 2 MPa

The sheet-shaped dry rubber extruded from the screw-type extruder was cooled to 50 ° C. and then cut with a cutter to obtain acrylic rubber (A) (sheet-shaped acrylic rubber molded product). Reactive group content, ash content, ash component content, specific gravity, gel amount, glass transition temperature (Tg), pH, water content, weight average molecular weight, and Mooney viscosity (ML1 + 4,100) of the obtained acrylic rubber (A). ° C.) was measured and shown in Table 2.

Next, before the temperature of the acrylic rubber (A) becomes 40 ° C. or lower, a plurality of cut acrylic rubbers (A) are laminated so as to form 20 parts (20 kg), and the veil-shaped acrylic rubber molded body (A) is formed. ) Was obtained. Reactive group content, ash content, ash component amount, specific gravity, gel amount, glass transition temperature (Tg), pH, water content, weight average molecular weight, and Mooney viscosity of the obtained veil-shaped acrylic rubber molded product (A). (ML1 + 4,100 ° C.) was measured. Each characteristic value of the bale-shaped acrylic rubber molded product (A) was the same as the characteristic value of the acrylic rubber (A) (sheet-shaped acrylic rubber molded product) shown in Table 2.

Next, 100 parts of acrylic rubber (A) (bale-shaped acrylic rubber molded product) and the compounding agent A of "formulation 1" shown in Table 1 were put into a Banbury mixer and mixed at 50 ° C. for 5 minutes (first stage mixing). .. The BIT at this time was measured to evaluate the processability of the acrylic rubber (A), and the results are shown in Table 2.

Further, each of the mixtures obtained in the first-stage mixing was transferred to a roll at 50 ° C., and the compounding agent B of "Formulation 1" was mixed and mixed (second-stage mixing) to obtain a rubber mixture. A cross-linking test of the rubber mixture using acrylic rubber (A) was performed before and after the storage stability test, changes in the cross-linking density (MH-ML) were measured, and the results are shown in Table 2.

The rubber mixture thus obtained 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 the obtained primary crosslink was obtained. The material was further heated in a gear oven at 180 ° C. for 2 hours for secondary cross-linking to obtain a sheet-shaped rubber cross-linked product. Then, a 3 cm × 2 cm × 0.2 cm test piece was cut out from the obtained sheet-shaped rubber crosslinked product to perform a water resistance test and a heat resistance test, and the results are shown in Table 2.

[Example 2]
Except for changing the monomer component to 4.5 parts of ethyl acrylate, 53.5 parts of n-butyl acrylate, 29.5 parts of methoxyethyl acrylate, 11 parts of hexyl methacrylate and 1.5 parts of monoethyl fumarate. Acrylic rubber (B) was obtained in the same manner as in Example 1 and each characteristic (the compounding agent was changed to "formulation 2") was evaluated. The results are shown in Table 2.

[Example 3]
The same procedure as in Example 2 was carried out except that the monomer component was changed to 48.6 parts of ethyl acrylate, 39 parts of n-butyl acrylate, 11 parts of butyl methacrylate and 1.4 parts of monoethyl fumarate. C) was obtained and each characteristic was evaluated. The results are shown in Table 2.

[Example 4]
The same procedure as in Example 2 was carried out except that the monomer component was changed to 42.3 parts of ethyl acrylate, 45.3 parts of n-butyl acrylate, 11 parts of butyl methacrylate, and 1.4 parts of monoethyl fumarate. Acrylic rubber (D) was obtained and each characteristic was evaluated. The results are shown in Table 2.

[Example 5]
The same as in Example 4 except that the water content after dehydration of the water-containing crumb with the screw type extruder (the water content of the water-containing crumb after drainage performed before the pre-drying for exhausting steam) is up to 30%. , Acrylic rubber (E) was obtained and each characteristic was evaluated. The results are shown in Table 2.

[Example 6]
After cleaning, the water-containing acrylic rubber was dried in the same manner as in Example 4 except that the water-containing crumb was directly dried to a water content of 0.4% in a hot air dryer without being subjected to a screw-type extruder. A 300 × 650 × 300 mm baler was filled and compacted at a pressure of 3 MPa for 30 seconds to obtain an acrylic rubber (F) (bale-shaped acrylic rubber molded product). Each property of the obtained acrylic rubber (F) was evaluated, and the results are shown in Table 2.

[Comparative Example 1]
In a polymerization reaction tank equipped with a thermometer and a stirrer, 200 parts of pure water, 42.3 parts of ethyl acrylate, 45.3 parts of n-butyl acrylate, and butyl methacrylate 11 as monomer components under a nitrogen stream. Add 1.4 parts of monoethyl fumarate, 2.5 parts of octyloxydioxyethylene phosphate and 0.5 parts of polyoxyethylene dodecyl ether as emulsifiers, 0.1 part of potassium persulfate, and 0 parts of sodium ascorbate. . 1 part was charged, then 0.1 part of potassium persulfate and 0.1 part of sodium ascorbate were added to initiate the reaction. The reaction was continued at room temperature, and it was confirmed that the polymerization conversion rate reached approximately 100%. Hydroquinone as a polymerization terminator was added to stop the polymerization reaction to obtain an emulsion polymerization solution.

Next, a 0.4% sodium sulfate aqueous solution (coagulant using sodium sulfate as a coagulant) was added to the emulsion polymer solution being stirred at a stirring blade rotation speed of 100 rpm (peripheral speed 0.5 m / s) of the stirrer. The polymer was solidified to obtain a solidified slurry containing a solidified product, an acrylic rubber crumb and water. Moisture was discharged from the solidified layer while filtering the crumbs from the obtained slurry to obtain a hydrous crumb.

194 parts of water at 25 ° C. was added to the coagulation tank in which the filtered hydrous crumbs remained, and the mixture was stirred for 15 minutes to wash the hydrous crumbs, and then water was discharged to wash the hydrous crumbs. The water-containing crumb after washing was dried with a hot air dryer to obtain a crumb-shaped acrylic rubber (G) having a water content of 0.4% by weight. Regarding this acrylic rubber (G), the reactive group content, ash content, ash component amount, specific gravity, gel amount, glass transition temperature (Tg), pH, water content, weight average molecular weight, and Mooney viscosity (ML1 + 4,100 ° C.) ) Was measured, and the results are shown in Table 2.

Next, 100 parts of acrylic rubber (G) and the compounding agent A of "formulation 2" shown in Table 1 were put into a Banbury mixer and mixed at 50 ° C. for 5 minutes (first stage mixing). The BIT at this time was measured to evaluate the processability of the acrylic rubber (G), and the results are shown in Table 2. Further, each of the mixtures obtained in the first-stage mixing was transferred to a roll at 50 ° C., and the compounding agent B of "Formulation 2" was mixed and mixed (second-stage mixing) to obtain a rubber mixture. A cross-linking test of a rubber mixture using acrylic rubber (G) was performed before and after the storage stability test, changes in the cross-linking density (MH-ML) were measured, and the results are 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. Was further heated in a gear-type oven at 180 ° C. for 2 hours for secondary cross-linking to obtain a sheet-shaped rubber cross-linked product. Then, a 3 cm × 2 cm × 0.2 cm test piece was cut out from the obtained sheet-shaped rubber crosslinked product to evaluate water resistance and heat resistance, and the results are shown in Table 2.

From Table 2, the binding unit (A) derived from acrylic acid ester (A) 10 to 98.9% by weight, the binding unit (B) derived from methacrylic acid ester (B) 1 to 50% by weight, and the binding unit derived from the reactive group-containing monomer ( C) Consisting of 0.1 to 10% by weight and a binding unit (D) derived from other monomers from 0 to 30% by weight, the total ash content is 1% by weight or less, and the total of magnesium and phosphorus in the total ash content. The acrylic rubbers (A) to (F) of the present invention in which the amount is 60% by weight or more as a ratio to the total ash content and the monomery viscosity (ML1 + 4,100 ° C.) is in the range of 10 to 150 are acrylic rubbers (G). It can be seen that the water resistance is highly improved without impairing the heat resistance of the above (comparison between Examples 1 to 6 and Comparative Example 1).

Regarding the water resistance of acrylic rubber, compared to Comparative Example 1 in which a phosphoric acid-based emulsifier and a sodium salt were used as a coagulant, a magnesium salt was used as a phosphoric acid-based emulsifier and a coagulant, and the coagulation reaction was vigorously stirred. It can be seen that the amount of ash in the acrylic rubber is remarkably reduced and highly improved by adding the emulsion polymerization solution to the magnesium salt aqueous solution and washing the hydrous crumb with warm water (Comparative Example 1 and Example). Comparison with 6). Further, by dehydrating the water-containing crumb after cleaning using a screw type extruder, the water resistance of the acrylic rubber is improved (comparison between Examples 6 and 1 to 5), and in particular, dehydration squeezed out from the water-containing crumb. It can be seen that the larger the amount, the higher the water resistance (comparison between Examples 1 to 4 and Example 5). Further, it can be seen that the amount of phosphorus and magnesium in the acrylic rubber is significantly reduced and the heat resistance is improved by dehydrating the hydrous crumb using a screw type extruder.

From Table 2, it can be seen that the acrylic rubbers (A) to (E) of the present invention, which have a small amount of gel in which the methyl ethyl ketone is insoluble, are highly improved in processability without impairing heat resistance (Examples). Comparison between 1 to 5 and Comparative Example 1). This is due to the fact that the water-containing crumbs of the washed acrylic rubber are rotated in a screw-type extruder to a state where they are substantially free of water and dehydrated and dried, thereby almost eliminating the amount of gel in the acrylic rubber and BIT. It can be seen that the workability of the screw is greatly improved.

From Table 2, it can be further seen that the acrylic rubbers (A) to (F) of the present invention having a large specific gravity and containing no air have highly improved storage stability without impairing heat resistance (Example). Comparison between 1 to 6 and Comparative Example 1). In particular, acrylic rubber (Examples 1 to 5), which is made by extruding and laminating a sheet of acrylic rubber in a sheet shape using a screw type extruder, is more air than acrylic rubber (Example 6) in which crumb-shaped acrylic rubber is compressed with a baler. It can be seen that the removal rate of acrylic rubber is high, the specific gravity is large, and the storage stability is greatly improved.

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

Claims (12)

Bonding unit (A) derived from acrylic acid ester (A) 10-98.9% by weight, binding unit (B) derived from methacrylate ester (B) 1-50% by weight, binding unit (C) derived from reactive group-containing monomer (C) 0. It consists of 1 to 10% by weight and a binding unit (D) derived from other monomers from 0 to 30% by weight, the total ash content is 1% by weight or less, and the total amount of magnesium and phosphorus in the total ash content is total ash. Acrylic rubber having a ratio of 60% by weight or more to a quantity and having a monomeric viscosity (ML1 + 4,100 ° C.) in the range of 10 to 150. The acrylic rubber according to claim 1, wherein the bonding unit (A) derived from the acrylic acid ester is a bonding unit derived from at least one acrylic acid ester selected from the group consisting of an acrylic acid alkyl ester and an acrylic acid alkoxyalkyl ester. The acrylic rubber according to claim 1 or 2, wherein the gel amount is 50% by weight or less. The acrylic rubber according to any one of claims 1 to 3, wherein the weight average molecular weight (Mw) is 1,000,000 or more. A monomer component composed of an acrylic acid ester (a), a methacrylic acid ester (b), a reactive group-containing monomer (c), and another monomer (d) that can be copolymerized if necessary. An emulsion polymerization step of emulsion polymerization with water and a phosphoric acid-based emulsifier and then emulsion polymerization in the presence of a polymerization catalyst to obtain an emulsion polymerization solution.
A coagulation step in which the obtained emulsion polymerization solution and a magnesium salt aqueous solution are brought into contact with each other to form a hydrous crumb,
A cleaning process to clean the generated hydrous crumb,
A drying process to dry the washed hydrous crumb,
Acrylic rubber manufacturing method including. The method for producing acrylic rubber according to claim 5, wherein the contact between the emulsion polymerization solution and the magnesium salt aqueous solution is to add the emulsion polymerization solution to the agitated magnesium salt aqueous solution. The method for producing acrylic rubber according to claim 5 or 6, wherein a dehydration step of squeezing out water from the water-containing crumb is provided between the washing step and the drying step. The method for producing acrylic rubber according to claim 7, wherein the hydrous crumb is dehydrated and dried by a screw type extruder. A sheet-shaped or veil-shaped acrylic rubber molded product made of the acrylic rubber according to any one of claims 1 to 4. The acrylic rubber molded product according to claim 9, which has a specific gravity of 0.8 or more. A rubber composition comprising a rubber component containing acrylic rubber according to any one of claims 1 to 4, a filler and a cross-linking agent. A rubber crosslinked product obtained by cross-linking the rubber composition according to claim 11.

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