JP3175790B2 - Method for producing particulate hydrogel polymer and water absorbent resin - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing a particulate hydrogel polymer and a water-absorbing resin. More specifically, the present invention relates to a method for producing a particulate hydrogel polymer, which comprises repeatedly applying a shearing force to a hydrogel polymer having a crosslinked structure at a specific temperature while applying a load in a specific range.
Further, the present invention relates to a method for producing a water-absorbent resin by drying the particulate hydrogel polymer.

[0002]

BACKGROUND OF THE INVENTION Water-absorbing resins include crosslinked polyacrylates, saponified acrylate-vinyl acetate copolymers, crosslinked polyvinyl alcohol modified products, crosslinked isobutylene-maleic anhydride copolymers, starch-acrylic acid. BACKGROUND ART Graft polymers and the like are known, and are applied to a wide range of uses such as sanitary napkins, disposable diapers and other sanitary absorbents, or water retention agents and dehydrating agents in the agricultural and horticultural fields and the civil engineering field.

As a method for producing these water-absorbing resins, there are known a reversed-phase suspension polymerization method, for example, JP-A-56-161408 and JP-A-56-161408.
-94,011, Nos. 57-158,209 and 57-198,714 are known, and as an aqueous solution polymerization method,
For example, JP-A-57-34,101, JP-B-48-42,466, JP-A-58-49,714, JP-B-59-37,003, USP 4,286,08
2 and USP 4,625,001 are known.

However, since the reversed-phase suspension polymerization method uses an organic solvent, not only the working environment is deteriorated, but also there is a danger of flammable explosion. In addition, the cost increases in conjunction with the removal cost. In addition, since a small amount of the organic solvent remains in the product, the cost is further increased to completely remove the organic solvent. Furthermore, since the water-absorbent resin obtained by the reversed-phase suspension polymerization method is spherical and has a small particle size, when used in, for example, a disposable diaper or the like, the water-absorbent resin is not retained by a fibrous absorbent core component such as pulp and easily falls off. In addition, handling is inconvenient.

On the other hand, the aqueous solution polymerization method has no such problems as described above, and the methods disclosed in JP-A-57-34,101 and US Pat. No. 4,625,001 are known. JP 57-34,101
No. 4,625,001 discloses an aqueous solution of a monomer and a polymerization initiator, which form a crosslinked structure during aqueous solution polymerization to form a hydrogel polymer, in a vessel equipped with stirring blades. This is a method for producing a crosslinked polymer, comprising performing radical aqueous solution polymerization while subdividing a hydrogel polymer produced as the process proceeds by the shearing force of a stirring blade caused by rotation of the stirring shaft. According to these manufacturing methods,
Not only is workability extremely good, but there is also an advantage that a finely divided hydrogel polymer having a crosslinked structure in the molecule can be produced with high productivity. However, even in such a method, a water-absorbent resin having a high water absorption capacity and a small amount of water-soluble matter may have a low productivity.

It is well known to those skilled in the art that the water absorption capacity is increased by lowering the cross-link density. It is also known that the minutes increase. The water-soluble component is leached out of the water-absorbent resin when the water-absorbent resin comes into contact with the liquid to be absorbed such as water, urine, and body fluid to form a hydrogel structure. The water-soluble component extracted by the liquid to be absorbed not only reduces the water absorption capacity of the water-absorbent resin, but also promotes the deterioration of the water-absorbent resin. In addition, such an unfavorable situation such as giving an unpleasant feeling or contaminating the liquid to be absorbed is created due to the nulling.

Therefore, there has been a demand for a method for producing a water-absorbing resin having a high water absorption ratio and a low water-soluble content.

US Pat. No. 4,654,039 and JP-A-1-144404 disclose a method for producing a water-absorbent resin having a high water absorption capacity and a low water-soluble content by polymerizing a monomer having a free acid type or a specific neutralization ratio in an aqueous solution. is suggesting. However, these production methods require post-neutralization, complicated operations, low productivity, and limited polymerization conditions.

On the other hand, the hydrogel polymer obtained by polymerization is generally marketed as a powdery product after pulverization through a drying step. Conventionally, in order to efficiently dry such a hydrogel polymer, a device for increasing the surface area of the hydrogel polymer as much as possible has been devised. For example,
A method of extruding and crushing a hydrogel polymer from a perforated plate is known (Japanese Patent Publication No. 54-32,176, Japanese Patent Application Laid-Open No. 50-136,348, etc.), but in the conventionally known method, it is finely crushed and extruded. The hydrogel polymer was reattached and became string-like, and a particulate hydrogel polymer could not be obtained.

When extruding a hydrogel polymer from a perforated plate and crushing it, a method of adding an additive such as a lubricant for the purpose of preventing re-adhesion of the hydrogel polymer (Japanese Patent Application Laid-Open No. 59-30,826)
JP-A-59-119,172), but additives remaining in the polymer sometimes adversely affect the performance of the product.

The above-mentioned JP-A-57-34,101 and
According to the method disclosed in U.S. Pat. No. 4,625,001, a hydrogel polymer having a relatively small particle size can be obtained, but the size is reduced to 10%.
Coarse gel particles having a size of not less than mm were produced from several weight% to several tens weight%, and had a defect that the particle size distribution was wide and the drying efficiency and the uniformity of the degree of drying were insufficient.

Furthermore, it has been difficult to obtain a sufficiently small hydrogel polymer having a small average particle diameter by a conventional method of pulverizing a hydrogel polymer, or the productivity has been extremely low. When the particulate hydrogel polymer is dried to obtain a product having a desired particle size, it is necessary to pulverize the dried product if the average particle diameter of the particulate hydrogel polymer is large. A fine powder smaller than the desired particle size is generated. It is well known to those skilled in the art that this fine powder is not preferable in terms of the performance and handleability of the water absorbent resin.

As described above, a method for producing a particulate hydrogel polymer and a water-absorbent resin with a simple process, high productivity, high water absorption ratio, and low water-soluble content has not been established. Further, a method for obtaining a particulate hydrogel polymer having a small particle size distribution and a good drying efficiency without containing additives such as a lubricant, and high productivity has not been established. A method for efficiently producing a particulate hydrogel polymer having a sufficiently small average particle size has not been established so far.

[0014]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method for producing a particulate hydrogel polymer having a high water absorption capacity and a low water-soluble content, and a water-absorbing resin.

Another object of the present invention is to provide a simple process,
Moreover, it is an object of the present invention to provide a method for producing a particulate hydrogel polymer and a water-absorbing resin with high productivity, high water absorption ratio, and low water-soluble content.

Another object of the present invention is to provide a method for producing a particulate hydrogel polymer which does not contain additives such as lubricants, has a narrow particle size distribution, and has good drying efficiency with high productivity. Is to do.

Still another object of the present invention is to provide a method for efficiently producing a particulate hydrogel polymer having a sufficiently small average particle size.

[0018]

Means for Solving the Problems In view of the above circumstances, the present inventors have conducted intensive studies on a method for producing a particulate hydrogel polymer and a water-absorbing resin, and as a result, have completed the present invention. Was.

That is, an object of the present invention is to provide a method for producing a particulate hydrogel polymer in which a shear force is applied to a hydrogel polymer having a crosslinked structure in a container to subdivide it into particles. A method for producing a particulate hydrogel polymer comprising repeatedly applying a shearing force to the hydrogel polymer heated to a temperature of from about to 110 ° C. while applying a load of from 0.01 to 1.5 kg / cm ^2. And a method for producing a water-absorbent resin, characterized by drying the particulate hydrogel polymer.

[0020]

The hydrogel polymer of the present invention is not particularly limited as long as it is a hydrogel having a crosslinked structure and exhibiting a gel state in a water-containing state, but usually has a water content of 40 to 90% by weight, more preferably 50% by weight. ~ 80% by weight of a hydrogel polymer. In the present invention, the water content of the hydrogel polymer refers to the content of water in the total weight of the hydrogel polymer expressed in terms of% by weight. The hydrogel polymer used in the present invention must have a crosslinked structure. Without the crosslinked structure, the object of the present invention cannot be achieved.

The hydrogel polymer of the present invention is prepared by, for example, a method of forming a crosslinked structure by aqueous solution polymerization in a mold, adding a monomer component to be a hydrogel polymer, and polymerizing the polymer (Japanese Patent Application Laid-Open No. No. 55-133,413) or a method of polymerizing the monomer component in a kneader having a stirring shaft capable of subdividing the hydrogel polymer formed therein (JP-A-57-34,101). And so on.

Examples of the water-soluble unsaturated monomer among the monomer components used in the above polymerization method include (meth)
Acrylic acid, (anhydride) maleic acid, fumaric acid, crotonic acid, itaconic acid, 2- (meth) acryloylethanesulfonic acid, 2- (meth) acryloylpropanesulfonic acid, 2- (meth) acrylamide-2-methylpropanesulfone Acid, vinyl sulfonic acid, styrene sulfonic acid,
Anionic monomers and salts thereof; (meth) acrylamide, N-substituted (meth) acrylamide, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, Nonionic hydrophilic group-containing monomers such as polyethylene glycol (meth) acrylate; N, N-dimethylaminoethyl (meth) acrylate, N, N-dimethylaminopropyl (meth) acrylate, N, N-dimethylaminopropyl Amino group-containing unsaturated monomers such as (meth) acrylamide and the like;
Grades and the like can be specifically mentioned. In addition, an amount of an acrylic ester such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, or vinyl acetate in an amount that does not extremely impair the hydrophilicity of the obtained hydrogel polymer. And a hydrophobic monomer such as vinyl propionate. One or more of these can be selected and used as the monomer component. However, considering the various water absorption properties of the finally obtained water-absorbing resin, (meth) acrylic acid (salt), 2- (meth) acryloylethanesulfonic acid (salt), 2- (meth) acrylamido-2-methylpropanesulfonic acid (salt), (meth) acrylamide, methoxypolyethylene glycol (meth) acrylate, N, N-dimethylaminoethyl One or more compounds selected from the group consisting of (meth) acrylates and quaternized products thereof are preferable, and those containing (meth) acrylic acid (salt) as an essential component are more preferable. In this case, (meth) acrylic acid 3
Most preferably, 0 to 90 mol% is neutralized with a basic substance.

The hydrogel polymer of the present invention may be a self-crosslinking type polymer obtained without using a crosslinking agent, or a water-absorbing polymer capable of obtaining a crosslinking agent having a polymerizable unsaturated group and / or a reactive functional group. A resin obtained by using the resin in a range in which various characteristics reach a desired standard may be used. Usually, the amount is 0.001 to 1.0 mol%, preferably 0.1 to 1.0 mol%, based on the monomer component.
01 to 0.5 mol%.

Examples of these crosslinking agents include, for example, N,
N'-methylenebis (meth) acrylamide, (poly)
Ethylene glycol (meth) acrylate, glycerin tri (meth) acrylate, trimethylolpropane tri (meth) acrylate, triallylamine, triallyl cyanurate, triallyl isocyanurate, glycidyl (meth) acrylate, (poly) ethylene glycol, diethylene glycol, (Poly) glycerin, propylene glycol, diethanolamine, trimethylolpropane, pentaerythritol, (poly) ethylene glycol diglycidyl ether, (poly) glycerol polyglycidyl ether, epichlorohydrin, ethylenediamine, polyethyleneimine, (poly) aluminum chloride, aluminum sulfate, Specific examples include calcium chloride and magnesium sulfate. It can be used alone or in combination.

In order to obtain a hydrogel polymer, the above monomer components are polymerized in the presence of a hydrophilic polymer such as starch, cellulose, polyvinyl alcohol or the like, so that a graft bond or complex is formed simultaneously with the polymerization. May be.

In polymerizing these monomer components, as a polymerization initiator, ammonium persulfate, potassium persulfate, hydrogen peroxide, t-butyl hydroperoxide, 2,2'-azobis-amidinopropane dihydrochloride, etc. May be used.

The hydrogel polymer of the present invention may be any hydrogel exhibiting a hydrogel, and may be any of those in which the polymerization reaction of the above-mentioned monomer components is in progress and those in which the polymerization reaction has been completed. . In general, a hydrogel polymer having a cross-linked structure exhibits a hydrogel at a polymerization rate of about several percent, so that the shear force under load is arbitrary with respect to a hydrogel polymer having a polymerization rate of several percent or more. It ’s good if it ’s time. Preferably the polymerization rate is 10 to 100%, more preferably 20 to 100%
Is a hydrogel polymer. As a matter of course, a normal stirring operation may be added to the monomer component before the hydrated gel is formed. However, when applying a shearing force at a time when the polymerization rate of the monomer component is low, it is expected that undesired phenomena such as a decrease in the basic molecular weight will occur when the method of applying the shearing force is excessive. Cost.

The method for producing a particulate hydrogel polymer of the present invention can be achieved by applying a shearing force to the hydrogel polymer under the above-mentioned conditions. Any embodiment can be adopted as appropriate. Typical specific embodiments include, for example: 1. applying a shearing force to the hydrogel polymer after the completion of the polymerization reaction under the above conditions; 2. applying a shearing force to the hydrogel polymer in the course of the polymerization reaction under the above conditions; An embodiment in which a shearing force is applied to the formed hydrogel polymer under the above conditions while the polymerization reaction proceeds.

Among the above-described embodiments, a preferred apparatus for implementing the second or third embodiment is the apparatus shown in FIG. 1 as an example. FIG. 2 is a schematic sectional view taken along the line aa of FIG. As shown in FIGS. 1 and 2, in the container 7 of the present embodiment, rotating arms 10 and 11 for applying a shearing force to the hydrogel polymer are respectively a rotary stirring shaft 12 and
12 ', and 13, 13' (not shown), which are fixed along the longitudinal direction in the container 7, the pressing lid 5 for applying a load keeps the rotating arm 10 even when it is lowered to its lowermost end. , 11 so as not to hinder the rotation of the rotating arm, and is installed at the opening of the container 7. In the state of FIG.
While the liquid supply port 1 and the gas supply port 2 are open with respect to the container 7, and the aqueous solution of the monomer component and the inert gas are supplied to the container 7. Supplied. At this time, the charged amount of the aqueous solution of the monomer component is usually the effective shear volume (the remaining space volume obtained by subtracting the volumes of the rotary stirring shaft and the rotary arm from the space volume formed by the rotation of the rotary arm of the rotary stirring shaft). ) 50-150%
It is. The inert gas supplied from the gas supply port 2 passes through the container 7 and is discharged from the gas discharge port 1 'or the nozzle 2'. At any time when the polymerization of the monomer component is started and the hydrogel polymer is formed, the cylinder 8 is moved by hydraulic or pneumatic pressure, and the pressure lid 5 is lowered onto the hydrogel polymer, and a desired load is applied. It is applied to the hydrogel polymer and subjected to repeated shearing force by the rotation of the rotating arms 10 and 11. FIG. 3 shows an example of this state. At this time,
The liquid supply port 1 and the gas supply port 2 are closed by the pressure lid 5, so that the hydrogel polymer does not enter.
On the other hand, the inert gas supplied from the gas supply port 2 is supplied to the stirring space 14 from the gap between the wall of the container 7 and the wall of the pressure lid 5. Under the inert gas atmosphere, from the preparation of the aqueous solution of the monomer component as described above, through the polymerization, through the application of a shear force while applying a load to the hydrogel polymer, until the removal of the particulate hydrogel polymer. Can be done with The liquid supply port 1 and the gas supply port 2 are preferably provided at positions higher than the hydrogel polymer surface when the load is removed. 1 to 3, a cover 4 is attached to the outside of a pressure lid 5 so as to be movable up and down relatively thereto. The cover 4 has a box shape having an opening at the lower end, and a lower end is provided with a flange facing the flange provided on the container 7, and a sealing material 9 is provided on the flange. Provided. When the pressure lid 5 is raised, the cover 4 comes into contact with the pressure lid 5 and is raised. On the other hand, when the pressure lid 5 is moved downward by the cylinder 8, the lower end of the pressure lid 5 starts to fit into the container 7, and the flange of the cover 4 is connected to the flange of the container 7 via the sealing material 9. The space in the cover 4 is sealed from the outside by its own weight. After the flange portions of both the cover 4 and the container 7 come into contact with each other via the sealing material 9, only the pressure lid 5 is moved downward by the cylinder 8. The cover 4 is provided with a gas supply port 3 and a gas discharge port 3 '.
In this state, by supplying an inert gas from the gas supply port 3, the inside of the cover 4 can be replaced with an inert gas atmosphere. Although the cover 4 is not always necessary, the container 7
This is a preferred embodiment when the internal inert gas atmosphere is made more complete.

Examples of the apparatus provided with the container used in the present invention include a conventional batch type kneader provided with a member (pressing lid) at an opening thereof, a mechanical pressure kneader,
An internal mixer, a Banbury mixer or the like can be used. Of these, a mechanical pressure kneader can be suitably used.

In the present invention, it is preferable that the number of the rotating arms is two or more, and it is particularly preferable that the rotating arms are of a double-arm type. Examples of the shape of the rotating arm used in the present invention include a sigma (δ) shape, a zet (Z) shape, a spiral (S) shape, a masticator shape, a fish tail shape, and a convex lens shape in cross section. Can be used. Further, when the rotating arm is a dual-arm type, as a combination of the shape of these rotating arms, for example, there is a combination of a sigma shape and a spiral shape or Zet shape,
These two rotating arms rotate in the opposite directions at a constant speed or at an irregular speed. Examples of the combination method include an overlap type and a tangential type, which are appropriately selected depending on various properties such as the viscosity of the hydrogel polymer. Generally, the hydrogel polymer has a high viscosity. If it is a substance, the tangential form is more suitable. When the rotating arm is used in an internal mixer, the rotating arm is rotated in the same direction by changing the phase of two pairs of rolls, and while applying pressure from above, similarly to a pressure kneader or a Banbury mixer. A shearing force can be applied to the hydrogel polymer.

As a material of the rotary arm used in the present invention, stainless steel or the like is specifically used.

The rotation speed of the rotary arm used in the present invention depends on various properties such as the viscosity of the hydrogel polymer, but is 0.01 to 10 m / s at the outer periphery, preferably 0.1 to 0.1 m / s.
1 to 5 m / s.

In the above embodiment, the jacket 6 is provided for heating or cooling the hydrogel polymer. However, the jacket is not limited as long as the hydrogel polymer can be heated or cooled. It may have a structure in which a medium for temperature control can flow through the pressure lid 5 and the rotating arm.

The shape of the pressure lid used in the present invention is shown in FIGS. 4 (a) and 4 (b) in addition to the shape adapted to the rotating part of the rotating arm as shown in FIG. As described above, a flat shape (FIG. 4A) or a shape in which only the container wall side is adapted to the peripheral moving portion (FIG. 4B) may be used. Among these, it is preferable that the entire hydrogel polymer is stirred and a shear force is uniformly applied to the entire hydrogel polymer. For this reason, in consideration of the fact that the hydrogel polymer is unlikely to stay in the container, the pressure lid having the shape shown in FIG. 1 is preferable. In addition,
The above-mentioned equality means that a specific hydrogel polymer does not continuously stay at a specific position in a container, and that a shear force is not continuously applied to only some hydrogel polymers. means.

In the present invention, the pressure lid is used to apply a load of 0.01 to 1.5 kg / cm ² to the hydrogel polymer. The load is applied by applying air pressure or oil pressure from above the pressure lid in addition to the load of the pressure lid itself. The load applied to the hydrogel polymer needs to be in the range of 0.01 to 1.5 kg / cm ² . More preferably 0.05 to 1.0 kg / cm ²
It is. The load on the hydrogel polymer is 0.01 kg
If it is less than / cm ² , no effective shearing force is applied to the hydrogel polymer, and it is difficult to obtain the particulate hydrogel polymer intended for the present invention, or it takes a long time to obtain. Or On the other hand, if the load applied to the hydrogel polymer exceeds 1.5 kg / cm ² , the power required to apply a shearing force to the hydrogel polymer is too large, and the hydrogel polymer is kneaded. This leads to a decrease in the physical properties of the obtained hydrogel polymer, which is not preferable.

In the pressure lid used in the present invention, the volume inside the container is 1.1 times the volume V ₀ of the hydrogel polymer.
~ 1.8 times, more preferably 1.2 to 1.7 times,
And volume of space consuming shear (hereinafter, referred to as shear effective volume) 1.0 to 2.0 times the V _1, more preferably 1.0
It is desirable to locate in the container so as to be 1.8 times. At this time, the space volume to which a shearing force is applied refers to the remaining space volume obtained by subtracting the volumes of the rotary stirring shaft and the rotary arm from the space volume formed by the maximum rotation circle of the rotary arm of the rotary stirring shaft. When the volume inside the container is less than 1.1 times the volume V ₀ of the hydrogel polymer, the power required to apply a shearing force to the hydrogel polymer is too large, and the hydrogel polymer is too large. However, there is a disadvantage that the physical properties are reduced because of the kneading. On the other hand, when the volume inside the container exceeds 1.8 times the volume V ₀ of the hydrogel polymer, the shear force is not effectively applied to the hydrogel polymer,
It is not preferable because it is difficult to obtain the particulate hydrogel polymer intended for the present invention, or it takes a long time to obtain it.

Further, the container internal volume of not less 2.0 times exceeds the effective shearing force to the hydrogel polymer shear effective volume V ₁ is, particulate hydrous gel for the purpose of the present invention It is not preferable because it is difficult to obtain a polymer or it takes a long time to obtain a polymer.

The hydrogel polymer of the present invention is not particularly limited as long as it can be put into a container for carrying out the present invention. For example, the method of the present invention is also carried out on a hydrogel polymer obtained by fragmentation obtained by the method described in JP-A-57-34,101. Thereby, the object of the present invention can be achieved.

In the present invention, it is an essential requirement that the temperature of the hydrogel polymer is raised to a temperature of 40 to 110 ° C., preferably 40 to 100 ° C., more preferably 50 to 95 ° C. . When the heating temperature of the hydrogel polymer is 4
When the temperature is less than 0 ° C., between the shear surface and the hydrogel polymer,
Alternatively, the friction between the hydrogel polymers increases, and the physical properties of the hydrogel polymers tend to decrease. On the other hand, if the heating temperature of the hydrogel polymer exceeds 110 ° C., the water from the hydrogel polymer evaporates violently and the hydrogel polymer foams, so that the shear force is applied to the hydrogel polymer. Is not sufficiently added, and there is a risk that a particulate hydrogel polymer having a sufficiently small particle diameter may not be obtained, and an increase in the soluble component due to deterioration of the hydrogel polymer may occur. Absent.

In the present invention, the time for applying the shearing force is not particularly limited. The time for applying the shearing force is generally shorter as the rotation speed of the rotary stirring shaft is increased and as the load applied to the hydrogel polymer is increased. However,
Applying a repeated shearing force described in the claims of the present invention means repeatedly applying a shearing force to a specific hydrogel polymer, for example, by using a screw-type extruder for the hydrogel polymer. It is different from the method of applying a transient shearing force, such as when extruding from a perforated plate. With a transient shearing force, it is not possible to obtain a particulate hydrogel polymer in which various physical properties, especially the water absorption rate, are sufficiently satisfactory.

FIG. 5 is a sectional view schematically showing another embodiment of a container used for applying a shearing force to the hydrogel polymer in the present invention.

The container 7 shown in FIG.
Has a structure similar to that of FIG. 1 except that a tube 18 for depressurizing the atmosphere in the container is provided on the upper part 17 of the pressure lid 5. In a container having such a structure, by reducing the atmosphere in the container through a mesh, the polymerization can proceed while suppressing an increase in the temperature in the container due to heat generated during the polymerization. If the removal of the heat of polymerization generated when applying a shearing force to the hydrogel polymer while polymerizing the monomer components to form the hydrogel polymer is insufficient, the temperature of the system is increased. In some cases, bumping may occur, and when the temperature is remarkable, the quality of the obtained polymer may deteriorate, which is not preferable. In order to increase the heat removal effect, it is possible to increase the heat transfer surface for heat removal by flowing cooling water or the like to the inside of the pressure lid and / or the rotating arm in addition to the jacket, but the heat removal is still insufficient Sometimes the method of reducing pressure is used effectively.

When the container shown in FIG. 5 is used, the degree of reduced pressure in the container is 1 to 500 mmHg, more preferably 1 to 40 mmHg.
It is preferably about 0 mmHg.

In the production method of the present invention, in order to facilitate the adjustment of the particle size of the hydrogel polymer, or to improve the handleability of the obtained hydrogel polymer, the hydrogel polymer is used. At any time, including before and after the step of applying a shearing force to the coalescence, an additive such as a surfactant may be added. In order to impart a new function to the obtained particulate hydrogel polymer and water-absorbent resin, a water-soluble polymer, a deodorant, a fragrance, a plant growth aid, a bactericide, a fungicide,
It is also possible to apply a shearing force in the presence of a foaming agent, a pigment, a dye, activated carbon, a hydrophilic short fiber and the like and a hydrogel polymer.

The method for producing a water-absorbent resin of the present invention is characterized in that the particulate hydrogel polymer obtained by the above-mentioned production method of the present invention is dried.

In the present invention, a conventionally known method can be employed for drying. For example, a box-type dryer, a ventilation-box-type dryer, a ventilation-band dryer, a ventilation-type vertical dryer, a rotary dryer, and the like can be given.

The drying temperature for drying the hydrogel polymer may be a conventionally known temperature, but is in the range of 80 to 250 ° C., preferably 100 to 200 ° C. If the temperature exceeds 250 ° C., the polymer may be deteriorated or decomposed. Regardless of the method required for drying, the time required for drying the particulate hydrogel polymer obtained by the method of the present invention is significantly shorter than that of a conventional hydrogel polymer.

A particularly advantageous embodiment of the process according to the invention is to carry out the drying process described in JP-A-64-26,604. This method is a preferable method for obtaining a polymer having a low residual monomer, but has a disadvantage that the drying efficiency (productivity) is low when a low level of the residual monomer amount is achieved. there were. By using the particulate hydrogel polymer obtained by the production method of the present invention, the drying efficiency is remarkably improved, the water absorption capacity of the object of the present invention is high, and it is satisfied that the water-soluble component is small. In addition, a water-absorbent resin having significantly less residual monomer can be obtained with high productivity.

The method for producing a water-absorbent resin of the present invention is characterized in that the particulate hydrogel polymer obtained by the above-mentioned production method of the present invention is dried, pulverized and / or crushed. In the present invention, a conventionally known pulverization method can be employed to obtain a powdery water-absorbent resin. For example, a high-speed rotary pulverizer (pin mill, hammer mill, etc.), a screw mill (coffee mill), a roll mill and the like can be mentioned. Above all, since the dried product of the particulate hydrogel polymer obtained by the production method of the present invention is a uniform dried product, it is pulverized (crushed) by a roll mill without passing through a step such as removal of an undried portion. By doing so, a water-absorbent resin having a small content of fine powder can be obtained.

The water-absorbing resin thus obtained can be converted into a water-absorbing agent whose surface properties have been modified by applying a conventionally known surface treatment method. For example, a water-absorbing resin and at least two functional groups capable of reacting with a functional group of the water-absorbing resin.
Mixing with a cross-linking agent having one or more functional groups in one molecule, a modification method of increasing the cross-linking density near the surface of the water-absorbent resin by reacting, or mixing a water-absorbent resin and a hydrophobic substance,
A reforming method of performing a hydrophobizing treatment by reacting as needed is mentioned.

A conventionally known granulation method may be applied to the water-absorbing resin obtained by carrying out the method of the present invention or the water-absorbing agent subjected to the above-mentioned surface treatment.

The water-absorbing resin or water-absorbing agent obtained according to the method of the present invention and a water-soluble polymer, a deodorant, a fragrance, a drug, a plant growth aid, a bactericide, a fungicide, a foaming agent, a pigment, a dye , Carbon black, activated carbon, single fiber, etc.
New functions can be imparted to the obtained water-absorbent resin.

[0054]

The present invention will be described in more detail with reference to the following Examples and Comparative Examples, but the scope of the present invention is not limited by these Examples.

Further, the particle size distribution of the particulate hydrogel polymer described in these examples on a dry basis, the particle size distribution of the dried and pulverized product, the water absorption capacity of the dried and pulverized product as a water-absorbing resin, the water-soluble component and The water absorption rate indicates a value measured by the following test method.

A: Particle size distribution of the particulate hydrogel polymer in terms of dryness 25 g of a sampled particulate hydrogel polymer (solid content α wt%) was added to a 20 wt% aqueous sodium chloride solution 12
In this case, the mixture was charged into the mixture, and the stirrer chip was rotated at 300 rpm and stirred for 60 minutes. After completion of the stirring, the sieve (opening 9.5 mm, 2.0 mm, 0.85 mm, 0.60 mm
mm, 0.30 mm, 0.075 mm), and 6000 g of a 20% by weight aqueous sodium chloride solution was slowly poured from above to classify the particulate hydrogel polymer. The classified hydrogel polymer particles on each of the classified screens were sufficiently drained and weighed. The sieve opening was converted into a sieve opening R (100) corresponding to a solid content of 100% by weight of the particulate hydrogel polymer according to the following formula 1. The particle size distribution of the particulate hydrogel polymer corresponding to a solid content of 100% by weight, that is, on a dry basis, was plotted on log probability paper.

[0057]

(Equation 1)

(Where R (100) is the sieve opening (mm) in terms of a particulate hydrogel polymer having a solid content of 100% by weight, w: the hydrogel polymer after classification and drainage) Γ: Opening (mm) of a sieve in which a hydrogel polymer swollen in a 20% aqueous sodium chloride solution is classified.) B: Particle size distribution of dry pulverized product JIS standard sieve The mesh is 16 mesh, 30 mesh, 50 mesh, 100 mesh, and the classifying dish of the saucer is overlapped, and a dried and crushed product of the hydrogel polymer is placed on the mesh.
After adding 0 g and shaking with a sieve shaker for 10 minutes, the classified material on each sieve was weighed and indicated in% by weight.

C: Water Absorption Ratio of Dry and Pulverized Product Approximately 0.2 g of a dry and pulverized hydrogel polymer classified from JIS standard sieve mesh of 16 mesh to 100 mesh.
Is weighed and a non-woven tea bag type bag (40 mm x 1
50 mm), dipped in 0.9% saline,
After one minute, the weight was measured, and the water absorption capacity was determined according to the following mathematical formula 2.

[0060]

(Equation 2)

D: Water-soluble content of dried pulverized product 0.5 g of a dried pulverized hydrogel polymer classified from a 16 mesh mesh of JIS standard sieve to 100 mesh was dispersed in 1000 ml of deionized water for 16 hours. After stirring, filter with filter paper (TOYO # 6) and at least 100
g of filtrate was obtained. Exactly 100 g of the filtrate was concentrated to about 2 to 3 ml with a rotary evaporator, and deionized water was added thereto, and transferred to a petri dish (W0 g). This was dried at 120 ° C. (W1 g). The water-soluble component was determined according to the following equation (3).

[0062]

(Equation 3)

E: Water absorption rate of dried and ground material: 100 ml of a 0.9% saline solution (30 ml) in a beaker.
° C) and a stirrer chip, and stirred at 600 rpm. Dry and crushed product of a hydrogel polymer classified from 16 mesh to 100 mesh of JIS standard screen 2.0
g was put into the beaker instantly, and the stopwatch was started. The stopwatch was stopped when the stirrer tip exposed in the center of the saline solution was covered with the swollen hydrogel polymer, and the obtained time was taken as the water absorption rate.

Example 1 A thermometer (15) having a double-arm Z wing having a total capacity of 75 liters and an effective shear volume of 24.9 liters as shown in FIGS. 1 and 2 was used.
The pressure lid (5) and the cover (4) of a stainless steel pressure kneader (7) with a jacket (6) provided with
In the state shown in (1), the liquid supply port (1) and the nozzle (2 ')
Is closed, and 50 liters /
Nitrogen was charged in minutes, and gas was discharged from the gas outlet (1 '). At this time, the cover (4) is in close contact with the pressure kneader (7) via the sealing material (9) by its own weight. On the other hand, nitrogen was introduced at a rate of 80 liter / min from the gas supply port (3), and gas was discharged from the gas discharge port (3 '). The above operation was continued for 10 minutes, and after the inside of the system was replaced with nitrogen, the gas outlet (3 ') was closed. 30 kg of an aqueous solution of a monomer component composed of 75 mol% of sodium acrylate and 25 mol% of acrylic acid in a separate container (37 wt% of monomer component)
Dissolved oxygen was expelled by blowing nitrogen gas into an aqueous solution of 18.6 g of trimethylolpropane triacrylate (0.05 mol% relative to the monomer component) as a crosslinking agent.
The obtained aqueous solution of the monomer component was charged from the liquid supply port (1) while being pressed with nitrogen. Next, the blades of the two kneaders were rotated at 30 rpm, and hot water at 35 ° C. was passed through the jacket (6) and the jacket (5 ′) inside the pressure lid to heat the monomer components. Next, an aqueous solution containing 15.0 g of sodium persulfate as a polymerization initiator and an aqueous solution containing 0.75 g of L-ascorbic acid were added from the liquid supply port (1). After the addition was completed, the liquid supply port (1) was closed. The polymerization started 4 minutes after the addition of the polymerization initiator, and 89 minutes after 13 minutes.
The polymerization peak temperature of ° C was reached. Stirring was further continued at 30 rpm to obtain a particulate hydrogel polymer (A) 25 minutes after the start of the polymerization. At this time, about 10% by weight of the hydrogel polymer (A) was a hydrogel polymer having a size of 10 mm or more. The amount of the hydrogel polymer having a size of 10 mm or more was determined by sampling 500 g of the hydrogel polymer, visually selecting a hydrogel polymer having a size of 10 mm or more, and displaying the weight%. . The temperature of the hot water in the jacket was raised to 70 ° C., and the cylinder (8) was moved by a hydraulic device to the hydrogel polymer (A) adjusted to about 65 ° C. while rotating the blades at 30 rpm. ) Was lowered to the state shown in FIG. That is, a hydrogel polymer (A) having a surface pressure of 0.40 kg / cm ²
The hydraulic pressure of the cylinder (8) is adjusted so that the hydrogel polymer (A) is loaded under a nitrogen atmosphere for 10 minutes under a load.
Was subjected to a shearing force to obtain a hydrogel polymer (1) finely divided into particles. At this time, the pressure lid was raised 43 mm from a completely closed position (that is, gel stirring space (14) / effective shear volume = 1). Gel stirring space (14) / shear effective volume = 1.33, and gel stirring space (14) /
The charged gel volume was 1.35. The obtained hydrogel polymer (1) is moved by a hydraulic device to move a cylinder (8), a pressure lid (5) is raised, and a pressure kneader (7).
Was tilted out and taken out. 1 kg each of the obtained hydrogel polymer (A) and hydrogel polymer (1)
Each was put in a wire net of 200 mm × 280 mm × 80 mm, and dried with hot air at 160 ° C. for 30 minutes. The hydrogel polymer (A) was uneven in dry state, had undried portions, and could not be ground. Then, drying of the hydrogel polymer (A) was further added for 35 minutes. Each of the obtained dried products is pulverized by a roll mill to obtain 16 mesh (1000 mμ).
A dry ground product (A) and a dry ground product (1) were obtained. The particle size distribution of the obtained hydrogel polymer and the particle size distribution of the dried and pulverized product, the water absorption capacity as a water-absorbent resin, the water-soluble content and the water absorption rate were measured by the above-mentioned test methods, and the results were shown in Tables 1 to 4. It was shown to.

Comparative Example 1 In Example 1, the pressurized lid (5) was not lowered to the state shown in FIG. 3, and the hydrogel polymer (A) was placed under a nitrogen atmosphere for 10 minutes under no load in the state shown in FIG. The same operation as in Example 1 was carried out except that a shearing force was applied to the comparative hydrogel polymer (1).
a) was obtained. The obtained comparative hydrogel polymer (1a) was dried with hot air at 160 ° C. for 30 minutes in the same manner as in Example 1. However, the dried state was not uniform, there were undried parts, and pulverization was impossible. Therefore, the comparative hydrogel polymer (1
a) was further dried for 30 minutes, and the obtained comparative dry product was pulverized in the same manner as in Example 1 to obtain a comparative dry pulverized product (1a). The obtained comparative hydrogel polymer and the comparative dry pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 2 In Example 1, when the polymerization peak temperature of 89 ° C. was reached, the cylinder (8) was moved by a hydraulic device, and the pressure lid (5) was lowered to the state shown in FIG. The same operation as in Example 1 was performed to obtain a hydrogel polymer (2). The obtained hydrogel polymer (2) was dried with hot air and pulverized in the same manner as in Example 1 to obtain a dry pulverized product (2). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 3 In Example 1, the pressure lid (5) was replaced immediately after the start of the polymerization.
The same operation as in Example 1 was performed, except that it was lowered to a position 20 mm above the completely closed position. The polymerization started 3 minutes after the addition of the polymerization initiator, and reached a polymerization peak temperature of 86 ° C. 12 minutes later. Stirring was further continued at 30 rpm to obtain a particulate hydrogel polymer (3) at 60 ° C. 40 minutes after the start of the polymerization. In view of the heat generated by the heat of polymerization, pressure began to be applied to the hydrogel polymer at a polymerization rate of about 60%, and the surface pressure was adjusted to 0.12 kg / cm ² . Finally, the pressure lid (5) is stabilized at a position 73 mm above the completely closed position, and the gel stirring space (14) at that time.
/ Shear effective volume = 1.57 and the gel stirring space (1
4) / prepared gel volume = 1.59. The obtained hydrogel polymer (3) was dried with hot air and pulverized in the same manner as in Example 1 to obtain a dry pulverized product (3). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 4 In Example 1, 36 kg of the aqueous solution of the monomer component (37% by weight of the monomer component) was used, and 22.3 g of trimethylolpropane triacrylate as a crosslinking agent (0.05 mol) was used.
1% relative to the monomer component), and the same operation as in Example 1 was performed except that the pressure lid (5) was lowered to a position 35 mm above the completely closed position immediately after the start of the polymerization. The polymerization started 3 minutes after the addition of the polymerization initiator, and reached a polymerization peak temperature of 94 ° C. 12 minutes later. Further 30 rpm
And stirring was continued for 25 minutes after the start of the polymerization to obtain a particulate hydrogel polymer (4) at 70 ° C. From the viewpoint of the heat generated by the polymerization heat, pressure began to be applied to the hydrogel polymer at a polymerization rate of about 60%, and the surface pressure was adjusted to 0.40 kg / cm ² . Finally, the pressure lid (5) is moved 6
It was stabilized at the position where it was lifted by 3 mm, and the gel stirring space (14) / effective shear volume at that time was 1.49, and the gel stirring space (14) / prepared gel volume was 1.25. The obtained hydrogel polymer (4) was dried with hot air and pulverized in the same manner as in Example 1 to obtain a dry pulverized product (4). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 5 Polymerization was carried out in the same manner as in Example 1 to obtain a hydrogel polymer (A) similar to that obtained in Example 1. The hydrogel polymer (A) was adjusted to about 50 ° C.
Pressing lid (5) by hydraulic device while rotating at rpm
Was dropped. The hydraulic pressure of the cylinder (8) was adjusted so that a surface pressure of 0.12 kg / cm ² was applied to the hydrogel polymer (A), and the shear force was applied to the hydrogel polymer (A) for 15 minutes under a nitrogen atmosphere. Was added to obtain a hydrogel polymer (5) finely divided into particles. At this time, the pressure lid (5) was lifted by 73 mm from the completely closed position, and the ratio of gel stirring space / effective shearing volume = 1.57, and the ratio of gel stirring space / prepared gel volume = 1.59. The obtained hydrogel polymer (5) was dried with hot air and pulverized in the same manner as in Example 1,
A dry pulverized product (5) was obtained. The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 6 In Example 5, the temperature of the hydrogel polymer (A) was changed to 7
The same operation as in Example 5 was carried out except that the rotating pressure of the blade was 10 rpm, the surface pressure applied to the hydrogel polymer (A) was 1.0 kg / cm ² , and the hydrogel polymer ( 6) was obtained. At this time, the pressure lid (5) was lifted by 15 mm from the completely closed position, and the ratio of gel stirring space / effective shearing volume = 1.12 and the ratio of gel stirring space / charged gel volume = 1.13. The obtained hydrogel polymer (6) was dried with hot air and pulverized in the same manner as in Example 5 to obtain a dry pulverized product (6). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 5, and the results are shown in Tables 1 to 4.

Comparative Example 2 Polymerization was carried out in the same manner as in Example 1 to obtain a hydrogel polymer (A) similar to that obtained in Example 1. This hydrogel polymer (A) was adjusted to 37 ° C., and the subsequent operations were performed in the same manner as in Example 1. The hydrogel polymer (A) is
The mixture was in a kneaded state, and a particulate hydrogel polymer was not obtained.

Comparative Example 3 The same operation as in Example 1 was carried out except that the surface pressure of 1.52 kg / cm ² was adjusted so as to apply to the hydrogel polymer (A). The ammeter of the blade drive motor greatly exceeded the rated value, making it impossible to operate the kneader.

Comparative Example 4 In Example 1, the pressure lid (5) was replaced immediately after the polymerization was started.
The same operation as in Example 1 was performed except that the polymerization initiator was lowered to a position that was lifted 115 mm from the completely closed position. The polymerization started 3 minutes after the addition of the polymerization initiator, and a polymerization peak at 88 ° C. was obtained 12 minutes later. Temperature reached. Further 30 rpm
And stirring was continued for 25 minutes after the start of the polymerization to obtain a comparative hydrogel polymer (4a) at 62 ° C. According to the movement of the pressure lid (5) and the ammeter of the blade drive motor, the pressure lid (5) is in contact with the hydrogel polymer, but almost no load is applied to the hydrogel polymer. I didn't think it was. At this time, gel stirring space / effective shear volume = 1.89, and gel stirring space / prepared gel volume = 1.91. The obtained comparative hydrogel polymer (4a) was used in Example 1.
Drying with hot air was performed at 160 ° C. for 30 minutes in the same manner as described above. However, the dried state was not uniform, there were undried parts, and pulverization was impossible. Therefore, the comparative hydrogel polymer (4a) was further dried for 30 minutes, and the obtained comparative dry product was pulverized in the same manner as in Example 1 to obtain a comparative dry pulverized product (4a). The obtained comparative hydrogel polymer and the comparative dry pulverized product were prepared in Example 1.
The results were shown in Tables 1-4.

Example 7 A jacketed stainless steel kneader having a double-armed sigma wing having a total capacity of 10 liters and an effective shear volume of 5.5 liters and equipped with a thermometer was charged with 75 mo of sodium acrylate.
5. an aqueous solution of a monomer component consisting of 1% and 25 mol% of 2-acrylamido-2-methylpropanesulfonic acid
6 kg (35% by weight of a monomer component) and 2.3 g of N, N'-methylenebisacrylamide as a cross-linking agent.
08 mol% based on the monomer component), and nitrogen gas was blown into the reaction system to replace the atmosphere with nitrogen. Next, while rotating the blades of the two kneaders at 45 rpm and heating the jacket with warm water at 35 ° C., 2.3 g of sodium persulfate and 0.1 g of L-ascorbic acid were added as polymerization initiators. The polymerization started 2 minutes after the addition of the polymerization initiator,
After 0 minute, the polymerization peak temperature of 89 ° C. was reached. 4 more
Stirring was continued at 5 rpm, and a particulate hydrogel polymer (B) was obtained 25 minutes after the start of the polymerization. At this time, about 15% by weight of the gel polymer (B) was a hydrogel polymer having a size of 10 mm or more. The hot water temperature of the jacket is 7
The temperature was raised to 5 ° C., and the pressure lid was lowered on the hydrogel polymer (B) adjusted to about 70 ° C. while rotating the blade at 45 rpm. The surface pressure of about 0.06 kg / cm ² was adjusted to be applied to the hydrogel polymer (B), and a shearing force was applied to the hydrogel polymer (B) for 15 minutes under a nitrogen atmosphere, and the hydrogel polymer was finely divided into particles. Thus, a hydrogel polymer (7) was obtained. At this time, the pressure lid is in a completely closed position (that is, the gel stirring space /
The effective shear volume was raised by 25 mm from 1), and the ratio of gel stirring space / effective shear volume = 1.25 and the ratio of gel stirring space / prepared gel volume = 1.25. The obtained hydrogel polymer (7) was dried with hot air and pulverized in the same manner as in Example 1 to obtain a dry pulverized product (7). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4.

Example 8 In Example 7, the same kneader as in Example 7 was used except that the bottom of the pressure lid was mesh-shaped and a pressure lid capable of reducing the pressure in the reaction system was used. An aqueous solution of the same monomer component as in Example 7 was charged, and nitrogen gas was blown into the reaction system to replace the inside of the reaction system with nitrogen. Next, the two kneader blades are
While rotating at 35 ° C. and heating while passing warm water at 35 ° C. through the jacket, sodium persulfate was used as a polymerization initiator.
3 g and 0.1 g of L-ascorbic acid were added. Immediately after the start of the polymerization, the pressure lid was lowered to a position 10 mm above the completely closed position. At this time, the pressure in the reaction system is reduced to 1
The pressure was reduced to 00 mmHg. The polymerization started 2 minutes after the addition of the polymerization initiator, and reached a polymerization peak temperature of 70 ° C. 10 minutes later. Further, the temperature of the hydrogel polymer is about 70
The temperature of the warm water in the jacket was raised to 75 ° C. so as to maintain the temperature, and the stirring was continued under reduced pressure. At this time, the pressure lid was raised 25 mm from the completely closed position, and the gel stirring space / effective shear volume = 1.25 and the gel stirring space / prepared gel volume = 1.25. Twenty minutes after the start of the polymerization, the inside of the reaction system was returned to normal pressure (760 mmHg).
Stirring was continued at 0 rpm, and 50 minutes after the start of the polymerization, a hydrogel polymer (8) finely divided into particles was obtained. The obtained hydrogel polymer (8) was dried with hot air and pulverized in the same manner as in Example 7 to obtain a dry pulverized product (8). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 7, and the results are shown in Tables 1 to 4.

Comparative Example 5 The procedure of Example 7 was repeated, except that the hydrogel polymer (B) was subjected to a shearing force without applying a load for 15 minutes under a nitrogen atmosphere without lowering the pressure lid. The same operation was performed to obtain a comparative hydrogel polymer (5a). The obtained comparative hydrogel polymer (5a) was treated at 160 ° C.
It was dried with hot air for 0 minutes. However, the dried state was not uniform, there were undried parts, and pulverization was impossible. Then, the comparative hydrogel polymer (5a) was further dried for 30 minutes, and the obtained dried product was pulverized in the same manner as in Example 7 to obtain a comparative dry pulverized product (5a). The obtained comparative hydrogel polymer and the comparative dry pulverized product were evaluated by the same test method as in Example 7, and the results are shown in Tables 1 to 4.

Example 9 The same operation as in Example 1 was carried out except that 37.5 g of sodium persulfate was used as the polymerization initiator, to obtain a hydrogel polymer (9). The obtained hydrogel polymer (9) was spread to a thickness of 35 mm in a hot-air drier (air-flow drier, see FIG. 6). Then, the gas from the fresh air introduction pipe and the steam introduction pipe is introduced into the heat exchanger, and heated by the heat transfer medium introduced from the heat medium introduction pipe to obtain a temperature of 105 ° C and a steam-air mixture gas having a dew point of 85 ° C. 0.8m / sec. The dried product was dried at about 50% in moisture content to about 8% in 50 minutes. A part of the mixed gas was exhausted from a discharge pipe and circulated to a heat exchanger by a blower. The obtained dried product was pulverized in the same manner as in Example 1 to obtain a dried and pulverized product (9). The obtained hydrogel polymer and dried and pulverized product were evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4. The amount of residual monomer in the dried and pulverized product was determined by the following method and found to be 20 ppm.

Method for Quantifying Residual Monomer Amount 0.50 g of the dried and pulverized material was dispersed in 1000 ml of deionized water, stirred for 2 hours, and filtered through Whatman filter paper GF / F (particle holding capacity: 0.7 micron). It was measured by liquid chromatography.

Comparative Example 6 The same operation as in Comparative Example 1 was carried out except that 37.5 g of sodium persulfate was used as a polymerization initiator, to obtain a comparative hydrogel polymer (6a). The obtained comparative hydrogel polymer (6a) was dried in the same manner as in Example 9. However, the dried state was not uniform, there were undried parts, and pulverization was impossible. Therefore, the comparative hydrogel polymer (6a) was further dried for 70 minutes, and the obtained dried product was pulverized in the same manner as in Example 9 to obtain a comparative dry pulverized product (6a). The obtained comparative hydrogel polymer and the comparative dry pulverized product were evaluated by the same test method as in Example 9, and the results are shown in Tables 1 to 4. Further, the amount of the residual monomer in the dried and pulverized product was determined by the same test method as in Example 9;
It was 0 ppm.

Example 10 100 parts by weight of the dry pulverized product (1) obtained in Example 1 was mixed with an aqueous mixture consisting of 1 part by weight of glycerin, 2 parts by weight of water and 8 parts by weight of isopropanol. The obtained mixture is put into a bowl immersed in an oil bath (195 ° C.), and is heat-treated under stirring for 45 minutes.
0) was obtained. The obtained water absorbing agent was evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4. The water absorption performance under pressure was evaluated by the following method. 5 minutes and 30
Water absorption capacity under pressure of 17 ml / g and 26
ml / g.

Method of Evaluating Water Absorption Under Pressure Using the apparatus shown in FIG. 7, the water absorption under pressure for 5 minutes and 30 minutes was measured, and the water absorption rate under pressure and the water absorption under pressure were evaluated. The upper port 32 of the buret 31 is plugged with the stopper 33, and the measuring table 34 and the air port 35 are set at the same height. A filter paper 37, 0.2 g of a water-absorbing agent 39 and a filter paper 37 are placed on a glass filter 36 having a diameter of 70 mm in a measurement table 34, and a weight 38 of 20 g / cm ² is further placed thereon. Urea 1.9%, NaCl
0.8%, 0.1% CaCl ₂ and MgSO ₄
0.1%) was taken as the water absorption capacity under pressure (ml / g).

Comparative Example 7 Comparative Example 7 was carried out in the same manner as in Example 10, except that the dried and ground product (1a) obtained in Comparative Example 1 was used instead of the dried and ground product (1). A water absorbing agent (7a) was obtained. The obtained water absorbing agent was evaluated by the same test method as in Example 1, and the results are shown in Tables 1 to 4. When the water absorption under pressure was evaluated in the same manner as in Example 10, the water absorption under pressure of 5 minutes and 30 minutes was 11 ml / g and 25 ml / g, respectively.

[0083]

[Table 1]

[0084]

[Table 2]

[0085]

[Table 3]

[0086]

[Table 4]

[0087]

As described above, by carrying out the method of the present invention, a particulate hydrogel polymer and a water-absorbing resin having a high water absorption capacity and a low water-soluble content can be produced with high productivity. It becomes possible. In addition, it is possible to obtain a particulate hydrogel polymer having a small particle size distribution and a good drying efficiency without containing additives such as a lubricant, with high productivity. Further, it becomes possible to obtain a water-absorbing resin having a high water absorption rate and a small fine powder content. In addition, it is possible to obtain a water-absorbing resin having a high water absorption rate under pressure. Furthermore, it becomes possible to obtain a water-absorbent resin having a remarkably small amount of residual monomer with high productivity.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view schematically showing one embodiment of a container used for applying a shearing force to a hydrogel polymer in the present invention.

FIG. 2 is a schematic sectional view taken along line aa of FIG.

FIG. 3 is a cross-sectional view schematically showing another embodiment of a container used for applying a shearing force to the hydrogel polymer in the present invention.

4 (a) and 4 (b) are cross-sectional views schematically showing another embodiment of the container used in the present invention.

FIG. 5 is a cross-sectional view schematically showing another embodiment of a container used for applying a shearing force to the hydrogel polymer in the present invention.

FIG. 6 is a schematic view of an apparatus used for drying a particulate hydrogel polymer obtained according to the present invention.

FIG. 7 is a schematic diagram of an apparatus used for measuring the water absorption under pressure of the particulate hydrogel polymer obtained according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Liquid supply port 2, 3 ... Gas supply port 1 ', 3' ... Gas discharge port 2 '... Nozzle 4 ... Cover 5 ... Pressure lid 5', 6 ... Jacket 7 ... Container (pressure kneader) 8 ... Cylinder 9: Sealing material 10, 11 ... Rotating arm 12, 12 ', 13
... Rotating stirring shaft 14 ... Gel stirring space 15 ... Thermometer 16 ... Bottom of pressure lid 17 ... Top of pressure lid 18 ... Tube 21 ... Hydrogel polymer 22 ... Fresh air introduction pipe 23 ... Steam introduction pipe 24 ... Exhaust exhaust pipe 25 Blower 26 Heat exchanger 27 Heat medium introduction pipe 31 Bullet 32 Bullet upper port 33 Plug 34 Measurement table 35 Air port 36 Glass filter 37 Filter paper 38 Weight 39 Water absorbing agent

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kazumasa Kimura 5-8 Nishiburi-cho, Suita-shi, Osaka Inside of Nippon Shokubai Central Research Laboratory Co., Ltd. (56) References JP-A-57-34101 (JP, A) Kaihei 1-26044 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) C08J 3/12 C08J 3/24

Claims (12)

(57) [Claims] In a container, a hydrogel polymer having a crosslinked structure heated to a temperature of 40 to 110 ° C. is added to a hydrogel polymer in an amount of 0.01 to 100 ° C.
A particulate hydrogel polymer is produced by repeatedly applying a shearing force while applying a load of 1.5 kg / cm ² to obtain a particulate hydrogel polymer. The particulate hydrogel polymer is dried and water-absorbed. A water-absorbent resin, mixing and reacting the water-absorbent resin with a cross-linking agent having at least two functional groups capable of reacting with the functional group of the water-absorbent resin, and reducing the crosslink density near the surface of the water-absorbent resin A method for producing a water-absorbing agent, characterized in that the method is increased. 2. A hydrogel polymer having a cross-linked structure heated to a temperature of 40 to 110 ° C. in a container is added with 0.01 to
A particulate hydrogel polymer is produced by repeatedly applying a shearing force while applying a load of 1.5 kg / cm ² to form a particulate hydrogel polymer. The particulate hydrogel polymer is dried, pulverized and pulverized. And / or crushing to produce a water-absorbent resin, mixing and reacting the water-absorbent resin with a crosslinking agent having at least two functional groups capable of reacting with the functional groups of the water-absorbent resin, A method for producing a water-absorbing agent, comprising increasing the crosslink density near the surface of a resin. 3. The method according to claim 1, wherein the container is a kneader having a plurality of rotary stirring shafts. 4. The remaining space volume (effective shear volume) obtained by subtracting the volume of the rotary stirring shaft and the rotary arm from the volume of the container whose volume in the container is formed by the rotation of the rotary arm of the rotary stirring shaft. The method for producing a water-absorbing agent according to claim 1, wherein the water-absorbing agent is 1.0 to 2.0 times V ₁ and 1.1 to 1.8 times the volume V ₀ of the hydrogel polymer. 5. A hydrated gel-like polymer formed by advancing polymerization of an ethylenically unsaturated monomer and a monomer component containing a cross-linking agent, the hydrated gel-like polymer being converted into a hydrated gel by polymerization. 3. The method for producing a water-absorbing agent according to claim 1, which is a polymer. 6. The method for producing a water-absorbing agent according to claim 5, wherein the hydrogel polymer is a hydrogel polymer having a polymerization rate of a monomer component of 10 to 100%. 7. The method for producing a water absorbing agent according to claim 5, wherein the polymerization of the monomer component is allowed to proceed under reduced pressure. 8. The method according to claim 7, wherein the degree of reduced pressure is 1 to 500 mmHg. 9. Drying is carried out by using a gas containing at least water vapor and having a dew point of 50 to 100 ° C.
The method for producing a water-absorbing agent according to claim 1, wherein the method is carried out by contacting at a temperature of: 10. The method for producing a water-absorbing agent according to claim 2, wherein the pulverization and / or pulverization is performed by a roll mill (roll rotary pulverizer). 11. A method for producing a particulate hydrogel polymer in which a shear force is applied to a hydrogel polymer having a crosslinked structure in a container to form a particulate hydrogel polymer, wherein the temperature is from 40 to 110 ° C. A method for producing a particulate hydrogel polymer, wherein a shear force is repeatedly applied to the heated hydrogel polymer while applying a load of 0.01 to 1.5 kg / cm ^2. The hydrogel polymer is a hydrogel polymer formed while the polymerization of an ethylenically unsaturated monomer and a monomer component containing a cross-linking agent that becomes a hydrogel by polymerization proceeds under reduced pressure. A method for producing a particulate hydrogel polymer. 12. The method for producing a particulate hydrogel polymer according to claim 11, wherein the degree of reduced pressure is 1 to 500 mmHg.