JP3391116B2 - Nitrile group-containing highly saturated copolymer rubber, method for producing the same, and vulcanizable rubber composition - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a nitrile group-containing highly saturated copolymer rubber, a method for producing the same and a vulcanizable rubber composition. More specifically, a nitrile group-containing highly saturated copolymer rubber obtained by hydrogenating an unsaturated nitrile-conjugated diene copolymer having an alkylthio group, a method for producing the same, and a blending method of the copolymer rubber and a vulcanizing agent. And a vulcanizable rubber composition. The nitrile group-containing highly saturated copolymer rubber of the present invention is superior in high-speed vulcanization property as compared with the conventional nitrile group-containing highly saturated copolymer rubber, and the vulcanized product has good mechanical strength and compression resistance. Has permanent set.

[0002]

2. Description of the Related Art In recent years, a nitrile group-containing highly saturated copolymer rubber represented by hydrogenated acrylonitrile-butadiene copolymer rubber has been attracting attention as a rubber material excellent in heat resistance, oil resistance and weather resistance, and has been widely used. Nitrile group-containing highly saturated copolymer rubbers have been proposed. For example, JP-A-54-132647 discloses a copolymer rubber obtained by hydrogenating a conjugated diene portion of an acrylonitrile-conjugated diene copolymer, which is particularly excellent in weather resistance, ozone resistance and gasoline (oil) resistance. Hydrogenated acrylonitrile-conjugated diene copolymer rubbers are described.

Hydrogenated acrylonitrile-conjugated diene copolymer rubbers are particularly excellent in weather resistance and ozone resistance as compared with acrylonitrile-conjugated diene copolymer rubbers, and like ethylene-propylene copolymer rubber (EPR). Excellent oil resistance compared to saturated polymer rubber. However, since the hydrogenated acrylonitrile-conjugated diene copolymer rubber has a low degree of unsaturation, it is difficult to vulcanize with a sulfur vulcanizing agent, and the vulcanized product has low mechanical strength and compression set. There is a big problem.

In injection molding of acrylonitrile-conjugated diene copolymer rubber, not only flow characteristics but also high crosslinking efficiency can be obtained by vulcanization at high temperature for a short time, that is,
High speed vulcanization is required. However, in general, the vulcanization of rubber has a tendency that the vulcanized state becomes blunt as the vulcanization temperature rises, and therefore the injection molded product is inferior in tensile stress and impact resilience to the compression molded product ( For example, Journal of Japan Rubber Association, Vol. 59, No. 4, pages 214-215, 198.
6 years). Such a tendency is remarkable also in hydrogenated acrylonitrile-conjugated diene copolymer rubber.

It has been proposed to incorporate various vulcanization accelerators in order to improve the rapid vulcanizability of hydrogenated acrylonitrile-conjugated diene copolymer rubbers. For example, as a vulcanization accelerator, a tellurium dithiocarbamate compound (Japanese Patent Application Laid-Open No. H06-242242)
No. 9822), a partial ester salt of a thiuram promoter and a di- and / or tricarboxylic acid (JP-A-4-26414).
5), and thiuram promoter and N-trichloromethylsulfenylbenzenesulfanilide (JP-A-2-24).
No. 8442) has been proposed. However, in such a conventionally proposed method, the high speed vulcanization property of the hydrogenated acrylonitrile-conjugated diene copolymer rubber may not be sufficiently achieved, and in addition, the physical properties of the vulcanized product may be impaired.

Further, in injection molding of hydrogenated acrylonitrile-conjugated diene copolymer rubber which is vulcanized at high temperature, so-called mold contamination is remarkable. That is, contaminants are gradually deposited and deposited on a mold that is repeatedly used in injection molding, and as a result, the molded product itself is also contaminated and a molded product having an excellent surface condition cannot be obtained. Therefore, the mold must be cleaned at regular intervals, which requires a lot of time and money, and is a major cause of lowering productivity. In order to prevent such mold contamination, a method of blending talc, sodium thiosulfate, carbon wax or silicone oil is known, but in the case of high temperature and high speed vulcanization such as injection molding, it is almost the same. Often no effect is seen.

[0007]

In view of the above circumstances, an object of the present invention is to maintain good weather resistance, oil resistance and heat resistance generally possessed by a nitrile group-containing highly saturated copolymer rubber. In particular, it has a high nitrile group content which is excellent in high-speed vulcanization suitability desired for injection molding applications, has good mechanical strength and compression set resistance, and gives a vulcanizate that does not cause mold contamination problems. An object is to provide a saturated copolymer rubber.

Another object of the present invention is to provide a method capable of producing such a nitrile group-containing highly saturated copolymer rubber with high productivity. Another object of the present invention is to provide a vulcanizable rubber composition which is excellent in high-temperature high-speed vulcanization property and gives a vulcanized product having good mechanical strength and compression set resistance.

[0009]

The above objects are achieved by the following (1) a nitrile group-containing highly saturated copolymer rubber, (2) a method for producing the same, and (3) a vulcanizable rubber composition containing the same. To be achieved. (1) A nitrile group-containing highly saturated copolymer rubber obtained by hydrogenating a conjugated diene portion of an unsaturated nitrile-conjugated diene copolymer, comprising at least three tertiary carbon atoms and at least one of them. Having a C12 to C16 alkylthio group having a sulfur atom directly bonded to the tertiary carbon atom in the molecule and having a Mooney viscosity of 15 to 200,
A nitrile group-containing highly saturated copolymer rubber having an iodine value of 80 or less.

(2) As a molecular weight regulator, at least 3
1 tertiary carbon atom and a carbon atom having a sulfur atom directly bonded to at least one tertiary carbon atom therein
2-16 alkyl thiol compound is used to copolymerize an unsaturated nitrile and a conjugated diene in the presence of a radical initiator, and the resulting unsaturated nitrile-conjugated diene copolymer is hydrogenated. A method for producing a nitrile group-containing highly saturated copolymer rubber. (3) A vulcanizable rubber composition comprising the nitrile group-containing highly saturated copolymer rubber according to claim 1 and 0.01 to 10 parts by weight of a sulfur-based vulcanizing agent per 100 parts by weight of the copolymer rubber. object.

The nitrile group-containing highly saturated copolymer rubber of the present invention comprises a carbon having at least three tertiary carbon atoms and a sulfur atom directly bonded to at least one of the tertiary carbon atoms. It is obtained by hydrogenating the conjugated diene portion of an unsaturated nitrile-conjugated diene copolymer having an alkylthio group of the formula 12 to 16 in the molecule and having a Mooney viscosity of 1
5-200, preferably 30-100, iodine value 80
The following is preferably 40 or less. Mooney viscosity is 15
If the amount is less than 1, a molded product with low strength can be obtained, which is not preferable. If it exceeds 200, the viscosity increases and molding becomes difficult. The lower limit of the iodine value is at least 1. If the iodine value is too low, sulfur vulcanization becomes difficult.

The unsaturated nitrile-conjugated diene copolymer used for producing the nitrile group-containing highly saturated copolymer rubber of the present invention preferably contains 3 to 20% by weight of a component having a number average molecular weight of 35,000 or less, More preferably 5 to 15% by weight
contains. If the content of the component having a number average molecular weight of 35,000 or less is excessively high, the mechanical strength will decrease. If it is too low, the workability will be poor. Number average molecular weight 35,0
By containing an appropriate amount of components of 00 or less, the workability can be improved while maintaining good mechanical strength. The ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) of the unsaturated nitrile-conjugated diene copolymer is usually 2.3 to 5.5, preferably 2.7. ~ 4. If Mw / Mn is excessively large, workability is poor even if an appropriate amount of a component having a number average molecular weight of 35,000 or less is contained.

The content of bound unsaturated nitrile unit in the copolymer is 10 to 60% by weight, and particularly 20 to 50% by weight.
Is preferred. In addition, the composition distribution width of the unsaturated nitrile (ΔA
N) is usually 35 or less, preferably 3 to 20, and more preferably 5 to 15. When ΔAN is excessively large, the balance between oil resistance and cold resistance becomes poor.

The unsaturated nitrile-conjugated diene copolymer used in the present invention preferably contains substantially no halogen. Here, "substantially containing no halogen" means that the content of halogen in the copolymer is about 3 ppm or less. Substantially no halogen is important for avoiding the problem of metal corrosion when the vulcanized molded article of the copolymer is used in contact with a metal such as a sealant.

Specific examples of unsaturated nitriles include acrylonitrile, methacrylonitrile and α-chloroacrylonitrile. Specific examples of the conjugated diene include 1,3-butadiene, 2,3-dimethylbutadiene, isoprene and 1,3-pentadiene.

In addition to these monomers, a part of all the monomers may be replaced with another copolymerizable monomer, if necessary, as long as the effects obtained by the present invention are not impaired. It is possible. Other copolymerizable monomers include vinyl-based monomers such as styrene, α-methylstyrene and vinylpyridine; non-conjugated diene-based monomers such as vinylnorbornene, dicyclopentadiene and 1,4-hexadiene. Methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, t-butyl acrylate, isobutyl acrylate, n-pentyl acrylate, isononyl acrylate, n-hexyl acrylate, 2-methyl-pentyl acrylate, n
-Acrylates and methacrylates having an alkyl group having about 1 to 18 carbon atoms such as octyl acrylate, 2-ethylhexyl acrylate, n-dotecil acrylate, methyl methacrylate, ethyl methacrylate; methoxymethyl acrylate, methoxyethyl acrylate, ethoxyethyl acrylate, butoxy. An acrylate having an alkoxyalkyl group having a total carbon number of about 2 to 12, such as ethyl acrylate, ethoxypropyl acrylate, methoxyethoxy acrylate, and ethoxybutoxy acrylate; α and β-cyanoethyl acrylate, α, β and γ-cyanopropyl acrylate, cyanobutyl. 2 carbon atoms such as acrylate, cyanohexyl acrylate, cyanooctyl acrylate
An acrylate having about 12 cyanoalkyl groups;
Acrylate having a hydroxyalkyl group such as 2-hydroxyethyl acrylate and hydroxypropyl acrylate; monoethyl maleate, dimethyl maleate, dimethyl fumarate, diethyl fumarate, di-n-butyl fumarate, di-2-ethylhexyl fumarate, Dimethyl itaconate, diethyl itaconate, di-itaconate
Unsaturated dicarboxylic acid mono- and dialkyl esters such as n-butyl and di-2-ethylhexyl itaconate; further dimethylaminomethyl acrylate, diethylaminoethyl acrylate, 3- (diethylamino) -2-
Unsaturated carboxylic acid ester monomers such as hydroxypropyl acrylate and 2,3-bis (difluoroamino) propyl acrylate; trifluoroethyl acrylate, tetrafluoropropyl acrylate, pentafluoropropyl acrylate, heptal orobutyl acrylate, octa Fluoropentyl acrylate, nonafluoropentyl acrylate, undecafluorohexyl acrylate, pentadecafluorooctyl acrylate, heptadecafluorononyl acrylate, heptadecafluorodecyl acrylate, nonadecafluorodecyl acrylate, trifluoroethyl methacrylate, tetrafluoropropyl methacrylate, octa Fluoropentyl methacrylate, dodecafluoroheptyl methacrylate Acrylates and methacrylates having fluoroalkyl groups such as pentadecafluorooctyl acrylate and hexadecafluorononyl methacrylate; fluorine-substituted benzyl acrylates and methacrylates such as fluorobenzyl acrylate, fluorobenzyl methacrylate and difluorobenzyl methacrylate; fluoroethyl vinyl ether, fluoropropyl vinyl ether, Fluoroalkyl vinyl ethers such as trifluoromethyl vinyl ether, trifluoroethyl vinyl ether, perfluoropropyl vinyl ether and perfluorohexyl vinyl ether, o- or p-trifluoromethylstyrene, vinyl pentafluorobenzoate, fluorine such as difluoroethylene and tetrafluoroethylene Inclusion Alkenyl-based monomers;
Furthermore, polyethylene glycol (meth) acrylate, polypropylene glycol (meth) acrylate,
Examples thereof include epoxy (meth) acrylate and urethane (meth) acrylate. The amount of these monomers used is not particularly limited, but it is usually used in the range of 80% by weight or less based on the total amount of the monomers, and particularly in the range of 10% by weight or less in applications where oil resistance is required. used.

In particular, the unsaturated carboxylic acid ester-based monomer and, if necessary, a combination thereof with a fluorine-containing vinyl-based monomer are copolymerized with an unsaturated nitrile and a conjugated diene to obtain the nitrile of the present invention. The cold resistance can be improved without impairing the ozone resistance and heat resistance of the group-containing highly saturated copolymer rubber. Among them, unsaturated dicarboxylic acid dialkyl ester is preferable. The amount of the unsaturated carboxylic acid ester-based monomer or the fluorine-containing vinyl-based monomer used is 1 to 80% by weight, preferably 15 to 60% by weight, and more preferably 20 to 40% by weight based on the total amount of the monomers.
It can be used in the range of% by weight.

Among the copolymer rubbers of unsaturated nitrile and conjugated diene, acrylonitrile having a bound acrylonitrile content of 10 to 60% by weight, preferably 20 to 50% by weight.
Butadiene copolymer rubber (hereinafter referred to as NBR) is suitable, and commercially available ones having a low nitrile amount to an extremely high nitrile amount can be used, and the optimum bound acrylonitrile content is NBR is selected.

The unsaturated nitrile-conjugated diene copolymer used in the present invention has a direct bond to at least three tertiary carbon atoms in the molecule and at least one tertiary carbon atom therein. Examples of the alkylthio group having a sulfur atom having 12 to 16 carbon atoms include 1,1-di (2,2-dimethylpropyl) -1-ethylthio group and 1,1-di (2,2).
A 2-dimethylpropyl) -1- (2,2,4,4-tetramethylpentyl) -1-ethylthio group may be mentioned, and these may be contained alone or in combination with each other in one molecule. Of these, a 1,1-di (2,2-dimethylpropyl) -1-ethylthio group is particularly preferable.

In the molecule of the unsaturated nitrile-conjugated diene copolymer used in the present invention, the above-mentioned alkylthio group is 0.03 mol or more, preferably 0.1% per 100 mol of the monomer unit constituting the molecule. It is present in an amount of 07 mol or more, more preferably 0.09 mol or more. The amount of the alkylthio group is usually 0.3 mol or less. When the amount of the alkylthio group is excessively low, high crosslinking efficiency cannot be obtained in high-temperature and short-time vulcanization such as injection molding, and therefore the tensile stress and impact resilience of the molded product are not improved and the desired high speed is achieved. Vulcanization is not achieved. Further, as the amount of the alkylthio group becomes higher, the scorch time (T ₅ ) becomes remarkably shortened, and further, the mold staining property is significantly improved,
Highly productive injection molding is possible. Particularly, when the amount is 0.09 mol or more, the crosslinking efficiency is greatly improved, and the maximum torque in the vulcanization curve measured by using the oscillating disc rheometer is dramatically increased.

The unsaturated nitrile-conjugated diene copolymer used in the present invention is used as a molecular weight modifier directly on at least three tertiary carbon atoms and at least one tertiary carbon atom therein. 12 to 12 carbon atoms having a bonded thiol group
It is produced by preparing a copolymer latex of an unsaturated nitrile and a conjugated diene by emulsion polymerization in the presence of a radical initiator using 16 alkylthiol compounds, and coagulating the latex.

The radical polymerization initiator used is not particularly limited, but organic peroxides, redox polymerization initiators, azo compounds, persulfates and the like are usually used. The amount of these polymerization initiators used is usually 100
It is 0.005 to 3 parts by weight per part by weight. The polymerization temperature is preferably in the range of 0 to 100 ° C.

Specific examples of the alkyl thiol compound used as a molecular weight adjusting agent in producing an unsaturated nitrile-conjugated diene copolymer include 2,2 ', 4,6,6'-
Pentamethylheptane-4-thiol and 2,2 ',
4,6,6 ', 8,8'-heptamethylnonane-4-thiol can be mentioned. Among them, 2, 2 ', 4, 6,
6'-Pentamethylheptane-4-thiol is particularly preferable, and the unsaturated nitrile-conjugated diene copolymer produced by using the thiol compound is hydrogenated to obtain a nitrile group-containing highly saturated copolymer rubber which has a high vulcanizability. Is very good.

The alkyl thiol compounds used as the molecular weight modifier in the production of the unsaturated nitrile-conjugated diene copolymer can be used alone or in combination. In addition, if necessary, it is also possible to use together with other compounds conventionally known as a molecular weight modifier in radical polymerization. In this case, the alkylthiol compound should be contained in at least 50% by weight, preferably 80% by weight or more, more preferably 95% by weight or more, based on the total weight of the molecular weight modifier used.

Other compounds known as molecular weight regulators in radical polymerization include 2,4,4-trimethylpentane-2-thiol, dodecane-12-thiol and 2,2,6,6-tetramethylheptane. Alkyl thiol compounds such as 4-methanethiol and 2,4,6-trimethylnonane-4-thiol; xanthogen disulfides such as dimethylxanthogen disulfide, diethylxanthogen disulfide, diisopropylxanthogen disulfide; tetramethylthiuram disulfide, tetraethylthiuram disulfide , Thiuram disulfides such as tetrabutyl thiuram disulfide; halogenated hydrocarbons such as carbon tetrachloride and ethylene bromide; hydrocarbons such as pentaphenylethane; and acrolein, Takurorein, allyl alcohol,
2-ethylhexyl thioglycolate, terpinolene, α-terpinene, γ-terpinene, dipentene, α
-Methylstyrene dimer (2-4-diphenyl-4-
Methyl-1-pentene is preferably 50% by weight or more), 2,5-dihydrofuran, 3,6-dihydro-2.
H-pin, phthalane, 1,2-butadiene, 1,4-hexadiene and the like can be mentioned.

The amount of the molecular weight modifier used in the radical polymerization is usually the monomer mixture 1 used in the copolymerization.
The amount is 0.05 to 3 parts by weight, preferably 0.1 to 1 part by weight, relative to 00 parts by weight, and the amount used in this range is advantageous in controlling the molecular weight of the resulting copolymer. The molecular weight modifier is added by dividing it during the polymerization,
It is possible to obtain polymers containing 3 to 20% by weight of low-molecular-weight components of n <35,000, which polymers have good processability. Generally, the total amount of the molecular weight modifier used is 10 to 9
It is preferable that 5% by weight is contained in the monomer mixture before polymerization, and the remaining amount of the molecular weight modifier is added to the polymerization system when the polymerization conversion rate reaches 20 to 70% by weight. The number of times of addition is appropriately determined as needed.

As an alternative method, irrespective of the method in which the molecular weight modifier is dividedly added during the polymerization process, two or more kinds of copolymers having different molecular weights, which are separately produced using the above molecular weight modifier, are mixed and prepared. You can also do it.

In the production of the unsaturated nitrile-conjugated diene copolymer used in the present invention, by using such a specific alkylthiol compound as a molecular weight modifier, the polymerization conversion rate of radical polymerization is 75% or more, preferably A high conversion rate of 80% or more can be achieved, and as a result,
The nitrile rubber can be produced with high productivity.

Generally, in the radical polymerization of nitrile rubber, the branching reaction or gelation reaction increases as the polymerization conversion rate increases. As a result, when the obtained nitrile rubber is vulcanized with a vulcanizing agent, high crosslinking efficiency cannot be obtained, and vulcanization physical properties such as tensile stress and impact resilience are deteriorated. Conventionally, t-dodecyl mercaptan used as a general-purpose molecular weight modifier in radical polymerization of nitrile rubber is a mixture of isomers of an alkylthiol compound having 9 to 16 carbon atoms, and a mixture of such isomers. The nitrile rubber obtained by using as a molecular weight modifier does not have sufficient high-speed vulcanizability during vulcanization at high temperature in a short time such as injection molding.

On the other hand, according to the method for producing an unsaturated nitrile-conjugated diene copolymer used in the present invention, even if the polymerization conversion rate is set to a high value of 80% or more, for example, oscillating It is possible to obtain a nitrile rubber excellent in high-speed vulcanization such that the maximum torque in the vulcanization curve measured using a disc rheometer shows a high value.

The total amount of the monomers to be polymerized can be charged all at once. Alternatively, the polymerization is initiated in the presence of 30 to 90% by weight of the total amount of the monomers used, and A method in which the remaining amount of the monomer is added to the polymerization system when the polymerization conversion rate reaches 20 to 70% can be adopted. The unsaturated nitrile-conjugated diene copolymer rubber composition obtained by this monomer division addition method is characterized by having good and well-balanced oil resistance and cold resistance.

The kind and amount of the monomer to be added in portions are appropriately selected according to the desired amount of the bound unsaturated nitrile and the composition distribution width (ΔAN) of the unsaturated nitrile. For example,
When the amount of the bound unsaturated nitrile is less than 37%, the unsaturated nitrile is generally added during the polymerization, and when the amount of the bound nitrile is 37% or more, the conjugated diene is generally added during the polymerization. The number of times of addition is appropriately determined as needed. When an unsaturated nitrile-conjugated diene copolymer latex is prepared by emulsion polymerization, a carboxylic acid-based emulsifier is used as an emulsifier, and the resulting copolymer has mold contamination during high-temperature short-time vulcanization such as injection molding. Sexual problems are further improved.

Examples of the carboxylic acid emulsifier used include fatty acid soap and rosin acid soap.
Specifically, fatty acid soap is a long-chain aliphatic carboxylic acid having 12 to 18 carbon atoms, for example, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, etc., and sodium of these mixed aliphatic carboxylic acids. It is selected from salts or potassium salts. Also, the rosin acid soap is selected from sodium salt or potassium salt of disproportionated or hydrogenated natural rosin such as gum rosin, wood rosin or tall oil rosin. These natural rosins are mainly composed of abietic acid, levopimaric acid, parastrinic acid, dehydroabietic acid, tetrahydroabietic acid, neoabietic acid and the like. The amount of the emulsifier used is not particularly limited, but is usually 0.05 to 10 parts by weight, preferably 0.5 to 3 parts by weight, per 100 parts by weight of the monomer.

In the process of emulsion copolymerization of unsaturated nitrile and conjugated diene, hydroxylamine, sodium carbamate, etc. are added to terminate the polymerization when a predetermined conversion rate is reached. Then, the residual monomer is removed from the produced copolymer latex by heating, steam distillation or the like.

The method for coagulating the copolymer latex prepared as described above is not particularly limited, and it is used in ordinary emulsion polymerization of an inorganic coagulant, a polymer coagulant or a dry heat coagulant. A coagulant can be added to coagulate. However, in order to produce the preferred unsaturated nitrile-conjugated diene copolymer used in the present invention, a nonionic surfactant is added to the copolymer latex prepared as described above, and then the copolymer latex is added. Put in a coagulation bath in which metal salt is dissolved and heat to coagulate.
By adopting such a preferred latex coagulation method, a crumb having an appropriate size and porosity and good drying property can be easily produced, and the use of a metal salt can be achieved by adding a nonionic surfactant. The amount can be reduced.

In the above-mentioned preferred latex coagulation method, specific examples of the nonionic surfactant added to the latex include alkylene oxide adducts of alkylphenol formalin condensates (for example, oxyethylene-oxypropylene co-adducts) and polyoxy. Examples thereof include ethylene alkyl ether, polyoxyethylene alkyl allyl ether, polyoxyethylene fatty acid ester, polyoxyethylene sorbitan fatty acid ester, polyoxyethylene oxypropylene block polymer, alkylsulfinyl alcohol, and fatty acid monoglyceride. These nonionic surfactants may be used alone or in combination of two or more, and are appropriately selected depending on the coagulation conditions.

Among the above nonionic surfactants, an oxyethylene-oxypropylene co-adduct of an alkylphenol formalin condensate is preferred. This co-adduct shows a good thermosensitive gel effect. Cloud point of co-adduct is 10 to 100 ° C
The range is preferable, and the range of 20 to 70 ° C. is more preferable.
If the cloud point is too low, the handleability is poor, while if it is too high, it becomes difficult to obtain the heat-sensitive gel effect. The amount of the nonionic surfactant added is 0.01 to 5 with respect to 100 parts by weight of the polymer.
Part by weight is preferable, and 0.05 to 2 parts by weight is more preferable. If the amount of addition is too small, the above-mentioned effect of addition is not observed, and even if the amount of addition exceeds 5 parts by weight, the effect is substantially unchanged.

As the metal salt which can be dissolved during solidification,
Usually, calcium sulfate, sodium chloride, and metal sulfate are used. In particular, when a halogen-free metal sulfate is used, it is possible to obtain a nitrile group-containing highly saturated copolymer rubber that does not cause the problem of metal corrosion. Specific examples of the metal sulfate include aluminum sulfate, magnesium sulfate, sodium sulfate and the like, among which aluminum sulfate and magnesium sulfate are preferable.

The amount of the metal salt used is preferably 0.5 to 50 parts by weight, more preferably 1 to 30 parts by weight, based on 100 parts by weight of the polymer. If the amount of the metal salt is less than 0.5 part by weight, the coagulation in the coagulation bath becomes insufficient or the crumbs become large.
On the other hand, if it exceeds 50 parts by weight, the solidification rate is dominated by the metal salt, and the crumb becomes poor in porosity.

When the coagulation bath containing the polymer latex is heated above the cloud point of the nonionic surfactant, the polymer in the system coagulates and separates. The cloud point of nonionic surfactant is 1
The range of 0 to 100 ° C. is preferable, and if the cloud point is too low, cooling is required to keep it below the cloud point, and conversely, if it is too high, high temperature heating is required to solidify.

The solidified polymer is recovered, washed with water and dried,
Next, the resulting unsaturated nitrile-conjugated diene copolymer is hydrogenated to obtain the desired nitrile group-containing highly saturated copolymer rubber. The method for hydrogenating the unsaturated nitrile-conjugated diene copolymer is not particularly limited and can be hydrogenated according to a conventional method. Examples of the catalyst used in the hydrogenation include palladium / silica and palladium complex (JP-A-3-252405). Further, it is described in JP-A-62-125858, JP-A-62-42937, JP-A-1-45402, JP-A-1-45403, JP-A-1-45404, and JP-A-1-45405. It is also possible to use rhodium or ruthenium compounds such as

The nitrile group-containing highly saturated copolymer rubber of the present invention can also be used in the form of an aqueous emulsion. The method for preparing the aqueous emulsion is not particularly limited, but usually a phase inversion method or a method of directly hydrogenating the latex of the unsaturated nitrile-conjugated diene copolymer is adopted. Hereinafter, these aqueous emulsion preparation methods will be described in detail.

The phase inversion method is a method in which a solution of a nitrile group-containing highly saturated copolymer rubber and an emulsifier aqueous solution are mixed, the rubber is emulsified and dispersed as fine particles in water by vigorous stirring, and the solvent is further removed. By this method, an aqueous dispersion of a nitrile group-containing highly saturated copolymer rubber is obtained. As the nitrile group-containing highly saturated copolymer rubber solution in that case, the solution at the end of the polymerization and the hydrogenation reaction may be used as it is, or may be concentrated or diluted, or the solid rubber may be used as a solvent. It can also be dissolved in and used. As the solvent, the rubber-soluble aromatic solvents such as benzene, toluene and xylene, halogenated hydrocarbon solvents such as dichloroethane and chloroform, ketones such as methyl ethyl ketone, acetone and tetrahydrofuran may be used alone or in combination. . The concentration of the nitrile group-containing highly saturated copolymer rubber in the solution is appropriately 1 to 25% by weight.

As the emulsifier used for preparing the aqueous solution of emulsifier, fatty acid such as oleic acid and stearic acid, potassium salt such as rosin acid, alkylbenzene sulfonic acid and alkyl sulfate, sodium salt, polyoxyethylene type nonionic emulsifier. Commonly known ones are used alone or as a mixture. The volume ratio with the nitrile group-containing highly saturated copolymer rubber solution is 3: 1 to 1: 2.
0 is suitable. As a stirrer when emulsifying and dispersing,
Various homomixers and ultrasonic emulsifiers are used.
Removal of the solvent from the emulsion is performed by a known method such as a steam stripping method. When provided as a product, the proportion of the total solid content in the nitrile group-containing highly saturated copolymer rubber aqueous dispersion is appropriately 1 to 70% by weight.

As a method for direct hydrogenation, a method using a palladium-based catalyst (for example, Japanese Patent Laid-Open No. 2-17) is used.
8305) and a method using a rhodium-based catalyst (for example, JP-A-59-115303 and JP-A-56-133).
219, U.S. Pat. No. 3,898,208), and a method using a ruthenium-based catalyst (for example, JP-A-6-
184223, JP-A-6-192323) and the like, but are not limited thereto. As a specific example, for example, when using a palladium-based catalyst,
As described in JP-A-2-178305, an organic solvent that dissolves or swells the nitrile group-containing unsaturated copolymer is added to the copolymer latex. According to this method, the nitrile group-containing unsaturated copolymer in the copolymer latex swells with an organic solvent, and the hydrogenation catalyst can be easily accessible to the double bond in the copolymer, so that the aqueous solution While maintaining the emulsion state,
The hydrogenation reaction can be performed efficiently.

Specific examples of the organic solvent include aromatic solvents such as benzene, toluene, xylene and ethylbenzene; halogenated hydrocarbon solvents such as dichloroethane, chloroform and chlorobenzene; carbon tetrachloride; methyl ethyl ketone, acetone, cyclohexanone, cyclo Ketones such as pentanone; Esters such as methyl acetate, ethyl acetate, propyl acetate and butyl acetate; Higher alcohols such as diacetone alcohol and benzen alcohol; Ethers such as dioxane and tetrahydrofuran; Acetonitrile, acrylonitrile, propio Examples thereof include nitriles such as nitrile, and these organic solvents can be used alone or in combination of two or more kinds.

The amount of the organic solvent used is the polymer latex /
The volume ratio of the organic solvent is in the range of 1/3 to 1/0. The hydrogenation reaction proceeds even if the amount exceeds this range, but if the amount of the solvent is too large, the emulsion is broken and the solvent phase and the aqueous phase are easily separated. Then, a new step for separating the aqueous phase and the solvent phase and a step for recovering the hydrogenated polymer from the solvent phase are required, which rather complicates the step. When the volume ratio of polymer latex / organic solvent is in the range of 1/3 to 1 / 1.5, the hydrogenation reaction can be carried out while maintaining the emulsion state, but the emulsion may be destroyed after the reaction. Therefore, when the emulsion state is maintained after the reaction, the volume ratio of polymer latex / organic solvent is 1 /
It is preferable to control in the range of 1 to 1/0.

Further, when it is desired to suppress the increase of emulsion particles under the hydrogenation reaction condition and make the emulsion particle size after the hydrogenation reaction substantially the same as that before the hydrogenation reaction,
The amount of the organic solvent used is an aqueous emulsion / organic solvent volume ratio in the range of 1/1 to 1/0. If it exceeds this range, the emulsion particles are coalesced or destroyed during the hydrogenation reaction, and it is not possible to obtain a nitrile group-containing hydrogenated polymer aqueous emulsion in which the average particle diameter of the emulsion does not substantially change before and after the hydrogenation reaction.

The lower limit of the amount of the organic solvent added is not particularly limited, but in order to carry out the hydrogenation reaction uniformly and efficiently, the volume ratio of polymer latex / organic solvent is preferably 1/1 to 1/1 /.
It is desirable to add it in a ratio of 0.05.
The timing of adding the organic solvent is not particularly limited, and the organic solvent may be added before, after, or simultaneously with the addition of the hydrogenation catalyst. When the hydrogenation catalyst is dissolved in an organic solvent, it is preferable to add it as a solution of the hydrogenation catalyst in an organic solvent to the polymer latex in terms of efficiency and operation of the hydrogenation reaction.

The hydrogenation catalyst used is not particularly limited as long as it is a palladium compound. Specific examples of the palladium compound include, for example, palladium salts of carboxylic acids such as formic acid, acetic acid, propionic acid, lauric acid, succinic acid, stearic acid, oleic acid, phthalic acid and benzoic acid; palladium chloride, dichloro (cyclooctadiene). ) Palladium, chlorinated palladium such as dichloro (norbornadiene) palladium, dichloro (benzonitrile) palladium, dichlorobis (triphenylphosphine) palladium, ammonium tetrachloropalladium (II) acid, ammonium hexachloropalladium (IV) acid; palladium bromide Examples thereof include, but are not limited to, inorganic compounds and complex salts such as palladium iodide, palladium sulfate dihydrate, potassium tetracyanopalladium (II) trihydrate, and the like. Among them,
Particularly preferred are palladium salts of carboxylic acids, dichloro (norbornadiene) palladium, ammonium hexachloropalladate and the like. The amount of the catalyst used may be appropriately determined depending on the kind of the copolymer to be hydrogenated and the desired hydrogenation rate, but usually 5 to 10,000 p per copolymer.
pm, preferably 10 to 6,000 ppm. 1
Although it may be used in an amount of 10,000 ppm or more, it is not economical.

The hydrogenation reaction temperature is 0 to 300 ° C, preferably 20 to 150 ° C. Although there is no problem even if it exceeds 150 ° C., side reactions easily occur, which is not desirable in the selective hydrogenation reaction of carbon-carbon double bonds. The side reaction includes, for example, hydrogenation of an organic solvent and hydrogenation of an ethylenically unsaturated monomer unit in a copolymer, for example, a nitrile group of acrylonitrile.

Gaseous hydrogen or dissolved hydrogen is used as the hydrogen source and is brought into contact with the nitrile group-containing unsaturated copolymer. The hydrogen pressure is in the range of atmospheric pressure to 300 kg / cm ² , preferably 5 to 200 kg / cm ² . 300 kg /
A high pressure of ² cm ² or more may be used, but the factors that impede its practical use, such as increased equipment costs and troublesome handling, increase. Usually, it is used in the range of several atmospheres to several tens of atmospheres.

After the completion of the hydrogenation reaction, a reaction system ion-exchange resin or the like is added to adsorb the catalyst, and then the catalyst can be removed by a usual catalyst removal method such as a centrifugal separation method or a filtration method. Further, the catalyst may be left as it is in the nitrile group-containing hydrogenated copolymer without being removed. In order to obtain an aqueous emulsion of a nitrile group-containing highly saturated copolymer rubber, the solvent added during the hydrogenation reaction may be removed by a known method such as an ordinary steam stripping method.

The aqueous emulsion of the hydrogenated copolymer thus obtained is optionally concentrated. Concentration is carried out by a conventional method such as a rotary evaporator and a high speed centrifuge so that the total solid content concentration is preferably in the range of 10 to 70% by weight. Aqueous emulsion of hydrogenated copolymer or reaction liquid whose emulsion state has been destroyed,
After direct contact with water vapor or by adding a poor solvent to precipitate the hydrogenated copolymer, it is subjected to a drying process such as hot air drying, reduced pressure drying, or extrusion drying to obtain a solid saturated nitrile group-containing copolymer. It can be collected as a united rubber.

According to such a method, the nitrile group-containing unsaturated polymer can be hydrogenated in the emulsion state. Therefore, after the nitrile group-containing unsaturated polymer is taken out from the polymerization system in a solid state, it is dissolved in an organic solvent. Then, the process can be greatly simplified as compared with the conventional method in which the hydrogenation reaction is carried out in a solution state.

By adding a sulfur-based vulcanizing agent to the nitrile group-containing highly saturated copolymer rubber of the present invention, it is possible to obtain a vulcanizable rubber composition having excellent rapid vulcanizability. As the sulfur-based vulcanizing agent to be used, sulfur such as powdered sulfur, sulfur flower, precipitated sulfur, colloidal sulfur, surface-treated sulfur and insoluble sulfur; sulfur chloride, sulfur dichloride, morpholine disulfide, alkylphenol disulfide, N, N ′ -Dithio-bis (hexahydro-2H-azepinone-2),
Sulfur compounds such as phosphorus-containing polysulfides and polymeric polysulfides; and vulcanization accelerators containing sulfur such as tetramethylthiuram disulfide, selenium dimethyldithiocarbamate, and 2- (4'-morpholinodithio) benzothiazole be able to.

Furthermore, in addition to these sulfur-based vulcanizing agents,
Vulcanization accelerators such as zinc white and stearic acid; guanidine-based, aldehyde-amine-based, aldehyde-ammonia-based, thiazole-based, sulfenamide-based, thiourea-based,
Other vulcanization accelerators such as the xanthate type can be used. The amount of the sulfur-based vulcanization accelerator used is not particularly limited, but is usually 0.10 to 10 parts by weight, preferably 0.1 to 10 parts by weight, per 100 parts by weight of the nitrile group-containing highly saturated copolymer rubber.
5 parts by weight.

If the rubber composition does not contain a sulfur-based vulcanizing agent as a vulcanizing agent, good high-speed vulcanizability cannot be achieved in high-temperature short-time vulcanization. However, for example, a vulcanizing agent other than the sulfur-based vulcanizing agent such as an organic peroxide-based vulcanizing agent can be appropriately used in combination with the sulfur-based vulcanizing agent.

Examples of the organic peroxide-based vulcanizing agent used in combination include t-butyl hydroperoxide, cumene hydroperoxide, di-t-butyl peroxide and t-butyl hydroperoxide.
Butylcumyl peroxide, 2,5-dimethyl-t-butylperoxyhexane, 2,5-dimethyl-t-butylperoxyhexyne, 1,3-bis (t-butylperoxyisopropyl) benzene, p-chlorobenzoyl peroxide, t-butyl peroxybenzoate, t
-Butyl peroxyisopropyl carbonate, t-butyl benzoate and the like. Other vulcanizing agents that can be used in combination include polyfunctional compounds such as trimethylolpropane trimethacrylate, divinylbenzene, ethylene dimethacrylate and triallyl isocyanurate. Furthermore, metallic soap / sulfur type, triazine / dithiocarbamate type, polycarboxylic acid / onium salt type, polyamine type (hexamethylenediamine, triethylenetetramine, hexamethylenediaminecarbamate, ethylenediaminecarbamate, triethylenediamine, etc.), ammonium benzoate A vulcanizing agent such as a salt-based agent can also be used in combination if necessary.

In the vulcanizable rubber composition of the present invention, if necessary, other conventional compounding agents used in the rubber field, such as a reinforcing agent (various carbon black, silica, talc, etc.), Fillers (calcium carbonate, clay, etc.), processing aids, process oils (plasticizers), antioxidants, antiozonants and the like can be added.

In particular, when the nitrile group-containing highly saturated copolymer rubber of the present invention is obtained by copolymerizing an ethylenically unsaturated carboxylic acid monomer such as acrylic acid, it can be selected from Group II of the periodic table. By compounding the metal oxide, a rubber material having excellent dynamic fatigue resistance can be obtained.

Examples of the ethylenically unsaturated carboxylic acid used for producing such a copolymer include acrylic acid, methacrylic acid, itaconic acid, fumaric acid, maleic acid and monoesters of these dicarboxylic acids. From the viewpoint of strength and dynamic fatigue resistance, the content of the ethylenically unsaturated carboxylic acid monomer unit is in the range of 0.1 to 15% by weight, and if it is less than 0.1% by weight, the strength and dynamic fatigue resistance are improved. However, if it exceeds 15% by weight, the water resistance is lowered.
It is preferably 0.5 to 10% by weight.

As oxides of metals of Group II of the periodic table,
Examples thereof include magnesium oxide, zinc oxide, calcium oxide and strontium oxide. Particularly preferred metal oxides are zinc oxide and magnesium oxide. The amount of the metal oxide used is usually per 100 parts by weight of the rubber (the same applies below)
It is 0.5 to 30 parts by weight.

In the vulcanizable rubber composition of the present invention, if necessary, acrylic rubber, fluororubber, styrene-butadiene copolymer rubber, ethylene-propylene-diene terpolymer rubber (EPDM), natural rubber. Other rubbers such as rubber and polyisoprene rubber can be used in combination with the unsaturated nitrile-conjugated diene copolymer. The method for producing the rubber composition of the present invention is not particularly limited, but usually, the rubber is obtained by kneading and mixing the raw material rubber and the vulcanizing system, and other compounding ingredients by a usual mixer such as a roll or a Banbury mixer. The composition is manufactured.

The vulcanizable rubber composition containing the nitrile group-containing highly saturated copolymer rubber of the present invention as a raw material rubber component may be used as it is, or may be a polyester woven fabric, a nylon woven fabric, cord-shaped glass fibers, aramid fibers, After being compounded with carbon fiber, steel fiber, etc., it undergoes a vulcanization process to obtain the desired rubber product.

[0066]

EXAMPLES The present invention will be described in more detail with reference to the following examples. The parts and% in Examples, Comparative Examples and Reference Examples are based on weight unless otherwise specified. The properties of the rubber composition and the raw material components were measured as follows. (1) High-speed vulcanization evaluation test Scorch at 160 ° C. by an oscillating disc rheometer using about 10 g of an unvulcanized rubber composition prepared according to the compounding recipe of Table 1 according to Japan Rubber Association Standard SRIS 3102. Time (T ₅ ) (Unit:
Min) and maximum torque (V _max ) (unit: kgf · cm) were measured. The smaller the value of T _5, the faster the vulcanization rate. Further, the larger the value of V _max, the higher the crosslinking efficiency.

(2) Vulcanization physical property evaluation test According to Japanese Industrial Standard JIS K6301, an unvulcanized rubber composition prepared according to the formulation of Table 1 was vulcanized at 160 ° C. for 20 minutes to obtain a thickness. A 2 mm sheet is punched out using a No. 3 dumbbell to make a test piece, and tensile strength (unit: kgf / cm ² ) and 100% tensile stress (unit: kgf / cm ² )
And elongation (unit:%) were measured. Also, the hardness is JI
It measured using the S spring type A hardness tester. Furthermore, the compression set is 22 at 120 ° C according to JIS K6301.
It was measured after holding for a time (unit:%).

Regarding the oil resistance test, the rubber test piece was immersed in lubricating oil No. 3 (kinematic viscosity 31.9 to 34.1, aniline point 69.5 ± 1 ° C, flash point 162.7 ° C) according to JIS K6301. Then, the volume change rate (unit:%) was measured (120 ° C., 72 hours). For cold resistance test, JIS K630
According to 1, it was evaluated by the Gehman torsion test. The temperature (T ₁₀ ) when the twist angle was 10 times the twist angle at low temperature (23 ° C.) was shown (unit: ° C.). The lower the temperature, the better the cold resistance. Ozone resistance (weather resistance)
According to JIS K6301, ozone concentration 80pphm, temperature 40
After static 20% elongation at 0 ° C., it was left for 12, 24, 48 and 72 hours, and then the state of crack initiation was observed.

Regarding the heat aging test, according to JIS K6301,
After holding at 120 ° C. for 72 hours, the rate of change in tensile strength, elongation and hardness (unit: ±%) was measured. Regarding the fatigue test, a constant stress extensional fatigue tester with a constant temperature bath manufactured by Kamijima Seisakusho was used, and JIS 3 was used at room temperature and 100 ° C.
No. dumbbell test pieces were repeatedly stretched at 0 to 50 kgf / cm ² at 400 times / minute, and the number of times of repeated stretching until cutting was determined (average value of 10 samples).

[0070]

[Table 1]

(3) Amount of bound nitrile According to Japanese Industrial Standard JIS K6384, the nitrogen content in the copolymer was measured by the Kjeldahl method, and the amount of bound nitrile was calculated (unit:%). (4) Mooney viscosity According to Japanese Industrial Standard JIS K6383, about 40 grams of the copolymer was used and measured at 100 ° C.

(5) Number average molecular weight Mn 35,000 or less of the amount of components By gel permeation (solvent: tetrahydrofuran), the number average molecular weight (Mn) converted to standard polystyrene of the unsaturated nitrile-conjugated diene copolymer before hydrogenation. ) And the weight average molecular weight (Mw) were measured, and the weight% of the component was obtained using the measured area of the entire molecular weight distribution and the area of the component having a number average molecular weight Mn of 35,000 or less.

(6) Composition Distribution Width of Unsaturated Nitrile of Copolymer Before Hydrogenation (ΔAN) The composition distribution width of unsaturated nitrile is determined by a high performance liquid chromatography method, and its outline is summarized in Rubber Chemistry and・ Technology (Rubber Chemistryand Tech
nology) 63 , (2), P181-191 (199)
0). That is, the unsaturated nitrile-conjugated diene copolymer was measured by high performance liquid chromatography under the following measurement conditions, and the half width of the chromatogram was Δ.
It is AN. When determining ΔAN, a calibration curve of elution amount-unsaturated nitrile amount is prepared using a sample with a known unsaturated nitrile amount.

1. Column gel: (2-chloroacrylonitrile / ethylene dimethacrylate) crosslinked polymer gel Particle size: 2 to 6 μm Column: Stainless steel column Column diameter x length: 0.46 cm x 25 cm 2. Eluent chloroform / n-hexane (weight ratio) 30/70 → 1
00/0 (gradient elution in 30 minutes). However, 20 with initial setting chloroform / n-hexane = 30/70
Run for minutes. 3. Flow rate 0.5 ml / min 4. Sample concentration 1% by weight chloroform solution 5. Injection volume 10 to 20 μl 6. Detector Light Scattering Mass Detector (Mass Detecto
r: Model 750 / I4 ACS Co.) 7. Equipment Trirotor VI type (made by JASCO Corporation)

(7) Concentration of 1,1-di (2,2-dimethylpropyl) -1-ethylthio group in the copolymer before hydrogenation The copolymer is dissolved in benzene and then solidified in methyl alcohol. The procedure was repeated 3 times for purification, and NMR measurement was performed on the purified copolymer. ¹ H-NMR measurement (4
00 MHz), a peak due to the proton of the terminal methyl group in the ethylthio group was detected at around 1.05 ppm, and further due to ¹³ C-NMR measurement (100 MHz), due to the carbon of the methylene group in the ethylthio group. Peak is detected around 54.6 ppm.

The concentration of the ethylthio group in the copolymer before hydrogenation was quantified by the integrated value of the peak due to the terminal methyl group in ¹ H-NMR measurement and the butadiene detected in the vicinity of 4.8 to 5.8 ppm. Was calculated by using the ratio with the integral value of the peak due to the proton bound to the unsaturated bond (unit: mol%).

(8) Evaluation of Mold Contamination Property The surface of the metal plate having a thickness of 2 mm, which is prepared by filling the unvulcanized rubber composition prepared according to the formulation of Table 1 in a hole having a diameter of 12 mm, was cleanly cleaned. A sheet of 1 mm metal plate (JIS G3141 mild steel plate) is sandwiched and vulcanized under the conditions of 220 ° C., 20 kg / cm ² , and 2 minutes. Then, the vulcanized rubber pieces are removed, the unvulcanized rubber composition is filled again, and the same operation is performed. After repeating this operation 50 times, the contamination of the surfaces of the upper and lower mild steel plates was evaluated. The evaluation is 1 if the surface of the mild steel plate is not contaminated.
The case where the entire surface was significantly contaminated was designated as 5, and the degree of contamination was expressed in 5 levels.

(9) Evaluation of workability In accordance with ASTM D-2230-77, the unvulcanized rubber composition was extruded using a Garve die to obtain the die swell (%) and the extrusion amount (g / min), and The shape or state was evaluated with respect to the degree of expansion / porosity and the states of edges, surfaces and corners, and displayed in 5 grades (5 is the best and 1 is the worst).

(10) Metal Corrosive Metal Motor SAE1 by General Motor (GM) method
020 was tested for corrosivity. The details of the test method are as follows. A test piece (2 mm x 5 cm x 5 cm) was prepared from a sheet having a thickness of 2 mm obtained by vulcanizing the unvulcanized rubber composition prepared by the formulation of Table 1 by a conventional method,
The test piece is inserted into two metal plates (SAE1020, 400 mesh polished), and a constant load is applied from above to leave it in a constant temperature and humidity chamber at 50 ° C. for 96 hours. After standing, the sample was taken out and the degree of corrosion on the surface of the metal plate was evaluated on the basis of 6 levels (0
To 5). 5 if the entire surface is corroded
And, the case where no corrosion was observed on the surface was set to 0.

Examples 1 to 5 2 parts of potassium oleate as an emulsifier and 0.1 part of potassium phosphate as a stabilizer were placed in a reactor having an internal volume of 10 liters.
And 150 parts of water were charged, and butadiene and acrylonitrile in the amounts shown in Table 2 and 2,2 ′, 4,6,6′-pentamethylheptane-4-thiol (hereinafter referred to as PMHT) as a molecular weight modifier. ) Was added, and emulsion polymerization was initiated at 10 ° C. in the presence of 0.015 part of ferrous sulfate as an activator and 0.05 part of paramenthane hydroperoxide as a polymerization initiator. Acrylonitrile (production of copolymers I to IV), butadiene (production of copolymer V) and PMHT (production of copolymers I to V) were carried out under the conditions shown in Table 2 when the predetermined polymerization addition rate was reached. Each was added in portions. When the predetermined polymerization addition rate is reached,
Polymerization was terminated by adding 0.2 part of hydroxylamine sulfate per 100 parts of the monomer. Subsequently, after heating and recovering the residual monomer by steam distillation under reduced pressure at about 70 ° C., 2 parts of alkylated phenol as an antioxidant was added to obtain a copolymer latex.

An alkylphenol-formalin condensate oxyethylene-oxypropylene adduct (Ramtel MP-
5150) 0.25 parts was added. Then, the above-mentioned copolymer latex was dropped into a 5 liter coagulation tank with a stirrer containing a coagulation water bath in which 3 parts of aluminum sulfate was dissolved as a coagulant, and the coagulation bath was kept at 50 ° C. to coagulate the polymer. The generated crumb was taken out, washed with water and dried under reduced pressure at 50 ° C. to obtain copolymers I to V.

Next, each copolymer was dissolved in methyl isobutyl ketone and hydrogenated in a pressure resistant vessel using a (Pd / silica) catalyst to prepare a nitrile group-containing highly saturated copolymer rubber. Table 2 shows the measurement results of polymerization conditions, the amount of bound butadiene and the amount of bound nitrile in each copolymer, the concentration of alkylthio groups, the Mooney viscosity of the hydrogenated copolymer and other properties. Next, each of the copolymers was kneaded with a Banbury mixer according to the formulation shown in Table 1 to obtain a rubber composition, which was then press-vulcanized at 160 ° C. for 20 minutes, and the physical properties of the vulcanizate obtained were evaluated. did. The results are shown in Table 3.

Comparative Examples 1 to 3 The molecular weight modifier was changed to commercially available t-dodecyl mercaptan (manufactured by Phillips Petroleum Co., Ltd.), and acrylonitrile, butadiene and PMHT were not added separately, and otherwise the same as in Example 2. Under the conditions, butadiene and acrylonitrile were copolymerized to obtain copolymers VI to VIII. Then, it was hydrogenated to obtain a nitrile group-containing highly saturated copolymer rubber. The polymerization results are shown in Table 2. Next, as in Example 1, the results of evaluating the physical properties of the vulcanizate of the highly saturated copolymer rubber are shown in Table 3.
Shown in.

[0084]

[Table 2]

[0085]

[Table 3]

The H-NMR measurement chart of the copolymer I obtained in Example 1 before hydrogenation is shown in FIG.
The ¹³ C-NMR measurement chart is shown in FIG. In addition, H of the highly saturated copolymer rubber obtained by hydrogenating the copolymer I
-The NMR measurement chart is shown in FIG. In addition, N of the acrylonitrile-butadiene copolymer obtained in other examples
The presence of 1,1-di (2,2-dimethylpropyl) -1-ethylthio group was confirmed by MR measurement.

From Table 3, the vulcanizable rubber compositions (Examples 1 to 5) in which the nitrile group-containing highly saturated copolymer rubber of the present invention and the sulfur-based vulcanizing agent are blended are oscillating disc rheometers. The scorch time (T ₅ ) measured at
Further, the maximum torque (V _max ) shows a high value, and it is understood that the high speed vulcanization is excellent. As a result, it can be seen that 100% tensile stress, tensile strength and hardness in the vulcanized physical properties are at a high level, the compression set is small, and vulcanization with high crosslinking efficiency is performed. Furthermore, since the nitrile group-containing highly saturated copolymer rubber is substantially halogen-free, it does not cause a metal corrosion problem. It is also excellent in mold contamination. The result of the heat aging test is also good,
It can be seen that the rubber material has excellent heat resistance.

In Examples 1 to 5, since acrylonitrile or butadiene was dividedly added during the copolymerization (copolymers I to V), other copolymers VI to VIII having the same amount of bound acrylonitrile were used. Compared with the cases (Comparative Examples 1 to 3), ΔAN is low, T ₁₀ according to the Gehman torsion test is low, and the volume change rate is low, so that oil resistance and cold resistance are maintained while maintaining a high level of mechanical strength. It can be seen that is good and well balanced. Further, in Examples 1 to 5, since the molecular weight modifier PMHT was added in a time-divided manner during polymerization, the processability evaluation results by the Garb die were also good, and the copolymers had excellent mechanical strength and processability. I understand.

On the other hand, those obtained by emulsion polymerization using t-dodecyl mercaptan (commercially available product), which has heretofore been known as a general-purpose molecular weight regulator in radical polymerization (Comparative Examples 1 to 3), are sufficient. High-speed vulcanizability cannot be obtained, mechanical strength is low, and impact resilience is also low. Mold contamination is also poor. Further, NMR measurement was performed on the copolymer obtained by using commercially available t-dodecyl mercaptan.
The presence of 1-di (2,2-dimethylpropyl) -1-ethylthio group was not confirmed.

Examples 6 to 11 The butadiene-acrylonitrile-unsaturated carboxylic acid ester copolymer rubbers shown in Table 4 were prepared by polymerizing in the same manner as in Example 1, each of which was dissolved in methyl isobutyl ketone. The butadiene portion in each copolymer rubber was partially hydrogenated using a palladium / silica catalyst to obtain highly saturated copolymer rubbers A to F. A rubber composition was prepared from the obtained highly saturated copolymer rubber in the same manner as in Example 1, and after vulcanization,
The vulcanized physical properties were measured.

The cold resistance test of the vulcanized product was evaluated by the TR test, and according to ASTM D-1329. In the heat aging test, the vulcanized physical properties after 150 ° C. × 72 hours were measured according to JIS K6301. The results are shown in Table 5. From the results in Table 5, it can be seen that copolymerizing the unsaturated carboxylic acid ester improves cold resistance without impairing heat resistance.

[0092]

[Table 4]

[0093]

[Table 5]

Examples 12 to 14 and Comparative Example 4 The butadiene-acrylonitrile-acrylic acid copolymer rubbers shown in Table 4 were hydrogenated in the same manner as in Example 1 to obtain highly saturated copolymer rubbers G to I. Further, the vulcanized physical properties of these copolymer rubbers and the copolymer rubber VI obtained in Comparative Example 1 were evaluated. The composition was in accordance with Table 6. The results are shown in Table 7. From the results in Table 7, it can be seen that the dynamic fatigue resistance of the vulcanizable composition of the present invention is improved.

[0095]

[Table 6]

[0096]

[Table 7]

[0097]

As described above, according to the present invention, a nitrile group which has excellent mechanical strength, exhibits excellent high-speed vulcanization particularly in vulcanization at high temperature for a short time, and has improved the problem of mold contamination. A highly saturated copolymer rubber containing is provided. Since this highly saturated copolymer rubber has excellent high-speed vulcanizability, it is particularly suitable for injection molding applications, and it is possible to improve productivity and save labor in molding rubber products.

Further, the vulcanized rubber of the hydride of the unsaturated nitrile-conjugated diene copolymer obtained by adding the monomers in portions during the polymerization has a composition distribution width ΔA of the unsaturated nitrile.
N is small and has good and well-balanced cold resistance and oil resistance. Further, unsaturated nitrile obtained by adding PMHT (molecular weight adjusting agent) in portions during polymerization
The hydride of the conjugated diene copolymer contains a relatively large amount of low molecular weight components having a number average molecular weight Mn of 35,000 or less,
Excellent workability. Further, when a coagulant containing no halogen such as metal sulfate is used in coagulating the copolymer latex, the highly saturated copolymer rubber does not substantially contain halogen, which does not cause the problem of metal corrosion. .

The vulcanizable rubber composition containing the nitrile group-containing highly saturated copolymer rubber of the present invention as a raw material rubber component has excellent high-speed vulcanizability, and the vulcanized product has excellent mechanical strength. Since it has good oil resistance and heat resistance, it is suitable as various sealing materials such as O-rings, gaskets, oil seals, freon seals, and belts such as V belts for automobiles, poly rib belts, toothed conduction belts, etc.・ Power steering hoses for automobiles, high pressure oil resistant hoses such as hydraulic hoses for various machines such as construction machinery, hoses such as fuel hoses for automobiles; Rolls; Rubber products used in oil wells and gas wells [packers, blowout preventers] (BO
P), pipe protectors, etc.]; various diaphragms;
Various types of anti-vibration rubber, electric products, automobile parts, including automobile clutch plates and brake shoes (these are blended with other compounding agents with thermosetting resins such as phenolic resins or epoxy resins) It can be used for a wide range of products such as industrial products, footwear and so on.

During the preparation of the unsaturated nitrile-conjugated diene copolymer, the ethylenically unsaturated carboxylic acid monomer was copolymerized, and during preparation of the vulcanizable rubber composition, the periodic table II was used.
The vulcanizate obtained from a compound of a Group III metal oxide is excellent in dynamic fatigue resistance, so among the above-mentioned various uses,
It is particularly useful for applications that undergo repeated deformation.

The nitrile group-containing highly saturated copolymer rubber of the present invention can be used in the form of an aqueous emulsion. That is, since the emulsion has extremely strong unvulcanized film strength and vulcanized film strength and excellent oil resistance and heat resistance, it is used for fiber treatment of nonwoven fabric binders, paper treatment of impregnated paper, and oil resistance. Special dipping products and foam rubber, thread rubber, binders such as cork, etc., and the aqueous emulsion is mixed with resorcin-formalin resin and nitrile group-containing polymer rubber and synthetic fiber such as polyamide and polyester, glass fiber It is also effective as an adhesive for vulcanization adhesion to the like.

Preferred specific embodiments of the nitrile group-containing highly saturated copolymer rubber of the present invention, the method for producing the same, and the vulcanizable rubber composition described in claims 1, 2 and 3 are as follows. is there.

(Claim 1) A nitrile group-containing highly saturated copolymer rubber obtained by hydrogenating a conjugated diene portion of an unsaturated nitrile-conjugated diene copolymer, comprising at least three tertiary carbon atoms and the same. Having 12 to 1 carbon atoms having a sulfur atom directly bonded to at least one tertiary carbon atom therein
It has 6 alkylthio groups in the molecule and has a Mooney viscosity of 1
A nitrile group-containing highly saturated copolymer rubber having an iodine value of 5 to 200 and an iodine value of 80 or less.

(1) The nitrile group according to claim 1, which has the alkylthio group in the molecule in a proportion of 0.03 mol or more, more preferably 0.07 mol or more, per 100 mol of the monomer units constituting the molecule. Containing highly saturated copolymer rubber. (2) The alkylthio group is a 1,1-di (2,2-dimethylpropyl) -1-ethylthio group and 1- (2,2-
The nitrile group-containing highly saturated copolymer rubber according to claim 1, which is at least one selected from dimethylpropyl) -1- (2,2,4,4-tetramethylpentyl) -1-ethylthio group.

(3) The nitrile group-containing highly saturated copolymer rubber according to claim 1, wherein the alkylthio group is a 1,1-di (2,2-dimethylpropyl) -1-ethylthio group. (4) The nitrile group-containing highly saturated copolymer rubber according to claim 1, wherein the amount of bound unsaturated nitrile is 10 to 60% by weight. (5) The nitrile group-containing highly saturated copolymer rubber according to claim 1, which is a hydride of a copolymer of 10 to 60% by weight of acrylonitrile and 90 to 40% by weight of butadiene and has a Mooney viscosity of 20 to 90.

(6) The number average molecular weight (Mn) is 35,000.
The nitrile group-containing highly saturated copolymer rubber according to claim 1, which contains 3 to 20% by weight of a low molecular weight component of 0 or less. (7) Weight average molecular weight (Mw) and number average molecular weight (Mn)
The ratio (Mw / Mn) with is 2.3 to 5.5.
The highly saturated copolymer rubber containing the nitrile group described.

(8) Composition distribution width of unsaturated nitrile (ΔA
The nitrile group-containing highly saturated copolymer rubber according to claim 1, wherein N) is 35 or less, more preferably 3 to 20. (9) The nitrile group-containing highly saturated copolymer rubber according to claim 1, which contains substantially no halogen atom.

(10) The unsaturated nitrile-conjugated diene copolymer is, in addition to the unsaturated nitrile and the conjugated diene, 1 to 80% by weight of unsaturated carboxylic acid ester or unsaturated carboxylic acid based on all monomers. The nitrile group-containing highly saturated copolymer rubber according to claim 1, which is a copolymer of an ester and a fluorine-containing vinyl monomer.

(Claim 2) (a) As a molecular weight modifier,
Using an alkylthiol compound having 12 to 16 carbon atoms having at least three tertiary carbon atoms and a sulfur atom directly bonded to at least one tertiary carbon atom in the presence of a radical initiator. A process for producing a nitrile group-containing highly saturated copolymer rubber, which comprises copolymerizing an unsaturated nitrile and a conjugated diene and hydrogenating the obtained unsaturated nitrile-conjugated diene copolymer.

(11) The alkylthiol compound is 2,
A compound selected from 2 ', 4,6,6'-pentamethylheptane-4-thiol and 2,2', 4,6,6 ', 8,8'-peptamethylnonane-4-thiol. Two
The manufacturing method described. (12) The method according to claim 2, wherein a carboxylic oxygen emulsifier is used as the emulsifier. (13) Polymerization is started in the presence of 30 to 80% by weight of all monomers, and the remaining amount of the monomers is added to the polymerization system when the polymerization conversion rate reaches 20 to 70%. 2. The manufacturing method according to 2.

(14) 10 to 95% of the total amount of the alkyl thiol compound used is contained in the monomer mixture before polymerization, and the alkyl thiol compound is added when the polymerization conversion rate reaches 20 to 70%. The manufacturing method according to claim 2, wherein the remaining amount of the above is added to the polymerization system. (15) Copolymerizing unsaturated nitrile and conjugated diene by emulsion polymerization to prepare a copolymer latex, adding a nonionic surfactant to the latex, and then adding the copolymer latex to a metal salt. The production method according to claim 2, wherein the unsaturated nitrile-conjugated diene copolymer obtained is placed in a dissolved substantially halogen-free coagulation bath, heated to coagulate, and hydrogenated.

(16) The nonionic surfactant is 10 ° C to 1 ° C.
The production method according to (15) above, which is an alkylene oxide adduct of an alkylphenol formalin condensate having a cloud point of 00 ° C. (17) The alkylene oxide adduct is oxyethylene-
The production method according to (16) above, which is an oxypropylene co-adduct.

(18) The production method according to the above (15), wherein the metal salt is at least one selected from aluminum sulfate, magnesium sulfate and aluminum sulfate. (19) Nitrile group-containing highly saturated copolymer rubber solution in a water-emulsion state by a phase inversion method or by directly hydrogenating an unsaturated nitrile-conjugated diene copolymer latex The manufacturing method according to claim 2, wherein rubber is manufactured.

(Claim 3) The nitrile group-containing highly saturated copolymer rubber according to claim 1, and 0.01 to 10 parts by weight of a sulfur-based vulcanizing agent per 100 parts by weight of the copolymer rubber. Vulcanizable rubber composition. (20) A nitrile group-containing highly saturated copolymer rubber is a hydride of a copolymer obtained by copolymerizing an unsaturated nitrile and a conjugated diene with an ethylenically unsaturated carboxylic acid monomer, The rubber composition according to claim 3, further comprising an oxide of a metal of Group II of the Periodic Table in the composition. (21) The rubber composition according to claim 3, which is for injection molding. (22) The rubber composition according to claim 3, which is for O-rings.

[Brief description of drawings]

FIG. 1 is a ¹ H-NMR measurement chart of unsaturated nitrile-conjugated diene copolymer I obtained in Example 1.

FIG. 2 is a ¹³ H-NMR measurement chart of the unsaturated nitrile-conjugated diene copolymer I obtained in Example 1.

FIG. 3 is an H-NMR measurement chart of a highly saturated nitrile group-containing copolymer rubber of the present invention obtained by hydrogenating the unsaturated nitrile-conjugated diene copolymer I.

Continuation of front page (51) Int.Cl. ⁷ identification code FI C08K 5/36 C08K 5/36 C08L 9/02 C08L 9/02 (56) Reference JP-A-8-73538 (JP, A) JP-A 8-67706 (JP, A) JP 7-53610 (JP, A) JP 7-53609 (JP, A) JP 6-287206 (JP, A) JP 8-100030 (JP, A) JP-A-7-118313 (JP, A) International Publication 94/22924 (WO, A1) (58) Fields investigated (Int. Cl. ⁷ , DB name) C08F 8 / 00-8 / 50

Claims (3)

(57) [Claims] 1. A nitrile group-containing highly saturated copolymer rubber obtained by hydrogenating a conjugated diene portion of an unsaturated nitrile-conjugated diene copolymer, comprising at least three tertiary carbon atoms and at least three of them. It has an alkylthio group having 12 to 16 carbon atoms having a sulfur atom directly bonded to one tertiary carbon atom in the molecule, and has a Mooney viscosity of 15 to 200.
And a nitrile group-containing highly saturated copolymer rubber having an iodine value of 80 or less. 2. A molecular weight modifier having 12 to 12 carbon atoms having at least three tertiary carbon atoms and a sulfur atom directly bonded to at least one tertiary carbon atom therein.
16 is used to copolymerize an unsaturated nitrile and a conjugated diene in the presence of a radical initiator, and hydrogenate the resulting unsaturated nitrile-conjugated diene copolymer. A method for producing a nitrile group-containing highly saturated copolymer rubber. 3. A vulcanizate comprising the nitrile group-containing highly saturated copolymer rubber according to claim 1 and 0.01 to 10 parts by weight of a sulfur-based vulcanizing agent per 100 parts by weight of the copolymer rubber. Rubber composition.