JP7034536B2 - 高吸水性樹脂の製造方法 - Google Patents
高吸水性樹脂の製造方法 Download PDFInfo
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Description
本出願は、2018年12月10日付の韓国特許出願第10-2018-0158524号および2019年12月19日付の韓国特許出願第10-2019-0163106号に基づく優先権の利益を主張し、当該韓国特許出願の文献に開示された全ての内容は本明細書の一部として含まれる。
(メタ)アクリル酸を含む水溶性エチレン系不飽和単量体を水酸化カリウムを含む塩基性物質、カプセル化された発泡剤、内部架橋剤および重合開始剤と混合して単量体組成物を製造する段階であって、前記水酸化カリウムを含む塩基性物質によって前記水溶性エチレン系不飽和単量体の酸性基のうちの少なくとも一部が中和する段階と;
前記単量体組成物を熱重合または光重合して含水ゲル状重合体を形成する段階と;
前記含水ゲル状重合体を乾燥および粉砕して粉末形態のベース樹脂を形成する段階と;
表面架橋剤の存在下で前記ベース樹脂の表面を追加架橋して表面架橋層を形成する段階と、を含み、
前記カプセル化された発泡剤は、炭化水素を含むコアおよび前記コアを囲み熱可塑性樹脂で形成されるシェルを含む構造を有し、膨張前の平均直径が5~30μmであり、空気中での最大膨張比が5~15倍である。
R1-COOM1
R1は、不飽和結合を含む炭素数2~5のアルキル基であり、
M1は、水素原子、1価または2価金属、アンモニウム基または有機アミン塩である。
カプセル化された発泡剤の用意
実施例で使用されるカプセル化された発泡剤として、コアはiso-ブタンであり、シェルはアクリレートおよびアクリロニトリルの共重合体からなる、Matsumoto社で製造したF-36Dを用意した。このとき、F-36Dの発泡開始温度(Tstart)は70℃~80℃であり、最大発泡温度(Tmax)は110℃~120℃である。
ガラス反応器にアクリル酸100g(1.388mol)を、45%の水酸化カリウム(KOH)溶液121.2g(KOH 0.972mol)、前記用意されたカプセル化された発泡剤F-36D 0.33g、内部架橋剤としてエチレングリコールジグリシジルエーテル0.18g、熱重合開始剤として過硫酸ナトリウム0.13g、光重合開始剤として(ジフェニル(2,4,6-トリメチルベンゾイル)ホスフィンオキシド)0.008gおよび水85.0gと混合して、全体固形分濃度が44.9重量%の単量体組成物を製造した。製造された単量体組成物で前記アクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例1で45%の水酸化カリウム(KOH)溶液121.2gの代わりに、45%の水酸化カリウム(KOH)溶液97.0g(KOH 0.778mol)および31.5%の水酸化ナトリウム(NaOH)溶液24.7g(NaOH 0.195mol)の混合物を使用したことを除いては、実施例1と同様の方法で、高吸水性樹脂を製造した。このとき、実施例2で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例1で45%の水酸化カリウム(KOH)溶液121.2gの代わりに、45%の水酸化カリウム(KOH)溶液60.6g(KOH 0.486mol)および31.5%の水酸化ナトリウム(NaOH)溶液61.7g(NaOH 0.486mol)の混合物を使用したことを除いては、実施例1と同様の方法で、高吸水性樹脂を製造した。このとき、実施例3で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でカプセル化された発泡剤F-36Dの代わりにF-65(MATSUMOTO社製)を使用したことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、実施例4で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でF-36D 0.4gを使用したことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、実施例5で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例1で45%の水酸化カリウム(KOH)溶液121.2gの代わりに、31.5%の水酸化ナトリウム(NaOH)溶液123.5g(NaOH 0.972mol)を使用したことを除いては、実施例1と同様の方法で、高吸水性樹脂を製造した。このとき、比較例1で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でカプセル化された発泡剤F-36Dを使用しないことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、比較例2で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でカプセル化された発泡剤F-36Dの代わりに重炭酸ナトリウム(NaHCO3)発泡剤を使用したことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、比較例3で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でカプセル化された発泡剤F-36Dの代わりに炭酸ナトリウムコア-ポリエチレングリコール(PEG)シェル構造の発泡剤を使用したことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、比較例4で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
実施例3でカプセル化された発泡剤F-36Dの代わりに炭化水素コア-熱可塑性樹脂シェル構造のEXPANCEL 930 DU 120(AkzoNobel社製)を使用したことを除いては、実施例3と同様の方法で、高吸水性樹脂を製造した。このとき、比較例5で製造された単量体組成物でアクリル酸の中和度は70モル%であり、組成物のpHは5.6であった。
前記実施例および比較例で製造した高吸水性樹脂に対し、以下の方法で遠心分離保水能(CRC)、吸収速度および1分間吸水能を測定し、その結果を下記表1に示す。
各樹脂の無荷重下吸収倍率による保水能をヨーロッパ不織布工業会(European Disposables and Nonwovens Association、EDANA)の規格EDANA WSP 241.3により測定した。
CRC(g/g)={[W2(g)-W1(g)]/W0(g)}-1
前記実施例および比較例での高吸水性樹脂の吸収速度は、国際公開第1987/003208号に記載された方法に準じて秒単位で測定した。
実施例および比較例での高吸水性樹脂1.0g(W5)を不織布製の封筒(15cm×15cm)に入れて、24℃の蒸留水500mLに1分間浸水させた。1分後に封筒を蒸留水から取り出した後、吊り下げて1分間放置した。以降、封筒の質量(W6)を測定した。また、高吸水性樹脂を使用せず同じ操作をした後、その時の質量W7(g)を測定した。
1分間吸水能(蒸留水)={[W7(g)-W6(g)-W5(g)]/W5(g)}
Claims (9)
- (メタ)アクリル酸を含む水溶性エチレン系不飽和単量体を水酸化カリウムを含む塩基性物質、カプセル化された発泡剤、内部架橋剤および重合開始剤と混合して単量体組成物を製造する段階であって、前記水酸化カリウムを含む塩基性物質によって前記水溶性エチレン系不飽和単量体の酸性基のうちの少なくとも一部が中和する段階と;
前記単量体組成物を熱重合または光重合して含水ゲル状重合体を形成する段階と;
前記含水ゲル状重合体を乾燥および粉砕して粉末形態のベース樹脂を形成する段階と;
表面架橋剤の存在下で前記ベース樹脂の表面を追加架橋して表面架橋層を形成する段階と、を含み、
前記カプセル化された発泡剤は、炭化水素を含むコアおよび前記コアを囲み熱可塑性樹脂で形成されるシェルを含む構造を有し、膨張前の平均直径が5~30μmであり、空気中での最大膨張比が5~15倍であり、
前記塩基性物質は、50~100モル%の水酸化カリウムと0~50モル%の水酸化ナトリウムとを含む、高吸水性樹脂の製造方法。 - 前記塩基性物質は、前記水溶性エチレン系不飽和単量体1モルに対して0.5~0.9モルで使用される、請求項1に記載の高吸水性樹脂の製造方法。
- 前記単量体組成物はpHが5~6である、請求項1または2に記載の高吸水性樹脂の製造方法。
- 前記カプセル化された発泡剤は、空気中での最大膨張サイズが20~190μmである、請求項1から3のいずれか一項に記載の高吸水性樹脂の製造方法。
- 前記カプセル化された発泡剤は、発泡開始温度(Tstart)が60℃~120℃であり、最大発泡温度(Tmax)が100℃~160℃である、請求項1から4のいずれか一項に記載の高吸水性樹脂の製造方法。
- 前記炭化水素は、n-プロパン、n-ブタン、iso-ブタン、シクロブタン、n-ペンタン、iso-ペンタン、シクロペンタン、n-ヘキサン、iso-ヘキサン、シクロヘキサン、n-ヘプタン、iso-ヘプタン、シクロヘプタン、n-オクタン、iso-オクタンおよびシクロオクタンで構成された群から選択される1種以上である、請求項1から5のいずれか一項に記載の高吸水性樹脂の製造方法。
- 前記熱可塑性樹脂としては(メタ)アクリレート、(メタ)アクリロニトリル、芳香族ビニル、酢酸ビニル、ハロゲン化ビニルおよびハロゲン化ビニリデンで構成された群から選択される1種以上のモノマーから形成されるポリマーである、請求項1から6のいずれか一項に記載の高吸水性樹脂の製造方法。
- 前記カプセル化された発泡剤は、前記水溶性エチレン系不飽和単量体100重量部に対して0.01~1.0重量部で使用される、請求項1から7のいずれか一項に記載の高吸水性樹脂の製造方法。
- 製造された高吸水性樹脂は、1分間吸水能(蒸留水)が170g/g以上であり、ボルテックス(Vortex)法による吸収速度が22秒以下である、請求項1から8のいずれか一項に記載の高吸水性樹脂の製造方法。
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