Polyacrylic acid (salt)-type water absorbent resin and method for producing of same

• US 9,023,951 B2
• Filed: 08/27/2010
• Issued: 05/05/2015
• Est. Priority Date: 08/27/2009
• Status: Active Grant

• Current Assignee: Nippon Shokubai Company Limited
• Original Assignee: Nippon Shokubai Company Limited
• Inventors: Nogi, Kozo, Ishizaki, Kunihiko, Kanzaki, Syuji
• Primary Examiner(s): Rabago, Roberto
• Application Number:
  US13/392,240
• Publication Number:
  US 20120157635A1
• Time in Patent Office: 1,712 Days
• Field of Search: 525/329.7, 525/329.9
• US Class Current: 525/329.7
• CPC Class Codes: A61L 15/24 Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof A61L15/225 takes precedence
• CPC Class Codes: A61L 15/60 Liquid-swellable gel-forming materials, e.g. super-absorbents
• CPC Class Codes: C08F 120/06 Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
• CPC Class Codes: C08F 220/06 Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
• CPC Class Codes: C08F 222/102 of dialcohols, e.g. ethylene glycol di(meth)acrylate or 1,4-butanediol dimethacrylate
• CPC Class Codes: C08J 2300/14 Water soluble or water swellable polymers, e.g. aqueous gels
• CPC Class Codes: C08J 2333/02 Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C08J 3/24 Crosslinking, e.g. vulcanising, of macromolecules mechanical aspects B29C35/00; crosslinking agents C08K
• CPC Class Codes: C08J 3/245 Differential crosslinking of one polymer with one crosslinking type, e.g. surface crosslinking
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters

Abstract

Disclosed is a method for producing a water absorbent resin, by which a surface-crosslinked water absorbent resin having excellent physical properties can be efficiently obtained at low cost, while assuring high productivity. When the production scale is increased to a continuous production on a huge scale (for example, 1 t/hr or more), the physical properties are improved and stabilized (for example, standard deviation of the physical properties is reduced) by a surface-crosslinking treatment, and the absorption against pressure (AAP) and liquid permeability (SFC) are further improved. Specifically disclosed is a method for producing a polyacrylic acid (salt)-type water absorbent resin, which comprises: a step of preparing an aqueous monomer solution using an acrylic acid (salt); a step of continuously polymerizing the aqueous monomer solution; shedding step of a hydrous gel-like crosslinked polymer during or after the polymerization; a step of drying the thus-obtained particulate hydrous gel-like crosslinked polymer; and a surface treatment step in which a surface-crosslinking agent is added to and reacted with the dried water absorbent resin powder. In the surface treatment step, the continuous mixing apparatus for the surface treatment agent and the continuous heating device are connected and periodic shielding is performed between the mixing apparatus and the heating device.

Claims

1. A method for producing a polyacrylic acid (salt)-type water absorbent resin, comprising a step of preparing an aqueous monomer solution of an acrylic acid (salt), a step of continuously polymerizing the aqueous monomer solution, a step of finely shredding a hydrous gel-like crosslinked polymer during or after polymerization, a step of drying the obtained particulate hydrous gel-like crosslinked polymer, and a surface treatment step of adding and reacting a surface treatment agent to and with the dried water absorbent resin powder, wherein in the surface treatment step, a continuous mixing apparatus for the surface treatment agent and a continuous heating apparatus are connected and periodical shielding is carried out between the mixing apparatus and the heating apparatus, wherein the periodical shielding is carried out at a shielding interval of 0.01 to 1 minutes and a shielding ratio of 2 to 40%, and the production amount of the polyacrylic acid (salt)-type water absorbent resin is 1 t/hr or more;

wherein a heating treatment in the surface treatment step is carried out in a transverse type continuous stirring apparatus having stirring means including a feeding inlet and a discharging outlet of a water absorbent resin and one or more rotary shafts having a plurality of stirring discs, and heating means, said transverse type continuous stirring apparatus having a stirring power index of 3 to 15 W ·

hr/kg,

wherein (stirring power index) =((power consumption of apparatus at the time surface treatment) −

(power consumption at the time of idling)) ×

average retention time)/(treatment amount per unit time ×

average retention time).

2. The production method according to claim 1, wherein in the surface treatment step, the continuous heating apparatus and a continuous cooling apparatus are connected and periodical shielding is carried out between the heating apparatus and the cooling apparatus.

3. The production method according to claim 1, wherein the periodic shielding is carried out by using at least one selected from a gate, a valve, a damper, a rotary feeder, and a table feeder.

4. The production method according to claim 1, wherein the surface treatment step has two or more lines for one line in the polymerization step.

5. The production method according to claim 1, wherein the surface-crosslinking agent is a dehydration reactive surface-crosslinking agent and the heating treatment temperature is 150 to 250°

C.

6. The production method according to claim 1, wherein the surface treatment step is carried out in reduced pressure.

7. The production method according to claim 1, wherein the water absorbent resin has 20 g/g or higher of water absorption against pressure (AAP) for an aqueous 0.9 mass% sodium chloride solution at a pressure of 4.8 kPa, 1 (×

10<sup>−

7</sup>·

cm³·

s ·

g<sup>−

1</sup>) or higher of flow conductivity of 0.69 mass% physiological saline solution (SFC), and 20 g/g or higher of water absorption under no pressure (CRC).

8. The production method according to claim 1, wherein the periodic shielding is further carried out also in the outlet side of the heating apparatus.