Gel pulverization device, method for manufacturing polyacrylic acid (polyacrylate) superabsorbent polymer powder, and superabsorbent polymer powder

Patent metadata

Field	Value
Publication number	US-9533433-B2
Application number	US-201414914146-A
Country	US
Kind code	B2
Filing date	Aug 28, 2014
Priority date	Aug 28, 2013
Publication date	Jan 3, 2017
Grant date	Jan 3, 2017

Abstract

Provided is a water absorbent resin that is useful to sanitary materials such as a disposable diaper, a sanitary napkin, and a blood absorbent for medical use each having a higher liquid permeability and a higher water absorbing speed. Further provided is a water absorbent resin powder that is useful to sanitary materials such as a disposable diaper, a sanitary napkin, and a blood absorbent for medical use each having a smaller amount of return of a liquid and a higher heat retaining property. A gel grinding device to be used to produce a water absorbent resin, includes: a screw; a feed opening; an extrusion opening; a porous plate; and a barrel, the screw including: a rotating shaft; and a flight, and the screw satisfying at least one of specific parameters.

First claim

The invention claimed is:

1. A gel grinding device to be used to produce a water absorbent resin, comprising:
a screw;
a feed opening;
an extrusion opening;
a porous plate; and
a barrel,
the screw including:
a rotating shaft being a center of rotation of the screw; and
a flight helically provided on the rotating shaft, and

the screw satisfying either one of the following (1) and (2):
0.215≦ B/A≦ 0.630; and  (1)

0.034< F/N≦ 0.20  (2)

where B is a cross-sectional area of the rotating shaft which cross-sectional area is obtained by cutting off the screw vertically to a direction in which a gel of the water absorbent resin is extruded; A is a cross-sectional area of a rotating part of the flight; N is a maximum inner diameter which prevents a contact between the screw and a return preventing member which is provided inside of the barrel; and F is a width of the flight which width is along a direction vertical to a direction in which the flight extends.

2. The gel grinding device as set forth in claim 1 , wherein the screw satisfies 0.001≦σ/N<0.043 where σ is a gap between the flight and the barrel.

3. The gel grinding device as set forth in claim 1 , wherein P/N of either one of a first winding and a second winding following the first winding of windings which are numbered in a direction from the extrusion opening toward the feed opening ranges from 0.15 to 0.68 where P is a pitch length of the screw.

4. The gel grinding device as set forth in claim 1 , wherein the screw and the porous plate are made of respective different materials.

5. The gel grinding device as set forth in claim 1 , wherein the screw is made of austenitic stainless steel.

6. The gel grinding device as set forth in claim 1 , wherein the gel grinding device is used at a temperature of 40° C. to 120° C. during a gel grinding step.

7. The gel grinding device as set forth in claim 1 , wherein the water absorbent resin is a polyacrylic acid (salt)-based water absorbent resin.

8. The gel grinding device as set forth in claim 1 , wherein the screw is provided with a rotary blade.

9. A method for producing a polyacrylic acid (salt)-based water absorbent resin powder, comprising:
a polymerization step of polymerizing an acrylic acid (salt)-based monomer aqueous solution;
a gel grinding step, carried out during or after the polymerization, of carrying out gel grinding with respect to a hydrogel-like crosslinked polymer; and
a drying step carried out after the gel grinding,
in the gel grinding step, the hydrogel-like crosslinked polymer being ground by use of a gel grinding device recited in claim 1 , the hydrogel-like crosslinked polymer having a resin solid content of 10 wt % to 80 wt %.

10. The method as set forth in claim 9 , wherein T/N 3 ranges from 0.05 to 2.0 where T is an amount [g/hr] in which the gel grinding device treats a hydrogel per hour and T/N 3 is a treatment amount-to-inner diameter ratio [g/hr/mm 3 ] that is a treatment amount per unit time of the gel grinding device.

11. The method as set forth in claim 9 , wherein the hydrogel which has been ground in the gel grinding step is dried under a condition where a through-flow belt-type dryer is used, a drying temperature is 150° C. to 250° C., and hot air blows in a vertical direction (an up-and-down direction) at an air velocity of 0.8 [m/s] to 2.5 [m/s].

12. The method as set forth in claim 9 , wherein the barrel of the gel grinding device has a temperature of 40° C. to 120° C. while the gel grinding step is being carried out.

13. A water absorbent resin powder comprising a polyacrylic acid (salt)-based water absorbent resin as a main component,
the water absorbent resin powder satisfying the following (A) to (C):
(A) the water absorbent resin powder containing particles smaller than 150 μm in a ratio of 0 mass % to 4.5 mass % before an impact resistance test, and the water absorbent resin powder containing, in a ratio of 0 mass % to 4.5 mass %, particles smaller than 150 and increased by the impact resistance test;
(B) the water absorbent resin powder having an absorption capacity under load (AAP) of not less than 17; and
(C) the water absorbent resin powder having a thermal conductivity of not more than 125 [mW/(m·K)].

14. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder has a saline flow conductivity (SFC) of not less than 10.

15. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder has an internal gas bubbles ratio of 0% to 3.7%, the internal gas bubbles ratio being specified by the following equation:
(internal gas bubbles ratio) [%]={(true density)−(apparent density)}/(true density)×100

16. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder contains at least one of a multivalent metal salt and inorganic microparticles.

17. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder has a mass average particle diameter D50 of 350 μm to 460 μm, or the water absorbent resin powder has a particle size distribution having a logarithmic standard deviation of 0.25 to 0.45.

18. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder contains, in a ratio of not more than 36 mass %, particles that pass through a sieve having a mesh size of 710 μm and do not pass through a sieve having a mesh size of 500 μm.

19. The water absorbent resin powder as set forth in claim 13 , wherein the water absorbent resin powder has a surface tension of not less than 69.0 [mN/m].

20. An absorbent body comprising:
a water absorbent resin powder recited in claim 13 ; and
a fibrous material.

21. The absorbent body as set forth in claim 20 , wherein the water absorbent resin powder is contained in an amount of 40 mass % to 100 mass % based on a total mass of the water absorbent resin powder and the fibrous material.

22. An absorbent article comprising an absorbent body recited in claim 20 .

Assignees

• Nippon Catalytic Chem Ind

Inventors

• Torii Kazushi
• Omori Kohei
• Tanaka Nobuya
• Sakamoto Shigeru
• Tada Kenji
• Sato Hironori

Classifications

• C08J2333/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title

• A61L15/42

  Use of materials characterised by their function or physical properties (liquid bandages A61L26/00) · CPC title

• C08F283/065 Primary

  on to unsaturated polyethers, polyoxymethylenes or polyacetals · CPC title

• C08J3/12

  Powdering or granulating · CPC title

• C08J2300/14

  Water soluble or water swellable polymers, e.g. aqueous gels · CPC title