Acrylic rubber with excellent injection molding properties

Abstract

Provided is an acrylic rubber having excellent injection moldability. An acrylic rubber according to the present invention is composed of a binding unit derived from at least one sort of (meth)acrylic acid ester selected in the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxy alkyl ethers, a binding unit derived from a monomer containing a ion reactive group, and if necessary, a binding unit derived from another monomer. In said acrylic rubber, the weight average molecular weight (Mw) is 1,000,000 to 5,000,000, the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) is in a range of 1.5 to 3, the ash content is 0.3 wt% or less, and the total content of sodium, sulfur, calcium, magnesium and phosphorus in the ash is 80 wt% or more.

Description

[Technical Field]

[0001] The present invention relates to an acrylic rubber, a method for producing the same, a rubber composition, and a cross-linked rubber product, and more specifically to an acrylic rubber that is excellent in injection moldability, strength properties, compression set resistance, and water resistance, a method for producing the same, a rubber composition containing the acrylic rubber, and a cross-linked rubber product obtained by cross-linking the acrylic rubber. [Background technology]

[0002] Acrylic rubber is a polymer whose main component is acrylic ester, and is generally known as a rubber with excellent heat resistance, oil resistance, and ozone resistance, and is widely used in the automotive field and other fields.

[0003] For example, Patent Document 1 (JP-A-11-12427) describes a polymerizable composition containing 100 parts of a monomer component including a monomer that introduces a carbon-carbon double bond into a side chain, such as ethyl acrylate, butyl acrylate, methoxyethyl acrylate, acrylonitrile, and allyl methacrylate, cyclopentenyloxyethyl acrylate, etc., 4 parts of sodium lauryl sulfate, 0.25 parts of p-menthane hydroperoxide as an organic radical generator, 0.01 parts of ferrous sulfate, 0.025 parts of sodium ethylenediaminetetraacetate, sodium formaldehyde, The method disclosed an acrylic rubber and crosslinked composition with excellent extrusion processability and scorch resistance, in which 0.04 parts of tert-dodecyl sulfoxylate and 0.01 to 0.05 parts of tert-dodecyl mercaptan as a chain transfer agent were charged into a nitrogen-substituted autoclave and reacted at a reaction temperature of 30°C until the conversion of the monomer mixture reached 100%, the resulting latex was coagulated by adding it to a 0.25% aqueous calcium chloride solution, the coagulated material was thoroughly washed with water, dried at about 90°C for 3 hours, and crosslinked with an organic peroxide such as 1,3-bis(tert-butylperoxyisopropyl)benzene. However, the acrylic rubber obtained by this method had problems such as insufficient injection moldability and Banbury processability, and poor storage stability, compression set resistance, water resistance, and strength.

[0004] Furthermore, Patent Document 2 (JP Patent Publication No. 5-86137A) discloses a method for producing acrylic rubber in which polymerization is initiated with an organic radical generator and a chain transfer agent is added to a monomer emulsion and continuously administered. Specifically, one-fifth of a mixture of a monomer mixture containing 2-(2-cyanoethoxy)ethyl acrylate, ethyl acrylate, n-butyl acrylate, and crosslinkable monomers such as vinyl chloroacetate and allyl glycidyl ether and an appropriate amount of n-dodecyl mercaptan is mixed and stirred with half of 1 part by weight of polyoxyethylene lauryl ether, 4 parts by weight of sodium lauryl sulfate, 0.7 parts by weight of disodium hydrogen phosphate, and 0.3 parts by weight of sodium dihydrogen phosphate to form an emulsion, which is then cooled to 15°C and then mixed with sodium ethylenediaminetetraacetate. The polymerization was initiated by adding 0.005 parts by weight of thorium iron(II), 0.02 parts by weight of tetrasodium ethylenediaminetetraacetate, 0.02 parts by weight of Rongalite, and 0.02 parts by weight of sodium hydrosulfite. A 0.2 wt% aqueous solution of tert-butyl hydroperoxide, an organic radical generator, was added dropwise at a rate of 1.5 parts per hour. While maintaining the temperature at 15°C, an emulsion consisting of a mixture of the remaining monomers and n-dodecyl mercaptan and an aqueous emulsifier solution was added dropwise over 3 hours to achieve a monomer conversion of 96-99%. The resulting copolymer latex was then poured into an aqueous calcium chloride solution at 85°C to isolate the copolymer. After thorough washing and drying, the desired copolymer rubber was obtained and sulfur-crosslinked. However, the acrylic rubber obtained by this method had problems such as insufficient injection moldability and poor storage stability, water resistance, and strength.

[0005] Furthermore, Patent Document 3 (WO 2019 / 188709 pamphlet) discloses a method for producing acrylic rubber by charging monomer components consisting of ethyl acrylate, butyl acrylate, methoxyethyl acrylate, and monobutyl fumarate, water, and sodium lauryl sulfate, repeatedly degassing under reduced pressure and purging with nitrogen, and then adding sodium aldehyde sulfoxylate and the organic radical generator cumene hydroperoxide to initiate emulsion polymerization at normal pressure and temperature, continuing the emulsion polymerization until a polymerization conversion rate of 95% by weight is reached, then coagulating the resulting mixture with an aqueous calcium chloride solution and dehydrating and drying it in an extruder dryer with a screw. However, the acrylic rubber obtained by this method suffers from problems such as poor injection moldability, storage stability, and water resistance.

[0006] Furthermore, Patent Document 4 (International Publication No. 2018 / 117037) discloses a method for producing acrylic rubber by adding monomer components consisting of ethyl acrylate and mono-n-butyl fumarate, water, and sodium dodecyl sulfate, and then performing vacuum degassing and nitrogen substitution three times to thoroughly remove oxygen. Then, organic radical generators azobis(isobutyronitrile) and ethyl-2-methyl-2-phenyltellanylpropionate are added, and a polymerization reaction is initiated at normal pressure and a temperature of 50°C. The polymerization is continued until a polymerization conversion rate of 89% is reached, after which the resulting mixture is coagulated with a calcium chloride solution, washed with water, and dried. However, the acrylic rubber obtained by this method suffers from problems such as poor injection moldability, Banbury processability, storage stability, and water resistance.

[0007] On the other hand, as a method for producing acrylic rubber using an inorganic radical generator, for example, Patent Document 5 (JP 2019-119772 A) describes a method for producing acrylic rubber using an inorganic radical generator, in which monomer components consisting of ethyl acrylate, butyl acrylate, methoxyethyl acrylate, and monobutyl maleate are made into a monomer emulsion using pure water and emulsifiers sodium lauryl sulfate and polyoxyethylene dodecyl ether, and then a portion of the monomer emulsion is charged into a polymerization reactor and cooled to 12°C under a nitrogen gas flow, and then the remaining monomer emulsion, ferrous sulfate, sodium ascorbate, and inorganic The method disclosed involves continuously adding dropwise an aqueous solution of potassium persulfate as a radical generator over a period of three hours, then maintaining the temperature at 23°C and continuing emulsion polymerization for another hour until the polymerization conversion reaches 97% by weight, then raising the temperature to 85°C and continuously adding sodium sulfate to obtain hydrous crumbs, which are coagulated and filtered off, and then washing the hydrous crumbs four times with water, once with acid, and once with pure water, before continuously producing sheet-shaped acrylic rubber in a screw extruder and crosslinking with an aliphatic polyamine compound such as hexamethylenediamine carbamate. However, the sheet-shaped acrylic rubber obtained by this method has problems such as poor injection moldability and storage stability, and the crosslinked product has poor water resistance.

[0008] Patent Document 6 (JP 1-135811 A) discloses a method for producing acrylic rubber and crosslinking it with sulfur by emulsifying one-quarter of a monomer mixture consisting of ethyl acrylate, caprolactone-added acrylic ester, cyanoethyl acrylate, and vinyl chloroacetate monomers with n-dodecyl mercaptan as a chain transfer agent in sodium lauryl sulfate, polyethylene glycol nonylphenyl ether, and distilled water, adding sodium sulfite and ammonium persulfate as an inorganic radical generator to initiate polymerization, adding the remaining monomer mixture and a 2% aqueous solution of ammonium persulfate dropwise over two hours while maintaining the temperature at 60°C, and continuing polymerization for another two hours after the dropwise addition. The resulting latex, with a polymerization conversion of 96-99%, is then poured into an aqueous sodium chloride solution at 80°C, coagulated, thoroughly washed with water, and dried to produce acrylic rubber, which is then crosslinked with sulfur. However, the acrylic rubber obtained by this method suffers from problems such as poor injection moldability, storage stability, and water resistance.

[0009] Patent Document 7 (Japanese Patent Laid-Open Publication No. 62-64809) discloses a sulfur-vulcanizable acrylic rubber characterized in that the copolymer has a monomer composition consisting of 50 to 99.9% by weight of at least one compound selected from acrylic acid alkyl esters and acrylic acid alkoxyalkyl esters, 0.1 to 20% by weight of a dihydrodicyclopentenyl group-containing ester of an unsaturated carboxylic acid, and 0 to 20% by weight of at least one other monovinyl-, monovinylidene-, and monovinylene-based unsaturated compound, and that the number-average molecular weight (Mn) calculated as polystyrene using tetrahydrofuran as a developing solvent is 200,000 to 1,200,000, and the ratio of weight-average molecular weight (Mw) to number-average molecular weight (Mn) (Mw / Mn) is 10 or less. Specific examples include acrylic rubbers containing monomer components including ethyl acrylate and radically crosslinkable dihydrodicyclopentenyl acrylate, an emulsifier sodium lauryl sulfate, an inorganic radical generator potassium persulfate, and molecular weight regulators octyl thioglycolate and t-dodecyl mercaptan in varying amounts, and having a number average molecular weight (Mn) of 530,000 to 1,150,000, a weight average molecular weight (Mw) of 3,540,000 to 6,260,000, and a ratio of weight average molecular weight (Mw) to number average molecular weight (Mn) (Mw / Mn) of 4.7 to 8. The examples and comparative examples show that when the amount of chain transfer agent is small, the number average molecular weight (Mw) is as high as 5 million and the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) is narrow at 1.4, while when the amount of chain transfer agent is large, the number average molecular weight (Mn) is as low as 200,000 and the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) is extremely wide at 17. However, the acrylic rubber obtained by this method is inferior in injection moldability, and in the crosslinking reaction, sulfur and a vulcanization accelerator are added as a crosslinking agent, and after kneading with a roll, the rubber is subjected to a pressure of 100 kg / cm. 2 However, there were problems with this method, such as requiring a long time for crosslinking, i.e., 15 minutes at 170°C in the vulcanization press and 4 hours at 175°C in a gear oven, and the resulting crosslinked product was inferior in water resistance, compression set resistance, and strength, and was also inferior in terms of changes in physical properties after thermal degradation. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Japanese Patent Application Publication No. 11-12427 [Patent Document 2] Japanese Patent Application Publication No. 2019-119772 [Patent Document 3] International Publication No. 2019 / 188709 Brochure [Patent Document 4] International Publication No. 2018 / 117037 Brochure [Patent Document 5] Japanese Patent Application Publication No. 2019-119772 [Patent Document 6] Japanese Patent Application Publication No. 1-135811 [Patent Document 7] Japanese Patent Application Publication No. 62-64809 Summary of the Invention [Problem to be solved by the invention]

[0011] The present invention has been made in view of the current state of the prior art, and an object of the present invention is to provide an acrylic rubber that is excellent in injection moldability, water resistance, compression set resistance and strength characteristics, a method for producing the same, a rubber composition containing the acrylic rubber, and a cross-linked rubber obtained by cross-linking the acrylic rubber. [Means for solving the problem]

[0012] In view of the above problems, the present inventors have conducted extensive research and found that an acrylic rubber containing a specific monomer component including an ion-reactive group-containing monomer, having a specific weight-average molecular weight (Mw), a specific ratio of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) (Mw / Mn), and a specific ash content or ash content, exhibits excellent injection moldability, water resistance, compression set resistance, and strength. In particular, the present inventors have found that the injection moldability of the acrylic rubber of the present invention is remarkably excellent in all of the properties of shape formability, fusion, and mold releasability.

[0013] The present inventors have also discovered that acrylic rubber having excellent injection moldability, water resistance, compression set resistance and strength properties can be efficiently produced by emulsifying specific monomer components containing an ion-reactive group-containing monomer with water and an emulsifier, then initiating emulsion polymerization in the presence of a redox catalyst consisting of an organic radical generator such as diisopropylbenzene hydroperoxide and a reducing agent, and carrying out emulsion polymerization by adding a chain transfer agent batchwise during the polymerization without adding it initially, coagulating the emulsion polymerization liquid using a specific method, and washing and then dehydrating the water-containing crumbs produced in the coagulation reaction before entering a drying step.

[0014] The inventors have discovered that to achieve a high level of balance between the strength properties and injection moldability of acrylic rubber, it is important to keep the weight-average molecular weight (Mw) and the ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) of the acrylic rubber within a specific range. To produce such acrylic rubber, emulsion polymerization using an organic radical generator alone results in a narrow ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn), making injection moldability poor. However, they have discovered that this can be achieved by batchwise adding a chain transfer agent during polymerization. On the other hand, acrylic rubber emulsion-polymerized using an inorganic radical generator has a ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) that is too wide, making it poor for injection molding.

[0015] The present inventors have also discovered that by drying the acrylic rubber using a specific extrusion dryer, and by melt-kneading and drying the acrylic rubber under optimal shear conditions using the specific extrusion dryer, it is possible to widen the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) without damaging the weight average molecular weight (Mw), and further to produce an acrylic rubber that has a high level of balance between injection moldability, Banbury processability, strength properties, and compression set resistance properties.

[0016] The present inventors have also discovered that acrylic rubber having bonding units of a monomer containing an ionically reactive group that undergoes an ionically reactive reaction with a crosslinking agent such as a carboxyl group, an epoxy group or a chlorine atom and having a weight average molecular weight within a specific range is remarkably excellent in normal state physical properties including compression set resistance and strength properties.

[0017] The present inventors have also discovered that in GPC measurement of ion-reactive acrylic rubber copolymerized with a monomer containing such an ion-reactive group, the rubber cannot be sufficiently dissolved in tetrahydrofuran, which is used in GPC measurement of radical-reactive acrylic rubber copolymerized with ethyl acrylate and dihydrodicyclopentenyl acrylate, etc., as in the above-mentioned prior art, and each molecular weight and molecular weight distribution cannot be measured clearly and with good reproducibility. However, by using a specific solvent with a higher SP value than tetrahydrofuran as a developing solvent, the rubber can be dissolved clearly and measured with good reproducibility, and moreover, by keeping each characteristic value within a specific range, the injection moldability, water resistance, compression set resistance and strength characteristics of the acrylic rubber can be highly controlled.

[0018] The inventors have found that water resistance is significantly affected by the ash content and ash components in the acrylic rubber. While it is particularly difficult to remove ash from acrylic rubber produced using large amounts of emulsifiers and coagulants, they have discovered that by coagulating the rubber using a specific method and concentrating the particle size of the resulting hydrous crumbs within a specific range, washing efficiency and ash removal efficiency during dehydration can be significantly improved, resulting in a significant reduction in the ash content of the acrylic rubber and improved water resistance. The inventors have also found that in addition to the ash content and ash component content, the use of a phosphate ester salt or sulfate ester salt as an emulsifier and / or an alkali metal salt or a Group 2 metal salt as a coagulant significantly improves the water resistance and mold releasability of the acrylic rubber.

[0019] The inventors have also found that the lower the gel content of methyl ethyl ketone-insoluble matter in acrylic rubber, the better its injection moldability, compression set resistance, and strength properties, as well as its Banbury processability. The gel content of methyl ethyl ketone-insoluble matter in acrylic rubber is generated during the polymerization reaction. It rapidly increases and becomes difficult to control, particularly when the polymerization conversion rate is increased to improve strength properties. However, they have found that this can be suppressed to some extent by emulsion polymerization in the presence of a chain transfer agent in the latter half of the polymerization reaction. Preferably, the rapidly increasing gel content of the specific solvent-insoluble matter disappears when the acrylic rubber is melt-kneaded and dried in a substantially water-free environment in a twin-screw screw extruder, significantly improving the Banbury processability of the acrylic rubber. The inventors have also found that acrylic rubber extruded and dried in a molten state with almost all water removed (water content less than 1% by weight) in a twin-screw screw extruder exhibits a high balance between strength properties and Banbury processability.

[0020] The inventors also discovered that the higher the specific gravity of the acrylic rubber, the better its injection moldability, water resistance, strength properties, and compression set resistance, as well as its storage stability. The acrylic rubber of the present invention, which contains specific ion-reactive groups such as carboxyl groups, epoxy groups, and chlorine atoms, is adhesive and has a high affinity for air, making it difficult to remove air once it has trapped it. Crumb-like acrylic rubber obtained by directly drying water-containing crumbs traps a large amount of air (leading to a low specific gravity), which deteriorates its storage stability. The inventors discovered that compressing the crumb-like acrylic rubber into bales using a high-pressure baler or similar device can remove some of the air, improving the storage stability of the acrylic rubber. Preferably, drying the water-containing crumbs in a screw-type twin-screw extruder and extruding them into an air-free sheet form for lamination can produce an acrylic rubber that is almost air-free (high specific gravity) and has significantly better storage stability. The present inventors have also found that the specific gravity taking into account the air content can be measured in accordance with JIS K6268 Crosslinked Rubber - Density Measurement Method A, which utilizes the difference in buoyancy.The present inventors have also found that acrylic rubber dried under reduced pressure using a screw-type twin-screw extruder dryer, or melted under reduced pressure and extruded and dried, has excellent and well-balanced properties in terms of storage stability, injection moldability, and strength characteristics.

[0021] The present inventors have also found that the injection moldability, water resistance, compression set resistance and strength properties can be highly improved by setting the monomer composition of the acrylic rubber, the type of ion-reactive group, the molecular weight distribution (Mz / Mw) with emphasis on the high molecular weight region, the complex viscosity at 60°C ([η]60°C), the ratio ([η]100°C / [η]60°C) of the complex viscosity at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C), the amount of specific elements in the ash and the amount ratio of specific elements within specific ranges.

[0022] The present inventors have found that by using an ionically crosslinkable organic compound as a crosslinking agent, the crosslinking properties are further improved and the properties of the resulting crosslinked rubber are greatly improved.

[0023] The present inventors have further discovered that in a rubber composition comprising the acrylic rubber, a filler, and a crosslinking agent of the present invention, blending carbon black or silica as a filler results in excellent Banbury processability, injection moldability, and short-time crosslinking, and the crosslinked product has excellent water resistance, strength, and compression set resistance. The present inventors have also discovered that the crosslinking agent is preferably an organic compound, a polyvalent compound, or an ionic crosslinking compound, and that a polyvalent ionic organic compound having multiple ion-reactive groups that react with ion-reactive groups of the acrylic rubber, such as amine groups, epoxy groups, carboxyl groups, or thiol groups, results in excellent Banbury processability, injection moldability, and short-time crosslinking, and the crosslinked product has excellent water resistance, strength, and compression set resistance.

[0024] Based on these findings, the present inventors have completed the present invention.

[0025] Thus, according to the present invention, there is provided an acrylic rubber which comprises bonding units derived from at least one (meth)acrylic ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, bonding units derived from an ion-reactive group-containing monomer, and, as necessary, bonding units derived from other monomers, and which has a weight-average molecular weight (Mw) of 1,000,000 to 5,000,000, a ratio (Mw / Mn) of weight-average molecular weight (Mw) to number-average molecular weight (Mn) in the range of 1.5 to 3, an ash content of 0.3% by weight or less, and a total content of sodium, sulfur, calcium, magnesium, and phosphorus in the ash of 80% by weight or more.

[0026] In the acrylic rubber of the present invention, the ratio (Mz / Mw) of the z-average molecular weight (Mz) to the weight-average molecular weight (Mw) is preferably 1.3 or more. In the acrylic rubber of the present invention, the ratio (Mz / Mw) of the z-average molecular weight (Mz) to the weight-average molecular weight (Mw) is preferably 4 or less.

[0027] The acrylic rubber of the present invention preferably has a number average molecular weight (Mn) in the range of 400,000 to 1,100,000. In the acrylic rubber of the present invention, the weight average molecular weight (Mw), the ratio of the weight average molecular weight (Mw) to the number average molecular weight (Mn) (Mw / Mn), or the ratio of the z average molecular weight (Mz) to the weight average molecular weight (Mw) (Mz / Mw) is preferably an absolute molecular weight or absolute molecular weight distribution measured by a GPC-MALS method.

[0028] In the acrylic rubber of the present invention, the measurement solvent for the GPC-MALS method is preferably a dimethylformamide-based solvent.

[0029] In the acrylic rubber of the present invention, the monomer composition of the acrylic rubber preferably comprises 50 to 99.99% by weight of bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, 0.01 to 10% by weight of bonding units derived from ion-reactive group-containing monomers, and 0 to 40% by weight of bonding units derived from other monomers.

[0030] In the acrylic rubber of the present invention, the ion-reactive group is preferably a carboxyl group or an epoxy group. In the acrylic rubber of the present invention, the gel content is preferably 50% by weight or less.

[0031] In the acrylic rubber of the present invention, the gel content is preferably 30% by weight or less. In the acrylic rubber of the present invention, it is preferable that the amount of gel is measured at any 20 points, and all values ​​are within the range of (average value ±5) wt %. The acrylic rubber of the present invention preferably has a specific gravity of 0.8 or more. In the acrylic rubber of the present invention, the total amount of magnesium and phosphorus in the ash is preferably 50% by weight or more.

[0032] In the acrylic rubber of the present invention, the ratio of magnesium to phosphorus in the ash ([Mg] / [P]) is preferably in the range of 0.4 to 2.5 by weight. In the acrylic rubber of the present invention, the complex viscosity at 60°C ([η]60°C) is preferably 15,000 [Pa·s] or less.

[0033] In the acrylic rubber of the present invention, the ratio ([η]100°C / [η]60°C) of the complex viscosity at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) is preferably 0.7 or more. The acrylic rubber of the present invention is preferably in the form of a sheet or a veil.

[0034] The acrylic rubber of the present invention is preferably obtained by emulsion polymerization using a phosphate ester salt or a sulfate ester salt as an emulsifier, and is preferably obtained by coagulating the emulsion-polymerized polymerization solution using an alkali metal salt or a Group 2 metal salt of the periodic table as a coagulant and then drying. Furthermore, the acrylic rubber of the present invention is preferably obtained by melt-kneading and drying after coagulation, and the melt-kneading and drying are preferably performed in a substantially water-free state and under reduced pressure. Furthermore, the acrylic rubber of the present invention is preferably obtained by cooling at a cooling rate of 40°C / hr or more after the melt-kneading and drying.

[0035] The acrylic rubber of the present invention is preferably one obtained by washing, dehydrating and drying water-containing crumbs in which the proportion of particles in the range of 710 μm to 6.7 mm is 50% by weight or more.

[0036] The present invention also provides a method for producing acrylic rubber, which includes: an emulsification step of emulsifying, with water and an emulsifier, a monomer component consisting of at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and, if necessary, other monomers; an emulsion polymerization step of initiating polymerization in the presence of a redox catalyst consisting of an organic radical generator and a reducing agent, and continuing the polymerization by post-adding a chain transfer agent batchwise during the polymerization to obtain an emulsion polymerization liquid; a coagulation step of adding the obtained emulsion polymerization liquid to a stirred coagulation liquid to coagulate and produce water-containing crumbs; a washing step of washing the produced water-containing crumbs; a dehydration step of dehydrating the washed water-containing crumbs; and a drying step of drying the dehydrated water-containing crumbs to a concentration of less than 1% by weight.

[0037] The method for producing an acrylic rubber of the present invention is preferably a method for producing the above-mentioned acrylic rubber.

[0038] In the method for producing the acrylic rubber of the present invention, it is preferable to carry out emulsion polymerization using a phosphate ester salt or a sulfate ester salt as an emulsifier in the emulsion polymerization step, and it is preferable to coagulate the polymer solution produced in the emulsion polymerization step by bringing it into contact with a coagulant containing an alkali metal salt or a Group 2 metal salt of the periodic table.

[0039] In the method for producing acrylic rubber of the present invention, it is preferable that the polymerization liquid produced in the emulsion polymerization step is brought into contact with a coagulant to solidify, and then melt-kneaded and dried. It is preferable that the melt-kneading and drying are carried out in a substantially water-free state, and that the melt-kneading and drying are carried out under reduced pressure. Furthermore, in the method for producing acrylic rubber of the present invention, it is preferable that the melt-kneading and drying of the water-containing crumbs are carried out using a screw-type twin-screw extruder dryer, and it is preferable that the maximum torque of the screw-type twin-screw extruder dryer during the melt-kneading and drying is in the range of 5 to 125 N·m. Furthermore, in the method for producing acrylic rubber of the present invention, it is preferable that the acrylic rubber after melt-kneading and drying is cooled at a cooling rate of 40°C / hr or more.

[0040] In the method for producing acrylic rubber of the present invention, the coagulating agent concentration in the coagulating liquid is preferably 1% by weight or more. In the method for producing acrylic rubber of the present invention, the stirring speed of the coagulation liquid is preferably 100 rpm or more. In the method for producing an acrylic rubber of the present invention, the peripheral speed of the stirred coagulation liquid is preferably 1 m / s or more. In the method for producing an acrylic rubber of the present invention, it is preferable that the reducing agent is added later in the emulsion polymerization step. In the method for producing acrylic rubber of the present invention, it is preferable to wash, dehydrate, and dry the water-containing crumbs, the proportion of which is 50% by weight or more of which particle diameter is in the range of 710 μm to 6.7 mm.

[0041] The present invention also provides a rubber composition comprising a rubber component containing the above-mentioned acrylic rubber, a filler, and a crosslinking agent.

[0042] In the rubber composition of the present invention, the filler is preferably a reinforcing filler. Also, in the rubber composition of the present invention, the filler is preferably a carbon black. Also, in the rubber composition of the present invention, the filler is preferably a silica.

[0043] In the rubber composition of the present invention, the crosslinking agent is preferably an organic crosslinking agent. Also, in the rubber composition of the present invention, the crosslinking agent is preferably a polyvalent compound. Also, in the rubber composition of the present invention, the crosslinking agent is preferably an ionically crosslinkable compound. Also, in the rubber composition of the present invention, the crosslinking agent is preferably an ionically crosslinkable organic compound. Also, in the rubber composition of the present invention, the crosslinking agent is preferably a polyvalent ionic organic compound.

[0044] In the rubber composition of the present invention, the ion of the ion-crosslinking compound, ion-crosslinking organic compound, or polyvalent ionic organic compound serving as the crosslinking agent is preferably at least one ion-reactive group selected from the group consisting of an amino group, an epoxy group, a carboxyl group, and a thiol group.

[0045] In the rubber composition of the present invention, the crosslinking agent is preferably at least one polyvalent ion compound selected from the group consisting of polyamine compounds, polyepoxy compounds, polycarboxylic acid compounds, and polythiol compounds.

[0046] In the rubber composition of the present invention, the content of the crosslinking agent is preferably in the range of 0.001 to 20 parts by weight per 100 parts by weight of the rubber component.

[0047] The rubber composition of the present invention preferably further contains an antioxidant, and the antioxidant in the rubber composition of the present invention is preferably an amine-based antioxidant.

[0048] The present invention also provides a method for producing a rubber composition, which comprises mixing a rubber component containing the above-mentioned acrylic rubber, a filler, and, if necessary, an antioxidant, and then mixing a crosslinking agent therein.

[0049] The present invention further provides a cross-linked rubber product obtained by cross-linking the above rubber composition. In the cross-linked rubber product of the present invention, it is preferable that the cross-linking of the rubber composition is carried out after molding. Furthermore, in the cross-linked rubber product of the present invention, it is preferable that the cross-linking of the rubber composition is carried out by primary cross-linking and secondary cross-linking. [Effects of the Invention]

[0050] According to the present invention, there are provided an acrylic rubber that is highly excellent in injection moldability, water resistance, compression set resistance, and strength properties, an efficient method for producing the same, a high-quality rubber composition containing the acrylic rubber, and a cross-linked rubber obtained by cross-linking the same. [Brief explanation of the drawings]

[0051] [Figure 1] FIG. 1 is a diagram schematically illustrating an example of an acrylic rubber production system used in the production of acrylic rubber according to one embodiment of the present invention. [Figure 2] FIG. 2 is a diagram showing the configuration of the screw extruder of FIG. 1. [Figure 3] FIG. 2 is a diagram showing the configuration of a transportable cooling device used as the cooling device in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0052] The acrylic rubber of the present invention is characterized in that it comprises bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, bonding units derived from an ion-reactive group-containing monomer, and, as necessary, bonding units derived from other monomers, and has a weight-average molecular weight (Mw) of 1,000,000 to 5,000,000, a ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) in the range of 1.5 to 3, an ash content of 0.3% by weight or less, and a total content of sodium, sulfur, calcium, magnesium, and phosphorus in the ash of 80% by weight or more.

[0053] <Monomer component> The monomer component of the acrylic rubber of the present invention comprises at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and, if necessary, other copolymerizable monomers. In the present invention, the term "(meth)acrylic acid ester" is used as a general term for esters of acrylic acid and / or methacrylic acid.

[0054] The (meth)acrylic acid alkyl ester is not particularly limited, but typically, a (meth)acrylic acid alkyl ester having an alkyl group with 1 to 12 carbon atoms, preferably a (meth)acrylic acid alkyl ester having an alkyl group with 1 to 8 carbon atoms, and more preferably a (meth)acrylic acid alkyl ester having an alkyl group with 2 to 6 carbon atoms is used.

[0055] Specific examples of (meth)acrylic acid alkyl esters include methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, n-hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, and cyclohexyl (meth)acrylate. Of these, ethyl (meth)acrylate and n-butyl (meth)acrylate are preferred, and ethyl acrylate and n-butyl acrylate are more preferred.

[0056] The (meth)acrylic acid alkoxyalkyl ester is not particularly limited, but typically an (meth)acrylic acid alkoxyalkyl ester having an alkoxyalkyl group of 2 to 12, preferably an (meth)acrylic acid alkoxyalkyl ester having an alkoxyalkyl group of 2 to 8, more preferably an (meth)acrylic acid alkoxyalkyl ester having an alkoxyalkyl group of 2 to 6 carbon atoms is used.

[0057] Specific examples of (meth)acrylic acid alkoxyalkyl esters include methoxymethyl (meth)acrylate, methoxyethyl (meth)acrylate, methoxypropyl (meth)acrylate, methoxybutyl (meth)acrylate, ethoxymethyl (meth)acrylate, ethoxyethyl (meth)acrylate, propoxyethyl (meth)acrylate, butoxyethyl (meth)acrylate, etc. Among these, methoxyethyl (meth)acrylate, ethoxyethyl (meth)acrylate, etc. are preferred, and methoxyethyl acrylate and ethoxyethyl acrylate are more preferred.

[0058] At least one (meth)acrylic acid ester selected from the group consisting of these (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters is used either alone or in combination of two or more thereof, and the proportion of this ester in the total monomer components is usually 50 to 99.99% by weight, preferably 62 to 99.95% by weight, more preferably 74 to 99.9% by weight, particularly preferably 80 to 99.5% by weight, and most preferably 87 to 99% by weight, which is suitable because the acrylic rubber has excellent weather resistance, heat resistance, and oil resistance.

[0059] The ion-reactive group-containing monomer is not particularly limited as long as it has a functional group that is involved in an ionic reaction, and may be appropriately selected depending on the intended use. Usually, it includes a monomer having at least one functional group selected from the group consisting of a carboxyl group, an epoxy group, and a chlorine atom. Preferably, it is a monomer having a carboxyl group and an epoxy group, and more preferably, it is a monomer having a carboxyl group, which can highly improve the short-term crosslinkability and the compression set resistance and water resistance of the crosslinked product.

[0060] The monomer having a carboxyl group is not particularly limited, but an ethylenically unsaturated carboxylic acid can be suitably used. Examples of the ethylenically unsaturated carboxylic acid include an ethylenically unsaturated monocarboxylic acid, an ethylenically unsaturated dicarboxylic acid, and an ethylenically unsaturated dicarboxylic acid monoester. Among these, an ethylenically unsaturated dicarboxylic acid monoester is particularly preferred because it can further improve the compression set resistance when the acrylic rubber is made into a rubber cross-linked product.

[0061] The ethylenically unsaturated monocarboxylic acid is not particularly limited, but is preferably an ethylenically unsaturated monocarboxylic acid having 3 to 12 carbon atoms, such as acrylic acid, methacrylic acid, α-ethylacrylic acid, crotonic acid, and cinnamic acid.

[0062] The ethylenically unsaturated dicarboxylic acid is not particularly limited, but is preferably an ethylenically unsaturated dicarboxylic acid having 4 to 12 carbon atoms, and examples thereof include butenedioic acids such as fumaric acid and maleic acid, itaconic acid, citraconic acid, etc. The ethylenically unsaturated dicarboxylic acid also includes those that exist as an anhydride.

[0063] The ethylenically unsaturated dicarboxylic acid monoester is not particularly limited, but typically includes an ethylenically unsaturated dicarboxylic acid having 4 to 12 carbon atoms and an alkyl monoester having 1 to 12 carbon atoms, preferably an ethylenically unsaturated dicarboxylic acid having 4 to 6 carbon atoms and an alkyl monoester having 2 to 8 carbon atoms, and more preferably an alkyl monoester having 2 to 6 carbon atoms of butenedioic acid having 4 carbon atoms.

[0064] Specific examples of the ethylenically unsaturated dicarboxylic acid monoester include butenedioic acid monoalkyl esters such as monomethyl fumarate, monoethyl fumarate, mono-n-butyl fumarate, monomethyl maleate, monoethyl maleate, mono-n-butyl maleate, monocyclopentyl fumarate, monocyclohexyl fumarate, monocyclohexenyl fumarate, monocyclopentyl maleate, and monocyclohexyl maleate; and itaconic acid monoalkyl esters such as monomethyl itaconate, monoethyl itaconate, mono-n-butyl itaconate, and monocyclohexyl itaconate; and among these, mono-n-butyl fumarate and mono-n-butyl maleate are preferred, with mono-n-butyl fumarate being particularly preferred.

[0065] Examples of the monomer having an epoxy group include epoxy group-containing (meth)acrylic acid esters such as glycidyl (meth)acrylate; epoxy group-containing vinyl ethers such as allyl glycidyl ether and vinyl glycidyl ether; and the like.

[0066] The monomer having a chlorine atom is not particularly limited, and examples thereof include unsaturated alcohol esters of chlorine atom-containing saturated carboxylic acids, (meth)acrylic acid chloroalkyl esters, (meth)acrylic acid chloroacyloxyalkyl esters, (meth)acrylic acid (chloroacetylcarbamoyloxy)alkyl esters, chlorine atom-containing unsaturated ethers, chlorine atom-containing unsaturated ketones, chloromethyl group-containing aromatic vinyl compounds, chlorine atom-containing unsaturated amides, and chloroacetyl group-containing unsaturated monomers.

[0067] Specific examples of unsaturated alcohol esters of chlorine-containing saturated carboxylic acids include vinyl chloroacetate, vinyl 2-chloropropionate, and allyl chloroacetate. Specific examples of (meth)acrylic acid chloroalkyl esters include chloromethyl (meth)acrylate, 1-chloroethyl (meth)acrylate, 2-chloroethyl (meth)acrylate, 1,2-dichloroethyl (meth)acrylate, 2-chloropropyl (meth)acrylate, 3-chloropropyl (meth)acrylate, and 2,3-dichloropropyl (meth)acrylate. Specific examples of (meth)acrylic acid chloroacyloxyalkyl esters include 2-(chloroacetoxy)ethyl (meth)acrylate, 2-(chloroacetoxy)propyl (meth)acrylate, 3-(chloroacetoxy)propyl (meth)acrylate, and 3-(hydroxychloroacetoxy)propyl (meth)acrylate. Examples of (meth)acrylic acid (chloroacetylcarbamoyloxy) alkyl esters include 2-(chloroacetylcarbamoyloxy)ethyl (meth)acrylate and 3-(chloroacetylcarbamoyloxy)propyl (meth)acrylate. Specific examples of chlorine atom-containing unsaturated ethers include chloromethyl vinyl ether, 2-chloroethyl vinyl ether, 3-chloropropyl vinyl ether, 2-chloroethyl allyl ether, and 3-chloropropyl allyl ether. Specific examples of chlorine atom-containing unsaturated ketones include 2-chloroethyl vinyl ketone, 3-chloropropyl vinyl ketone, and 2-chloroethyl allyl ketone. Specific examples of chloromethyl group-containing aromatic vinyl compounds include p-chloromethylstyrene, m-chloromethylstyrene, o-chloromethylstyrene, and p-chloromethyl-α-methylstyrene. Specific examples of chlorine atom-containing unsaturated amides include N-chloromethyl(meth)acrylamide. Specific examples of the chloroacetyl group-containing unsaturated monomer include 3-(hydroxychloroacetoxy)propyl allyl ether and p-vinylbenzyl chloroacetate.

[0068] These ion-reactive group-containing monomers may be used alone or in combination of two or more, and the proportion of these in the total monomer components is usually in the range of 0.01 to 10% by weight, preferably 0.05 to 8% by weight, more preferably 0.1 to 6% by weight, particularly preferably 0.5 to 5% by weight, and most preferably 1 to 3% by weight.

[0069] Monomers other than those mentioned above (abbreviated as "other monomers" in the present invention) that can be used together with the above-mentioned monomers as needed are not particularly limited as long as they are copolymerizable with the above-mentioned monomers, and examples thereof include aromatic vinyls such as styrene, α-methylstyrene, and divinylbenzene; ethylenically unsaturated nitriles such as acrylonitrile and methacrylonitrile; acrylamide-based monomers such as acrylamide and methacrylamide; and olefin-based monomers such as ethylene, propylene, vinyl acetate, ethyl vinyl ether, and butyl vinyl ether.

[0070] These other monomers may be used alone or in combination of two or more, and the proportion of these other monomers in the total monomer components is usually kept within the range of 0 to 40% by weight, preferably 0 to 30% by weight, more preferably 0 to 20% by weight, particularly preferably 0 to 15% by weight, and most preferably 0 to 10% by weight.

[0071] <Acrylic rubber> The acrylic rubber of the present invention is made from the above-mentioned monomer components and is characterized by having a weight average molecular weight (Mw), a ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn), an ash content, and an ash component content all within specific ranges.

[0072] The monomer of the acrylic rubber of the present invention comprises bonding units from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and other monomers contained as necessary, and the proportion of each in the acrylic rubber is such that the bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters are usually 50 to 99.99% by weight, preferably 62 to 99% by weight. The content of bonding units derived from ion-reactive group-containing monomers is usually 0.01 to 10% by weight, preferably 0.05 to 8% by weight, more preferably 0.1 to 6% by weight, particularly preferably 0.5 to 5% by weight, and most preferably 1 to 3% by weight, and the content of bonding units derived from other monomers is usually 0 to 40% by weight, preferably 0 to 30% by weight, more preferably 0 to 20% by weight, particularly preferably 0 to 15% by weight, and most preferably 0 to 10% by weight. When the monomer composition of the acrylic rubber is within this range, properties such as short-term crosslinkability, compression set resistance, weather resistance, heat resistance, and oil resistance are highly balanced, making it suitable.

[0073] The weight average molecular weight (Mw) of the acrylic rubber of the present invention is preferably in the range of 1,000,000 to 5,000,000, preferably 1,100,000 to 4,000,000, more preferably 1,200,000 to 3,000,000, particularly preferably 1,500,000 to 2,500,000, and most preferably 1,600,000 to 2,200,000, whereby the injection moldability, strength properties, and compression set resistance properties of the acrylic rubber are highly balanced.

[0074] The number average molecular weight (Mn) of the acrylic rubber of the present invention is not particularly limited, but when it is in the range of usually 300,000 to 1,500,000, preferably 350,000 to 1,300,000, more preferably 400,000 to 1,100,000, particularly preferably 500,000 to 1,000,000, and most preferably 550,000 to 750,000, the injection moldability, strength properties, and compression set resistance properties of the acrylic rubber are well balanced and are therefore suitable.

[0075] The z-average molecular weight (Mz) of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the intended use, but is usually 1.5 million or more, preferably 2 million or more, more preferably 2.5 million or more, and particularly preferably 3 million or more. The z-average molecular weight (Mz) of the acrylic rubber of the present invention is also preferably in the range of usually 1.5 million to 6 million, preferably 1.8 million to 5.5 million, more preferably 2 million to 5 million, particularly preferably 2.2 million to 4.5 million, and most preferably 2.5 million to 4 million, because the injection moldability, Banbury processability, strength properties, and compression set resistance properties of the acrylic rubber are highly balanced.

[0076] The ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) of the acrylic rubber of the present invention is preferably in the range of 1.5 to 3, more preferably 1.8 to 2.7, more preferably 2 to 2.6, and particularly preferably 2.2 to 2.6, whereby the injection moldability of the acrylic rubber and the strength properties and compression set resistance when crosslinked are well balanced. In particular, when the ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) of the acrylic rubber of the present invention is in this range, the acrylic rubber exhibits outstandingly excellent properties in all of the shape formability, fusion properties, and mold releasability of the injection moldability, and the strength properties and compression set resistance of the crosslinked product are well balanced and preferred.

[0077] The molecular weight distribution of the acrylic rubber of the present invention, with emphasis on the high molecular weight region, is not particularly limited, but when the ratio (Mz / Mw) of the z-average molecular weight (Mz) to the weight-average molecular weight (Mw) is typically 1.3 or higher, preferably 1.4 or higher, more preferably 1.5 or higher, particularly preferably 1.6 or higher, and most preferably 1.7 or higher, it is preferable to prevent deterioration in mold releasability and shape formability (burr formation) that would occur if the weight-average molecular weight (Mw) were too low. Furthermore, when the molecular weight distribution (Mz / Mw) of the acrylic rubber of the present invention, with emphasis on the high molecular weight region, is typically 4 or lower, preferably 3 or lower, more preferably 2.5 or lower, particularly preferably 2.2 or lower, and most preferably 2 or lower, it is preferable to prevent deterioration in shape formability (insufficient shape) and fusion properties that would occur if the weight-average molecular weight (Mw) were too high. When the molecular weight distribution (Mz / Mw) of the acrylic rubber of the present invention, with emphasis on the high molecular weight region, is further in the range of usually 1.3 to 3, preferably 1.4 to 2.5, more preferably 1.5 to 2.2, particularly preferably 1.6 to 2, and most preferably 1.7 to 1.9, injection moldability and Banbury processability can be highly improved without impairing the strength properties of the acrylic rubber, and this is suitable.

[0078] The measurement of the molecular weights (Mn, Mw, Mz) and molecular weight distributions (Mw / Mn, Mz / Mw) of the acrylic rubber of the present invention is not particularly limited, but it is preferable to measure the absolute molecular weights (Mn, Mw, Mz) and absolute molecular weight distributions (Mw / Mn, Mz / Mw) by the GPC-MALS method, since each property can be determined more accurately.

[0079] The measurement solvent for the GPC-MALS method used to measure the molecular weight (Mn, Mw, Mz) and molecular weight distribution (Mw / Mn, Mz / Mw) of the acrylic rubber of the present invention is not particularly limited as long as it can dissolve and measure the acrylic rubber of the present invention, but dimethylformamide-based solvents are preferred. The dimethylformamide-based solvent used is not particularly limited as long as it is primarily composed of dimethylformamide, but 100% dimethylformamide or dimethylformamide with a polar substance added can be used. The proportion of dimethylformamide in the dimethylformamide-based solvent is 90% by weight or more, preferably 95% by weight or more, and more preferably 97% by weight or more. The compound added to dimethylformamide is not particularly limited, but in the present invention, a solution in which 0.05 mol / L of lithium chloride and 0.01% of 37% concentrated hydrochloric acid are added to dimethylformamide is particularly preferred.

[0080] The ash content of the acrylic rubber of the present invention is 0.3% by weight or less, preferably 0.2% by weight or less, more preferably 0.18% by weight or less, particularly preferably 0.15% by weight or less, and most preferably 0.13% by weight or less. When the ash content is within this range, the compatibility of water resistance, storage stability, strength properties, processability and injection moldability as an acrylic rubber is highly balanced and is suitable.

[0081] There is no particular limitation on the lower limit of the ash content of the acrylic rubber of the present invention, and it may be selected appropriately depending on the intended use, but when the ash content is usually 0.0001% by weight or more, preferably 0.0005% by weight or more, more preferably 0.001% by weight or more, particularly preferably 0.005% by weight or more, and most preferably 0.01% by weight or more, metal adhesion of the rubber is reduced, resulting in excellent workability and also excellent injection moldability, particularly mold releasability, and these are suitable.

[0082] When the acrylic rubber of the present invention has a high balance of water resistance, storage stability, strength properties, processability, workability, and injection moldability compatibility and releasability, the ash content is usually in the range of 0.0001 to 0.3% by weight, preferably 0.0005 to 0.2% by weight, more preferably 0.001 to 0.18% by weight, particularly preferably 0.005 to 0.15% by weight, and most preferably 0.01 to 0.13% by weight.

[0083] When the total amount of sodium, magnesium, calcium, phosphorus and sulfur in the ash of the acrylic rubber of the present invention is 80% by weight or more, preferably 90% by weight or more, and more preferably 95% by weight or more, the water resistance of the acrylic rubber and the fusion properties and releasability in injection molding are highly improved, and this is suitable.

[0084] There are no particular limitations on the total amount of magnesium and phosphorus in the ash of the acrylic rubber of the present invention, and it may be selected appropriately depending on the intended use, but when it is usually 30% by weight or more, preferably 50% by weight or more, more preferably 70% by weight or more, particularly preferably 80% by weight or more, and most preferably 90% by weight or more, the acrylic rubber will have a high level of balance in terms of water resistance, strength properties, injection molding compatibility, releasability and processability, and is therefore suitable.

[0085] The amount of magnesium in the ash of the acrylic rubber of the present invention is not particularly limited and is selected appropriately depending on the intended use, but is usually 10% by weight or more, preferably 15 to 60% by weight, more preferably 20 to 50% by weight, particularly preferably 25 to 45% by weight, and most preferably in the range of 30 to 40% by weight.

[0086] The amount of phosphorus in the ash of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the intended use, but is usually 10% by weight or more, preferably 20 to 90% by weight, more preferably 30 to 80% by weight, particularly preferably 40 to 70% by weight, and most preferably in the range of 50 to 60% by weight.

[0087] The ratio of magnesium to phosphorus in the ash of the acrylic rubber of the present invention ([Mg] / [P]) is not particularly limited and may be selected appropriately depending on the intended use, but when the ratio is in the range of usually 0.4 to 2.5, preferably 0.45 to 1.2, more preferably 0.45 to 1, particularly preferably 0.5 to 0.8, and most preferably 0.55 to 0.7 by weight, the acrylic rubber will have a high level of balance in terms of water resistance, strength properties, injection molding compatibility, releasability, and processability.

[0088] Here, the ash content in the acrylic rubber is mainly derived from the emulsifier used when the monomer components are emulsified and emulsion polymerized, and the coagulant used when the emulsion polymerization liquid is coagulated, but the total ash content and the magnesium and phosphorus contents in the ash vary not only depending on the conditions of the emulsion polymerization step and the coagulation step, but also on the conditions of each subsequent step.

[0089] In order to achieve a high level of balance between the water resistance, strength properties, injection molding compatibility, releasability, and processability of the acrylic rubber, it is particularly suitable to use an anionic emulsifier, cationic emulsifier, or nonionic emulsifier, as described below, preferably an anionic emulsifier, and more preferably a phosphate ester salt or a sulfate ester salt, as an emulsifier. The water resistance of acrylic rubber is uniquely correlated with the ash content in the acrylic rubber and the total amount of sodium, magnesium, calcium, phosphorus, and sulfur in the ash, and the use of the above-mentioned emulsifiers is preferred because it allows for an even higher level of balance between the water resistance, strength properties, injection molding compatibility, releasability, and processability of the acrylic rubber.

[0090] In order to achieve a high level of balance between the water resistance, strength properties, injection molding compatibility, releasability, and processability of the acrylic rubber, it is particularly preferable to use a metal salt, described below, preferably an alkali metal salt or a Group 2 metal salt of the periodic table, as a coagulant. The water resistance of acrylic rubber is primarily correlated with the ash content in the acrylic rubber and the total amount of sodium, magnesium, calcium, phosphorus, and sulfur in the ash, but the use of the above coagulant is preferable because it further achieves a high level of balance between the water resistance, strength properties, injection molding compatibility, releasability, and processability of the acrylic rubber.

[0091] The glass transition temperature (Tg) of the acrylic rubber of the present invention may be appropriately selected depending on the intended use of the acrylic rubber, but is generally excellent in processability and cold resistance when it is 20°C or lower, preferably 10°C or lower, and more preferably 0°C or lower. The lower limit of the glass transition temperature (Tg) of the acrylic rubber is not particularly limited, but is generally -80°C or higher, preferably -60°C or higher, and more preferably -40°C or higher. By setting the glass transition temperature at or above the lower limit, it is possible to achieve excellent oil resistance and heat resistance, and by setting it at or below the upper limit, it is possible to achieve excellent processability, crosslinkability, and cold resistance.

[0092] The complex viscosity of the acrylic rubber of the present invention at 100°C ([η]100°C) is not particularly limited and may be selected appropriately depending on the intended use, but when it is in the range of usually 15,000 [Pa·s] or less, preferably 1,000 to 10,000 [Pa·s], more preferably 2,000 to 8,000 [Pa·s], particularly preferably 3,000 to 5,000 [Pa·s], and most preferably 3,500 to 4,000 [Pa·s], excellent processability, oil resistance, injection moldability, and shape retention are achieved, and it is suitable.

[0093] The ratio ([η]100°C / [η]60°C) of the complex viscosity at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the intended use, but is usually 0.5 or more, preferably 0.6 or more, and more preferably 0.7 or more. The ratio ([η]100°C / [η]60°C) of the complex viscosity at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) of the acrylic rubber of the present invention is also preferably in the range of usually 0.5 to 0.99, preferably 0.55 to 0.95, more preferably 0.6 to 0.9, particularly preferably 0.65 to 0.85, and most preferably 0.7 to 0.8, in which case processability, oil resistance, and shape retention are highly balanced.

[0094] The gel content of the acrylic rubber of the present invention is not particularly limited and may be selected appropriately depending on the intended use, but when the methyl ethyl ketone insoluble content is usually 50% by weight or less, preferably 30% by weight or less, more preferably 15% by weight or less, particularly preferably 10% by weight or less, and most preferably 5% by weight or less, the processability during kneading in a Banbury mix or the like and the injection moldability are highly improved, and this is suitable.

[0095] Although there are no particular limitations on the values ​​of the gel amount of the acrylic rubber of the present invention when measured at any 20 points, it is preferable that all 20 points fall within a range of (average value ±5) weight%, and preferably all 20 points fall within a range of (average value ±3) weight%, since this eliminates processability variations and stabilizes the physical properties of the rubber mixture and cross-linked rubber. Note that when the gel amount of the acrylic rubber veil is measured at any 20 points, all 20 values ​​fall within a range of the average value ±5 means that the gel amounts measured at all 20 points fall within a range of (average value -5) to (average value +5) weight%, and for example, if the average value of the measured gel amounts is 20 weight%, this means that all 20 measured values ​​fall within a range of 15 to 25 weight%.

[0096] The acrylic rubber of the present invention is preferably one which is obtained by melt-kneading and drying the water-containing crumbs produced in the coagulation step in a state where almost all of the water has been removed (water content less than 1% by weight) using a screw-type twin-screw extruder dryer, as this provides a high level of balance between Banbury processability and strength properties.

[0097] The specific gravity of the acrylic rubber of the present invention is not particularly limited, but is generally 0.7 or higher, preferably 0.8 or higher, more preferably 0.9 or higher, particularly preferably 0.95 or higher, and most preferably 1 or higher, which is suitable for containing almost no air and providing excellent storage stability. The specific gravity of the acrylic rubber molded product of the present invention is also generally within the range of 0.7 to 1.6, preferably 0.8 to 1.5, more preferably 0.9 to 1.4, particularly preferably 0.95 to 1.3, and most preferably 1.0 to 1.2, which is suitable for achieving a high balance of productivity, storage stability, and the stability of the crosslinking properties of the crosslinked product. An excessively low specific gravity of the acrylic rubber indicates a high amount of air in the acrylic rubber, which is undesirable as it significantly affects storage stability, including oxidation degradation. The specific gravity of the acrylic rubber of the present invention is calculated by dividing the mass by the volume including voids, i.e., by dividing the mass measured in air by the buoyancy, and is usually measured in accordance with JIS K6268 Crosslinked Rubber - Density Measurement, Method A.

[0098] Furthermore, the acrylic rubber of the present invention is preferably obtained by drying the water-containing crumbs produced in the solidification step under reduced pressure using a screw-type twin-screw extruder dryer, or by melting the crumbs under reduced pressure and extruding and drying them, as this provides excellent and highly balanced storage stability, injection moldability, and strength properties.

[0099] The water content of the acrylic rubber of the present invention is not particularly limited and is selected appropriately depending on the intended use, but when it is generally less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less, the vulcanization characteristics of the acrylic rubber are optimized and properties such as heat resistance and water resistance are highly improved, which is preferable.

[0100] The pH of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the intended use, but the storage stability of the acrylic rubber is highly improved when the pH is generally 6 or less, preferably 2 to 6, more preferably 2.5 to 5.5, and most preferably in the range of 3 to 5.

[0101] The Mooney viscosity (ML1+4, 100°C) of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the intended use, but when it is usually in the range of 10 to 150, preferably 20 to 100, and more preferably 25 to 70, the processability and strength properties of the acrylic rubber are well balanced and it is suitable.

[0102] The shape of the acrylic rubber of the present invention is not particularly limited and may be appropriately selected depending on the purpose of use. For example, the acrylic rubber may be in any shape such as powder, crumb, strand, sheet, or bale, but is preferably in a sheet or bale shape, as these are excellent in workability and storage stability and are therefore suitable.

[0103] When the acrylic rubber of the present invention is in sheet form, the thickness is not particularly limited and is selected appropriately depending on the intended use, but is typically within the range of 1 to 40 mm, preferably 2 to 35 mm, more preferably 3 to 30 mm, and most preferably 5 to 25 mm, providing a high level of balance between workability, storage stability, and productivity. The width of the sheet-like acrylic rubber of the present invention is also selected appropriately depending on the intended use, but is typically within the range of 300 to 1200 mm, preferably 400 to 1000 mm, and more preferably 500 to 800 mm, providing particularly excellent handleability. The length of the sheet-like acrylic rubber sheet of the present invention is not particularly limited, but is typically within the range of 300 to 1200 mm, preferably 400 to 1000 mm, and more preferably 500 to 800 mm, providing particularly excellent handleability.

[0104] When the acrylic rubber of the present invention is in the form of a veil, the size is not particularly limited and can be selected appropriately depending on the intended use, but it is appropriate that the width is usually 100 to 800 mm, preferably 200 to 500 mm, and more preferably 250 to 450 mm, the length is usually 300 to 1,200 mm, preferably 400 to 1,000 mm, and more preferably 500 to 800 mm, and the height (thickness) is usually 50 to 500 mm, preferably 100 to 300 mm, and more preferably 150 to 250 mm. The shape of the acrylic rubber veil of the present invention is also not limited and can be selected appropriately depending on the intended use of the acrylic rubber veil, but in many cases a rectangular parallelepiped is suitable.

[0105] <Acrylic rubber manufacturing method> The method for producing the acrylic rubber is not particularly limited, and examples thereof include a method for producing an acrylic rubber including: an emulsifying step of emulsifying, with water and an emulsifier, a monomer component consisting of at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and, as necessary, other monomers; an emulsion polymerization step of initiating polymerization in the presence of a redox catalyst consisting of an organic radical generator and a reducing agent, and continuing the polymerization by post-adding a chain transfer agent batchwise during the polymerization to obtain an emulsion polymerization liquid; a coagulation step of adding the obtained emulsion polymerization liquid to a stirred coagulation liquid to coagulate and produce water-containing crumbs; a washing step of washing the produced water-containing crumbs; a dehydration step of dehydrating the washed water-containing crumbs; and a drying step of drying the dehydrated water-containing crumbs to a concentration of less than 1% by weight.

[0106] (Emulsification process) The emulsification step in the method for producing the acrylic rubber of the present invention is a step of emulsifying a monomer component consisting of at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and, if necessary, other monomers, with water and an emulsifier.

[0107] (monomer component) The monomer components used in the present invention comprise at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and other copolymerizable monomers as needed, and are the same as the examples and preferred ranges of the monomer components already described. The amounts of the monomer components used are also as already described, and in emulsion polymerization, the respective monomers may be appropriately selected so as to obtain the above-described composition of the acrylic rubber of the present invention.

[0108] (emulsifier) The emulsifier used in the present invention is not particularly limited, but examples thereof include anionic emulsifiers, cationic emulsifiers, and nonionic emulsifiers, with anionic emulsifiers being preferred.

[0109] The anionic emulsifier is not particularly limited, and examples thereof include salts of fatty acids such as myristic acid, palmitic acid, oleic acid, and linolenic acid; alkylbenzenesulfonates such as sodium dodecylbenzenesulfonate; sulfates such as sodium lauryl sulfate; phosphates such as polyoxyalkylene alkyl ether phosphates; and alkyl sulfosuccinates. Among these anionic emulsifiers, phosphates and sulfates are preferred, with phosphates being particularly preferred, and divalent phosphates being most preferred, as they can provide a high level of balance between the water resistance, strength, injection molding fusibility, mold releasability, and processability of the resulting acrylic rubber. Furthermore, alkali metal salts of phosphates and sulfates, and more preferably sodium salts of phosphates and sulfates, are preferred as these can provide a high level of balance between the water resistance, strength, mold releasability, and processability of the resulting acrylic rubber.

[0110] The divalent phosphate salt is not particularly limited as long as it can be used as an emulsifier in an emulsion polymerization reaction, and examples thereof include alkyloxypolyoxyalkylene phosphate salts, alkylphenyloxypolyoxyalkylene phosphate salts, etc., and among these, metal salts of these are preferred, alkali metal salts of these are more preferred, and sodium salts of these are most preferred.

[0111] Examples of the alkyloxy polyoxyalkylene phosphate salts include alkyloxy polyoxyethylene phosphate salts and alkyloxy polyoxypropylene phosphate salts, and among these, alkyloxy polyoxyethylene phosphate salts are preferred.

[0112] Specific examples of alkyloxypolyoxyethylene phosphate ester salts include octyloxydioxyethylene phosphate ester, octyloxytrioxyethylene phosphate ester, octyloxytetraoxyethylene phosphate ester, decyloxytetraoxyethylene phosphate ester, dodecyloxytetraoxyethylene phosphate ester, tridecyloxytetraoxyethylene phosphate ester, tetradecyloxytetraoxyethylene phosphate ester, hexadecyloxytetraoxyethylene phosphate ester, octadecyloxytetraoxyethylene phosphate ester, octyloxypentaoxyethylene phosphate ester, decyloxypentaoxyethylene phosphate ester, dodecyloxypentaoxyethylene phosphate ester, tridecyloxypentaoxyethylene phosphate ester, tetradecyloxypentaoxyethylene phosphate ester, hexadecyloxypentaoxyethylene phosphate ester, octyloxypentaoxyethylene phosphate ester, and metal salts of hexaoxyethylene phosphate, octyloxyhexaoxyethylene phosphate, decyloxyhexaoxyethylene phosphate, dodecyloxyhexaoxyethylene phosphate, tridecyloxyhexaoxyethylene phosphate, tetradecyloxyhexaoxyethylene phosphate, hexadecyloxyhexaoxyethylene phosphate, octadecyloxyhexaoxyethylene phosphate, octyloxyoctaoxyethylene phosphate, decyloxyoctaoxyethylene phosphate, dodecyloxyoctaoxyethylene phosphate, tridecyloxyoctaoxyethylene phosphate, tetradecyloxyoctaoxyethylene phosphate, hexadecyloxyoctaoxyethylene phosphate, and octadecyloxyoctaoxyethylene phosphate. Among these, alkali metal salts thereof, particularly sodium salts, are preferred.

[0113] Specific examples of alkyloxypolyoxypropylene phosphate salts include octyloxydioxypropylene phosphate, octyloxytrioxypropylene phosphate, octyloxytetraoxypropylene phosphate, decyloxytetraoxypropylene phosphate, dodecyloxytetraoxypropylene phosphate, tridecyloxytetraoxypropylene phosphate, tetradecyloxytetraoxypropylene phosphate, hexadecyloxytetraoxypropylene phosphate, octadecyloxytetraoxypropylene phosphate, octyloxypentaoxypropylene phosphate, decyloxypentaoxypropylene phosphate, dodecyloxypentaoxypropylene phosphate, tridecyloxypentaoxypropylene phosphate, tetradecyloxypentaoxypropylene phosphate, hexadecyloxypentaoxypropylene phosphate, octyloxypentaoxypropylene phosphate, decyloxypentaoxypropylene phosphate, dodecyloxypentaoxypropylene phosphate, tridecyloxypentaoxypropylene phosphate, tetradecyloxypentaoxypropylene phosphate, hexadecyloxypentaoxypropylene phosphate, octadecyloxypentaoxypropylene phosphate, Examples of the octadecyloxypropylene phosphate include octyloxyhexaoxypropylene phosphate, octyloxyhexaoxypropylene phosphate, decyloxyhexaoxypropylene phosphate, dodecyloxyhexaoxypropylene phosphate, tridecyloxyhexaoxypropylene phosphate, tetradecyloxyhexaoxypropylene phosphate, hexadecyloxyhexaoxypropylene phosphate, octadecyloxyhexaoxypropylene phosphate, octyloxyoctaoxypropylene phosphate, decyloxyoctaoxypropylene phosphate, dodecyloxyoctaoxypropylene phosphate, tridecyloxyoctaoxyethylene phosphate, tetradecyloxyoctaoxypropylene phosphate, hexadecyloxyoctaoxypropylene phosphate, octadecyloxyoctaoxypropylene phosphate, and metal salts thereof. Among these, alkali metal salts, particularly sodium salts thereof, are preferred.

[0114] Specific examples of the alkylphenyloxy polyoxyalkylene phosphate salts include alkylphenyloxy polyoxyethylene phosphate salts and alkylphenyloxy polyoxypropylene phosphate salts, and among these, alkylphenyloxy polyoxyethylene phosphate salts are preferred.

[0115] Specific examples of alkylphenyloxypolyoxyethylene phosphate ester salts include methyloxytetraoxyethylene phosphate ester, ethylphenyloxytetraoxyethylene phosphate ester, butylphenyloxytetraoxyethylene phosphate ester, hexylphenyloxytetraoxyethylene phosphate ester, nonylphenyloxytetraoxyethylene phosphate ester, dodecylphenyloxytetraoxyethylene phosphate ester, octadecyloxytetraoxyethylene phosphate ester, methylphenyloxypentaoxyethylene phosphate ester, ethylphenyloxypentaoxyethylene phosphate ester, butylphenyloxypentaoxyethylene phosphate ester, hexylphenyloxypentaoxyethylene phosphate ester, nonylphenyloxypentaoxyethylene phosphate ester, dodecylphenyloxypentaoxyethylene phosphate ester, and metal salts thereof, such as hexaoxyethylene phosphate, methylphenyloxyhexaoxyethylene phosphate, ethylphenyloxyhexaoxyethylene phosphate, butylphenyloxyhexaoxyethylene phosphate, hexylphenyloxyhexaoxyethylene phosphate, nonylphenyloxyhexaoxyethylene phosphate, dodecylphenyloxyhexaoxyethylene phosphate, methylphenyloxyhexaoxyethylene phosphate, ethylphenyloxyoctaoxyethylene phosphate, butylphenyloxyoctaoxyethylene phosphate, hexylphenyloxyoctaoxyethylene phosphate, nonylphenyloxyoctaoxyethylene phosphate, and dodecylphenyloxyoctaoxyethylene phosphate. Among these, alkali metal salts thereof, particularly sodium salts, are preferred.

[0116] Specific examples of alkylphenyloxypolyoxypropylene phosphate salts include methylphenyloxytetraoxypropylene phosphate, ethylphenyloxytetraoxypropylene phosphate, butylphenyloxytetraoxypropylene phosphate, hexylphenyloxytetraoxypropylene phosphate, nonylphenyloxytetraoxypropylene phosphate, dodecylphenyloxytetraoxypropylene phosphate, methylphenyloxypentaoxypropylene phosphate, ethylphenyloxypentaoxypropylene phosphate, butylphenyloxypentaoxypropylene phosphate, hexylphenyloxypentaoxypropylene phosphate, nonylphenyloxypentaoxypropylene phosphate, dodecylphenyloxypentaoxypropylene phosphate, methyl Examples of suitable phosphates include metal salts of phenyloxyhexaoxypropylene phosphate, ethylphenyloxyhexaoxypropylene phosphate, butylphenyloxyhexaoxypropylene phosphate, hexylphenyloxyhexaoxypropylene phosphate, nonylphenyloxyhexaoxypropylene phosphate, dodecylphenyloxyhexaoxypropylene phosphate, methylphenyloxyoctaoxypropylene phosphate, ethylphenyloxyoctaoxypropylene phosphate, butylphenyloxyoctaoxypropylene phosphate, hexylphenyloxyoctaoxyethylene phosphate, nonylphenyloxyoctaoxypropylene phosphate, and dodecylphenyloxyoctaoxypropylene phosphate. Among these, alkali metal salts thereof, particularly sodium salts, are preferred.

[0117] As the phosphate ester salt, a monovalent phosphate ester salt such as a sodium di(alkyloxypolyoxyalkylene) phosphate ester salt can be used alone or in combination with a divalent phosphate ester salt. Examples of sulfate salts include sodium lauryl sulfate, potassium lauryl sulfate, ammonium lauryl sulfate, sodium myristyl sulfate, sodium polyoxyethylene alkyl sulfate, and sodium polyoxyethylene alkylaryl sulfate, with sodium lauryl sulfate being preferred.

[0118] Examples of cationic emulsifiers include alkyltrimethylammonium chloride, dialkylammonium chloride, and benzylammonium chloride.

[0119] Examples of nonionic emulsifiers include polyoxyalkylene fatty acid esters such as polyoxyethylene stearate ester; polyoxyalkylene alkyl ethers such as polyoxyethylene dodecyl ether; polyoxyalkylene alkylphenol ethers such as polyoxyethylene nonylphenyl ether; and polyoxyethylene sorbitan alkyl esters. Polyoxyalkylene alkyl ethers and polyoxyalkylene alkylphenol ethers are preferred, and polyoxyethylene alkyl ethers and polyoxyethylene alkylphenol ethers are more preferred.

[0120] These emulsifiers can be used alone or in combination of two or more, and the amount used is usually in the range of 0.01 to 10 parts by weight, preferably 0.1 to 5 parts by weight, and more preferably 1 to 3 parts by weight, per 100 parts by weight of the monomer component.

[0121] The method (mixing system) for mixing the monomer component, water, and emulsifier may be conventional, for example, a method in which the monomer, emulsifier, and water are stirred using a stirrer such as a homogenizer or a disk turbine. The amount of water used is usually 1 to 1,000 parts by weight, preferably 5 to 500 parts by weight, more preferably 4 to 300 parts by weight, particularly preferably 3 to 150 parts by weight, and most preferably 20 to 80 parts by weight, per 100 parts by weight of the monomer component.

[0122] (Emulsion polymerization process) The emulsion polymerization step in the method for producing acrylic rubber of the present invention is a step in which polymerization is initiated in the presence of a redox catalyst comprising an organic radical generator and a reducing agent, and a chain transfer agent is added batchwise during the polymerization to continue the polymerization, thereby obtaining an emulsion polymerization liquid.

[0123] (organic radical generator) The polymerization catalyst used in the present invention is characterized by the use of a redox catalyst consisting of an organic radical generator and a reducing agent, and is suitable because it can highly improve the injection moldability and strength properties of the resulting acrylic rubber. In particular, the use of an organic radical generator is suitable because it can highly improve the injection moldability of the acrylic rubber produced.

[0124] The organic radical generator is not particularly limited as long as it is one that is commonly used in emulsion polymerization, and examples thereof include organic peroxides and azo compounds.

[0125] The organic peroxide is not particularly limited as long as it is a known peroxide used in emulsion polymerization, and examples thereof include 2,2-di(4,4-di-(t-butylperoxy)cyclohexyl)propane, 1-di-(t-hexylperoxy)cyclohexane, 1,1-di-(t-butylperoxy)cyclohexane, 4,4-di-(t-butylperoxy)n-butyl valerate, 2,2-di-(t-butylperoxy)butane, t-butyl hydroperoxide, cumene hydroperoxide, diisopropylbenzene hydroperoxide, and paramenthane hydroperoxide. oxide, benzoyl peroxide, 1,1,3,3-tetraethylbutyl hydroperoxide, t-butylcumyl peroxide, di-t-butyl peroxide, di-t-hexyl peroxide, di(2-t-butylperoxyisopropyl)benzene, dicumyl peroxide, diisobutyryl peroxide, di(3,5,5-trimethylhexanoyl) peroxide, dilauroyl peroxide, disuccinic acid peroxide, dibenzoyl peroxide, di(3-methylbenzoyl) peroxide, benzoyl(3-methylbenzyl) peroxide, diisobutyryl peroxydicarbonate, di-n-propyl peroxydicarbonate, di(2-ethylhexyl) peroxydicarbonate, di-sec-butyl peroxydicarbonate, 1,1,3,3-tetramethylbutyl peroxyneodecanate, t-hexyl peroxypivalate, t-butyl peroxyneodecanate, t-hexyl peroxypivalate, t-butyl peroxypivalate, 2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane, 1,1,3,3-tetramethyl t-butylperoxy-2-ethylhexanate, t-hexylperoxy-2-ethylhexanate, t-butylperoxy-3,5,5-trimethylhexanate, t-hexylperoxyisopropyl monocarbonate, t-butylperoxyisopropyl monocarbonate, t-butylperoxy-2-ethylhexyl monocarbonate, 2,5-dimethyl-2,5-di(benzoylperoxy)hexane, t-butylperoxyacetate, t-hexylperoxybenzoate, t-butylperoxybenzoate, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, and the like. Among these, diisopropylbenzene hydroperoxide, cumene hydroperoxide, paramenthane hydroperoxide, benzoyl peroxide, and the like are preferred.

[0126] Examples of azo compounds include azobisisobutyronitrile, 4,4'-azobis(4-cyanovaleric acid), 2,2'-azobis[2-(2-imidazolin-2-yl)propane, 2,2'-azobis(propane-2-carboxamidine), 2,2'-azobis[N-(2-carboxyethyl)-2-methylpropanamide], 2,2'-azobis{2-[1-(2-hydroxyethyl)-2-imidazolin-2-yl]propane}, 2,2'-azobis(1-imino-1-pyrrolidino-2-methylpropane), and 2,2'-azobis{2-methyl-N-[1,1-bis(hydroxymethyl)-2-hydroxyethyl]propanamide}.

[0127] These organic radical generators can be used alone or in combination of two or more kinds, and the amount used is usually in the range of 0.0001 to 5 parts by weight, preferably 0.0005 to 1 part by weight, and more preferably 0.001 to 0.5 part by weight, per 100 parts by weight of the monomer component.

[0128] (reducing agent) The reducing agent used in the present invention is not particularly limited as long as it is one that is normally used in emulsion polymerization, but it is preferable to use at least two types of reducing agents, and it is preferable to combine a metal ion compound in a reduced state with another reducing agent, as this allows for an even higher level of balance between the injection moldability and strength properties of the resulting acrylic rubber.

[0129] The reduced metal ion compound is not particularly limited, but examples thereof include ferrous sulfate, sodium iron hexamethylenediaminetetraacetate, and cuprous naphthenate, with ferrous sulfate being preferred. These reduced metal ion compounds can be used alone or in combination of two or more, and the amount used is typically 0.000001 to 0.01 parts by weight, preferably 0.00001 to 0.001 parts by weight, and more preferably 0.00005 to 0.0005 parts by weight, per 100 parts by weight of the monomer component.

[0130] The reducing agent other than a metal ion compound in a reduced state used in the present invention is not particularly limited, and examples thereof include ascorbic acid or a salt thereof such as ascorbic acid, sodium ascorbate, potassium ascorbate, etc.; erythorbic acid or a salt thereof such as erythorbic acid, sodium erythorbate, potassium erythorbate, etc.; sulfinates such as sodium hydroxymethanesulfinate; sulfites such as sodium sulfite, potassium sulfite, sodium hydrogensulfite, aldehyde sodium hydrogensulfite, potassium hydrogensulfite; pyrosulfites such as sodium pyrosulfite, potassium pyrosulfite, sodium hydrogensulfite, potassium pyrosulfite; thiosulfates such as sodium thiosulfate and potassium thiosulfate; phosphorous acid or a salt thereof such as phosphorous acid, sodium phosphite, potassium phosphite, sodium hydrogen phosphite, potassium hydrogen phosphite; pyrophosphorous acid or a salt thereof such as pyrophosphorous acid, sodium pyrophosphite, potassium pyrophosphite, sodium hydrogen pyrophosphite, potassium hydrogen pyrophosphite, etc.; sodium formaldehyde sulfoxylate, etc. Among these, ascorbic acid or its salts, sodium formaldehyde sulfoxylate, etc. are preferred, and ascorbic acid or its salts are particularly preferred.

[0131] These reducing agents other than reduced metal ion compounds can be used alone or in combination of two or more, and the amount used is usually in the range of 0.001 to 1 part by weight, preferably 0.005 to 0.5 parts by weight, and more preferably 0.01 to 0.1 part by weight, per 100 parts by weight of the monomer component.

[0132] A preferred combination of a reduced metal ion compound and another reducing agent is ferrous sulfate and ascorbic acid or a salt thereof and / or sodium formaldehyde sulfoxylate, more preferably ferrous sulfate and ascorbic acid or a salt thereof. In this case, the amount of ferrous sulfate used is typically 0.000001 to 0.01 part by weight, preferably 0.00001 to 0.001 part by weight, and more preferably 0.00005 to 0.0005 part by weight, per 100 parts by weight of the monomer component. The amount of ascorbic acid or a salt thereof and / or sodium formaldehyde sulfoxylate used is typically 0.001 to 1 part by weight, preferably 0.005 to 0.5 parts by weight, and more preferably 0.01 to 0.1 part by weight, per 100 parts by weight of both components.

[0133] The amount of water used in the emulsion polymerization reaction may be the same as the amount used in emulsifying the monomer components, but is adjusted to be in the range of usually 10 to 1,000 parts by weight, preferably 50 to 500 parts by weight, more preferably 80 to 400 parts by weight, and most preferably 100 to 300 parts by weight, per 100 parts by weight of the monomer components used in the polymerization.

[0134] The emulsion polymerization reaction may be carried out in a conventional manner, and may be carried out in a batch, semi-batch, or continuous manner. The polymerization temperature and polymerization time are not particularly limited and can be appropriately selected depending on the type of polymerization initiator used, etc. The polymerization time is usually 0.5 to 100 hours, and preferably 1 to 10 hours. The emulsion polymerization reaction is an exothermic reaction, and if not controlled, the temperature will rise and the polymerization reaction may be shortened. However, in the present invention, controlling the emulsion polymerization reaction temperature to usually 35°C or less, preferably 0 to 35°C, more preferably 5 to 30°C, and particularly preferably 10 to 25°C, is suitable as this achieves a high level of balance between the strength properties of the acrylic rubber produced and the processability during kneading in a Banbury kneader or the like.

[0135] (Post-addition of chain transfer agent) The present invention is characterized in that the chain transfer agent is not added at the initial stage but is added batchwise during the polymerization, and by doing so, an acrylic rubber in which high molecular weight components and low molecular weight components are separated can be produced, and the strength properties and injection moldability of the produced acrylic rubber are suitably well balanced.

[0136] The chain transfer agent to be used is not particularly limited as long as it is one that is commonly used in emulsion polymerization, and for example, a mercaptan compound can be suitably used.

[0137] As the mercaptan compound, an alkyl mercaptan compound having usually 2 to 20 carbon atoms, preferably an alkyl mercaptan compound having 5 to 15 carbon atoms, more preferably an alkyl mercaptan compound having 6 to 14 carbon atoms can be used.

[0138] The alkyl mercaptan compound may be any of an n-alkyl mercaptan compound, a sec-alkyl mercaptan compound, and a t-alkyl mercaptan compound, but an n-alkyl mercaptan compound or a t-alkyl mercaptan compound is preferred, and an n-alkyl mercaptan compound is more preferred, as this allows the chain transfer agent effect to be stably exerted and the injection moldability of the acrylic rubber produced to be highly improved.

[0139] Specific examples of alkyl mercaptan compounds include n-pentyl mercaptan, n-hexyl mercaptan, n-heptyl mercaptan, n-octyl mercaptan, n-decyl mercaptan, n-dodecyl mercaptan, n-tridecane mercaptan, n-tetradecyl mercaptan, n-hexadecyl mercaptan, n-octadecyl mercaptan, sec-pentyl mercaptan, sec-hexyl mercaptan, sec-heptyl mercaptan, sec-octyl mercaptan, sec-decyl mercaptan, sec-dodecyl mercaptan, sec-tridecane mercaptan, and sec-tetradecyl mercaptan. Examples of the mercaptan include decyl mercaptan, sec-hexadecyl mercaptan, sec-octadecyl mercaptan, t-pentyl mercaptan, t-hexyl mercaptan, t-heptyl mercaptan, t-octyl mercaptan, t-decyl mercaptan, t-dodecyl mercaptan, n-tridecane mercaptan, t-tetradecyl mercaptan, t-hexadecyl mercaptan, and t-octadecyl mercaptan. Preferred are n-octyl mercaptan, n-dodecyl mercaptan, and t-dodecyl mercaptan, and more preferred are n-octyl mercaptan and n-dodecyl mercaptan.

[0140] These chain transfer agents can be used alone or in combination of two or more. The amount of chain transfer agent used is not particularly limited, but when it is in the range of usually 0.0001 to 1 part by weight, preferably 0.0005 to 0.5 parts by weight, more preferably 0.001 to 0.5 parts by weight, particularly preferably 0.005 to 0.1 parts by weight, and most preferably 0.01 to 0.06 parts by weight, relative to 100 parts by weight of the monomer component, the strength properties and injection moldability of the produced acrylic rubber are well balanced, which is suitable.

[0141] The present invention is characterized in that the chain transfer agent is not added at the initial stage of polymerization but is added batchwise during the polymerization, which is advantageous in that it allows the production of high molecular weight components and low molecular weight components of the acrylic rubber, and allows the molecular weight distribution to be within a specific range, thereby achieving a high level of balance between strength properties and injection moldability.

[0142] The number of batchwise post-additions of the chain transfer agent is not particularly limited and is appropriately selected depending on the intended use, but it is generally suitable to add the chain transfer agent 1 to 5 times, preferably 2 to 4 times, more preferably 2 to 3 times, and particularly preferably 2 times, in order to obtain a high level of balance between the strength properties and injection moldability of the acrylic rubber produced when the number of times is 1 to 5, more preferably 2 to 3, and particularly preferably 2 times.

[0143] There are no particular limitations on the timing for starting the batchwise post-addition of the chain transfer agent, and it is selected appropriately depending on the purpose of use. However, it is suitable to start the batchwise post-addition of the chain transfer agent within a range of usually 20 minutes or more after the start of polymerization, preferably 30 minutes or more after the start of polymerization, more preferably 30 to 200 minutes, particularly preferably 35 to 150 minutes, and most preferably 40 to 120 minutes after the start of polymerization, since this range allows for a high level of balance between the strength properties and injection moldability of the acrylic rubber to be produced.

[0144] There are no particular limitations on the amount of chain transfer agent added each time in batchwise post-addition, and it is selected appropriately depending on the intended use, but an amount in the range of usually 0.00005 to 0.5 parts by weight, preferably 0.0001 to 0.1 parts by weight, more preferably 0.0005 to 0.05 parts by weight, particularly preferably 0.001 to 0.03 parts by weight, and most preferably 0.002 to 0.02 parts by weight, per 100 parts by weight of the monomer component, is suitable, as this allows for a high level of balance between the strength properties and injection moldability of the acrylic rubber produced.

[0145] After the addition of the chain transfer agent, the polymerization reaction is continued for usually 30 minutes or more, preferably 45 minutes or more, more preferably 1 hour or more, without any particular limitation, and then can be terminated.

[0146] (Post-addition of reducing agent) In the present invention, the reducing agent for the redox catalyst can be added later during the polymerization, which is preferable because it allows the strength properties and injection moldability of the acrylic rubber to be produced to be well balanced.

[0147] The reducing agent added later during the polymerization has the same examples and preferred ranges as those of the reducing agent described above. In the present invention, ascorbic acid or a salt thereof is preferred as the reducing agent added later.

[0148] The amount of reducing agent used to be added later during polymerization is not particularly limited and may be selected appropriately depending on the intended use, but an amount in the range of usually 0.0001 to 1 part by weight, preferably 0.0005 to 0.5 parts by weight, more preferably 0.001 to 0.5 parts by weight, particularly preferably 0.005 to 0.1 parts by weight, and most preferably 0.01 to 0.05 parts by weight, relative to 100 parts by weight of the monomer components is suitable because this range not only provides excellent productivity in acrylic rubber production but also achieves a high level of balance between the strength properties and injection moldability of the acrylic rubber produced.

[0149] The reducing agent added during polymerization may be added either continuously or batchwise, but is preferably added batchwise. When the reducing agent is added batchwise during polymerization, the number of times is not particularly limited, but is usually 1 to 5 times, preferably 1 to 3 times, and more preferably 1 to 2 times.

[0150] When the reducing agent added at the beginning of polymerization or during polymerization is ascorbic acid or a salt thereof, the ratio of the amount of ascorbic acid or a salt thereof added at the beginning to the amount of ascorbic acid or a salt thereof added later is not particularly limited, but a weight ratio of "initially added ascorbic acid or a salt thereof" / "batchwise later added ascorbic acid or a salt thereof" in the range of usually 1 / 9 to 8 / 2, preferably 2 / 8 to 6 / 4, and more preferably 3 / 7 to 5 / 5 is suitable, as this provides excellent productivity in acrylic rubber production and achieves a high level of balance between the strength properties and injection moldability of the acrylic rubber produced.

[0151] There are no particular limitations on the timing of post-addition of the reducing agent, and it is selected appropriately depending on the intended use, but a time within the range of usually 1 hour or more after the start of polymerization, preferably 1 to 3 hours, and more preferably 1.5 to 2.5 hours after the start of polymerization, is suitable because it provides excellent productivity in acrylic rubber production and also enables the strength properties and injection moldability of the acrylic rubber produced to be well balanced.

[0152] There are no particular limitations on the amount of reducing agent added each time in batchwise post-addition, and it is selected appropriately depending on the intended use, but an amount in the range of usually 0.00005 to 0.5 parts by weight, preferably 0.0001 to 0.1 parts by weight, more preferably 0.0005 to 0.05 parts by weight, and particularly preferably 0.001 to 0.03 parts by weight, per 100 parts by weight of the monomer component, is suitable, as this allows for a high level of balance between the strength properties and injection moldability of the acrylic rubber produced.

[0153] The procedure after the addition of the reducing agent is not particularly limited, but the polymerization reaction can be terminated after the polymerization reaction is continued for usually 30 minutes or more, preferably 45 minutes or more, and more preferably 1 hour or more.

[0154] The polymerization conversion rate of the emulsion polymerization reaction is 90% by weight or more, preferably 95% by weight or more, and the acrylic rubber produced in this manner has excellent strength characteristics and is free of monomer odor, making it suitable. A polymerization terminator may be used to terminate the polymerization.

[0155] (solidification process) The coagulation step in the method for producing acrylic rubber of the present invention is a step in which the above-obtained emulsion polymerization liquid is added to a stirring coagulation liquid to coagulate and produce water-containing crumbs.

[0156] The solid content of the emulsion polymerization liquid used in this coagulation reaction is not particularly limited, but is usually adjusted to within the range of 5 to 50% by weight, preferably 10 to 45% by weight, and more preferably 20 to 40% by weight.

[0157] The coagulant for the coagulation liquid used is not particularly limited, but a metal salt is usually used. Examples of the metal salt include alkali metals, Group 2 metal salts of the periodic table, and other metal salts, and alkali metal salts and Group 2 metal salts of the periodic table are preferred, more preferably Group 2 metal salts of the periodic table, and particularly preferably magnesium salts, which are suitable for achieving a high level of balance between the water resistance, strength properties, injection molding fusibility, releasability, and processability of the resulting acrylic rubber.

[0158] Examples of alkali metal salts include sodium salts such as sodium chloride, sodium nitrate, and sodium sulfate; potassium salts such as potassium chloride, potassium nitrate, and potassium sulfate; and lithium salts such as lithium chloride, lithium nitrate, and lithium sulfate. Of these, sodium salts are preferred, and sodium chloride and sodium sulfate are particularly preferred.

[0159] Examples of the salt of a metal of Group 2 of the periodic table include magnesium chloride, calcium chloride, magnesium nitrate, calcium nitrate, magnesium sulfate, and calcium sulfate, with calcium chloride and magnesium sulfate being preferred.

[0160] Examples of other metal salts include zinc chloride, titanium chloride, manganese chloride, iron chloride, cobalt chloride, nickel chloride, aluminum chloride, tin chloride, zinc nitrate, titanium nitrate, manganese nitrate, iron nitrate, cobalt nitrate, nickel nitrate, aluminum nitrate, tin nitrate, zinc sulfate, titanium sulfate, manganese sulfate, iron sulfate, cobalt sulfate, nickel sulfate, aluminum sulfate, and tin sulfate.

[0161] These coagulants can be used alone or in combination of two or more, and the amount used is usually 0.01 to 100 parts by weight, preferably 0.1 to 50 parts by weight, and more preferably 1 to 30 parts by weight, per 100 parts by weight of the monomer component. When the coagulant is in this range, it is preferable because it can sufficiently coagulate the acrylic rubber while highly improving the compression set resistance and water resistance when the acrylic rubber is crosslinked.

[0162] In the coagulation step of the present invention, focusing the particle size of the generated hydrous crumbs into a specific region is particularly preferred, as this significantly increases the efficiency of washing and the efficiency of ash removal during dehydration. There are no particular limitations on the proportion of the generated hydrous crumbs in the range of 710 μm to 6.7 mm (those that do not pass through 710 μm but pass through 6.7 mm), but it is preferred that this proportion be generally 30% by weight or more, preferably 50% by weight or more, more preferably 60% by weight or more, particularly preferably 70% by weight or more, and most preferably 80% by weight or more, relative to the total generated hydrous crumbs, as this significantly improves the water resistance of the acrylic rubber. Furthermore, the proportion of the water-containing crumbs produced in the range of 710 μm to 4.75 mm (not passing through 710 μm but passing through 4.75 mm) is not particularly limited, but is preferably 30% by weight or more, more preferably 50% by weight or more, more preferably 60% by weight or more, particularly preferably 70% by weight or more, and most preferably 80% by weight or more, relative to the total water-containing crumbs produced, as this significantly improves the water resistance of the acrylic rubber. Furthermore, the proportion of the water-containing crumbs produced in the range of 710 μm to 3.35 mm (not passing through 710 μm but passing through 3.35 mm) is not particularly limited, but is preferably 20% by weight or more, more preferably 30% by weight or more, more preferably 40% by weight or more, particularly preferably 50% by weight or more, and most preferably 60% by weight or more, relative to the total water-containing crumbs produced, as this significantly improves the water resistance of the acrylic rubber.

[0163] There are no particular limitations on the means for producing hydrous crumbs with a particle size within the above range. For example, the coagulant can be added to the coagulation liquid (aqueous coagulant solution) being stirred with the emulsion polymerization liquid, or the coagulant concentration in the coagulation liquid, or the stirring rate or peripheral speed of the coagulation liquid being stirred, can be within a specific range.

[0164] The coagulation liquid used is usually used as an aqueous solution, and the coagulant concentration in the aqueous solution is usually in the range of 0.1 to 20% by weight, preferably 0.5 to 15% by weight, more preferably 1 to 10% by weight, and particularly preferably 1.5 to 5% by weight, which is suitable for concentrating the particle size of the resulting hydrous crumbs uniformly in a specific region.

[0165] The temperature of the coagulation liquid is not particularly limited, but when it is generally 40°C or higher, preferably in the range of 40 to 90°C, more preferably 50 to 80°C, uniform water-containing crumbs are formed.

[0166] As a method for bringing the emulsified heavy liquid into contact with the coagulation liquid, a method in which the emulsion polymerization liquid is added to the coagulation liquid while being stirred is selected, and this is preferable because the washing efficiency and dehydration efficiency of the generated water-containing crumbs are remarkably excellent, and the water resistance and storage stability of the obtained acrylic rubber are highly improved.

[0167] The stirring speed (rotation speed) of the stirred coagulation liquid, i.e., the rotation speed of the stirring blades of the stirring device, is not particularly limited, but is usually 100 rpm or more, preferably 200 rpm or more, more preferably 200 to 1000 rpm, particularly preferably 300 to 900 rpm, and most preferably in the range of 400 to 800 rpm.

[0168] A rotation speed that provides a certain degree of vigorous stirring is preferable, as it allows the resulting hydrous crumbs to be small and uniform in particle size. By setting the rotation speed above the lower limit, it is possible to prevent crumbs with excessively large and small particle sizes from being produced, and by setting the rotation speed below the upper limit, it is possible to more easily control the coagulation reaction.

[0169] The peripheral speed of the stirred coagulation liquid, i.e., the speed of the outer periphery of the stirring blade of the stirring device, is not particularly limited, but stirring to a certain extent is preferred because the particle size of the generated hydrous crumbs can be made small and uniform, and is usually 0.5 m / s or more, preferably 1 m / s or more, more preferably 1.5 m / s or more, particularly preferably 2 m / s or more, and most preferably 2.5 m / s or more. On the other hand, the upper limit of the peripheral speed is not particularly limited, but is usually 50 m / s or less, preferably 30 m / s or less, more preferably 25 m / s or less, and most preferably 20 m / s or less, which makes it easier to control the coagulation reaction.

[0170] By setting the above-mentioned conditions for the coagulation reaction (contact method, solids concentration of the emulsion polymerization liquid, concentration and temperature of the coagulation liquid, rotation speed and peripheral speed when stirring the coagulation liquid, etc.) within specific ranges, the shape and diameter of the water-containing crumbs that are produced become uniform and concentrated, and removal of the emulsifier and coagulant during washing and dehydration is significantly improved, resulting in highly improved water resistance and storage stability of the acrylic rubber that is produced, which is therefore preferred.

[0171] (Cleaning process) The washing step in the method for producing acrylic rubber of the present invention is a step of washing the water-containing crumbs produced as described above.

[0172] The washing method is not particularly limited, and for example, the produced water-containing crumbs can be mixed with a large amount of water.

[0173] The amount of water added for washing is not particularly limited, but when the amount per washing is generally 50 parts by weight or more, preferably 50 to 15,000 parts by weight, more preferably 100 to 10,000 parts by weight, and even more preferably 500 to 5,000 parts by weight, per 100 parts by weight of the monomer component, it is suitable because this allows the ash content in the acrylic rubber to be effectively reduced.

[0174] The temperature of the water used is not particularly limited, but it is preferable to use warm water, which is usually 40° C. or higher, preferably 40 to 100° C., more preferably 50 to 90° C., and is particularly optimal at 60 to 80° C., as this significantly improves the cleaning efficiency. By using water at a temperature above the above-mentioned lower limit, the emulsifier and coagulant are released from the water-containing crumbs, further improving the cleaning efficiency.

[0175] The washing time is not particularly limited, but is usually in the range of 1 to 120 minutes, preferably 2 to 60 minutes, and more preferably 3 to 30 minutes.

[0176] The number of washings (water washings) is not particularly limited either, and is usually 1 to 10 times, preferably 1 to 5 times, and more preferably 2 to 3 times. From the viewpoint of reducing the amount of coagulant remaining in the finally obtained acrylic rubber, it is desirable to wash with water more frequently, but the number of water washings can be significantly reduced by setting the shape and diameter of the wet crumbs within specific ranges as described above, and / or by setting the washing temperature within the above ranges.

[0177] (Dehydration process) The dehydration step in the method for producing acrylic rubber of the present invention is a step of dehydrating the washed water-containing crumbs.

[0178] The method for dehydrating the hydrous crumbs is not particularly limited as long as it is a method that can squeeze out the water from the hydrous crumbs, and it can usually be carried out using a dehydrator, etc. This is preferable because it reduces the amount of ash from the emulsifier and coagulant contained in the hydrous crumbs that could not be removed in the washing step, and greatly improves the water resistance of the acrylic rubber.

[0179] The dehydrator is not particularly limited, and for example, a centrifuge, a squeezer, a screw-type extruder, etc. can be used. However, a screw-type extruder is particularly suitable because it can significantly reduce the moisture content of the water-containing crumb. In a centrifuge, etc., the acrylic rubber adheres to the wall surface and between the slits, and it can usually only be dehydrated to about 45 to 55% by weight. In contrast, a screw-type extruder is suitable because it has a mechanism that forcibly squeezes out the moisture.

[0180] The water content of the dehydrated hydrous crumb is not limited, but is usually in the range of 1 to 50% by weight, preferably 1 to 40% by weight, more preferably 10 to 40% by weight, and more preferably 15 to 35% by weight. By setting the water content after dehydration to the above lower limit or more, the dehydration time can be shortened and deterioration of the acrylic rubber can be suppressed, while by setting it to the above upper limit or less, the ash content can be sufficiently reduced.

[0181] (drying process) The drying step in the method for producing acrylic rubber of the present invention is a step of drying the dehydrated water-containing crumbs to a moisture content of less than 1% by weight.

[0182] The method for drying the water-containing crumbs after dehydration is not particularly limited, but can be carried out using, for example, a screw-type twin-screw extruder dryer. The screw-type twin-screw extruder dryer used is not particularly limited as long as it is an extruder dryer having two screws, but in the present invention, it is particularly preferable to use a screw-type twin-screw extruder dryer having two screws to dry the water-containing crumbs under high shear conditions, since this allows for a high level of balance between the injection moldability, Banbury processability, and strength properties of the acrylic rubber obtained.

[0183] In the present invention, the acrylic rubber can be obtained by melting the water-containing crumb in a screw-type twin-screw extruder dryer and extruding and drying it. The drying temperature (set temperature) of the screw-type twin-screw extruder dryer may be selected appropriately, but a temperature in the range of usually 100 to 250°C, preferably 110 to 200°C, and more preferably 120 to 180°C is suitable because it allows efficient drying without causing discoloration or deterioration of the acrylic rubber.

[0184] In the present invention, when the water-containing crumbs produced in the solidification step are melt-kneaded and dried under reduced pressure in a screw-type twin-screw extruder, the storage stability of the acrylic rubber is highly improved without impairing the injection moldability or strength properties of the acrylic rubber, which is preferable. The degree of reduced pressure in the screw-type twin-screw extruder, which is suitable for removing the air contained in the acrylic rubber at this stage and improving the storage stability, may be selected as appropriate, but is usually in the range of 1 to 50 kPa, preferably 2 to 30 kPa, and more preferably 3 to 20 kPa.

[0185] In the present invention, when the water-containing crumbs generated in the solidification step are melt-kneaded and dried in a state in which almost all of the water has been removed using a screw-type twin-screw extruder, this is preferable because it highly improves the Banbury processability without impairing the injection moldability or strength properties of the acrylic rubber. The state in which almost all of the water has been removed, which highly improves the Banbury processability, may be selected as appropriate, but the water content of the acrylic rubber is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less. Note that, in the present invention, "melt-kneading" or "melt-kneading and drying" means that the acrylic rubber is kneaded (mixed) in a molten state in a screw-type twin-screw extruder or extruded in a molten state and dried at that stage, or that the acrylic rubber is kneaded in a molten (plasticized) state using a screw-type twin-screw extruder and then extruded and dried.

[0186] There are no particular limitations on the maximum torque of the screw-type twin-screw extruder used in the present invention, but a maximum torque in the range of usually 5 to 125 N m, preferably 10 to 100 N m, more preferably 10 to 50 N m, and particularly preferably 15 to 45 N m is suitable, as this allows the injection moldability, Banbury processability, and strength properties of the acrylic rubber produced to be well balanced.

[0187] There are no particular limitations on the specific power of the screw-type twin-screw extruder used in the present invention, but when it is in the range of usually 0.01 to 0.3 [kW·h / kg] or more, preferably 0.05 to 0.25 [kW·h / kg], and more preferably 0.1 to 0.2 [kW·h / kg], the injection moldability, Banbury processability and strength properties of the obtained acrylic rubber are well balanced, which is suitable.

[0188] There are no particular limitations on the specific power of the screw-type twin-screw extruder used in the present invention, but when it is in the range of usually 0.1 to 0.6 [A·h / kg] or more, preferably 0.15 to 0.55 [A·h / kg], and more preferably 0.2 to 0.5 [A·h / kg], the injection moldability, Banbury processability and strength properties of the obtained acrylic rubber are well balanced, which is suitable.

[0189] The shear rate of the screw-type twin-screw extruder used in the present invention is not particularly limited, but when it is in the range of usually 5 to 150 [1 / s] or more, preferably 10 to 100 [1 / s], more preferably 25 to 75 [1 / s], the storage stability, injection moldability, Banbury processability and strength properties of the obtained acrylic rubber are well balanced, and this is suitable.

[0190] There are no particular limitations on the shear viscosity of the acrylic rubber in the screw-type twin-screw extruder dryer used in the present invention, but when the shear viscosity is in the range of usually 4000 to 8000 [Pa·s] or less, preferably 4500 to 7500 [Pa·s], and more preferably 5000 to 7000 [Pa·s], the storage stability, injection moldability, Banbury processability, and strength properties of the obtained acrylic rubber are well balanced, which is suitable.

[0191] In the present invention, when the cooling rate of the acrylic rubber after melt-kneading and drying is usually 40°C / hr or more, preferably 50°C / hr or more, more preferably 100°C / hr or more, and particularly preferably 150°C / hr or more, the scorch stability of the acrylic rubber composition is remarkably excellent, which is suitable.

[0192] The acrylic rubber of the present invention thus obtained is excellent in injection moldability, strength properties, and water resistance, and can be used in a variety of applications. The form of the acrylic rubber of the present invention is not particularly limited and can be selected depending on the intended use, and examples include powder, crumb, strand, sheet, and bale forms, with sheet and bale forms being preferred because of their excellent workability and storage stability.

[0193] (Method for manufacturing sheet or veil acrylic rubber) There are no particular limitations on the method for producing sheet-like or bale-like acrylic rubber of the present invention, but sheet-like acrylic rubber can be easily produced by using a screw-type twin-screw extruder dryer having a dehydrating barrel with a dehydration slit, a drying barrel under reduced pressure, and a die at the tip, to dehydrate the washed water-containing crumbs in the dehydrating barrel to a moisture content of 1 to 40% by weight, and then drying in the drying barrel to a moisture content of less than 1% by weight, and extruding the dried sheet-like rubber through the die, and further by stacking the extruded dried sheet-like rubber to form bales, bale-like acrylic rubber can be easily produced.

[0194] In the present invention, the water-containing crumbs to be supplied to the screw-type twin-screw extrusion dryer are preferably those from which free water has been removed (drained) after washing.

[0195] (Draining process) In the present invention, it is preferable to provide a draining step in which free water is separated from the washed wet crumbs using a drainer in order to increase the dewatering efficiency.

[0196] Any known drainer can be used without any particular limitation, and examples thereof include wire mesh, screens, and electric sieves, with wire mesh and screens being preferred.

[0197] There are no particular limitations on the mesh size of the drainer, but a mesh size in the range of usually 0.01 to 5 mm, preferably 0.1 to 1 mm, more preferably 0.2 to 0.6 mm is suitable as it minimizes loss of water-containing crumb and allows efficient draining.

[0198] The moisture content of the drained wet crumbs, i.e., the moisture content of the wet crumbs fed into the dehydration and drying process, is not particularly limited, but is usually in the range of 50 to 80% by weight, preferably 50 to 70% by weight, and more preferably 50 to 60% by weight.

[0199] The temperature of the hydrous crumbs after draining, i.e., the temperature of the hydrous crumbs fed into the dehydration and drying step, is not particularly limited, but is usually 40°C or higher, preferably 40 to 100°C, more preferably 50 to 90°C, particularly preferably 55 to 85°C, and most preferably in the range of 60 to 80°C, because hydrous crumbs such as the acrylic rubber of the present invention, which have a high specific heat of 1.5 to 2.5 KJ / kg K and are difficult to raise in temperature, can be efficiently dehydrated and dried using a screw-type twin-screw extruder dryer.

[0200] (Dehydration of wet crumbs in the dehydration barrel) The dehydration of the hydrous crumbs is carried out in a dehydration barrel in a screw-type twin-screw extruder dryer having a dehydration slit. The opening of the dehydration slit may be selected appropriately depending on the conditions of use, but is usually in the range of 0.01 to 5 mm, preferably 0.1 to 1 mm, more preferably 0.2 to 0.6 mm, which is suitable for minimizing hydrous crumb loss and enabling efficient dehydration of the hydrous crumbs.

[0201] The number of dehydration barrels in the screw-type twin-screw extrusion dryer is not particularly limited, but it is generally suitable to have more than one, preferably 2 to 10, and more preferably 3 to 6, in order to efficiently dehydrate the sticky acrylic rubber.

[0202] There are two ways to remove water from the wet crumb in the dehydration barrel: in liquid form (wastewater) through the dehydration slit, and in vapor form (exhaust steam). In this invention, we distinguish between the two by defining wastewater as dehydration and exhaust steam as pre-drying.

[0203] The water discharged from the dewatering slit during dehydration of the hydrous crumbs may be in either a liquid state (wastewater) or a vapor state (exhaust steam), but when a screw-type twin-screw extruder dryer equipped with a plurality of dehydration barrels is used, a combination of wastewater and exhaust steam is preferred because this allows for efficient dehydration of the adhesive acrylic rubber.Whether a drainage-type dehydration barrel or an exhaust steam-type dehydration barrel is selected in a screw-type twin-screw extruder dryer equipped with three or more dehydration barrels can be selected appropriately depending on the intended use, but typically, the number of drainage-type barrels is increased when the ash content in the acrylic rubber to be produced is reduced, and the number of exhaust steam-type barrels is increased when the moisture content is reduced.

[0204] The set temperature of the dehydration barrel is appropriately selected depending on the monomer composition, ash content, water content, and operating conditions of the acrylic rubber, but is usually in the range of 60 to 150°C, preferably 70 to 140°C, and more preferably 80 to 130°C. The set temperature of the dehydration barrel for dehydration in a wastewater state is usually 60 to 120°C, preferably 70 to 110°C, and more preferably 80 to 100°C. The set temperature of the dehydration barrel for dehydration in an exhaust steam state is usually 100 to 150°C, preferably 105 to 140°C, and more preferably 110 to 130°C.

[0205] The moisture content after dehydration in the drainage dehydration method in which moisture is squeezed out of the hydrous crumb is not particularly limited, but a moisture content of usually 1 to 40% by weight, preferably 5 to 35% by weight, and more preferably 10 to 35% by weight is suitable, as it provides a high level of balance between productivity and ash removal efficiency.

[0206] When dehydrating adhesive acrylic rubber having reactive groups using a centrifuge or the like, the acrylic rubber adheres to the dehydration slits and is barely dehydrated (water content reaches approximately 45 to 55% by weight). However, in the present invention, by using a screw-type twin-screw extrusion dryer that has a dehydration slit and is forcibly squeezed by a screw, it is possible to reduce the water content to this extent.

[0207] When a drainage type dehydration barrel and a steam exhaust type dehydration barrel are provided, the moisture content of the hydrous crumb after drainage in the drainage type dehydration barrel is usually 5 to 40% by weight, preferably 10 to 40% by weight, more preferably 15 to 35% by weight, and the moisture content after pre-drying in the steam exhaust type dehydration barrel is usually 1 to 30% by weight, preferably 3 to 20% by weight, more preferably 5 to 15% by weight.

[0208] By setting the water content after dehydration to the lower limit or more, the dehydration time can be shortened and deterioration of the acrylic rubber can be suppressed, and by setting it to the upper limit or less, the ash content can be sufficiently reduced.

[0209] (Drying of moist crumbs in the drying barrel) The dehydrated hydrous crumb is dried in a screw-type twin-screw extruder having a drying barrel under reduced pressure. Drying the acrylic rubber under reduced pressure increases the production efficiency of drying and also removes the air contained in the acrylic rubber, making it possible to produce an acrylic rubber with a high specific gravity and excellent storage stability. In the present invention, the storage stability of the acrylic rubber can be highly improved by melting the acrylic rubber under reduced pressure and extrusion drying. The storage stability of acrylic rubber is largely correlated with the specific gravity of the acrylic rubber and can be controlled; however, when controlling high storage stability due to a high specific gravity, it can be controlled by the degree of vacuum reduction during extrusion drying, etc.

[0210] The degree of reduced pressure in the drying barrel may be selected as appropriate, but is usually 1 to 50 kPa, preferably 2 to 30 kPa, and more preferably 3 to 20 kPa, which is suitable because it allows the water-containing crumb to be dried efficiently and removes air from the acrylic rubber, thereby significantly improving the storage stability of the acrylic rubber.

[0211] The temperature setting for the drying barrel may be selected as appropriate, but is generally suitable within the range of 100 to 250°C, preferably 110 to 200°C, and more preferably 120 to 180°C, as this allows for efficient drying without discoloration or deterioration of the acrylic rubber and also reduces the amount of gel insoluble in methyl ethyl ketone in the sheet-like or veil-like acrylic rubber.

[0212] The number of drying barrels in a screw-type twin-screw extruder is not particularly limited, but is usually multiple, preferably 2 to 10, and more preferably 3 to 8. When multiple drying barrels are used, the degree of reduced pressure may be similar for all drying barrels or may be different. When multiple drying barrels are used, the set temperatures may be similar for all drying barrels or may be different, but it is preferable to make the temperature of the discharge section (closer to the die) higher than the temperature of the introduction section (closer to the dehydration barrel) in order to improve drying efficiency.

[0213] The moisture content of the dried rubber after drying is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less. In the present invention, it is particularly preferable to melt-extrude the dried rubber in a screw-type twin-screw extruder until the moisture content reaches this value (a state in which almost all water has been removed), as this reduces the amount of gel in the sheet- or bale-shaped acrylic rubber that is insoluble in methyl ethyl ketone. In the present invention, acrylic rubber, preferably sheet- or bale-shaped acrylic rubber, melt-kneaded or melt-kneaded and dried in a screw-type twin-screw extruder is preferable because it has a high balance of both strength properties and Banbury processability. Note that "melt-kneading" or "melt-kneading and drying" in the present invention means that the acrylic rubber is kneaded (mixed) in a molten state in a screw-type twin-screw extruder or extruded in a molten state and then dried, or that the acrylic rubber is kneaded in a molten (plasticized) state in a screw-type twin-screw extruder and then extruded and dried.

[0214] In the present invention, the shear rate applied to the acrylic rubber in the drying barrel of the screw-type twin-screw extruder dryer in a state where it is substantially free of water is not particularly limited, but a rate within the range of usually 5 [1 / s] or more, preferably 10 to 400 [1 / s], and more preferably 20 to 250 [1 / s] is preferred because the sheet-like or veil-like acrylic rubber obtained has a highly balanced storage stability, injection moldability, Banbury processability, strength properties, and compression set resistance.

[0215] There are no particular limitations on the shear viscosity of the acrylic rubber inside the screw-type twin-screw extruder dryer used in the present invention, particularly in the drying barrel, but when the viscosity is in the range of usually 12,000 [Pa·s] or less, preferably 1,000 to 12,000 [Pa·s], more preferably 2,000 to 10,000 [Pa·s], particularly preferably 3,000 to 7,000 [Pa·s], and most preferably 4,000 to 6,000 [Pa·s], the storage stability, injection moldability, Banbury processability and strength properties of the resulting sheet- or veil-like acrylic rubber are well balanced and are therefore suitable.

[0216] (Extrusion of dry rubber from the die) The dried rubber dehydrated and dried in the screw sections of the dehydration barrel and drying barrel is sent to a screw-less straightening die section, from which it is extruded into the desired shape. A breaker plate or wire mesh may or may not be provided between the screw section and the die section.

[0217] The dried rubber to be extruded is preferably extruded in the form of a sheet using a die having a substantially rectangular shape, which results in a dried rubber with less air entrapment, a high specific gravity, and excellent storage stability.

[0218] The resin pressure in the die section is not particularly limited, but is usually set in the range of 0.1 to 10 MPa, preferably 0.5 to 5 MPa, and more preferably 1 to 3 MPa, which is suitable because it reduces air entrapment in the sheet-like or veil-like acrylic rubber (high specific gravity) and provides excellent productivity.

[0219] (Screw-type twin-screw extruder and operating conditions) The screw length (L) of the screw-type twin-screw extruder used may be appropriately selected depending on the purpose of use, but is usually in the range of 3000 to 15000 mm, preferably 4000 to 10000 mm, and more preferably 4500 to 8000 mm.

[0220] The screw diameter (D) of the screw-type twin-screw extruder used may be appropriately selected depending on the purpose of use, but is usually in the range of 50 to 250 mm, preferably 100 to 200 mm, more preferably 120 to 160 mm.

[0221] The ratio (L / D) of the screw length (L) to the screw diameter (D) of the screw-type twin-screw extruder dryer used is not particularly limited, but is usually in the range of 10 to 100, preferably 20 to 80, and more preferably 30 to 60, which is suitable because the moisture content can be reduced to less than 1% by weight without causing a decrease in the molecular weight of the dried rubber or burning.

[0222] The rotation speed (N) of the screw-type twin-screw extruder used may be selected appropriately depending on the various conditions, but a rotation speed of usually 10 to 1,000 rpm, preferably 50 to 750 rpm, more preferably 100 to 500 rpm, and most preferably 120 to 300 rpm is suitable, as this allows the water content of the sheet-like or veil-like acrylic rubber and the amount of gel insoluble in methyl ethyl ketone to be efficiently reduced.

[0223] The extrusion rate (Q) of the screw-type twin-screw extruder used is not particularly limited, but is usually in the range of 100 to 1500 kg / hr, preferably 300 to 1200 kg / hr, more preferably 400 to 1000 kg / hr, and most preferably 500 to 800 kg / hr.

[0224] The ratio (Q / N) of the extrusion rate (Q) to the rotation speed (N) of the screw-type twin-screw extruder used is not particularly limited, but is usually in the range of 2 to 10, preferably 3 to 8, and more preferably 4 to 6.

[0225] There are no particular limitations on the maximum torque of the screw-type twin-screw extruder used, but a maximum torque in the range of usually 5 to 125 N m, preferably 10 to 100 N m, more preferably 10 to 50 N m, and particularly preferably 15 to 45 N m is suitable, as this allows for a high level of balance to be achieved between the injection moldability, Banbury processability, and strength properties of the sheet- or veil-like acrylic rubber produced.

[0226] There are no particular limitations on the specific power of the screw-type twin-screw extruder dryer used, but when it is usually in the range of 0.01 to 0.3 [kW·h / kg] or more, preferably 0.05 to 0.2 [kW·h / kg], and more preferably 0.1 to 0.2 [kW·h / kg], the injection moldability, Banbury processability and strength properties of the resulting sheet- or veil-like acrylic rubber are well balanced and are therefore suitable.

[0227] There are no particular limitations on the specific power of the screw-type twin-screw extruder dryer used, but when it is in the range of usually 0.1 to 0.6 [A·h / kg] or more, preferably 0.15 to 0.55 [A·h / kg], and more preferably 0.2 to 0.5 [A·h / kg], the injection moldability, Banbury processability and strength properties of the resulting sheet- or veil-like acrylic rubber are well balanced and are therefore suitable.

[0228] There are no particular limitations on the shear rate of the screw-type twin-screw extruder used, but a shear rate in the range of usually 5 to 150 [1 / s] or more, preferably 10 to 100 [1 / s], and more preferably 25 to 75 [1 / s] is suitable because the sheet-like or veil-like acrylic rubber obtained has a high level of balance in terms of storage stability, injection moldability, Banbury processability and strength properties.

[0229] There are no particular limitations on the shear viscosity of the acrylic rubber in the screw-type twin-screw extruder dryer used, but when the shear viscosity is in the range of usually 4000 to 8000 [Pa·s] or less, preferably 4500 to 7500 [Pa·s], and more preferably 5000 to 7000 [Pa·s], the storage stability, injection moldability, Banbury processability and strength properties of the resulting sheet- or veil-like acrylic rubber are well balanced, which is suitable.

[0230] Thus, in the present invention, the use of an extrusion dryer having two screws is preferable because it enables dehydration, drying and molding under high shear conditions.

[0231] (Dry rubber sheet) The dried rubber extruded from the screw-type twin-screw extruder is in the form of a sheet, which is preferable because it does not trap air and can increase the specific gravity, thereby highly improving storage stability. The dried rubber sheet extruded from the screw-type twin-screw extruder is usually cooled and cut to be used as sheet acrylic rubber.

[0232] The thickness of the dry rubber sheet extruded from the screw-type twin-screw extruder is not particularly limited, but is usually 1 to 40 mm, preferably 2 to 35 mm, more preferably 3 to 30 mm, and most preferably 5 to 25 mm, which is suitable for excellent workability and productivity. In particular, since the thermal conductivity of the dry rubber sheet is as low as 0.15 to 0.35 W / mK, the thickness of the dry rubber sheet, in order to significantly improve productivity by increasing cooling efficiency, is usually 1 to 30 mm, preferably 2 to 25 mm, more preferably 3 to 15 mm, and particularly preferably 4 to 12 mm.

[0233] The width of the sheet-like dried rubber extruded from the screw-type twin-screw extruder is appropriately selected depending on the intended use, but is usually in the range of 300 to 1200 mm, preferably 400 to 1000 mm, and more preferably 500 to 800 mm.

[0234] The temperature of the dried rubber extruded from the screw-type twin-screw extruder is not particularly limited, but is usually in the range of 100 to 200°C, preferably 110 to 180°C, and more preferably 120 to 160°C.

[0235] The moisture content of the dried rubber extruded from the screw-type twin-screw extruder is not particularly limited, but is usually less than 1% by weight, preferably 0.8% by weight or less, and more preferably 0.6% by weight or less.

[0236] The complex viscosity at 100°C ([η]100°C) of the dry rubber sheet extruded from the screw-type twin-screw extruder is not particularly limited, but is typically in the range of 1500 to 6000 [Pa·s], preferably 2000 to 5000 [Pa·s], more preferably 2500 to 4500 [Pa·s], and most preferably 3000 to 4000 [Pa·s], which provides a high level of balance between extrudability and shape retention as a sheet. That is, by setting the viscosity at or above the lower limit, excellent extrudability can be achieved, and by setting the viscosity at or below the upper limit, deformation and breakage of the dry rubber sheet can be suppressed.

[0237] The dried rubber sheet extruded from the screw-type twin-screw extruder may be folded as is and used, but it is usually cut into pieces before use.

[0238] There are no particular limitations on the cutting of the sheet-like dry rubber, but since the acrylic rubber of the present invention has strong adhesiveness, it is preferable to cool the sheet-like dry rubber before cutting in order to cut it continuously without entraining air.

[0239] There is no particular limitation on the cutting temperature of the dry rubber sheet, but a temperature of usually 60°C or less, preferably 55°C or less, more preferably 50°C or less is suitable as it provides a high balance between cuttability and productivity.

[0240] The complex viscosity of the dry rubber sheet at 60°C ([η]60°C) is not particularly limited, but is usually 15,000 [Pa·s] or less, preferably 2,000 to 10,000 [Pa·s], more preferably 2,500 to 7,000 [Pa·s], and most preferably 2,700 to 5,500 [Pa·s], which allows continuous cutting without entraining air.

[0241] The ratio ([η]100°C / [η]60°C) of the complex viscosity of the dry rubber sheet at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) is not particularly limited and may be selected appropriately depending on the intended use, but is usually 0.5 or more, preferably 0.6 or more, more preferably 0.7 or more. The ratio ([η]100°C / [η]60°C) of the complex viscosity of the dry rubber sheet at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) is also usually 0.5 to 0.99, preferably 0.55 to 0.95, more preferably 0.6 to 0.9, particularly preferably 0.65 to 0.85, and most preferably 0.7 to 0.8. When this ratio is in the range of 0.5 to 0.99, preferably 0.55 to 0.95, more preferably 0.6 to 0.9, particularly preferably 0.65 to 0.85, and most preferably 0.7 to 0.8, air entrapment is reduced and cutting and productivity are well balanced.

[0242] The cooling method for the dried rubber sheet is not particularly limited, and it may be left at room temperature. However, since the thermal conductivity of the dried rubber sheet is very low at 0.15 to 0.35 W / mK, forced cooling such as air cooling using ventilation or air conditioning, water spraying, or immersion in water is preferred to increase productivity, and air cooling using ventilation or air conditioning is particularly preferred.

[0243] In the air-cooling method for sheet-form dry rubber, for example, the sheet-form dry rubber can be extruded from a screw extruder onto a conveyor such as a belt conveyor and then conveyed and cooled while being blown with cold air. The temperature of the cold air is not particularly limited, but is usually in the range of 0 to 25°C, preferably 5 to 25°C, and more preferably 10 to 20°C. The cooling length is also not particularly limited, but a cooling rate of usually 40°C / hr or more, preferably 50°C / hr or more, more preferably 100°C / hr or more, and particularly preferably 150°C / hr or more is preferred for ease of cutting. In the present invention, the scorch stability of the acrylic rubber composition is excellent when the cooling rate of the sheet-form dry rubber is usually 40°C / hr or more, preferably 50°C / hr or more, more preferably 100°C / hr or more, and particularly preferably 150°C / hr or more.

[0244] The cut length of the dry rubber sheet is not particularly limited and is appropriately selected depending on the intended use, but is usually in the range of 100 to 800 mm, preferably 200 to 500 mm, and more preferably 250 to 450 mm.

[0245] The sheet-like acrylic rubber thus obtained is superior in operability to crumb-like acrylic rubber, and is also excellent in injection moldability, crosslinkability, strength properties and compression set resistance, as well as in storage stability, Banbury processability and water resistance, and can be used as is or after being laminated to form a bale.

[0246] (Lamination process) The method for producing the veil-like acrylic rubber of the present invention is not particularly limited, but it is preferable to laminate the above-mentioned sheet-like acrylic rubber to obtain a veil-like acrylic rubber with little air entrapment and excellent storage stability.

[0247] The lamination temperature for the sheet-like acrylic rubber is not particularly limited, but is usually 30°C or higher, preferably 35°C or higher, and more preferably 40°C or higher, so that air entrapped during lamination can be released. The number of layers to be laminated may be appropriately selected depending on the size or weight of the acrylic rubber veils. The acrylic rubber veils of the present invention are integrated by the weight of the laminated acrylic rubber sheets.

[0248] The veil-like acrylic rubber of the present invention thus obtained is superior in operability to crumb-like acrylic rubber, and is excellent in injection moldability, crosslinkability, strength properties and compression set resistance, as well as in storage stability, Banbury processability and water resistance. The veil-like acrylic rubber can be used as is, or the required amount can be cut and fed into a mixer such as a Banbury mixer or roll mixer.

[0249] <Rubber composition> The rubber composition of the present invention is characterized by comprising a rubber component containing the acrylic rubber, a filler, and a crosslinking agent.

[0250] The acrylic rubber of the present invention may be used alone as the rubber component that is the main component of the rubber composition of the present invention, or, if necessary, the acrylic rubber of the present invention may be used in combination with other rubber components. The content of the acrylic rubber of the present invention in the rubber component may be selected depending on the intended use, and is, for example, usually 30% by weight or more, preferably 50% by weight or more, and more preferably 70% by weight or more.

[0251] The other rubber component to be combined with the acrylic rubber of the present invention is not particularly limited, and examples thereof include natural rubber, polybutadiene rubber, polyisoprene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, silicone rubber, fluororubber, olefin-based elastomer, styrene-based elastomer, vinyl chloride-based elastomer, polyester-based elastomer, polyamide-based elastomer, polyurethane-based elastomer, and polysiloxane-based elastomer.

[0252] These other rubber components can be used alone or in combination of two or more. The shape of these other rubber components may be any of crumb, strand, veil, sheet, powder, etc. The content of the other rubber components in the total rubber component is appropriately selected within a range that does not impair the effects of the present invention, and is, for example, usually 70% by weight or less, preferably 50% by weight or less, and more preferably 30% by weight or less.

[0253] The filler contained in the rubber composition is not particularly limited, and examples thereof include reinforcing fillers and non-reinforcing fillers. Reinforcing fillers are preferred, as they provide the rubber composition with excellent Banbury processability, injection moldability, and short-time crosslinking properties, and the crosslinked product with excellent water resistance, strength properties, and compression set resistance.

[0254] Examples of reinforcing fillers include carbon blacks such as furnace black, acetylene black, thermal black, channel black, and graphite; silicas such as wet silica, dry silica, and colloidal silica; etc. Examples of non-reinforcing fillers include quartz powder, diatomaceous earth, zinc oxide, basic magnesium carbonate, activated calcium carbonate, magnesium silicate, aluminum silicate, titanium dioxide, talc, aluminum sulfate, calcium sulfate, and barium sulfate.

[0255] These fillers can be used alone or in combination of two or more. The amount of filler added is appropriately selected within a range that does not impair the effects of the present invention, and is usually 1 to 200 parts by weight, preferably 10 to 150 parts by weight, and more preferably 20 to 100 parts by weight, per 100 parts by weight of the rubber component.

[0256] The crosslinking agent used in the rubber composition is not particularly limited, and conventionally known crosslinking agents can be selected depending on the intended use. Examples include inorganic crosslinking agents such as sulfur compounds and organic crosslinking agents, with organic crosslinking agents being preferred. The crosslinking agent may be either a polyvalent compound or a monovalent compound, with polyvalent compounds having two or more reactivities being preferred. The crosslinking agent may further be either an ionically crosslinkable compound or a radically crosslinkable compound, with ionically crosslinkable compounds being preferred. The organic crosslinking agent is not particularly limited, but an ionically crosslinkable organic compound is preferred, and a polyvalent ion organic compound is particularly preferred. When the crosslinking agent is a polyvalent ion organic compound (polyvalent ion crosslinkable compound), the rubber composition has excellent Banbury processability, injection moldability, and short-term crosslinking properties, and the crosslinked product has excellent water resistance, strength properties, and compression set resistance, making it particularly suitable. The "ion" in ionically crosslinkable or polyvalent ion is an ionically reactive ion, and is not particularly limited as long as it ionically reacts with the ionically reactive group of the ionically reactive group-containing monomer of the acrylic rubber. Preferred examples include ionically crosslinkable organic compounds having ionically reactive groups such as amine groups, epoxy groups, carboxyl groups, and thiol groups.

[0257] Specific examples of polyvalent ion organic compounds include polyvalent amine compounds, polyvalent epoxy compounds, polyvalent carboxylic acid compounds, and polyvalent thiol compounds, and polyvalent amine compounds and polyvalent thiol compounds are preferred, and polyvalent amine compounds are more preferred.

[0258] Examples of polyvalent amine compounds include aliphatic polyvalent amine compounds such as hexamethylenediamine, hexamethylenediamine carbamate, and N,N'-dicinnamylidene-1,6-hexanediamine; and aromatic polyvalent amine compounds such as 4,4'-methylenedianiline, p-phenylenediamine, m-phenylenediamine, 4,4'-diaminodiphenyl ether, 3,4'-diaminodiphenyl ether, 4,4'-(m-phenylenediisopropylidene)dianiline, 4,4'-(p-phenylenediisopropylidene)dianiline, 2,2'-bis[4-(4-aminophenoxy)phenyl]propane, 4,4'-diaminobenzanilide, 4,4'-bis(4-aminophenoxy)biphenyl, m-xylylenediamine, p-xylylenediamine, and 1,3,5-benzenetriamine. Among these, hexamethylenediamine carbamate, 2,2'-bis[4-(4-aminophenoxy)phenyl]propane, etc. are preferred. Carbonates of these compounds can also be used as polyamine compounds. These polyamine compounds are particularly suitable for use in combination with carboxyl group-containing acrylic rubber or epoxy group-containing acrylic rubber.

[0259] As the polyvalent thiol compound, a triazine thiol compound is preferably used, such as 6-trimercapto-s-triazine, 2-anilino-4,6-dithiol-s-triazine, 1-dibutylamino-3,5-dimercaptotriazine, 2-dibutylamino-4,6-dithiol-s-triazine, 1-phenylamino-3,5-dimercaptotriazine, 2,4,6-trimercapto-1,3,5-triazine, 1-hexylamino-3,5-dimercaptotriazine, etc. These triazine thiol compounds are particularly preferably used in combination with chlorine atom-containing acrylic rubber.

[0260] Examples of other polyvalent organic compounds include polycarboxylic acid compounds such as tetradecanedioic acid, metal dithiocarbamate salts such as zinc dimethyldithiocarbamate, etc. These other polyvalent organic compounds are particularly suitable for use in combination with epoxy group-containing acrylic rubber.

[0261] These crosslinking agents can be used alone or in combination of two or more, and the blending amount is usually 0.001 to 20 parts by weight, preferably 0.1 to 10 parts by weight, and more preferably 0.1 to 5 parts by weight, per 100 parts by weight of the rubber component. By blending the amount of the crosslinking agent within this range, it is possible to ensure sufficient rubber elasticity while also providing excellent mechanical strength as a crosslinked rubber product, which is suitable.

[0262] The rubber composition of the present invention may contain an antioxidant as needed. The type of antioxidant is not particularly limited, but examples thereof include 2,6-di-t-butyl-4-methylphenol, 2,6-di-t-butylphenol, butylhydroxyanisole, 2,6-di-t-butyl-α-dimethylamino-p-cresol, octadecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, styrenated phenol, 2,2'-methylene-bis(6-α-methyl-benzyl-p-cresol), 4,4'-methylene Others such as bis(2,6-di-t-butylphenol), 2,2'-methylene-bis(4-methyl-6-t-butylphenol), 2,4-bis[(octylthio)methyl]-6-methylphenol, 2,2'-thiobis-(4-methyl-6-t-butylphenol), 4,4'-thiobis-(6-t-butyl-o-cresol), 2,6-di-t-butyl-4-(4,6-bis(octylthio)-1,3,5-triazin-2-ylamino)phenol Phenolic antioxidants; phosphite ester antioxidants such as tris(nonylphenyl)phosphite, diphenyl isodecyl phosphite, and tetraphenyldipropylene glycol diphosphite; sulfur ester antioxidants such as dilauryl thiodipropionate; phenyl-α-naphthylamine, phenyl-β-naphthylamine, p-(p-toluenesulfonylamido)-diphenylamine, and 4,4'-(α,α-dimethylbenzyl)diphenylamine. Examples of antioxidants include amine-based antioxidants such as amine, N,N-diphenyl-p-phenylenediamine, N-isopropyl-N'-phenyl-p-phenylenediamine, and butyraldehyde-aniline condensates; imidazole-based antioxidants such as 2-mercaptobenzimidazole; quinoline-based antioxidants such as 6-ethoxy-2,2,4-trimethyl-1,2-dihydroquinoline; and hydroquinone-based antioxidants such as 2,5-di-(t-amyl)hydroquinone. Among these, amine-based antioxidants are particularly preferred.

[0263] These antioxidants can be used alone or in combination of two or more kinds, and the amount to be added is in the range of 0.01 to 15 parts by weight, preferably 0.1 to 10 parts by weight, and more preferably 1 to 5 parts by weight, per 100 parts by weight of the rubber component.

[0264] The rubber composition of the present invention contains a rubber component containing the acrylic rubber of the present invention, a filler, and a crosslinking agent as essential components, and optionally an antioxidant, and may further contain other additives commonly used in the relevant technical field, such as crosslinking aids, crosslinking accelerators, crosslinking retarders, silane coupling agents, plasticizers, processing aids, lubricants, pigments, colorants, antistatic agents, foaming agents, etc. These other additives may be used alone or in combination of two or more, and the amount added is selected appropriately within a range that does not impair the effects of the present invention.

[0265] Examples of methods for producing the rubber composition of the present invention include a method of mixing a rubber component containing the acrylic rubber of the present invention, a filler, a crosslinking agent, and an antioxidant and other compounding ingredients that can be contained as needed, and any means conventionally used in the field of rubber processing can be used for mixing, such as an open roll, a Banbury mixer, various kneaders, etc. The mixing procedure for each component may be a normal procedure used in the field of rubber processing, and for example, it is preferable to thoroughly mix components that are resistant to reaction or decomposition by heat, and then mix components that are resistant to reaction or decomposition by heat, such as a crosslinking agent, for a short period of time at a temperature at which reaction or decomposition does not occur.

[0266] <Rubber cross-linked products> The cross-linked rubber product of the present invention is obtained by cross-linking the above rubber composition.

[0267] The cross-linked rubber product of the present invention can be produced by using the rubber composition of the present invention, molding it into a desired shape using a molding machine such as an extruder, injection molding machine, compressor, or roll, and then heating it to cause a cross-linking reaction and fix the shape as a cross-linked rubber product. In this case, cross-linking may be carried out after molding in advance, or simultaneously with molding. The molding temperature is usually 10 to 200°C, preferably 25 to 150°C. The cross-linking temperature is usually 100 to 250°C, preferably 130 to 220°C, and more preferably 150 to 200°C, and the cross-linking time is usually 0.1 minute to 10 hours, preferably 1 minute to 5 hours. The heating method may be appropriately selected from methods used for cross-linking rubber, such as press heating, steam heating, oven heating, and hot air heating.

[0268] The cross-linked rubber product of the present invention may be further heated to carry out secondary cross-linking depending on the shape, size, etc. of the cross-linked rubber product. The secondary cross-linking time varies depending on the heating method, cross-linking temperature, shape, etc., but is preferably carried out for 1 to 48 hours. The heating method and heating temperature may be selected appropriately.

[0269] The cross-linked rubber of the present invention has excellent compression set resistance and water resistance while maintaining basic rubber properties such as tensile strength, elongation, and hardness.

[0270] Taking advantage of the above-mentioned properties, the cross-linked rubber product of the present invention can be suitably used, for example, as sealing materials such as O-rings, packings, diaphragms, oil seals, shaft seals, bearing seals, mechanical seals, wellhead seals, seals for electric and electronic equipment, and seals for air compressors; various gaskets such as rocker cover gaskets attached to the connecting portion between a cylinder block and a cylinder head, oil pan gaskets attached to the connecting portion between an oil pan and a cylinder head or a transmission case, gaskets for fuel cell separators attached between a pair of housings sandwiching a unit cell having a positive electrode, an electrolyte plate, and a negative electrode, and gaskets for the top covers of hard disk drives; cushioning materials, vibration-proofing materials; wire coating materials; industrial belts; tubes and hoses; sheets; and the like.

[0271] The cross-linked rubber product of the present invention can also be suitably used as extrusion molded articles and mold cross-linked articles for automotive applications, for example, various hoses such as fuel oil hoses for fuel tanks, such as fuel hoses, filler neck hoses, vent hoses, paper hoses and oil hoses, air hoses, such as turbo air hoses and mission control hoses, radiator hoses, heater hoses, brake hoses and air conditioner hoses.

[0272] <Device configuration used in the production of acrylic rubber> Next, the configuration of the equipment used in the production of acrylic rubber according to one embodiment of the present invention will be described. Fig. 1 is a diagram schematically showing an example of an acrylic rubber production system having the configuration of the equipment used in the production of acrylic rubber according to one embodiment of the present invention. For example, the acrylic rubber production system 1 shown in Fig. 1 can be used to produce acrylic rubber according to the present invention.

[0273] The acrylic rubber production system 1 shown in FIG. 1 is composed of an emulsion polymerization reactor, a coagulation device 3, a washing device 4, a drainer 43, and a screw-type twin-screw extrusion dryer, none of which are shown.

[0274] The emulsion polymerization reactor is configured to perform the treatment related to the emulsion polymerization step described above. Although not shown in FIG. 1 , this emulsion polymerization reactor includes, for example, a polymerization reaction tank, a temperature control unit for controlling the reaction temperature, and a stirring device equipped with a motor and stirring blades. In the emulsion polymerization reactor, the monomer components for forming the acrylic rubber are mixed with water and an emulsifier and emulsified while being appropriately stirred with a stirrer. The emulsion polymerization reaction is initiated in the presence of a redox catalyst consisting of an organic radical generator and a reducing agent. A chain transfer agent is added batchwise during the polymerization to obtain an emulsion polymerization liquid. The emulsion polymerization reactor may be a batch, semi-batch, or continuous reactor, and may be either a tank reactor or a tubular reactor.

[0275] The coagulation device 3 shown in Fig. 1 is configured to perform the treatment related to the coagulation step described above. As schematically shown in Fig. 1, the coagulation device 3 includes, for example, a stirring tank 30, a heating unit 31 that heats the inside of the stirring tank 30, a temperature control unit (not shown) that controls the temperature inside the stirring tank 30, a stirring device 34 equipped with a motor 32 and stirring blades 33, and a drive control unit (not shown) that controls the number of rotations and rotation speed of the stirring blades 33. In the coagulation device 3, the emulsion polymerization liquid obtained in the emulsion polymerization reactor can be brought into contact with a coagulation liquid and coagulated to produce water-containing crumbs.

[0276] In the coagulation device 3, for example, the emulsion polymerization liquid is brought into contact with the coagulation liquid by adding the emulsion polymerization liquid to the coagulation liquid being stirred. That is, the stirring tank 30 of the coagulation device 3 is filled with the coagulation liquid, and the emulsion polymerization liquid is added to and brought into contact with the coagulation liquid to coagulate the emulsion polymerization liquid, thereby producing water-containing crumbs.

[0277] The heating unit 31 of the solidification device 3 is configured to heat the solidification liquid filled in the stirring tank 30. The temperature control unit of the solidification device 3 is configured to control the heating operation of the heating unit 31 while monitoring the temperature inside the stirring tank 30 measured by a thermometer, thereby controlling the temperature inside the stirring tank 30. The temperature of the solidification liquid inside the stirring tank 30 is controlled by the temperature control unit to be normally 40°C or higher, preferably in the range of 40 to 90°C, and more preferably 50 to 80°C.

[0278] The agitator 34 of the solidification device 3 is configured to agitate the coagulation liquid filled in the agitation tank 30. Specifically, the agitator 34 includes a motor 32 that generates rotational power and an agitator blade 33 that extends in a direction perpendicular to the rotation axis of the motor 32. The agitator blade 33 rotates around the rotation axis by the rotational power of the motor 32 within the coagulation liquid filled in the agitation tank 30, thereby causing the coagulation liquid to flow. The shape, size, and number of the agitator blades 33 to be installed are not particularly limited.

[0279] The drive control unit of the solidification device 3 is configured to control the rotational drive of the motor 32 of the agitator 34 to set the rotation number and rotation speed of the agitator blade 33 of the agitator 34 to a predetermined value. The drive control unit controls the rotation of the agitator blade 33 so that the agitation speed of the solidification liquid is, for example, typically 100 rpm or higher, preferably 200 to 1000 rpm, more preferably 300 to 900 rpm, and particularly preferably 400 to 800 rpm. The drive control unit controls the rotation of the agitator blade 33 so that the peripheral speed of the solidification liquid is typically 0.5 m / s or higher, preferably 1 m / s or higher, more preferably 1.5 m / s or higher, particularly preferably 2 m / s or higher, and most preferably 2.5 m / s or higher. Furthermore, the drive control unit controls the rotation of the agitator blade 33 so that the upper limit of the peripheral speed of the solidification liquid is typically 50 m / s or lower, preferably 30 m / s or lower, more preferably 25 m / s or lower, and most preferably 20 m / s or lower.

[0280] The cleaning device 4 shown in FIG. 1 is configured to perform the above-described cleaning process. 1, the washing device 4 has, for example, a washing tank 40, a heating unit 41 that heats the inside of the washing tank 40, and a temperature control unit (not shown) that controls the temperature inside the washing tank 40. In the washing device 4, the water-containing crumbs produced in the coagulation device 3 are mixed with a large amount of water and washed, thereby making it possible to effectively reduce the amount of ash in the acrylic rubber that is finally obtained.

[0281] The heating unit 41 of the cleaning device 4 is configured to heat the inside of the cleaning tank 40. The temperature control unit of the cleaning device 4 is configured to control the heating operation of the heating unit 41 while monitoring the temperature inside the cleaning tank 40 measured by a thermometer, thereby controlling the temperature inside the cleaning tank 40. As described above, the temperature of the cleaning water inside the cleaning tank 40 is controlled to be usually 40°C or higher, preferably in the range of 40 to 100°C, more preferably 50 to 90°C, and most preferably 60 to 80°C.

[0282] The water-containing crumbs washed in the washing device 4 are supplied to a screw-type twin-screw extruder dryer 5, which performs a dehydration step and a drying step. At this time, the washed water-containing crumbs are preferably supplied to the screw-type twin-screw extruder dryer 5 through a drainer 43 capable of separating free water. The drainer 43 may be, for example, a wire mesh, a screen, or an electric sieve.

[0283] Furthermore, when the washed wet crumbs are supplied to the screw twin-screw extruder 5, the temperature of the wet crumbs is preferably 40°C or higher, more preferably 60°C or higher. For example, the temperature of the water used for washing in the washing device 4 may be set to 60°C or higher (e.g., 70°C), so that the temperature of the wet crumbs when supplied to the screw twin-screw extruder 5 can be maintained at 60°C or higher, or the wet crumbs may be heated to a temperature of 40°C or higher, preferably 60°C or higher, when transported from the washing device 4 to the screw twin-screw extruder 5. This makes it possible to effectively perform the subsequent dehydration and drying steps, and significantly reduce the moisture content of the finally obtained dried rubber.

[0284] The screw twin-screw extruder dryer 5 shown in Fig. 1 is configured to perform the treatments related to the dehydration step and drying step described above. Although the screw twin-screw extruder dryer 5 is shown in Fig. 1 as a suitable example, a centrifuge or squeezer may also be used as a dehydrator that performs the treatment related to the dehydration step, and a hot air dryer, reduced pressure dryer, expander dryer, kneader dryer, etc. may also be used as a dryer that performs the treatment related to the drying step.

[0285] The screw twin-screw extrusion dryer 5 is configured to mold the dried rubber obtained through the dehydration process and the drying process into a predetermined shape and discharge it. Specifically, the screw twin-screw extrusion dryer 5 is equipped with a dehydration barrel section 53 that functions as a dehydrator for dehydrating the water-containing crumbs washed in the washing device 4, and a drying barrel section 54 that functions as a dryer for drying the water-containing crumbs, and is further equipped with a die 59 downstream of the screw twin-screw extrusion dryer 5 that has a molding function for molding the water-containing crumbs.

[0286] Hereinafter, the configuration of the screw-type twin-screw extrusion dryer 5 will be described with reference to FIG. Fig. 2 shows the configuration of a specific example suitable for the screw-type twin-screw extrusion dryer 5 shown in Fig. 1. This screw-type twin-screw extrusion dryer 5 can suitably carry out the above-mentioned dehydration and drying process.

[0287] The screw-type twin-screw extruder 5 shown in FIG. 2 is a twin-screw extruder dryer equipped with a pair of screws (not shown) in a barrel unit 51. The screw-type twin-screw extruder dryer 5 has a drive unit 50 that rotates and drives the pair of screws in the barrel unit 51. This configuration is suitable for applying an optimal shear to the acrylic rubber for drying. The drive unit 50 is attached to the upstream end (left end in FIG. 2) of the barrel unit 51. The screw-type twin-screw extruder dryer 5 also has a die 59 at the downstream end (right end in FIG. 2) of the barrel unit 51.

[0288] The barrel unit 51 has a supply barrel section 52, a dehydration barrel section 53, and a drying barrel section 54, from the upstream side to the downstream side (from the left side to the right side in FIG. 2).

[0289] The supply barrel section 52 is made up of two supply barrels, that is, a first supply barrel 52a and a second supply barrel 52b.

[0290] The dehydration barrel section 53 is made up of three dehydration barrels, namely, a first dehydration barrel 53a, a second dehydration barrel 53b, and a third dehydration barrel 53c.

[0291] The drying barrel section 54 is composed of eight drying barrels, namely, a first drying barrel 54a, a second drying barrel 54b, a third drying barrel 54c, a fourth drying barrel 54d, a fifth drying barrel 54e, a sixth drying barrel 54f, a seventh drying barrel 54g, and an eighth drying barrel 54h.

[0292] In this way, the barrel unit 51 is configured by connecting 13 divided barrels 52a to 52b, 53a to 53c, and 54a to 54h from the upstream side to the downstream side.

[0293] The screw-type twin-screw extruder 5 also includes heating means (not shown) that individually heat each of the barrels 52a-52b, 53a-53c, and 54a-54h to heat the water-containing crumb in each of the barrels 52a-52b, 53a-53c, and 54a-54h to a predetermined temperature. The number of heating means corresponds to the number of barrels 52a-52b, 53a-53c, and 54a-54h. Examples of such heating means include, but are not limited to, a steam supply means that supplies high-temperature steam to a steam distribution jacket formed in each of the barrels 52a-52b, 53a-53c, and 54a-54h. The screw-type twin-screw extruder 5 also includes temperature control means (not shown) that control the set temperature of each heating means corresponding to each of the barrels 52a-52b, 53a-53c, and 54a-54h.

[0294] The number of supply barrels, dewatering barrels, and drying barrels that respectively constitute each of barrel portions 52, 53, and 54 in barrel unit 51 is not limited to the embodiment shown in FIG. 2, and can be set to a number that depends on factors such as the moisture content of the water-containing acrylic rubber crumbs to be dried.

[0295] For example, the number of supply barrels installed in supply barrel section 52 is, for example, 1 to 3. The number of dehydration barrels installed in dehydration barrel section 53 is, for example, preferably 2 to 10, and more preferably 3 to 6, since this allows for efficient dehydration of the water-containing crumbs of sticky acrylic rubber. The number of drying barrels installed in drying barrel section 54 is, for example, preferably 2 to 10, and more preferably 3 to 8.

[0296] The pair of screws in the barrel unit 51 are driven to rotate by a driving means such as a motor housed in the drive unit 50. The pair of screws extend from the upstream side to the downstream side within the barrel unit 51, and by being driven to rotate, the wet crumb supplied to the supply barrel section 52 can be mixed and transported downstream. The pair of screws are preferably of a twin-screw intermeshing type in which the crests and troughs of the screws are intermeshed with each other, which can improve the dewatering efficiency and drying efficiency of the wet crumb.

[0297] The pair of screws may rotate in the same direction or in opposite directions, but from the viewpoint of self-cleaning performance, a type in which they rotate in the same direction is preferred. The screw shape of the pair of screws is not particularly limited as long as it has a shape required for each of barrel portions 52, 53, and 54.

[0298] The supply barrel section 52 is a region for supplying the wet crumbs into the barrel unit 51. The first supply barrel 52a of the supply barrel section 52 has a feed port 55 for supplying the wet crumbs into the barrel unit 51.

[0299] The dewatering barrel section 53 is a region where a liquid (serum water) containing a coagulant and the like is separated from the water-containing crumbs and discharged.

[0300] The first to third dewatering barrels 53a to 53c constituting the dewatering barrel section 53 each have dewatering slits 56a, 56b, and 56c for discharging moisture from the wet crumbs to the outside. A plurality of dewatering slits 56a, 56b, and 56c are formed in each of the dewatering barrels 53a to 53c.

[0301] The slit width, i.e., opening, of each dewatering slit 56a, 56b, 56c may be selected appropriately depending on the conditions of use, and is typically 0.01 to 5 mm. In order to minimize loss of water-containing crumb and enable efficient dewatering of the water-containing crumb, the slit width is preferably 0.1 to 1 mm, and more preferably 0.2 to 0.6 mm.

[0302] There are two ways to remove water from the wet crumb in each of the dewatering barrels 53a to 53c of the dewatering barrel section 53: removal in liquid form from the respective dewatering slits 56a, 56b, 56c, and removal in vapor form. In the dewatering barrel section 53 of this embodiment, removal of water in liquid form is defined as drainage, and removal of water in vapor form is defined as exhaust steam, to distinguish between the two.

[0303] In the dehydration barrel section 53, a combination of drainage and steam discharge is preferable because it can efficiently reduce the moisture content of the adhesive acrylic rubber. In the dehydration barrel section 53, which of the first to third dehydration barrels 53a to 53c is used for drainage or steam discharge can be appropriately selected depending on the intended use. However, to reduce the ash content of the acrylic rubber produced, it is generally recommended to increase the number of dehydration barrels used for drainage. In this case, as shown in FIG. 2, for example, drainage is performed in the first and second upstream dehydration barrels 53a and 53b, and steam discharge is performed in the third downstream dehydration barrel 53c. Furthermore, if the dehydration barrel section 53 has four dehydration barrels, for example, drainage can be performed in the three upstream dehydration barrels and steam discharge in the one downstream dehydration barrel. On the other hand, to reduce the moisture content, it is recommended to increase the number of dehydration barrels used for steam discharge.

[0304] As described above in the dehydration / drying process, the set temperature of the dehydration barrel section 53 is usually in the range of 60 to 150°C, preferably 70 to 140°C, and more preferably 80 to 130°C. The set temperature of the dehydration barrel for dehydration in a drained state is usually in the range of 60 to 120°C, preferably 70 to 110°C, and more preferably 80 to 100°C. The set temperature of the dehydration barrel for dehydration in an exhausted steam state is usually in the range of 100 to 150°C, preferably 105 to 140°C, and more preferably 110 to 130°C.

[0305] The drying barrel section 54 is a region where the dehydrated wet crumbs are dried under reduced pressure. Of the first to eighth drying barrels 54a to 54h that make up the drying barrel section 54, the second drying barrel 54b, the fourth drying barrel 54d, the sixth drying barrel 54f, and the eighth drying barrel 54h each have vent ports 58a, 58b, 58c, and 58d for degassing. Vent pipes (not shown) are connected to the vent ports 58a, 58b, 58c, and 58d, respectively.

[0306] A vacuum pump (not shown) is connected to the end of each vent pipe, and operation of these vacuum pumps reduces the pressure inside the drying barrel section 54 to a predetermined level. The screw extruder 5 has pressure control means (not shown) that controls the operation of these vacuum pumps to control the degree of pressure reduction inside the drying barrel section 54.

[0307] The degree of reduced pressure in the drying barrel section 54 may be selected as appropriate, but as described above, it is usually set to 1 to 50 kPa, preferably 2 to 30 kPa, and more preferably 3 to 20 kPa.

[0308] The temperature set in the drying barrel section 54 may be selected as appropriate, but as described above, it is usually set to 100 to 250°C, preferably 110 to 200°C, and more preferably 120 to 180°C.

[0309] In each of the drying barrels 54a to 54h that make up the drying barrel section 54, the set temperatures within all of the drying barrels 54a to 54h may be similar or different, but it is preferable to set the temperature on the downstream side (die 59 side) higher than the temperature on the upstream side (dehydration barrel section 53 side), as this improves drying efficiency.

[0310] The die 59 is a mold placed at the downstream end of the barrel unit 51 and has a discharge opening of a predetermined nozzle shape. The acrylic rubber dried in the drying barrel section 54 passes through the discharge opening of the die 59 and is extruded into a shape that corresponds to the predetermined nozzle shape. The acrylic rubber that passes through the die 59 can be molded into various shapes such as granules, columns, rods, and sheets depending on the nozzle shape of the die 59, but in the present invention, it is molded into a sheet. A breaker plate or wire mesh may or may not be provided between the screw and the die 59.

[0311] The hydrous crumbs of acrylic rubber obtained through the washing step are supplied to the supply barrel section 52 from the feed port 55. The hydrous crumbs supplied to the supply barrel section 52 are transferred from the supply barrel section 52 to the dehydration barrel section 53 by the rotation of the pair of screws in the barrel unit 51. In the dehydration barrel section 53, the water contained in the hydrous crumbs is drained and steam is exhausted from the dehydration slits 56a, 56b, 56c provided in the first to third dehydration barrels 53a to 53c, respectively, as described above, and the hydrous crumbs are dehydrated.

[0312] The water-containing crumbs dewatered in the dewatering barrel section 53 are sent to the drying barrel section 54 by the rotation of a pair of screws in the barrel unit 51. The water-containing crumbs sent to the drying barrel section 54 are plasticized and mixed to form a melt, and are transported downstream while generating heat and increasing in temperature. The water contained in this acrylic rubber melt then vaporizes, and the water (vapor) is discharged to the outside through vent pipes (not shown) connected to each of the vent ports 58a, 58b, 58c, and 58d.

[0313] As described above, by passing through the drying barrel section 54, the water-containing crumb is dried and becomes a melted acrylic rubber, and the acrylic rubber is supplied to the die 59 by the rotation of a pair of screws in the barrel unit 51 and extruded from the die 59.

[0314] Here, an example of the operating conditions of the screw-type twin-screw extruding dryer 5 according to this embodiment will be given.

[0315] The rotation speed (N) of the pair of screws in the barrel unit 51 may be appropriately selected depending on various conditions, and is normally set to 10 to 1000 rpm. From the viewpoint of efficiently reducing the water content and methyl ethyl ketone insoluble content of the acrylic rubber, the rotation speed is preferably 50 to 750 rpm, more preferably 100 to 500 rpm, and most preferably 120 to 300 rpm.

[0316] The extrusion rate (Q) of the acrylic rubber is not particularly limited, but is usually 100 to 1500 kg / hr, preferably 300 to 1200 kg / hr, more preferably 400 to 1000 kg / hr, and most preferably 500 to 800 kg / hr.

[0317] The ratio (Q / N) of the extrusion rate (Q) of the acrylic rubber to the screw rotation speed (N) is not particularly limited, but is usually 1 to 20, preferably 2 to 10, more preferably 3 to 8, and particularly preferably 4 to 6.

[0318] The maximum torque in barrel unit 51 is not particularly limited, but is usually in the range of 5 to 125 N·m, preferably 10 to 100 N·m, more preferably 10 to 50 N·m, and particularly preferably 15 to 45 N·m.

[0319] The specific power within barrel unit 51 is not particularly limited, but is usually in the range of 0.01 to 0.3 [kw·h / kg] or more, preferably 0.05 to 0.25 [kw·h / kg], and more preferably 0.1 to 0.2 [kw·h / kg].

[0320] The specific power within barrel unit 51 is not particularly limited, but is usually in the range of 0.1 to 0.6 [A·h / kg] or more, preferably 0.15 to 0.55 [A·h / kg], and more preferably 0.2 to 0.5 [A·h / kg].

[0321] The shear rate in barrel unit 51 is not particularly limited, but is usually in the range of 5 to 150 [1 / s] or more, preferably 10 to 100 [1 / s], and more preferably 25 to 75 [1 / s].

[0322] The shear viscosity of the acrylic rubber in the barrel unit 51 is not particularly limited, but is usually in the range of 4000 to 8000 [Pa·s], preferably 4500 to 7500 [Pa·s], and more preferably 5000 to 7000 [Pa·s].

[0323] The cooling device 6 shown in Fig. 1 is configured to cool the dried rubber obtained through the dehydration process using a dehydrator and the drying process using a dryer. As a cooling method using the cooling device 6, various methods can be adopted, including an air-cooling method using a fan or air conditioner, a water-spraying method in which water is sprayed, and an immersion method in which the dried rubber is immersed in water. The dried rubber may also be cooled by leaving it at room temperature.

[0324] As described above, the dried rubber discharged from the screw extruder 5 is extruded and molded into various shapes such as granules, columns, rods, and sheets depending on the nozzle shape of the die 59, but in the present invention, it is molded into a sheet. Hereinafter, with reference to Figure 3, a conveying cooling device 60 that cools the dried rubber sheet 10 molded into a sheet will be described as an example of the cooling device 6.

[0325] Fig. 3 shows the configuration of a conveying-type cooling device 60 suitable for use as the cooling device 6 shown in Fig. 1. The conveying-type cooling device 60 shown in Fig. 3 is configured to cool the dry rubber sheet 10 discharged from the discharge port of the die 59 of the screw extruder 5 by air cooling while conveying the dry rubber sheet 10. By using this conveying-type cooling device 60, the dry rubber sheet discharged from the screw extruder 5 can be suitably cooled.

[0326] The conveying cooling device 60 shown in FIG. 3 is used by being directly connected to the die 59 of the screw-type extruder 5 shown in FIG.

[0327] The conveying type cooling device 60 has a conveyor 61 that conveys the sheet-like dried rubber 10 discharged from the die 59 of the screw-type extruder 5 in the direction of arrow A in Figure 3, and a cooling means 65 that blows cold air onto the sheet-like dried rubber 10 on the conveyor 61.

[0328] The conveyor 61 has rollers 62 and 63, and a conveyor belt 64 that is wound around the rollers 62 and 63 and on which the sheet-like dry rubber 10 is placed. The conveyor 61 is configured to continuously transport the sheet-like dry rubber 10 discharged from the die 59 of the screw-type extruder 5 onto the conveyor belt 64 downstream (to the right in FIG. 3).

[0329] The cooling means 65 is not particularly limited, but may be, for example, a means configured to blow cooling air sent from a cooling air generating means (not shown) onto the surface of the sheet-like dried rubber 10 on the conveyor belt 64.

[0330] The length L1 of the conveyor 61 and cooling means 65 of the transportable cooling device 60 (the length of the portion where cooling air can be blown) is not particularly limited, but is, for example, 10 to 100 m, and preferably 20 to 50 m. The transport speed of the dry rubber sheet 10 in the transportable cooling device 60 may be adjusted appropriately depending on the length L1 of the conveyor 61 and cooling means 65, the discharge speed of the dry rubber sheet 10 discharged from the die 59 of the screw extruder 5, the target cooling speed and cooling time, and the like, but is, for example, 10 to 100 m / hr, and more preferably 15 to 70 m / hr.

[0331] According to the conveying type cooling device 60 shown in Figure 3, the sheet-like dry rubber 10 discharged from the die 59 of the screw-type extruder 5 is transported on a conveyor 61, and cooling air is blown onto the sheet-like dry rubber 10 from a cooling means 65, thereby cooling the sheet-like dry rubber 10.

[0332] 3, the transportable cooling device 60 is not particularly limited to a configuration including one conveyor 61 and one cooling means 65, but may be configured to include two or more conveyors 61 and two or more corresponding cooling means 65. In that case, the total length of each of the two or more conveyors 61 and cooling means 65 may be within the above range.

[0333] The baling apparatus 7 shown in Fig. 1 is configured to process dried rubber extruded from the screw extruder 5 and cooled in the cooler 6 to produce bales, which are single blocks. As described above, the screw extruder 5 is capable of extruding dried rubber into various shapes such as granules, columns, rods, and sheets, and the baling apparatus 7 is configured to bale the dried rubber molded into these various shapes. The weight and shape of the acrylic rubber bales produced by the baling apparatus 7 are not particularly limited, but for example, approximately 20 kg acrylic rubber bales in a roughly rectangular parallelepiped shape are produced.

[0334] The baling device 7 may include, for example, a baler, and the cooled, dried rubber may be compressed by the baler to produce baled acrylic rubber.

[0335] Furthermore, when the screw-type extruder 5 is used to produce the dry rubber sheet 10, a bale of acrylic rubber may be produced by laminating the dry rubber sheet 10. For example, a cutting mechanism for cutting the dry rubber sheet 10 may be provided in the baling device 7 disposed downstream of the conveying cooling device 60 shown in FIG. 3. Specifically, the cutting mechanism of the baling device 7 is configured, for example, to continuously cut the cooled dry rubber sheet 10 at predetermined intervals to process it into cut dry rubber sheets 16 of a predetermined size. A plurality of cut dry rubber sheets 16 cut to a predetermined size by the cutting mechanism are laminated to produce a bale of acrylic rubber comprising laminated cut dry rubber sheets 16.

[0336] When producing a veil-shaped acrylic rubber laminated with cut sheet-shaped dry rubber 16, it is preferable to laminate the cut sheet-shaped dry rubber 16 at a temperature of, for example, 40° C. or higher. By laminating the cut sheet-shaped dry rubber 16 at a temperature of 40° C. or higher, good air release is achieved by further cooling and compression due to its own weight. [Example]

[0337] The present invention will be described in more detail below with reference to examples and comparative examples. In each example, "parts," "%," and "ratio" are by weight unless otherwise specified. Various physical properties were evaluated according to the following methods.

[0338] [Monomer composition] Regarding the monomer composition of acrylic rubber, the monomer composition of each monomer unit in acrylic rubber is 1 The remaining activity of reactive groups in the acrylic rubber was confirmed by H-NMR, and the content of each reactive group was confirmed by the following method. The content ratio of each monomer unit in the acrylic rubber was calculated from the amount of each monomer used in the polymerization reaction and the polymerization conversion rate. Specifically, the polymerization reaction was an emulsion polymerization reaction, and the polymerization conversion rate was approximately 100%, with no unreacted monomers detected, so the content ratio of each monomer unit in the rubber was set to be the same as the amount of each monomer used.

[0339] [Reactive group content] The content of reactive groups in the acrylic rubber was measured by the following method. (1) The amount of carboxyl groups was calculated by dissolving the sample (acrylic rubber) in acetone and performing potentiometric titration with potassium hydroxide solution. (2) The amount of epoxy groups was calculated by dissolving the sample in methyl ethyl ketone, adding a specified amount of hydrochloric acid to react with the epoxy groups, and titrating the amount of residual hydrochloric acid with potassium hydroxide. (3) The amount of chlorine was calculated by completely burning the sample in a combustion flask, absorbing the generated chlorine into water, and titrating it with silver nitrate.

[0340] [Ash content] The ash content (%) in the acrylic rubber was measured in accordance with JIS K6228 Method A.

[0341] [Ash content] The amount (%) of each component in the acrylic rubber ash was calculated as a percentage of the above ash content by pressing the ash sampled during the above ash content measurement onto a Φ20 mm titration filter paper, measuring the component amount (ppm) by XRF using ZSX Primus (manufactured by Rigaku).

[0342] [Molecular weight and molecular weight distribution] The molecular weights (Mw, Mn, Mz) and molecular weight distributions (Mw / Mn and Mz / Mw) of acrylic rubber are absolute molecular weights and absolute molecular weight distributions measured by the GPC-MALS method using a solution of dimethylformamide with 0.05 mol / L lithium chloride and 0.01% 37% concentrated hydrochloric acid as the solvent. Here, "GPC-MALS" refers to the following: GPC (gel permeation chromatography) is a type of liquid chromatography that separates molecules based on differences in molecular size. Specifically, a multi-angle laser light scattering spectrometer (MALS) and a differential refractometer (RI) are incorporated into a GPC (gel permeation chromatography) apparatus. The light scattering intensity and refractive index difference of the molecular chain solution separated by size in the GPC apparatus are measured over the melting time, allowing the molecular weight and solute content to be calculated sequentially, ultimately determining the absolute molecular weight distribution and absolute average molecular weight of the polymeric substance.

[0343] The gel permeation chromatography multi-angle light scattering photometer consists of a pump (LC-20ADOpt, manufactured by Shimadzu Corporation), a differential refractometer (Optilab rEX, manufactured by Wyatt Technology) as a detector, and a multi-angle light scattering detector (DAWN HELEOS, manufactured by Wyatt Technology).

[0344] In this way, the molecular weight of the solute and its content were calculated sequentially. The measurement conditions and method using the GPC device are as follows. Column: Two TSKgel α-M columns (φ7.8 mm x 30 cm, manufactured by Tosoh Corporation) Column temperature: 40℃ Flow rate: 0.8ml / mm Sample preparation: 5 ml of solvent was added to 10 mg of rubber sample, and the mixture was gently stirred at room temperature (dissolution was visually confirmed), followed by filtration using a 0.5 μm filter.

[0345] [Glass transition temperature (Tg)] The glass transition temperature (Tg) of the acrylic rubber was measured using a differential scanning calorimeter (DSC, product name "X-DSC7000", manufactured by Hitachi High-Tech Science Corporation).

[0346] [Gel amount] The gel content (%) of the acrylic rubber is the amount of insoluble matter in methyl ethyl ketone, and was determined by the following method. Approximately 0.2 g of acrylic rubber (X g) was weighed out, immersed in 100 ml of methyl ethyl ketone, and left to stand at room temperature for 24 hours. After that, the insoluble matter in methyl ethyl ketone was filtered off using an 80-mesh wire netting. The filtrate, in other words, the filtrate containing only the rubber components soluble in methyl ethyl ketone, was evaporated, dried, and solidified. The dry solid content (Y g) was then weighed and calculated using the following formula. Gel volume (%) = 100 × (XY) / X

[0347] [specific gravity] The specific gravity of the acrylic rubber was measured in accordance with JIS K6268 Crosslinked Rubber - Density Measurement Method A. The measurement value obtained by the following measurement method is density, and the density of water is 1 Mg / m 3 The specific gravity is calculated as follows. Specifically, the specific gravity of a rubber sample determined in accordance with JIS K6268 Cross-linked Rubber - Density Measurement, Method A, is calculated by dividing the mass by the volume including the voids in the rubber sample, and is calculated by dividing the density of the rubber sample measured in accordance with JIS K6268 Cross-linked Rubber - Density Measurement, Method A, by the density of water (if the density of a rubber sample is divided by the density of water, the numerical value remains the same but the unit is lost). More specifically, the specific gravity of a rubber sample can be calculated according to the following procedure. (1) A 2.5g test piece is cut out from a rubber sample that has been left to stand at standard temperature (23°C ± 2°C) for at least 3 hours, and suspended from the hook of an analytical balance with an accuracy of 1 mg using a thin nylon thread with a mass of less than 0.010g so that the bottom of the test piece is 25mm above the distributing pan of the analytical balance. The mass (m1) of the test piece is measured twice in the air to the nearest mg. (2) Next, place a 250 cm 3 Fill a cubic meter beaker with distilled water that has been boiled and then cooled to the standard temperature, immerse the test piece in it, remove any air bubbles adhering to the surface of the test piece, observe the movement of the balance pointer for several seconds, and confirm that the pointer gradually stops touching due to convection, then measure the mass (m2) of the test piece in the water twice in mg. (3) Also, the density of the test piece is 1 Mg / m 3 If the test specimen is less than this (if the test specimen floats in water), attach a weight to the test specimen and measure the mass of the weight in water (m3) and the mass of the test specimen and weight (m4) twice in mg units. (4) The specific gravity of the rubber sample was calculated by the density (Mg / m) according to the following formula using the average values ​​of m1, m2, m3, and m4 measured above. 3 ) and multiply the calculated density by the density of water (1.00 Mg / m 3 ) to find the answer. (Density of rubber sample without weight) Density=m1 / (m1-m2) (Density of rubber sample when weight is used) Density=m1 / (m1+m3-m4)

[0348] [Water content] The water content (%) was measured in accordance with JIS K6238-1: Oven A (volatile content measurement) method.

[0349] [pH] The pH was measured with a pH electrode after dissolving 6 g (±0.05 g) of acrylic rubber in 100 g of tetrahydrofuran and adding 2.0 ml of distilled water to confirm complete dissolution.

[0350] [Complex viscosity] The complex viscosity η was determined by measuring the temperature dispersion (40 to 120°C) at 1 Hz and 473% strain using a dynamic viscoelasticity measuring device, Rubber Process Analyzer RPA-2000 (manufactured by Alpha Technology Co., Ltd.). Here, the dynamic viscoelasticity at 60°C was taken as the complex viscosity η(60°C) and the dynamic viscoelasticity at 100°C as the complex viscosity η(100°C), and the ratio η(100°C) / η(60°C) was calculated.

[0351] [Mooney viscosity (ML1+4, 100℃)] The Mooney viscosity (ML1+4, 100°C) was measured in accordance with the physical testing method for uncrosslinked rubber of JIS K6300.

[0352] [Injection moldability] For injection moldability, shape formability, mold releasability, and fusion properties were observed and scored using a small injection molding machine (SLIM15-30, manufactured by Daihan Co., Ltd.), and an overall evaluation was performed based on the total score according to the following criteria. Shape formability and mold releasability were evaluated by preparing a mold with three cylindrical shapes (A: 4 mmφ, B: 3 mmφ, C: 2 mmφ) with an axial length of more than 150 mm and different diameters, and injecting the rubber composition into the mold under conditions of a screw temperature of 90°C, an injection time of 30 seconds, and an injection pressure of 7 MPa. After crosslinking at a mold temperature of 170°C for 1 minute and 30 seconds, the injection-molded cylindrical molded product was removed, and the cylindrical molded product and the mold were observed and scored according to the following criteria. To evaluate fusion properties, a mold was prepared in the shape of a fusion observation zone 0.5 mm thick x 5 mm wide x 40 mm long, with 5 mm diameter pipes connected to both longitudinal ends. The rubber composition was poured into the fusion observation zone from each of the 5 mm diameter pipes at a screw temperature of 90°C, an injection time of 30 seconds, and an injection pressure of 7 MPa. After crosslinking at a mold temperature of 170°C for 1 minute and 30 seconds, the degree of fusion of the rubber composition in the fusion observation object was observed and scored according to the following criteria.

[0353] (Shape formation) 5 points: A, B, and C all produced cylindrical molded products, and the shape of the tip of the molded product perfectly followed the mold, and no burrs were observed. 4 points: A, B, and C all produced cylindrical molded products, but in C, only a small part of the tip of the molded product did not completely follow the shape of the mold. 3 points: A and B were able to produce cylindrical molded products, and C was able to produce more than half of the molded products. 2 points: A and B produced cylindrical molded products, but C only produced half of the molded product. 1 point: A molded product is produced, but B molded product is not completely produced. 0 points: A molded product cannot be produced

[0354] (Mold releasability) 5 points: Easy to release from the mold and no mold residue 4 points: The part can be easily released from the mold, but there is a small amount of mold residue. 3 points: Easy to release from the mold, but there is a small amount of mold residue 2 points: Slightly difficult to remove from the mold, but no residue remains 1 point: It is slightly difficult to remove from the mold and some mold remains. 0 points: Difficult to remove from the mold

[0355] (fusion) 5 points: Complete fusion 0 points: Incomplete fusion (malfusion)

[0356] comprehensive evaluation ◎: Full marks (15 points) 〇:14 points □:13 points △:11~12 points ×: 10 points or less

[0357] [Banbury processability] The Banbury processability of the rubber sample was evaluated by adding the rubber sample to a Banbury mixer heated to 50°C and masticating for 1 minute, then adding compounding ingredient A of the rubber mixture formulation shown in Table 1, and measuring the time until the rubber mixture in the first stage was integrated and showed the maximum torque value, i.e., the Black Incorporation Time (BIT), and calculating an index based on Comparative Example 2 being 100, and evaluating it according to the following criteria. ◎: 20 or less 〇: Over 20 and under 40 □: Over 40 and under 60 △: Over 60 and under 80 ×: Over 80

[0358] [Storage stability evaluation] The storage stability of the rubber samples was evaluated by placing the rubber samples in a constant temperature and humidity chamber (SH-222 manufactured by ESPEC Co., Ltd.) at 45°C x 80% RH, calculating the rate of change in water content before and after a 7-day test, and calculating an index with Comparative Example 2 set at 100, according to the following criteria. ◎: 20 or less 〇: Over 20 and under 50 □: Over 50 and under 90 △: Over 90 and under 100 ×: Over 100

[0359] [Water resistance evaluation] The water resistance of the rubber sample was evaluated according to JIS K6258 by conducting an immersion test in which a cross-linked rubber sample was immersed in distilled water at a temperature of 85°C for 100 hours, measuring the volume change rate before and after immersion, and calculating an index based on the result of Comparative Example 2 being 100, according to the following criteria. ◎: 1 or less 〇: Over 1 and under 5 □: More than 5 and less than 10 △: Over 10 and under 50 ×: Over 50

[0360] [Compression set resistance] The compression set resistance of the rubber sample was evaluated according to the following criteria by measuring the compression set rate after leaving the cross-linked rubber sample at 175°C for 90 hours in a state where it was compressed by 25% in accordance with JIS K6262. ◎: Compression set rate is less than 15% ×: Compression set rate is 15% or more

[0361] [Normal state physical property evaluation] The normal physical properties of the rubber samples were evaluated according to the following criteria by measuring the breaking strength, 100% tensile stress and breaking elongation of the cross-linked rubber samples in accordance with JIS K6251. (1) The breaking strength was evaluated as follows: 10 MPa or more is rated as ⊚, and less than 10 MPa is rated as x. (2) The 100% tensile stress was evaluated as ⊚ when it was 5 MPa or more, and x when it was less than 5 MPa. (3) The breaking elongation was evaluated as ⊚ when it was 150% or more, and x when it was less than 150%.

[0362] [Evaluation of gel amount variation] The variation in gel amount of a rubber sample is evaluated by measuring the gel amount at 20 points arbitrarily selected from 20 parts (20 kg) of the rubber sample, and evaluating it based on the following criteria. ◎: The average gel amount of the 20 measured points was calculated, and all 20 measured points were within the range of the average value ±3. ○: The average gel amount of the 20 measured points was calculated, and all 20 measured points were within the range of the average value ±5 (even one of the 20 measured points would be outside the range of the average value ±3, but all 20 points were within the range of the average value ±5) ×: The average value of the gel amounts at 20 measured points was calculated, and even one of the 20 measured points was outside the range of the average value ±5.

[0363] [Evaluation of processing stability by suppressing Mooney scorch] The cooling rate of a sheet-like acrylic rubber extruded from a screw-type twin-screw extrusion dryer described in Japanese Patent No. 6683189 and the Mooney scorch storage stability of the acrylic rubber composition were evaluated.

[0364] [Example 1] As shown in Table 2-1, 46 parts of pure water, 48.5 parts of ethyl acrylate, 50 parts of n-butyl acrylate, and 1.5 parts of mono-n-butyl fumarate as monomer components, and 1.8 parts of tridecyloxyhexaoxyethylene phosphate sodium salt as an emulsifier were charged into a mixing vessel equipped with a homomixer and stirred to obtain a monomer emulsion.

[0365] A polymerization reactor equipped with a thermometer and a stirrer was charged with 170 parts of pure water and 3 parts of the monomer emulsion obtained above, cooled to 12°C under a nitrogen stream, and then charged with 0.00033 parts of ferrous sulfate, 0.02 parts of sodium ascorbate, and 0.0045 parts of diisopropylbenzene hydroperoxide (an organic radical generator) to initiate the polymerization reaction. The temperature in the polymerization reactor was maintained at 23°C, and the remaining monomer emulsion was continuously added dropwise over 3 hours. 50 minutes after the start of the reaction, 0.012 parts of n-dodecyl mercaptan, 100 minutes after the start of the reaction, and 120 minutes after the start of the reaction, 0.012 parts of n-dodecyl mercaptan, and 0.4 parts of sodium L-ascorbate were added to continue the polymerization reaction. When the polymerization conversion reached approximately 100%, hydroquinone was added as a polymerization terminator to terminate the polymerization reaction, yielding an emulsion polymerization liquid.

[0366] Next, in a coagulation tank equipped with a thermometer and a stirrer, the emulsion polymerization liquid obtained above was heated to 80°C and continuously added to 350 parts of a 2% aqueous magnesium sulfate solution (coagulation liquid using magnesium sulfate as a coagulant) heated to 80°C and vigorously stirred at a stirring blade rotation speed of 600 rpm (circumferential speed of 3.1 m / s) of the stirrer, thereby coagulating the polymer and obtaining a coagulated slurry containing acrylic rubber crumbs as the coagulated product and water. The crumbs were filtered out from the obtained slurry, and water-containing crumbs were obtained by draining the water from the coagulated layer.

[0367] 194 parts of hot water (70°C) was added to the coagulation tank containing the filtered wet crumbs and stirred for 15 minutes to wash the wet crumbs. The water was then drained, and 194 parts of hot water (70°C) was added again and stirred for 15 minutes to wash the wet crumbs (a total of two washes). The washed wet crumbs (wet crumb temperature 65°C) were fed to a screw-type twin-screw extruder 15, where they were dehydrated and dried, and a dry rubber sheet 300 mm wide and 10 mm thick was extruded. Next, the dry rubber sheet was cooled at a cooling rate of 200°C / hr using a conveying-type cooling device directly connected to the screw-type twin-screw extruder 15.

[0368] The screw-type twin-screw extruder used in Example 1 was composed of one feed barrel, three dehydration barrels (first to third dehydration barrels), and five drying barrels (first to fifth drying barrels). The first dehydration barrel discharges water, and the second and third dehydration barrels discharge steam. The operating conditions for the screw-type twin-screw extruder were as follows. Table 2-1 shows the water content after dehydration (drainage), maximum torque, specific power, specific power, shear rate, and shear viscosity of the screw-type twin-screw extruder.

[0369] Water content: Moisture content of the wet crumb after draining in the first dewatering barrel: 20% Moisture content of wet crumb after steaming in the third dehydration barrel: 10% Moisture content of wet crumb after drying in the fifth drying barrel: 0.4% Rubber Temperature: Temperature of wet crumbs fed into the feeding barrel: 65℃ Temperature of rubber discharged from the screw-type twin-screw extruder: 140℃

[0370] Set temperature for each barrel: First dehydration barrel: 100℃ Second dehydration barrel: 120℃ Third dehydration barrel: 120℃ First drying barrel: 120℃ Second drying barrel: 130℃ Third drying barrel: 140℃ Fourth drying barrel: 160℃ Fifth drying barrel: 180℃

[0371] Operating conditions: Screw diameter (D): 132mm Total length of screw (L): 4620mm Length / Distance: 35 Screw speed: 135 rpm Drying barrel vacuum level: 10kPa Rubber extrusion rate from die: 700 kg / hr Resin pressure in the die: 2MPa Maximum torque in screw-type twin-screw extruder: 40N·m

[0372] The extruded sheet-like dried rubber was cooled to 50°C and then cut with a cutter, and laminated to 20 parts (20 kg) before the temperature dropped below 40°C to obtain veil-like acrylic rubber (A). The reactive group content, ash content, ash component content, gel content, pH, specific gravity, glass transition temperature (Tg), water content, molecular weight, molecular weight distribution, and complex viscosity at 100°C and 60°C of the obtained veil-like acrylic rubber (A) were measured and are shown in Table 2-2. In addition, a storage stability test was conducted on the veil-like acrylic rubber (A) to determine the rate of change in water content, and the results are shown in Table 2-2.

[0373] Next, 100 parts of the veiled acrylic rubber (A) and compounding ingredient A of "Compound 1" shown in Table 1 were added to a Banbury mixer and mixed at 50°C for 5 minutes (first-stage mixing). At this time, the BIT was measured to evaluate Banbury processability, and the results are shown in Table 2-2. Next, the resulting mixture was transferred to a roll at 50°C, and compounding ingredient B of "Compound 1" shown in Table 1 was blended and mixed (second-stage mixing) to obtain a rubber composition. The injection moldability of the resulting rubber composition was evaluated, and the results are shown in Table 2-2.

[0374] [Table 1]

[0375] The remaining rubber composition was then placed in a mold measuring 15 cm in length, 15 cm in width, and 0.2 cm in depth, and pressed at 180°C for 10 minutes while applying a pressure of 10 MPa to effect primary crosslinking. The resulting primary crosslinked product was then further heated in a gear oven at 180°C for 2 hours to effect secondary crosslinking, thereby obtaining a sheet-like crosslinked rubber product. Test pieces measuring 3 cm x 2 cm x 0.2 cm were then cut from the resulting sheet-like crosslinked rubber product and evaluated for water resistance, compression set resistance, and normal state physical properties. The results are shown in Table 2-2.

[0376] [Example 2] As shown in Table 2-1, the same procedure as in Example 1 was carried out except that the monomer components were changed to 48.25 parts of ethyl acrylate, 50 parts of n-butyl acrylate, and 1.75 parts of mono-n-butyl fumarate, to obtain a veil-like acrylic rubber (B). The compounding agent was "Compound 2" (see Table 1). The results are shown in Table 2-2.

[0377] [Example 3] The same procedure as in Example 1 was carried out, except that the post-addition of n-dodecyl mercaptan was changed to three times: 0.008 parts after 50 minutes, 0.008 parts after 100 minutes, and 0.008 parts after 120 minutes. A veil-like acrylic rubber (C) was obtained and its properties were evaluated. The results are shown in Table 2-2.

[0378] [Example 4] The same procedure as in Example 2 was carried out, except that the post-addition of n-dodecyl mercaptan was changed to three times: 0.008 parts after 50 minutes, 0.008 parts after 100 minutes, and 0.008 parts after 120 minutes. A veil-like acrylic rubber (D) was obtained and its properties were evaluated. The results are shown in Table 2-2.

[0379] [Example 5] As shown in Table 2-1, the same procedures as in Example 1 were carried out except that the maximum torque of the screw-type twin-screw extruder was changed to 15 N m, and veil-like acrylic rubber (E) was obtained and its properties were evaluated. The results are shown in Table 2-2.

[0380] [Example 6] The same procedures as in Example 2 were carried out except that the maximum torque of the screw-type twin-screw extruder was changed to 15 N m, and acrylic rubber veils (F) were obtained and their properties were evaluated. The results are shown in Table 2-2.

[0381] [Example 7] The same procedure as in Example 5 was carried out except that the water content after dewatering in the dewatering barrel of the screw-type twin-screw extruder was set to 30% by weight, and a veil-like acrylic rubber (G) was obtained, and its properties were evaluated. The results are shown in Table 2-2.

[0382] [Example 8] The same procedure as in Example 6 was carried out except that the water content after dewatering in the dewatering barrel of the screw-type twin-screw extruder was set to 30% by weight, and a veil-like acrylic rubber (H) was obtained, and its properties were evaluated. The results are shown in Table 2-2.

[0383] [Example 9] The washed water-containing crumbs were dried to a moisture content of 0.4% using a hot air dryer at 160°C to obtain crumb-like acrylic rubber (I), which was then loaded into a 300 x 650 x 300 mm baler and pressed at a pressure of 3 MPa for 25 seconds to obtain baled acrylic rubber (I). The same procedures as in Example 2 were carried out, except that the properties of the baled acrylic rubber bale were evaluated, and the results are shown in Table 2-2.

[0384] [Example 10] The same procedure as in Example 9 was carried out except that the monomer components were changed to 28 parts of ethyl acrylate, 38 parts of n-butyl acrylate, 27 parts of methoxyethyl acrylate, 5 parts of acrylonitrile, and 2 parts of allyl glycidyl ether, to obtain a veil-like acrylic rubber (J), and the properties thereof (the compounding agent was changed to "Compound 3" (see Table 1)) were evaluated. The results are shown in Table 2-2.

[0385] [Example 11] The same procedure as in Example 9 was carried out except that the monomer components were changed to 42.2 parts of ethyl acrylate, 35 parts of n-butyl acrylate, 20 parts of methoxyethyl acrylate, 1.5 parts of acrylonitrile, and 1.3 parts of vinyl chloroacetate, to obtain a veil-like acrylic rubber (K), and the properties thereof (the compounding agent was changed to "Compound 4" (see Table 1)) were evaluated. The results are shown in Table 2-2.

[0386] [Example 12] The same procedure as in Example 11 was carried out, except that the post-addition of n-dodecyl mercaptan was changed to three times: 0.008 parts after 50 minutes, 0.008 parts after 100 minutes, and 0.008 parts after 120 minutes. A veil-like acrylic rubber (L) was obtained and its properties were evaluated. The results are shown in Table 2-2.

[0387] [Example 13] The same procedure as in Example 11 was carried out except that the amount of diisopropylbenzene hydroperoxide was changed to 0.0048 parts and 0.024 parts of n-dodecyl mercaptan was added continuously to the monomer emulsion and not added later, to obtain a veil-like acrylic rubber (M), and the properties thereof were evaluated. The results are shown in Table 2-2.

[0388] [Comparative Example 1] The same procedure as in Example 13 was carried out except that the coagulation reaction was carried out by adding a 0.7% aqueous magnesium sulfate solution to the stirred emulsion polymerization liquid (stirring speed 100 rpm, peripheral speed 0.5 m / s) after emulsion polymerization and that the crumb-like acrylic rubber was obtained without baling using a baler, and the crumb-like acrylic rubber (N) was obtained and its properties were evaluated. The results are shown in Table 2-2.

[0389] Comparative Example 2 The same procedure as in Comparative Example 1 was carried out except that the amount of diisopropylbenzene hydroperoxide was changed to 0.005 parts and no chain transfer agent was added, to obtain a crumb-like acrylic rubber (O), and the properties thereof were evaluated. The results are shown in Table 2-2.

[0390] [Table 2-1]

[0391] [Table 2-2]

[0392] From Table 2-2, it can be seen that the acrylic rubbers (A) to (M) of the present invention, which are composed of bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, bonding units derived from an ion-reactive group-containing monomer, and, as necessary, bonding units derived from other monomers, have a weight-average molecular weight (Mw) of 1,000,000 to 5,000,000, a ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) in the range of 1.5 to 3, an ash content of 0.3% by weight or less, and a total amount of sodium, sulfur, calcium, magnesium, and phosphorus in the ash of 80% by weight or more, are excellent in normal state physical properties including injection moldability, water resistance, compression set resistance, and strength properties, and also have excellent Banbury processability and storage stability (Examples 1 to 13).

[0393] Table 2-2 shows that the acrylic rubbers (A) to (O) of the present examples and comparative examples have excellent compression set resistance due to the presence of carboxyl, epoxy, or chlorine ion-reactive groups, and that the acrylic rubbers (A) to (O) produced under the conditions of the present examples and comparative examples all have weight-average molecular weights (Mw) far exceeding 1 million, so that they also have excellent normal-state physical properties, including strength characteristics (Examples 1 to 13 and Comparative Examples 1 and 2). However, the acrylic rubbers (N) to (O) are inferior in injection moldability, Banbury processability, water resistance, and storage stability (Comparative Examples 1 and 2).

[0394] From Table 2-2, it can be seen that injection moldability is strongly affected by the molecular weight distribution (Mw / Mn) of the acrylic rubber, with Comparative Example 2 having Mw / Mn=1.3 / injection moldability: ×, Example 13 having Mw / Mn=1.55 / injection moldability: △, Example 12 having Mw / Mn=1.99 / injection moldability: ◯, Examples 3 to 11 having Mw / Mn 2.39 to 2.45 / injection moldability: ◎, and Examples 1 and 2 having Mw / Mn=2.91 to 2.94 / injection moldability: ◯, indicating that the acrylic rubber of the present invention has excellent injection moldability when Mw / Mn is around 2.4. It is also clear that when the molecular weight distribution (Mz / Mw) with an emphasis on the high molecular weight region is sufficiently broad, and the number average molecular weight (Mn), weight average molecular weight (Mw) and z-average molecular weight (Mz) are sufficiently large and within the Mw / Mn range of the present invention, the injection moldability can be improved without impairing the strength properties (comparison between Examples 1 to 13 and Comparative Example 2).

[0395] Tables 2-1 and 2-2 show that acrylic rubbers (A) to (M) having molecular weight distributions (Mw / Mn) within specific ranges, which provide excellent injection moldability without impairing strength properties, can be produced by using specific amounts of an organic radical generator and a chain transfer agent, particularly n-dodecyl mercaptan as the chain transfer agent (Examples 1 to 13).Tables 2-1 and 2-2 also show that injection moldability can be improved without impairing strength properties by adding the chain transfer agent (n-dodecyl mercaptan) batchwise rather than initially (Example 13), compared to adding the chain transfer agent (n-dodecyl mercaptan) continuously (Example 13). This is presumably because, by not adding a chain transfer agent initially and reducing the amount of organic radical generator, a single polymer chain is extended, and by adding a chain transfer agent during polymerization, a balanced production of high-molecular-weight and low-molecular-weight components is achieved, resulting in a molecular weight distribution (Mw / Mn) within a specific range, even though the GPC chart does not clearly show two peaks. This results in a high balance between strength and injection moldability. Furthermore, the number of batch post-additions has a significant effect on efficiently broadening the molecular weight distribution (Mw / Mn), with two batch post-additions resulting in a broader molecular weight distribution (Mw / Mn) than three (comparison of Examples 9-11 and Example 12). Furthermore, although not shown in Tables 2-1 and 2-2, in the present examples, the reducing agent sodium ascorbate was added 120 minutes after the start of polymerization. This facilitated the production of high-molecular-weight components of the acrylic rubber, enhancing the effect of the post-addition of the chain transfer agent in broadening the molecular weight distribution (Mw / Mn).

[0396] Tables 2-1 and 2-2 also show that if the drying of the water-containing crumb is changed from direct drying to a screw-type twin-screw extruder and operation is carried out under normal conditions, the molecular weight distribution (Mw / Mn) does not change (comparison between Examples 5-8 and Examples 9-11), but that by using an optimal shear screw-type twin-screw extruder under drying conditions, the molecular weight distribution (Mw / Mn) of the acrylic rubber can be broadened, further improving the injection moldability of the acrylic rubber (comparison between Examples 3-4 and Example 12), but if the molecular weight distribution (Mw / Mn) is too broad, the effect of injection moldability decreases (comparison between Examples 1-2 and Examples 5-8). Furthermore, although not shown in the examples and comparative examples of this application, it can be seen that if a redox catalyst as an inorganic radical generator is used, the molecular weight distribution (Mw / Mn) of the resulting acrylic rubber becomes too broad, resulting in poor injection moldability. This is thought to be because, in the case of organic radical generators, the polymerization catalyst is present within the micelles for emulsion polymerization and polymerization occurs continuously within the micelles, whereas in the case of inorganic radical generators, the polymerization catalyst is present outside the micelles and polymerization occurs outside the micelles, resulting in a difference in molecular weight distribution and affecting injection moldability.

[0397] Table 2-2 shows that the acrylic rubbers (A) to (M) of the present invention are superior in terms of water resistance (comparison between Examples 1 to 13 and Comparative Examples 1 and 2), and that among them, the order is acrylic rubbers (A) to (F) > acrylic rubbers (G) to (H) > acrylic rubbers (I) to (J) > acrylic rubbers (K) to (M), with acrylic rubbers (A) to (F) being particularly superior (comparison between Examples 1 to 13), and that these are greatly affected by the ash content in the acrylic rubber (comparison between Examples 1 to 13 and Comparative Examples 1 and 2).

[0398] Tables 2-1 and 2-2 show that the ash content of the acrylic rubber can be significantly reduced by increasing the coagulation liquid concentration (2%) during the coagulation reaction, changing the method to add the emulsion polymerization liquid to the stirred coagulation liquid (Lx↓), and vigorously stirring the coagulation liquid (stirring speed 600 rpm / circumferential speed 3.1 m / s) (Comparison of Examples 9-13 and Comparative Example 1). This is because the coagulation reaction is carried out by adding the emulsion polymerization liquid to the coagulation liquid under particularly vigorous stirring. As shown in the data below, the crumb diameters of the hydrous crumbs produced during this coagulation reaction are concentrated in the small particle size range of 710 μm to 4.75 mm. This significantly improves the efficiency of washing with hot water and the efficiency of removing emulsifiers and coagulants during dehydration, reducing the ash content in the acrylic rubber and significantly improving water resistance. Furthermore, it can be seen that, with regard to water resistance, acrylic rubbers (I) to (J) are superior to acrylic rubbers (K) to (M) in Examples 9-13, despite the similar ash content. This shows that, among ion-reactive groups, acrylic rubbers having carboxyl groups or epoxy groups are superior to those having chlorine atoms in terms of water resistance (comparison between Examples 9 and 10 and Examples 11 to 13).

[0399] Tables 2-1 and 2-2 also show that, with regard to water resistance, by dehydrating the hydrous crumbs (squeezing out the water) before drying, the ash content in the acrylic rubber can be further reduced significantly and water resistance can be improved dramatically (comparison between Examples 1 to 8 and Examples 9 to 13), and that squeezing out more water from the hydrous crumbs so that the water content after dehydration is 20% rather than 30%, can reduce the ash content and improve the water resistance of the acrylic rubber dramatically (comparison between Examples 1 to 6 and Examples 7 and 8).

[0400] Tables 2-1 and 2-2 further show that the ash components of the acrylic rubbers (A) to (M) of the present invention and the acrylic rubbers (N) to (O) of the comparative examples have a total of 80% by weight or more or 90% by weight or more of phosphorus (P), magnesium (Mg), sodium (Na), calcium (Ca), and sulfur (S), and that reducing the ash content improves water resistance. Furthermore, when the ash components are these components, the acrylic rubber exhibits significantly better releasability. Table 2-2 also shows that the ash components of the acrylic rubbers (A) to (M) of the present invention, which were coagulated, washed, and dehydrated using the method of the present invention, consisted of 80% or more or 90% or more of phosphorus (P) and magnesium (Mg) (Examples 1 to 13 and Comparative Examples 1 and 2). This is because the ash content in the acrylic rubber does not come from the emulsifier and coagulant used in production, which remain as they are. Rather, during the coagulation reaction, the emulsifier's sodium salt of phosphate is exchanged with the coagulant's magnesium sulfate (MgSO4) and becomes contained within the water-resistant magnesium salt of phosphate; this cannot be fully removed in the washing process, but can be reduced by dehydrating the acrylic rubber in a screw-type twin-screw extruder dryer (squeezing the water out of the water-containing crumbs) (Examples 1 to 8). It is clear that squeezing more water out of the water-containing crumbs, so that the water content after dehydration is 20% rather than 30%, reduces the ash content and significantly improves the water resistance of the acrylic rubber (compare Examples 1 to 6 with Examples 7 and 8).

[0401] Regarding water resistance, although data is omitted in the examples of this application, it has been confirmed that when phosphate ester salts are used as emulsifiers, they are difficult to reduce during the washing process, and in particular, washing at room temperature hardly reduces the ash content no matter how many times the washing is performed, and that this can be improved by washing with warm water. On the other hand, when sulfate ester salts such as sodium lauryl sulfate are used as emulsifiers, they have better water resistance than ash containing a lot of sulfur (S) or sodium (Na), and in particular, at the same ash content, they are more than five times more water-resistant. Furthermore, even when sulfate ester salts such as sodium lauryl sulfate are used as emulsifiers, the ash content can be reduced to 0.1% by weight or less by performing the coagulation reaction of this invention, followed by hot water washing and dehydration, and water resistance can be significantly improved.

[0402] Tables 2-1 and 2-2 show that Banbury processability is correlated with gel content (comparison between Examples 1-13 and Comparative Examples 1-2). The gel content of methyl ethyl ketone-insoluble components of acrylic rubber can be reduced by emulsion polymerization in the presence of a chain transfer agent (comparison between Examples 9-13 and Comparative Examples 1 and 2). In particular, since the gel content increases rapidly when the polymerization conversion rate is increased to improve strength properties, it can be seen that in Examples 9-13, where the chain transfer agent was added later in the polymerization reaction, gel formation of methyl ethyl ketone-insoluble components was suppressed. Furthermore, the gel content of acrylic rubber was significantly reduced by drying the water-containing crumb using a twin-screw extruder, significantly improving the Banbury processability of the resulting acrylic rubber (comparison between Examples 1-8 and Examples 9-13). Although not shown in the Examples, it has been confirmed that the amount of gel of methyl ethyl ketone insoluble matter that rapidly increases during emulsion polymerization without adding a chain transfer agent (Comparative Examples 1 and 2) disappears when the mixture is melt-kneaded in a substantially water-free state (water content less than 1% by weight) in a screw-type twin-screw extruder, thereby significantly improving Banbury processability.

[0403] From Table 2-2, it can be seen that the acrylic rubbers (A) to (M) of the present invention are excellent in normal state physical properties including injection moldability, Banbury processability, water resistance, compression set resistance, and strength properties, as well as in storage stability. In particular, the storage stability of the acrylic rubbers (A) to (H) of the present invention is remarkably excellent.

[0404] Tables 2-1 and 2-2 show that the specific gravities of the acrylic rubber bales (A) to (M) are significantly higher than those of the acrylic rubber crumbs (N) to (O), indicating that storage stability is influenced by the specific gravity, i.e., the amount of air entrapped (comparison between Examples 1 to 8, Examples 9 to 13, and Comparative Examples 1 and 2). Acrylic rubber bales with high specific gravity can be obtained by compressing acrylic rubber crumbs into bales using a baler (Examples 9 to 13), or more preferably by extruding the acrylic rubber into sheets using a twin-screw extruder and laminating them to form bales (Examples 1 to 8). It also shows that the lower the ash content, the better the storage stability of the acrylic rubber (Examples 1 to 13). When the properties of the acrylic rubber (M) in Example 13 were measured directly after drying without using a baler, the results were similar to those of Example 13 in Table 2-2, except for the specific gravity, which was lower at 0.769. In addition, it is important for the storage stability of acrylic rubber that the pH be 6 or less.

[0405] [Particle size of the resulting hydrous crumb] For the hydrous crumbs generated in the solidification process in Examples 1 to 13 and Comparative Examples 1 and 2, the proportion of the total hydrous crumbs in the ranges of (1) 710 μm to 6.7 mm (not passing through 710 μm but passing through 6.7 mm), (2) 710 μm to 4.75 mm (not passing through 710 μm but passing through 4.75 mm), and (3) 710 μm to 3.35 mm (not passing through 710 μm but passing through 3.35 mm) was measured using a JIS sieve. The results are shown below.

[0406] Example 1: (1) 91% by weight, (2) 91% by weight, (3) 84% by weight Example 2: (1) 96% by weight, (2) 95% by weight, (3) 89% by weight Example 3: (1) 91% by weight, (2) 85% by weight, (3) 79% by weight Example 4: (1) 93% by weight, (2) 90% by weight, (3) 84% by weight Example 5: (1) 95% by weight, (2) 93% by weight, (3) 90% by weight Example 6: (1) 89% by weight, (2) 85% by weight, (3) 79% by weight Example 8: (1) 94% by weight, (2) 93% by weight, (3) 87% by weight Example 9: (1) 95% by weight, (2) 94% by weight, (3) 91% by weight Example 10: (1) 89% by weight, (2) 86% by weight, (3) 83% by weight Example 11: (1) 95% by weight, (2) 94% by weight, (3) 88% by weight Example 12: (1) 93% by weight, (2) 93% by weight, (3) 90% by weight Example 13: (1) 93% by weight, (2) 89% by weight, (3) 78% by weight Comparative example 1: (1) 17% by weight, (2) 3% by weight, (3) 0% by weight Comparative example 2: (1) 10% by weight, (2) 2% by weight, (3) 0% by weight

[0407] These results show that even if the same washing is performed on the size of the water-containing crumbs generated in the coagulation process, the amount of ash remaining in the acrylic rubber differs, and that those with a high proportion of the specific compounds (1) to (3) have high washing efficiency, reduced ash content, and excellent water resistance (comparison of Examples 9 to 13 with Comparative Examples 1 and 2 in Table 2-2). Furthermore, those with a high proportion of the specific compounds (1) to (3) also have a high ash removal rate during dehydration, and those with a dehydration rate (water content) of 20% by weight (Examples 1 to 6) have a lower ash content than those with a dehydration rate (water content) of 30% by weight (Examples 7 and 8), improving the water resistance of the acrylic rubber.

[0408] For reference, the same procedure as in Comparative Example 1 was carried out (Reference Example 1) except that the emulsion polymerization liquid was added to the coagulation liquid in the coagulation step, and the same procedure as in Comparative Example 1 was carried out (Reference Example 2) except that the emulsion polymerization liquid was added to the coagulation liquid and the coagulant concentration in the coagulation liquid was changed from 0.7% by weight to 2% by weight, and the particle size ratios (1) to (3) of the generated water-containing crumbs and the ash content (4) in the acrylic rubber were measured.

[0409] Reference example 1: (1) 91% by weight, (2) 57% by weight, (3) 25% by weight, (4) 0.51% by weight Reference example 2: (1) 92% by weight, (2) 75% by weight, (3) 42% by weight, (4) 0.40% by weight

[0410] For the acrylic rubber compositions containing the sheet-like acrylic rubbers (A) to (H) of Examples 1 to 8, the Mooney scorch time t5 (minutes) at a temperature of 125°C was measured in accordance with JIS K 6300 using the method for evaluating processing stability by Mooney scorch inhibition described above, and the Mooney scorch storage stability was evaluated according to the following criteria. As a result, all of them were given a good result of "A". ◎: Mooney scorch time t5 exceeds 3.3 minutes 〇: Mooney coach time t5 is 2 to 3.3 minutes ×: Mooney scorch time t5 is less than 2 minutes In addition, for these sheet-shaped acrylic rubbers (A) to (H), the cooling rate of the sheet-shaped dried rubber extruded from the screw-type twin-screw extrusion dryer is actually as fast as about 200°C / hr, similar to Example 1, and all are 40°C / hr or more.

[0411] Furthermore, the variation in the methyl ethyl ketone insoluble content of each rubber sample was evaluated by the method described above. That is, the variation in the methyl ethyl ketone insoluble content of the rubber sample was evaluated by measuring the methyl ethyl ketone insoluble content at 20 points randomly selected from 20 parts (20 kg) of the rubber sample and evaluating it based on the criteria described above.

[0412] When the acrylic rubbers (A) to (H) obtained in Examples 1 to 8 and the acrylic rubber (O) obtained in Comparative Example 2 were evaluated for gel content variation as rubber samples, the results for the acrylic rubbers (A) to (H) were all "◎", while the result for the acrylic rubber (O) was "×".

[0413] This is presumably because, when the acrylic rubbers (A) to (H) are melt-kneaded and dried in the screw-type twin-screw extruder, the gel content of the methyl ethyl ketone-insoluble components almost disappears and the variation in the gel content is also almost eliminated, thereby significantly improving the Banbury processability.

[0414] On the other hand, the crumb-like acrylic rubber that had been subjected to emulsion polymerization and coagulation washing under the conditions for producing the acrylic rubber (O) of Comparative Example 2 was fed into a screw-type twin-screw extruder dryer under the same conditions as in Example 1, and extruded and dried to obtain an acrylic rubber. The gel amount and gel amount variation measured for the acrylic rubber were found to be reduced to a level almost equivalent to that of the acrylic rubber (A), and the Banbury processability was found to be significantly improved.

[0415] [Mold releasability] The rubber compositions of acrylic rubbers (A) to (H) obtained in Examples 1 to 8 were pressed into a mold of 10 mmφ×200 mm, and crosslinked for 2 minutes at a mold temperature of 165°C. The crosslinked rubbers were then removed and evaluated for mold releasability according to the following criteria. All of the acrylic rubbers (A) to (H) were evaluated as good, with a rating of "◎". ◎: Easily released from the mold with no residue 〇: It can be easily released from the mold, but a small amount of mold residue is visible. △: It can be easily released from the mold, but there is a small amount of mold residue ×: Difficult to remove from the mold [Explanation of symbols]

[0416] 1. Acrylic rubber manufacturing system 3 Coagulation device 4 Cleaning equipment 5-screw extruder 6 Cooling device 7 Baling equipment

Claims

1. An acrylic rubber comprising bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, bonding units derived from an ion-reactive group-containing monomer, and, if necessary, bonding units derived from other monomers, having a weight-average molecular weight (Mw) of 1,000,000 to 5,000,000, a ratio (Mw / Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) in the range of 1.5 to 3, an ash content of 0.3% by weight or less, and a total content of sodium, sulfur, calcium, magnesium, and phosphorus in the ash of 80% by weight or more.

2. 2. The acrylic rubber according to claim 1, wherein the ratio (Mz / Mw) of the z-average molecular weight (Mz) to the weight-average molecular weight (Mw) is 1.3 or more.

3. 3. The acrylic rubber according to claim 1, wherein the ratio (Mz / Mw) of the z-average molecular weight (Mz) to the weight-average molecular weight (Mw) is 4 or less.

4. The acrylic rubber according to any one of claims 1 to 3, wherein the number average molecular weight (Mn) is in the range of 400,000 to 1,100,000.

5. The acrylic rubber according to any one of claims 1 to 4, wherein the weight average molecular weight (Mw), the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn), or the ratio (Mz / Mw) of the z average molecular weight (Mz) to the weight average molecular weight (Mw) is an absolute molecular weight or absolute molecular weight distribution measured by a GPC-MALS method.

6. 6. The acrylic rubber according to claim 5, wherein the measurement solvent in the GPC-MALS method is a dimethylformamide-based solvent.

7. The acrylic rubber according to any one of claims 1 to 6, wherein the monomer composition of the acrylic rubber consists of 50 to 99.99% by weight of bonding units derived from at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, 0.01 to 10% by weight of bonding units derived from ion-reactive group-containing monomers, and 0 to 40% by weight of bonding units derived from other monomers.

8. The acrylic rubber according to any one of claims 1 to 7, wherein the ion-reactive group is a carboxyl group or an epoxy group.

9. The acrylic rubber according to any one of claims 1 to 8, wherein the gel content is 50% by weight or less.

10. The acrylic rubber according to any one of claims 1 to 9, wherein the gel content is 30% by weight or less.

11. The acrylic rubber according to any one of claims 1 to 10, wherein the amount of gel is measured at any 20 points, and all values ​​thereof are within the range of (average value ±5)% by weight.

12. The acrylic rubber according to any one of claims 1 to 11, which has a specific gravity of 0.8 or more.

13. The acrylic rubber according to any one of claims 1 to 12, wherein the total amount of magnesium and phosphorus in the ash is 50% by weight or more.

14. The acrylic rubber according to any one of claims 1 to 13, wherein the ratio of magnesium to phosphorus in the ash ([Mg] / [P]) is in the range of 0.4 to 2.5 by weight.

15. The acrylic rubber according to any one of claims 1 to 14, having a complex viscosity at 60°C ([η]60°C) of 15,000 [Pa s] or less.

16. The acrylic rubber according to any one of claims 1 to 15, wherein the ratio ([η]100°C / [η]60°C) of the complex viscosity at 100°C ([η]100°C) to the complex viscosity at 60°C ([η]60°C) is 0.7 or more.

17. The acrylic rubber according to any one of claims 1 to 16, wherein the acrylic rubber is in the form of a sheet or a veil.

18. an emulsification step of emulsifying a monomer component consisting of at least one (meth)acrylic acid ester selected from the group consisting of (meth)acrylic acid alkyl esters and (meth)acrylic acid alkoxyalkyl esters, an ion-reactive group-containing monomer, and, as necessary, other monomers, with water and an emulsifier; an emulsion polymerization step in which polymerization is initiated in the presence of a redox catalyst comprising an organic radical generator and a reducing agent, and polymerization is continued by batchwise post-addition of a chain transfer agent during the polymerization to obtain an emulsion polymerization liquid; a coagulation step in which the obtained emulsion polymerization liquid is added to a stirring coagulation liquid to coagulate and produce water-containing crumbs; A washing step of washing the produced water-containing crumbs; a dehydration step of dehydrating the washed wet crumbs; a drying step of drying the dehydrated wet crumbs until their moisture content is less than 1% by weight; A method for producing the acrylic rubber according to any one of claims 1 to 17, comprising:

19. The method for producing an acrylic rubber according to claim 18, wherein the emulsion polymerization is carried out using a phosphate ester salt or a sulfate ester salt as an emulsifier in the emulsion polymerization step.

20. 20. The method for producing an acrylic rubber according to claim 18 or 19, wherein the emulsion polymerization liquid produced in the emulsion polymerization step is coagulated by contacting it with a coagulation liquid containing an alkali metal salt or a Group 2 metal salt of the periodic table.

21. The method for producing an acrylic rubber according to any one of claims 18 to 20, wherein the emulsion polymerization liquid produced in the emulsion polymerization step is brought into contact with a coagulation liquid to be coagulated, and then melt-kneaded and dried.

22. The method for producing an acrylic rubber according to claim 21, wherein the melt-kneading and drying are carried out in a state that is substantially free of moisture.

23. The method for producing an acrylic rubber according to claim 21 or 22, wherein the melt-kneading and drying are carried out under reduced pressure.

24. The method for producing an acrylic rubber according to any one of claims 21 to 23, wherein the melt-kneading and drying are carried out using a screw-type twin-screw extruder dryer.

25. The method for producing acrylic rubber according to claim 24, wherein the maximum torque of the screw-type twin-screw extruder during the melt-kneading and drying is in the range of 5 to 125 N m.

26. The method for producing an acrylic rubber according to any one of claims 21 to 25, wherein the acrylic rubber after melt-kneading and drying is cooled at a cooling rate of 40°C / hr or more.

27. The method for producing an acrylic rubber according to any one of claims 18 to 26, wherein the coagulating agent concentration in the coagulation liquid is 1% by weight or more.

28. The method for producing an acrylic rubber according to any one of claims 18 to 27, wherein the stirring speed of the coagulation liquid is 100 rpm or more.

29. The method for producing an acrylic rubber according to any one of claims 18 to 28, wherein the peripheral speed of the stirred coagulation liquid is 1 m / s or more.

30. The method for producing an acrylic rubber according to any one of claims 18 to 29, wherein a reducing agent is added later in the emulsion polymerization step.

31. The method for producing acrylic rubber according to any one of claims 18 to 30, wherein the proportion of the hydrous crumbs that do not pass through a JIS 710 μm sieve but pass through a JIS 6.7 mm sieve is 50% by weight or more, and the proportion of the hydrous crumbs in the particle diameter range of 710 μm to 6.7 mm is 50% by weight or more, is washed, dehydrated, and dried.

32. A rubber composition comprising a rubber component containing the acrylic rubber according to any one of claims 1 to 17, a filler, and a crosslinking agent.

33. The rubber composition according to claim 32, wherein the filler is a reinforcing filler.

34. The rubber composition according to claim 32, wherein the filler is a carbon black including any one of furnace black, acetylene black, thermal black, channel black, and graphite.

35. The rubber composition according to claim 32, wherein the filler is a silica including any one of wet silica, dry silica, and colloidal silica.

36. The rubber composition according to any one of claims 32 to 35, wherein the crosslinking agent is an organic crosslinking agent.

37. The rubber composition according to any one of claims 32 to 36, wherein the crosslinking agent is a polyvalent compound.

38. The rubber composition according to any one of claims 32 to 37, wherein the crosslinking agent is an ionically crosslinkable compound.

39. 39. The rubber composition according to claim 38, wherein the crosslinking agent is an ionically crosslinkable organic compound.

40. 40. The rubber composition according to claim 38 or 39, wherein the crosslinking agent is a polyvalent ionic organic compound.

41. The rubber composition according to any one of claims 38 to 40, wherein the ion of the ion-crosslinking compound, the ion-crosslinking organic compound, or the polyvalent ionic organic compound serving as the crosslinking agent is at least one ion-reactive group selected from the group consisting of an amino group, an epoxy group, a carboxyl group, and a thiol group.

42. The rubber composition according to claim 40, wherein the crosslinking agent is at least one polyvalent ion compound selected from the group consisting of polyamine compounds, polyepoxy compounds, polycarboxylic acid compounds, and polythiol compounds.

43. The rubber composition according to any one of claims 32 to 42, wherein the content of the crosslinking agent is in the range of 0.001 to 20 parts by weight per 100 parts by weight of the rubber component.

44. The rubber composition according to any one of claims 32 to 43, further comprising an antioxidant.

45. The rubber composition according to claim 44, wherein the antioxidant is an amine-based antioxidant.

46. A method for producing a rubber composition, comprising mixing a rubber component containing the acrylic rubber according to any one of claims 1 to 17, a filler, and optionally an antioxidant, and then mixing a crosslinking agent.

47. A cross-linked rubber product obtained by cross-linking the rubber composition according to any one of claims 32 to 45.

48. The cross-linked rubber product according to claim 47, wherein the cross-linking of the rubber composition is carried out after molding.

49. The cross-linked rubber product according to claim 47 or 48, wherein the cross-linking of the rubber composition is performed by primary cross-linking and secondary cross-linking.

Images