Note: Descriptions are shown in the official language in which they were submitted.
CA 02527362 2005-11-28
(METH)ACRYLIC ESTER FOR ALKYLENYLENE
GLYCOL AND THE USE THEREOF
The present invention relates to novel (meth)acrylic esters of polyalkoxylated
glycols, a
simplified process for preparing these esters and the use of reaction mixtures
thus
obtainable.
Swellable hydrogel-forming addition polymers, known as superabsorbent polymers
or
SAPs, are known from the prior art. They are networks of flexible hydrophilic
addition
polymers, which can be both ionic and nonionic in nature. They are capable of
absorbing and binding aqueous fluids by forming a hydrogel and therefore ace
preferentially used for manufacturing tampons, diapers, sanitary napkins,
incontinence
articles, training pants for children, insoles and other hygiene articles for
the absorption
of body fluids. Superabsorbents are also used in other fields of technology
where
fluids, especially water or aqueous solutions, are absorbed. These fields
include for
example storage, packaging, transportation (packaging material for water-
sensitive
articles, for example flower transportation, shock protection); food sector
(transportation of fish, fresh meat; absorption of water, blood in fresh
fishlmeat packs);
medicine (wound plasters, water-absorbent material for burn dressings or for
other
weeping wounds), cosmetics (carrier material for pharmaceuticals and
medicaments,
rheumatic plasters, ultrasound gel, cooling gel, cosmetic thickeners,
sunscreen);
thickeners for oil/water or waterloil emulsions; textiles (gloves, sportswear,
moisture
regulation in textiles, shoe inserts); chemical process industry applications
(catalyst for
organic reactions, immobilization of large functional molecules (enzymes),
adhesive for
agglomerations, heat storage media, filtration aids, hydrophilic component in
polymer
laminates, dispersants, liquefiers); building and construction, installation
(powder
injection molding, clay-based renders, vibration-inhibiting medium, assistants
in relation
to tunneling in water-rich ground, cable sheathing); water treatment, waste
treatment
(in particular solidification of aqueous waste), water removal (deicers,
reusable
sandbags); cleaning; agriculture industry (irrigation, retention of meltwater
and dew
precipitates, composting additive, protection of forests against fungal and
insect
infestation, delayed release of active ingredients to plants); fire protection
(flying
sparks)(covering houses or house walls with SAP gel, since water has a very
high heat
capacity, ignition can be prevented; spraying of SAP gel in the case of fires
such as for
example forest fires); coextrusion agent in thermoplastic polymers
(hydrophilicization of
multilayer films); production of films and thermoplastic moldings capable of
absorbing
water (for example agricultural films capable of storing rain and dew water);
SAP-
containing films for keeping fresh fruit and vegetables which can be packed in
moist
films; the SAP stores water released by the fruit and vegetables without
forming
condensation droplets and partly reemits the water to -the fruit and
vegetables, so that
neither fouling nor wilting occurs; SAP-polystyrene coextrudates for example
for food
PF 55145
CA 02527362 2005-11-28
2
packs such as meat, fish, poultry, fruit and vegetables); carrier substance in
active-
ingredient formulations (drugs, crop protection). Within hygiene articles,
superabsorbents are generally positioned in an absorbent core which comprises
other
materials, including fibers (cellulose fibers), which act as a kind of liquid
reservoir to
intermediately store the spontaneously applied liquid insults and are intended
to ensure
efficient channelization of the body fluids in the absorbent core toward the
superabsorbent.
The current trend in diaper design is toward ever thinner constructions having
a
reduced cellulose fiber content and an increased hydrogel content. The trend
toward
ever thinner diaper constructions has substantially changed the performance
profile
required of the water swellable hydrophilic polymers over the years. Whereas
at the
start of the development of highly absorbent hydrogels it was initially solely
the very
high swellability on which interest focused, it was subsequently determined
that the
ability of the superabsorbent to transmit and distribute fluid is also of
decisive
importance. It has been determined that conventional superabsorbents greatly
swell at
the surface on wetting with liquid, so that transportation of liquid into the
particle interior
is substantially compromised or completely prevented. This trait of
superabsorbents is
known as gel blocking. The greater amount of polymer per unit area in the
hygiene
article must not cause the swollen polymer to form a barrier layer to
subsequent fluid. A
product having good transportation properties will ensure optimal utilization
of the
entire hygiene article. This prevents the phenomenon of gel blocking, which in
the
extreme case will cause the hygiene article to leak. Fluid transmission and
distribution
is thus of decisive importance with regard to the initial absorption of body
fluids.
Good transportation properties are possessed for example by hydrogels having
high
gel strength in the swollen state. Gels lacking in strength are deformable
under an
applied pressure, for example pressure due to the bodyweight of the wearer of
the
hygiene article, and clog the pores in the SAP/cellulose fiber absorber and so
prevent
continued absorption of fluid. Enhanced gel strength is generally obtained
through a
higher degree of crosslinking, although this reduces retention performance of
the
product. An elegant way to enhance gel strength is surface postcrosslinking.
In this
process, dried superabsorbents having an average crosslink density are
subjected to
an additional crosslinking step. Surface postcrosslinking increases the
crosslink density
in the sheath of the superabsorbent particle, whereby the absorbency under
load is
raised to a higher level. Whereas the absorption capacity decreases in the
superabsorbent particle sheath, the core has an improved absorption capacity
(compared to the sheath) owing to the presence of mobile polymer chains, so
that
sheath construction ensures improved fluid transmission without occurrence of
the gel
blocking effect. It is perfectly desirable for the total capacity of the
superabsorbent to be
occupied nut spontaneously but with time delay. Since the hygiene article is
generally
PF 55145
CA 02527362 2005-11-28
3
repeatedly insulted with urine, the absorption capacity of the superabsorbent
should
sensibly not be exhausted after the first disposition.
Highly swellable hydrophilic hydrogels are especially polymers of
(co)polymerized
hydrophilic monomers, graft (co)polymers of one or more hydrophilic monomers
on a
suitable grafting base, crosslinked cellulose or starch ethers, crosslinked
carboxymethylcellulose, partially crosslinked polyalkylene oxide or natural
products
which swell in aqueous fluids, for example guar derivatives. Such hydrogels
are used
as products which absorb aqueous solutions to produce diapers, tampons,
sanitary
napkins and other hygiene articles, but also as water-retaining agents in
market
gardening.
To improve the performance properties, for example Rewet in the diaper and
AUL,
highly swellable hydrophilic hydrogels are generally surface or gel
postcrosslinked.
This postcrosslinking is known per se to one skilled in the art and is
preferably effected
in aqueous gel phase or as surface postcrosslinking of the ground and
classified
polymer particles.
WO 93121237 discloses (meth)acrylates of alkoxylated polyhydric CZ - C,o
hydrocarbons that are useful as crosslinkers. The trimethylolpropane
crosslinkers used
correspond to SR 351, SR 454, SR 502, SR 9035 and SR 415. These crosslinkers
have 0, 3, 9, 15 or 20 EO units per TMP. WO 93/21237 says it is advantageous
to have
3 times 2 - 7 EO units per TMP, and especially 3 times 4 - 6 EO units per TMP.
The disadvantage with these compounds is that costly and inconvenient
purifying
operations are needed for at least partial removal of starting materials and-
by-products;
the crosslinkers used in the reference cited have an acrylic acid content of
less than
0.1 % by weight.
EP 264841 has EO-PO-EO block polymers being esterified with methacrylic acid.
DE 2215512 and DE 2215509 describe diacrylates of polyethylene glycol useful
as a
crosslinker for addition copolymers for dicarboxylic anhydrides.
EP 559476 and US 4351922 describe diacrylates of polyethylene glycol and
polyethylene glycol-polypropylene glycol blocks useful as a crosslinker for
hydrogels.
Known crosslinkers give rise to increased extractables due to polymer
degradation
during use of a hygiene article which comprises swollen superabsorbent.
The production of such higher (meth)acrylic esters by acid-catalyzed
esterification of
(meth)acrylic acid with the corresponding alcohols in the presence of an
PF 55145 CA 02527362 2005-11-28
4
inhibitor/inhibitor system and in the presence or absence of a solvent such as
benzene,
toluene or cyclohexane is common knowledge.
Since the formation of the ester from (meth)acrylic acid and alcohol is known
to be
based on an equilibrium reaction, it is customary to use one starting material
in excess
and/or to remove the esterification water formed andlor the target ester from
the
equilibrium in order that commercial conversions may be obtained.
Therefore, in the production of higher (meth)acrylic esters, it is customary
to remove
the water of reaction and to use an excess of (meth)acrylic acid.
US 4 187 383 describes an esterification process of (meth)acrylic acid with
organic
polyols at a reaction temperature of from 20 to 80°C using an
equivalent excess of from
2:1 to 3:1.
The disadvantage of this process is that the low reaction temperature means
that the
reaction times are up to 35 hours and that excess acid in the reaction mixture
is
removed by neutralization followed by phase separation.
WO 2001/14438 (Derwent,abstract No. 2001-191644119) and WO 2001110920
(Chemical Abstracts 134:163502) describe processes for esterifying
(meth)acrylic acid
with polyalkylene glycol monoalkyl ethers in a ratio of 3:1 - 50:1 in the
presence of
acids and polymerization inhibitors and, after deactivation of the acidic
catalyst,
copolymerization of the residue of (meth)acrylic ester and (meth)acrylic acid
at pH 1.5 -
3.5, and also the use of said residue as a cement additive.
The disadvantage with these processes is that they are restricted to
polyalkylene glycol
monoalkyl ethers, that the catalyst has to be deactivated and that such
copolymers
cannot be used as crosslinkers for hydrogels since they only have one
functionality.
It is an object of the present invention to provide further compounds which
can be used
as free-radical crosslinkers for polymers and especially for superabsorbents
and to
simplify the process for preparing substances which are useful as free-radical
crosslinkers for superabsorbents. There shall further be provided crosslinkers
whose
hydrolysis stability is high and/or which at the same time produce a very
readily
divisible gel in the manufacturing process for superabsorbents.
We have found that this object is achieved by an ester F of the formula I
PF 55145
CA 02527362 2005-11-28
O O
AO)p~~O~O~~AO~p2
R1 R2
I
where AO is independently at each instance -O-CHR3-CHR4- or
-CHR3-CHR4-O- where R3 and R4 are independently H, linear or
5 branched C1-C8-alkyl,
p 1 is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21,
22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or 35,
p2 is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21,
22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or 35,
n is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
21,
22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40,
41, 42, 43, 44, 45, 46, 447, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59,
60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78,
79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97,
98, 99, 100,
R1 and R2 are independently H or CH3,
wherein there is at least one AO in _(AO)p1 and also at least one AO in
(AO)p2 where R3 and R4 are not both H at one and the same time.
The AO units have been incorporated in such a way that polyethers are formed
and not
peroxides.
Preference is given to esters F as defined above wherein for all AOs R3 and R4
independently have the same meaning, i.e., for example are accessible by
alkoxylation
of ethylene glycol or polyethylene glycol with just one alkylene oxide, for
example
propylene oxide.
Preference is given to esters F as defined above wherein R3 or R4 is H.
Preference is given to esters F as defined above wherein R3 or R4 is
independently
CH3, CH2CH3, (CH2)2-CH3 or (CH2)7-CH3, preferably CH3.
PF 55145
CA 02527362 2005-11-28
6
Preference is also given to esters F as defined above wherein p1 is 1, 2, 3, 4
or 5,
more preferably 1, 2 or 3, especially 1 or is a number between 14 and 27.
Preference is also given to esters F as defined above wherein p2 is 1, 2, 3, 4
or 5,
more preferably 1, 2 or 3, especially 1 or is a number between 14 and 27.
Preference is given to esters F as defined above wherein n is a number between
2 and
50, preferably between 5 and 30 and especially between 10 and 26.
Preference is given to esters F as defined above wherein the diol component
(AO)p1-[-O-CH2-CH2-]n-O-(AO)p2 has an average molecular weight between 300 and
500 and especially around 400.
Preference is given to esters F as defined above wherein the diol component
(AO)p1-[-O-GH2-CH2-]n-O-(AO)p2 has an average molecular weight 2000 and 4000
and more preferably between 2500 and 3500.
Preference is given to diol components in esters F as defined above that have
a
symmetrical construction amongst each other with regard to (AO)p1 and (AO)p2.
By
symmetrical is meant that p1 and p2 are substantially equal, i.e., the
absolute amount
of the difference between p1 and p2 is 3 or less, preferably 2 or less, more
preferably 1
or less and especially is equal to 0.
Preference is further given to diol components in ester F as defined above
that have a
structurally similar construction to each other with regard to (AO)p1 and
(AO)p2. By
structurally similar is meant that the respective (AO)p1 and (AO)p2
components.are
prepared by simultaneous synthesis on the (poly)ethylene glycol and thus are
accessible either both from mixtures of different alkoxides (random (AO)p
components
or from sequential synthesis (block (AO)p components). Preference is given in
particular to diol components when all the AOs have the same meaning and are
preferably formed from propylene oxide.
Preference is given to esters F as defined above wherein R1 and R2 are
identical and
preferably H.
According to the present invention, the esters F of the abovementioned formula
having
the stated meanings can be used for preparing hydrogel-forming polymers
capable of
absorbing aqueous fluids and especially as internal crosslinkers. Further
preferred
internal crosslinkers are di(meth)acrylates, especially diacrylates of
polypropylene
glycol having 2, 3, 4 or 5 and especially 2 or 3 propylene glycol units.
By alkoxylated glycol is hereinafter a compound of the formula II
PF 55145
CA 02527362 2005-11-28
7
,H
LO~/~ AO
~(AO)pi~ ~O'~ )P2
I I
where AO, R3, R4, p1, p2 and n are each as defined above or p1 is equal to n
is equal
to 0, p2 is equal to 2, 3, 4 or 5, R3 is equal to H and R4 is equal to CH3.
We have found that the object is further achieved by a process for preparing
an ester F
of alkoxylated glycol with (meth)acrylic acid, comprising the steps of
a) reacting alkoxylated glycol II with (meth)acrylic acid in the presence of
at least one
esterification catalyst C and of at least one polymerization inhibitor D and
optionally also of a water-azeotroping solvent E to form an ester F,
b) optionally removing from the reaction mixture some or all of the water
formed in
a), during andlor after a),
f) optionally neutralizing the reaction mixture,
h) when a solvent E was used, optionally removing this solvent by
distillation, and/or
i) stripping with a gas which is inert under the reaction conditions.
In a preferred embodiment
- the molar excess of (meth)acrylic acid to alkoxylated glycol is at least
2.1:1 and
- the optionally neutralized (meth)acrylic acid present in the reaction
mixture after
the last step substantially remains in the reaction mixture.
(Meth)acrylic acid in the context of the present invention comprehends
methacrylic
acid, acrylic acid or mixtures of methacrylic acid and acrylic acid. Acrylic
acid is
preferred.
When the ester F is desired in pure form, it can be purified by known
separation
processes.
The molar excess of (meth)acrylic acid to alkoxylated glycol is at least
2.1:1, preferably
at least 2.2:1, more preferably at least 2.5:1, even more preferably at least
3:1 and
especially at least 5:1.
In a preferred embodiment, (meth)acrylic acid is used in an excess of for
example
greater than 10:1, preferably greater than 20:1, more preferably greater than
40:1,
even more preferably greater than 100:1, especially greater than 150:1 and
specifically
greater than 200:1.
PF 55145
CA 02527362 2005-11-28
The esterification products thus obtainable can be used as radical
crosslinkers in
hydrogels substantially without further purification, specifically without
substantial
removal of the excess of (meth)acrylic acid and of the esterification catalyst
C.
Unless otherwise mentioned, crosslinking as used herein is to be understood as
meaning radical crosslinking (gel crosslinking; internal crosslinking; cross-
linking
together of linear or lightly crosslinked polymer). This crosslinking can take
place via
free-radical or cationic polymerization mechanisms or other mechanisms, for
example
Michael addition, esterification or transesterification mechanisms, but is
preferably
effected by free-radical polymerization.
Hydrogel-forming polymers capable of absorbing aqueous fluids preferably are
capable
of absorbing at least their own weight, preferably 10 times their own weight
and more
preferably 20 times their own weight of distilled water and they are
preferably capable
of achieving this absorption even under a pressure of 0.7 psi.
The reaction of glycol with an alkylene oxide is known per se to one skilled
in the art.
Possible ways of conducting the reaction may be found in Houben-Weyl, Methoden
der
Organischen Chemie, 4th edition, 1979, Thieme Verlag Stuttgart, editor Heinz
Kropf,
volume 6/1a, part 1, pages 373 to 385.
An example of a way to prepare compounds of the formula II is to react the
glycol first
with EO (to obtain the desired polyethylene glycol) and then with PO.
This can be accomplished for example by placing about 72 g of glycol or the
corresponding amount of polyethylene glycol with 0.5 g of KOH, 45% in water as
an
initial charge in an autoclave and dewatering the initial charge at
80°C and reduced
pressure (about 20 mbar). The appropriate amount of propylene oxide is then
added at
145 to 155°C and allowed to react at this temperature under elevated
pressure. The
reaction has ended when no further change in pressure is observed. The
reaction
mixture is then stirred for a further 30 min at 150 °C: The appropriate
amount of
propylene oxide is subsequently added at 120 to 130°C over a prolonged
period and
likewise allowed to react. After purging with inert gas and cooling down to
60°C, the
catalyst is separated off by addition of sodium pyrophosphate and subsequent
filtration.
However, it is also possible to use commercially available akoxylated glycols,
for
example di- and tripropylene glycol and triblock polymers of the PO-EO-PO
type, for
example the Pluronic~ RPE polymers, of the type 1720, 1740, 2035, 2510, 2520,
2525
or 3110.
The viscosity of the polyalcohols which can be used according to the present
invention
is not subject to any particular requirements bar that they should be readily
pumpable
PF 55145
CA 02527362 2005-11-28
9
to about 80°C, preferably they should have a viscosity below 1000 mPas,
preferably
below 800 mPas and most preferably below 500 mPas.
Useful esterification catalysts C for the present invention are sulfuric acid,
aryl or alkyl
sulfonic acids or mixtures thereof. Examples of aryl sulfonic acids are
benzenesulfonic
acid, para-toluenesulfonic acid and dodecylbenzenesulfonic acid, and examples
of
alkyl sulfonic acids are methanesulfonic acid, ethanesulfonic acid and
trifluoromethanesulfonic acid. Similarly, strongly acidic ion exchangers or
zeofites are
useful as esterification catalysts. Preference is given to sulfuric acid and
ion
exchangers.
Useful polymerization inhibitors D for the present invention include for
example phenols
such as alkylphenols, for example, o-, m- or p-cresol (methylphenol), 2-tert-
butyl-
4-methylphenol, 6-tert-butyl-2,4-dimethylphenol, 2,6-di-tert-butyl-4-
methylphenol, 2-tert-
butylphenol, 4-tert-butylphenol, 2,4-di-tert-butylphenol, 2-methyl-4-tert-
butylphenol,
4-tert-butyl-2,6-dimethylphenol, or 2,2'-methylenebis(6-tert-butyl-4-
methylphenol),
4,4'-oxydiphenyl, 3,4-(methylenedioxy)phenol (sesamol), 3,4-dimethylphenol,
hydroquinone, pyrocatechol (1,2-dihydroxybenzene), 2-(1'-methylcyclohex-1'-yl)-
4,6-dimethylphenol, 2- or 4-(1'-phenyleth-1'-yl)phenol, 2-tert-butyl-6-
methylphenol,
2,4,6-tris-tert-butylphenol, 2,6-di-tert-butylphenol, 2,4-di-tert-butylphenol,
4-tert-
butylphenol, nonylphenol [11066-49-2], octylphenol [140-66-9], 2,6-
dimethylphenol,
bisphenol A, bisphenol F, bisphenol B, bisphenol C, bisphenoi S, 3,3',5,5'-
tetrabromo-
bisphenol A, 2,6-di-tert-butyl-p-cresol, Koresin~ from BASF AG, methyl 3,5-di-
tert-
butyl-4-hydroxybenzoate, 4-tert-butylpyrocatechol, 2-hydroxybenzyl alcohol,
2-methoxy-4-methylphenol, 2,3,6-trimethylphenol, 2,4,5-trimethylphenol,
2,4,6-trimethylphenol, 2-isopropylphenol, 4-isopropylphenol, 6-isopropyl-rrt-
cresol,
n-octadecyl (3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, 1,1,3-tris(2-
methyl-
4-hydroxy-5-tert-butylphenyl)butane, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-
butyl-
4-hydroxybenzyl)benzene, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)
isocyanurate,
1,3,5-tris(3,5-di-tert-butyl-4-t~ydroxyphenyl)propionyloxyethyl isocyanurate,
1,3,5-tris(2,6-dimethyl-3-hydroxy-4-tert-butylbenzyl) isocyanurate or
pentaerythritol
tetrakis[(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 2,6-di-tert-butyl-
4-dimethyl-
aminomethylphenol, 6-sec-butyl-2,4-dinitrophenol, Irganox~ 565, 1141, 1192,
1222
and 1425 from Ciba Spezialitatenchemie, octadecyl 3-(3',5'-di-tert-butyl-4'-
hydroxy-
phenyl)propionate, hexadecyl 3-(3',5'-di-tert-butyl-4'-
hydroxyphenyl)propionate, octyl
3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate, 3-this-1,5-pentanediol
bis[(3',5'-di-
tert-butyl-4'-hydroxyphenyi)propionate], 4,8-dioxa-1,11-undecanediol
bis[(3',5'-di-fert-
butyl-4'-hydroxyphenyl)propionate], 4,8-dioxa-1,11-undecanediol bis[(3'-tent-
butyl-
4'-hydroxy- 5'-methylphenyl)propionate], 1,9-nonanediol bis[(3',5'-di-terf-
butyl-
4'-hydroxyphenyl)propionate], 1,7-heptanediamine bis[3-(3',5'-di-tert-butyl-
4'-hydroxyphenyl)propionamide], 1,1-methanediamine bis[3-(3',5'-di-tert-butyl-
4'-hydroxyphenyl)propionamide], 3-(3',5'-di-tert-butyl-4'-
hydroxyphenyl)propionic acid
PF 55145
CA 02527362 2005-11-28
hydrazide, 3-(3',5'-di-methyl-4'-hydroxyphenyl)propionic acid hydrazide, bis(3-
tent-butyl-
5-ethyl-2-hydroxyphen-1-yl)methane, bis(3,5-di-tert-butyl-4-hydroxyphen-1-
yl)methane,
bis[3-(1'-methylcyclohex-1'-yl)-5- methyl-2-hydroxyphen-1-yl]methane, bis(3-
tent-butyl-
2-hydroxy-5-methylphen-1-yl)methane, 1,1-bis(5-tert-butyl-4-hydroxy-2-
methylphen-
5 1-yl)ethane, bis(5-tent-butyl-4-hydroxy-2-methylphen-1-yl) sulfide, bis(3-
tent-butyl-
2-hydroxy-5-methylphen-1-yl) sulfide, 1,1-bis(3,4-dimethyl-2-hydroxyphen-1-yl)-
2-methylpropane, 1,1-bis(5-tert-butyl-3-methyl-2-hydroxyphen-1-yl)butane,
1,3,5-tris-
[1'-(3",5"-di-tert-butyl-4"-hydroxyphen-1 "-yl)meth-1'-yl]-2,4,6-
trimethylbenzene,
1,1,4-tris(5'-tert-butyl-4'-hydroxy-2'-methylphen-1'-yl)butane, aminophenols,
for
10 example para-aminophenoi, nitrosophenols, for example para-nitrosophenol, p-
nitroso-
o-cresol, alkoxyphenols, for example 2-methoxyphenol (guajacol, pyrocatechol
monomethyl ether), 2-ethoxyphenol, 2-isopropoxyphenol, 4-methoxyphenol
(hydroquinone monomethyl ether), mono- or di-tert-butyl-4-methoxyphenol, 3,5-
di-tert-
butyl-4-hydroxyanisole, 3-hydroxy-4-methoxybenzyl alcohol, 2,5-dimethoxy-
4-hydroxybenzyl alcohol (syringa alcohol), 4-hydroxy-3-methoxybenzaldehyde
(vanillin), 4-hydroxy-3-ethoxybenzaldehyde (ethylvanillin), 3-hydroxy-4-
methoxy-
benzaldehyde (isovanillin), 1-(4-hydroxy-3-methoxyphenyl)ethanone
(acetovanillone),
eugenol, dihydroeugenol, isceugenol, tocopherols, for example a-, [3-, y-, 8-
and
E-tocopherol, tocol, a-tocopherolhydroquinone, and also 2,3-dihydro-2,2-
dimethyl-
7-hydroxybenzofuran (2,2-dimethyl-7-hydroxycoumaran), quinones and
hydroquinones
such as hydroquinone or hydroquinone monomethyl ether, 2,5-di-tert-butylhydro-
quinone, 2-methyl-p-hydroquinone, 2,3-dimethylhydroquinone,
trimethylhydroquinone,
4-methylpyrocatechol, tert-butylhydroquinone, 3-methylpyrocatechol,
benzoquinone,
2-methyl-p-hydroquinone, 2,3-dimethylhydroquinone, trimethylhydroquinone,
3-methylpyrocatechol, 4-methylpyrocatechol, tert-butylhydroquinone, 4-
ethoxyphenol,
4-butoxyphenol, hydroquinone monobenzyl ether, p-phenoxyphenol, 2-methylhydro-
quinone, 2,5-di-tert-butylhydroquinone, tetramethyl-p-benzoquinone, diethyl
1,4-cyclohexanedion-2,5-dicarboxylate, phenyl-p-benzoquinone, 2,5-dimethyl-3-
benzyl-
p-benzoquinone, 2-isopropyl-5-methyl-p-benzoquinone (thymoquinone),
2,6-diisopropyl-p-benzoquinone, 2,5-dimethyl-3-hydroxy-p-benzoquinone,
2,5-dihydroxy-p-benzoquinone, embelin, tetrahydroxy-p-benzoquinone, 2,5-
dimethoxy-
1,4-benzoquinone, 2-amino-5-methyl-p-benzoquinone, 2,5-bisphenylamino-1,4-
benzo-
quinone, 5,8-dihydroxy-1,4-naphthoquinone, 2-anilino-1,4-naphthoquinone,
anthraquinone, N,N-dimethylindoaniline, N,N-Biphenyl-p-benzoquinonediimine,
1,4-benzoquinone dioxime, coerulignone, 3,3'-di-tert-butyl-5,5'-
dimethyldipheno-
quinone, p-rosolic acid (aurine), 2,6-di-tert-butyl-4-benzylidenebenzoquinone,
2,5-di-
tert-amylhydroquinone, nitroxide free radicals such as 4-hydroxy-2,2,6,6-tetra-
methylpiperidinyloxy free radical, 4-oxo-2,2,6,6-tetramethylpiperidinyloxy
free radical,
4-acetoxy-2,2,6,6-tetramethylpiperidinyloxy free radical, 2,2,6,6-tetramethyl-
piperidinyloxy free radical, 4,4',4"-tris(2,2,6,6-tetramethylpiperidinyloxy)
phosphite,
3-oxo-2,2,5,5-tetramethylpyrrolidinyloxy free radical, 1-oxyl-2,2,6,6-
tetramethyl-
4-methoxypiperidine, 1-oxyl-2,2,6,6-tetramethyl-4-trimethylsilyloxypiperidine,
1-oxyl-
PF 55145 CA 02527362 2005-11-28
11
2,2,6,6-tetramethylpiperidin-4-yl 2-ethylhexanoate, 1-oxyl-2,2,6,6-
tetramethylpiperidin-
4-yl stearate, 1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl benzoate, 1-oxyl-
2,2,6,6-tetra-
methylpiperidin-4-yl (4-tert-butyl)benzoate, bis(1-oxyi-2,2,6,6-
tetramethylpiperidin-4-yl)
succinate, bis(1-oxyl-2,2,6,6-tetramethyfpiperidin-4-yl) adipate, bis(1-oxyl-
2,2,6,6-tetra-
methyl-4-piperidinyl) 1,10-decanedioate, bis(1-oxyl-2,2,6,6-tetramethyl-4-
piperidinyl)
n-butylmalonate, bis(1-oxyl-2,2,6,6-tetramethyl-4-piperidinyl) phthalate,
bis(1-oxyl-
2,2,6,6-tetramethyl-4-piperidinyl) isophthalate, bis(1-oxyl-2,2,6,6-
tetramethyl-
4-piperidinyl) terephthalate, bis(1-oxyl-2,2,6,6-tetramethyl-4-piperidinyl)
hexahydro-
terephthalate, N,N'-bis(1-oxyl-2,2,6,6-tetramethyl-4-piperidinyl)adipamide, N-
(1-oxyl-
2,2,6,6-tetramethyl-4-piperidinyl)caprolactam, N-(1-oxyl-2,2,6,6-tetramethyl-
4-piperidinyl)dodecylsuccinimide, 2,4,6-tris[N-butyl-N-(1-oxyl-2,2,6,6-
tetramethyl-
4-piperidinyl]triazine, N,N'-bis(1-oxyl-2,2,6,6-tetramethyl-4-piperidinyl)-
N,N'-
bisformyl-1,6-diaminohexane, 4,4'-ethylenebis(1-oxyl-2,2,6,6-tetramethyl-
3-piperazinone), aromatic amines such as phenylenediamines, N,N-diphenylamine,
N-nitrosodiphenylamine, nitrosodiethylaniline, N,N'-dialkyl-para-
phenylenediamine,
wherein the alkyl radicals can be the same or different and may each
independently
contain from 1 to 4 carbon atoms and be straight-chain or branched, for
example
N,N'-di-iso-butyl-p-phenylenediamine, N,N'-di-iso-propyl-p-phenylenediamine,
Irganox
5057 from Ciba Spezialitatenchemie, N,N'-di-iso-butyl-p-phenylenediamine, N,N'-
di-iso-
propyl-p-phenylenediamine, p-phenylenediamine, N-phenyl-p-phenylenediamine,
N,N'-Biphenyl-p-phenylenediamine, N-isopropyl-N-phenyl-p-phenylenediamine,
N,N'-di-sec-butyl-p-phenylenediamine (Kerobit~ BPD from BASF AG), N-phenyl-
N'-isopropyl-p-phenylenediamine (Vulkanox~ 4010 from Bayer AG), N-(1,3-
dimethyl-
butyl)-N'-phenyl-p-phenylenediamine, N-phenyl-2-naphthylamine, iminodibenzyl,
N,N'-diphenylbenzidine, N-phenyltetraaniline, acridone, 3-
hydroxydiphenylamine,
4-hydroicydiphenylamine, hydroxylamines such as N,N-diethylhydroxylamine, urea
derivatives such as urea or thiourea, phosphorus compounds, such as
triphenylphosphine, triphenyl phosphite, hypophosphorous acid or triethyl
phosphite,
sulfur compounds such as Biphenyl sulfide, phenothiazine or metal salts, for
example
copper chloride, copper dithiocarbamate, copper sulfate, copper salicylate,
copper
acetate, manganese chloride, manganese dithiocarbamate, manganese sulfate,
manganese salicylate, manganese acetate, cerium chloride, cerium
dithiocarbamate,
cerium sulfate, cerium salicylate, cerium acetate, nickel chloride, nickel
dithiocarbamate, nickel sulfate, nickel salicylate, nickel acetate, chromium
chloride,
chromium dithiocarbamate, chromium sulfate, chromium salicylate, chromium
acetate
or mixtures thereof. Preference is given to the phenols and quinones
mentioned,
particular preference is given to hydroquinone, hydroquinone monomethyl ether,
2-tert-
butyl-4-methylphenol, 6-tert-butyl-2,4-dimethylphenol, 2,6-di-tert-butyl-4-
methylphenol,
2,4-di-tert-butylphenol, triphenyl phosphite, hypophosphorous acid, CuCl2 and
guajacol, and very particular preference is given to hydroquinone and
hydroquinone
monomethyl ether.
PF 55145
CA 02527362 2005-11-28
12
Particular preference is given to hydroquinone monomethyl ether, hydroquinone
and
afkylphenols, optionally in combination with triphenyl phosphite andlor
hypophosphorous acid.
Very particular preference is given to a-tocopherol (vitamin E), ~i-
tocopherol,
y-tocopherol or 8-tocopherol, optionally in combination with triphenyl
phospite and/or
hypophosphorous acid.
Very particular preference is given to using just sterically hindered phenols
as
stabilizers that produce less dark product mixes for the same end-product acid
number
during the esterification reaction compared with hydroquinone monomethyl
ether.
Examples of such most preferred stabilizers are a-tocopherol and 2,6-di-tert-
butyl-
4-methylphenol.
Stabilization may be further augmented by the presence of an oxygen-containing
gas,
preferably air or a mixture of air and nitrogen (lean air).
Among the recited stabilizers, preference is given to those which are aerobic,
ie those
which require the presence of oxygen to fully develop their inhibiting effect.
Useful solvents E for the present invention are particularly solvents which
are suitable
for a~eotropic removal of the water of reaction, if desired, in particular
aliphatic,
cycloaliphatic and aromatic hydrocarbons or mixtures thereof.
Preference is given to n-pentane, n-hexane, n-heptane, cyclohexane,
methylcyclohexane, benzene, toluene or xjrlene. Particular preference is given
to
cyclohexane, methylcyclohexane and toluene.
The esterification may be carried out by conventional preparation and/or
workup
processes for polyhydric alcohols, for example the processes mentioned at the
beginning or the processes described in DE-A 199 41 136, DE-A 38 43 843,
DE-A 38 43 854, DE-A 199 37 911, DE-A 199 29 258, EP-A 331 845, EP 554 651 or
US 4 187 383.
In general, the esterification may be carried out as follows:
The esterification apparatus comprises a stirred reactor, preferably a reactor
with
circulatory evaporator and an added distillation unit with condenser and phase
separation vessel.
The reactor may be for example a reactor with jacketed heating andlor internal
heating
coils. Preference is given to using a reactor having an external heat
exchanger and
PF 55145 CA 02527362 2005-11-28
13
natural or forced circulation, ie through use of a pump, more preferably
natural
circulation where circulation is accomplished without mechanical aids.
It will be appreciated that the reaction can also be carried out in a
plurality of reaction
zones, for example a reactor battery of two to four and preferably two or
three reactors.
Suitable circulatory evaporators are known to one skilled in the art and are
described
for example in R. Billet, Verdampfertechnik, HTB-Verlag, Bibliographisches
Institut
Mannheim, 1965, 53. Examples of circulatory evaporators are tube-bundle heat
exchangers, plate-type heat exchangers, etc.
It will be appreciated that the circulatory system may also include a
plurality of heat
exchangers.
The distillation unit is of conventional design. It may be a simple
distillation unit which if
appropriate is equipped with a splash guard or it may be a rectification
column.
Suitable column internals include in principle all common internals, for
example trays,
structured packings and/or dumped packings. Preferred trays include bubble
trays,
sieve trays, valve trays, Thormann trays and/or dual-flow trays, while
preferred dumped
packings are those of rings, coils, saddles or braids.
In general, from 5 to 20 theoretical plates are sufficient.
The condenser and the separation vessel are of traditional design.
The (meth)acrylic acid and the alkoxylated glycol are generally used in the
esterification a) in a molar excess as indicated above. The excess used can be
up to
about 3000:1, if desired.
Useful esterification catalysts C include those recited above.
They are generally used in an amount of 0.1-5% by weight, based on the
esterification
mixture, preferably 0.5-5%, more preferably 1-4% and most preferably 2-4% by
weight.
If necessary, the esterification catalyst can be removed from the reaction
mixture with
the aid of an ion exchanger. The ion exchanger can be added directly to the
reaction
mixture and then subsequently filtered off, or the reaction mixture can be
passed
through an ion exchanger bed.
Preferably, the esterification catalyst is left in the reaction mixture.
However, where the
catalyst is an ion exchanger, the ion exchanger is preferably removed, for
example by
filtration.
PF 55145
CA 02527362 2005-11-28
14
Stabilization may be further supported by the presence of an oxygen-containing
gas,
preferably air or a mixture of air and nitrogen (lean air).
This oxygen-containing gas is preferably metered into the bottom region of a
column
andlor into a circulatory evaporator andlor passed through and/or over the
reaction
mixture.
The polymerization inhibitor (mixture) D (as indicated above) is used in a
total amount
of 0.01-1% by weight, based on the esterification mixture, preferably 0.02-
0.8% and
more preferably 0.05-0.5% by weight.
The polymerization inhibitor (mixture) D may be used for example as an aqueous
solution or as a solution in a reactant or product.
b) The water of reaction formed in the course of the reaction can be distilled
off during
or after the esterification a), in which case this operation can be augmented
by a
solvent which forms an azeotrope with water.
Useful solvents E for azeotropic removal of the water of reaction, if desired,
include the
compounds recited above.
The esterification is preferably carried out in the presence of a solvent.
The amount of solvent used is 10-200% by weight, preferably 20-100% by weight
and
more preferably from 30% to 100% by weight, based on the sum total of
alkoxylated
glycol and (meth)acrylic acid.
However, an operation without entrainer is also conceivable, as described for
example
in DE-A1 38 43 854, column 2 line 18 to column 4 line 45, but in
contradistinction to the
cited reference with the abovementioned stabilizers.
When the water in the reaction mixture is not removed via an azeotrope-forming
solvent, it may be removed by stripping with an inert gas, preferably an
oxygen-
containing gas and more preferably air or lean air as described for example in
DE-A 38 43 843.
The reaction temperature for the esterification a) is generally in the range
from 40 to
160°C, preferably in the range from 60 to 140°C and more
preferably in the range from
80 to 120°C. The temperature may remain constant or rise in the course
of the reaction
and preferably it is raised in the course of the reaction. In this case, the
final
temperature of the esterification is 5-30°C higher than the initial
temperature. The
PF 55145
CA 02527362 2005-11-28
temperature of the esterification can be determined and controlled by varying
the
solvent concentration in the reaction mixture, as described in DE-A 199 41 136
and
the German application under file reference 100 63 175.4.
5 When a solvent is used, it can be distilled out of the reaction mixture
through the
distillation unit added on top of the reactor.
The distillate may selectively be removed or, after condensation, fed into a
phase
separation apparatus. The aqueous phase thus obtained is generally removed
from the
10 system, while the organic phase can be fed as reflux into the distillation
unit and/or
passed directly into the reaction zone and/or fed into a circulatory
evaporator as
described in the German patent application under file reference 100 63 175.4.
When used as reflux, the organic phase can be used as described in DE-A 199 41
136
15 for controlling the temperature in the esterification.
The esterification a) can be carried out with no pressure, at superatmospheric
or
reduced pressure and is prefierably carried out at atmospheric pressure.
The reaction time is generally in the range from 2 to 20 hours, preferably in
the range
from 4 to 15 hours and more preferably in the range from 7 to 12 hours.
The order in which the individual reaction components are added is not
essential to the
present invention. All components can be introduced as a mixed initial charge
and
subsequently heated, or one or more components may be omitted from or only
partly
included in the initial charge and added only after the initial charge has
been heated
up.
The (meth)acrylic acid which can be used is not restricted in its composition
and may
comprise for example the following components:
(Meth)acrylic acid 90 -
99.9%
by weight
Acetic acid 0.05 3% by weight
-
Propionic acid 0.01 1 % by weight
-
Diacrylic acid 0.01 5% by weight
-
Water 0.05 5% by weight
-
Carbonylics 0.01 0.3% by
- weight
Inhibitors 0.01 0.1 % by
- weight
Malefic acid or 0.001 - 0.5% by
anhydride weight
The crude (meth)acrylic acid used is generally stabilized with 200-600 ppm of
phenothiazine or other stabilizers in amounts which permit comparable
stabilization.
PF 55145
CA 02527362 2005-11-28
16
Carbonylics here refers for example to acetone and lower aldehydes, for
example
formaldehyde, acetaldehyde, crotonaldehyde, acrolein, 2-furfural, 3-furfural
and
benzaldehyde.
Crude (meth)acrylic acid here refers to the (meth)acrylic acid mixture which
is obtained
after absorption of the reaction gases of the propane/propene/acrolein or
isobutanelisobutenelmethacrolein oxidation in an absorbent and subsequent
removal
of the absorbent, or which is obtained by fractional condensation of the
reaction gases.
It is obviously also possible to use pure (meth)acrylic acid, for example of
the following
purity:
(Meth)acrylic acid 99.7 - 99.99% by weight
Acetic acid 50 - 1000 weight ppm
Propionic acid 10 - 500 weight ppm
Diacrylic acid 10 - 500 weight ppm
Water 50 - 1000 weight ppm
Carbonylics 1 - 500 weight ppm
Inhibitors 1 - 300 weight ppm
Malefic acid or anhydride1 - 200 weight ppm
The pure (meth)acrylic acid used is generally stabilized with 100-300 ppm of
hydroquinone monomethyl ether or other storage stabilizers in amounts which
permit
comparable stabilization.
Pure or prepurified (meth)acrylic acid generally refers to (meth)acrylic acid
whose
purity is at least 99.5% by weight and which is substantially free of
aldehydic, other
carbonylic and high-boiling components.
The aqueous phase, distilled off during the esterification, of the condensate
removed
via the added column (if present) may generally comprise 0.1-10% by weight of
(meth)acrylic acid, and is separated off and removed from the system. The
(meth)acrylic acid it contains may preferably be extracted with an extractant,
preferably
with any solvent used in the esterification, for example with cyclohexane, at
from 10 to
40°C and a ratio of 1:5-30 and preferably 1:10-20 for aqueous phase to
extractant, and
returned into the esterification.
Circulation may be further supported by passing an inert gas, preferably an
oxygen-
containing gas, more preferably air or a mixture of air and nitrogen (lean
air) into the
circulation or through or over the reaction mixture, for example at rates of
0.1-1,
preferably 0.2-0.8 and more preferably 0.3-0.7 m3/m3h; based on the volume of
the
reaction mixture.
PF 55145
CA 02527362 2005-11-28
17
The course of the esterification a) can be monitored by monitoring the amount
of water
carried out and/or the decrease in the carboxylic acid concentration in the
reactor.
The reaction can be ended for example as soon as 90%, preferably at least 95%
and
more preferably at least 98% of the theoretically expected amount of water has
been
carried out by the solvent.
The end of the reaction can be detected for example from the fact that
substantially no
further water of reaction is removed via the entrainer. When (meth)acrylic
acid is
carried out together with the water of reaction, its fraction is determinable
for example
by backtitrating an aliquot of the aqueous phase.
The removal of the water of reaction can be dispensed with for example when
the
(meth)acrylic acid is used in a high stoichiometric excess, for example of at
least 3:1,
preferably at least 5:1 and most preferably at least 10:1. In this case, a
substantial
portion of the amount of water formed will remain in the reaction mixture.
Merely that
fraction of water is removed from the reaction mixture during or after the
reaction which
is determined by the volatility at the employed temperature and beyond that no
measures are carried out to remove the resulting water of reaction. For
instance, at
feast 10% by weight of the resulting water of reaction can remain in the
reaction
mixture, preferably at Least 20% by weight, more preferably at least 30% by
weight,
even more preferably at least 40% by weight and most preferably at least 50%
by
weight.
c) After the end-of the esterification the reaction mixture can be
conventionally cooled
to 10-30°C and if necessary by addition of a solvent which may be the
same as any
solvent used for azeotropic removal of water or a different solvent adjusted
to any
desired target ester concentration.
In a further embodiment, the reaction can be stopped with a suitable diluent G
and
diluted to a concentration of for example 10-90% by weight, preferably 20-80%,
more
preferably 20-60%, even more preferably 30-50% and most preferably about 40%,
for
example in order to reduce the viscosity.
What is important is that a substantially homogeneous solution forms after
dilution.
This is preferably accomplished only relatively shortly before use in the
production of
the hydrogei, for example not more than 24 hours before, preferably not more
than
20 hours before, more preferably not more than 12 hours before, even more
preferably
not more than 6 hours before and most preferably not more than 3 hours before.
PF 55145
CA 02527362 2005-11-28
18
The diluent G is selected from the group consisting of water, a mixture of
water with
one or more organic solvents which are soluble in water in any proportion and
a
mixture of water with one or more monohydric or polyhydric alcohols, for
example
methanol and glycerol. The alcohols preferably bear 1, 2 or 3 hydroxyl groups
and
preferably have from 1 to 10 and especially up to 4 carbon atoms. Preference
is given
to primary and secondary alcohols.
Preferred alcohols are methanol, ethanol, isopropanol, ethylene glycol,
glycerol,
1,2-propanediol and 1,3-propanediol.
d) If necessary, the reaction mixture may be decolorized, for example by
treatment with
active carbon or metal oxides, for example alumina, silica, magnesium oxide,
zirconium
oxide, boron oxide or mixtures thereof, in amounts for example of 0.1-50% by
weight,
preferably from 0.5% to 25% by weight, more preferably 1-10°l°
by weight at
temperatures of for example from 10 to 100°C, preferably from 20 to
80°C and more
preferably from 30 to 60°C.
This can be effected by adding the pulverulent or granular decolorizing agent
to the
reaction mixture and subsequent filtration or by passing the reaction mixture
through a
bed of the decolorizing agent in t!~e form of any desired suitable moldings.
The decolorizing of the reaction mixture can be effected at any desired stage
in the
workup process, for example at the stage of the crude reaction mixture or
after any
prewash, neutralization, wash or solvent removal.
The reaction mixture can further be subjected to a prewash e) and/or a
neutralization f)
and/or an afterwash g), preferably merely to a neutralization f). If desired,
a
neutralization f) and a prewash e) can be interchanged in the sequence.
(Meth)acrylic acid, andlor catalyst C can be at least partly recovered from
the aqueous
phase of the washes e) and g) and/or neutralization f) by acidification and
extraction
with a solvent and reused.
For a pre- or afterwash e) or g), the reaction mixture is treated in a wash
apparatus
with a wash liquor, for example water or a 5-30% by weight, preferably 5-20%
and
more preferably 5-15% by weight sodium chloride, potassium chloride, ammonium
chloride, sodium sulfate or ammonium sulfate solution, preferably water or
sodium
chloride solution.
The ratio of reaction mixture to wash liquor is generally in the range from
1:0.1 to 1:1,
preferably in the range from 1:0.? to 1:0.8 and more preferably in the range
from 1:0.3
to 1:0.7.
PF 55145
CA 02527362 2005-11-28
19
The wash or neutralization can be carried out for example in a stirred
container or in
other conventional apparatuses for example in a column or a mixer-settler
apparatus.
In terms of process engineering, any wash or neutralization in the process
according to
the present invention can be carried out using conventional extraction and
washing
processes and apparatuses, for example those described in Ullmann's
Encyclopedia of
Industrial Chemistry, 6th ed, 1999 Electronic Release, Chapter: Liquid -
Liquid
Extraction - Apparatus. For example, the choice may be for single- or multi-
staged,
preferably single-staged, extractions, and also for those in cocurrent or
countercurrent
mode and preferably in countercurrent mode.
Preference is given to using sieve tray columns, arrangedly or randomly packed
columns, stirred vessels or mixer-settler apparatuses and also pulsed columns
or
columns having rotating internals.
The prewash e) is preferably used whenever metal salts and preferably copper
or
copper salts are (concomitantly) used as inhibitors.
An afterwash g) may be preferable to remove traces of base or salt traces from
the
reaction mixture neutralized in f).
By way of neutralization f), the reaction mixture which may have been
prewashed and
which may still contain small amounts of catalyst and the main amount of
excess
(meth)acrylic acid can be neutralized with a 5-25%, preferably 5-20% and more
preferably 5-15% by weight aqueous solution of a base, for example alkali
metal or
alkaline earth metal oxides, hydroxides, carbonates or bicarbonates,
preferably
aqueous sodium hydroxide solution, aqueous potassium hydroxide solution,
sodium
bicarbonate, sodium carbonate, potassium bicarbonate, calcium hydroxide, milk
of
lime, ammonia gas, ammonia water or potassium carbonate, to which solution 5-
15%
by weight of sodium chloride, potassium chloride, ammonium chloride or
ammonium
sulfate may have been added, if desired, more preferably with aqueous sodium
hydroxide solution or aqueous sodium hydroxide-sodium chloride solution. The
degree
of neutralization is preferably in the range from 5 to 60 mol%, preferably in
the range
from 10 to 40 mol%, more preferably in the range from 20 to 30 mol%, based on
the
monomers comprising acid groups. This neutralization can take place before
andlor
during the polymerization, preferably before the polymerization. Another
preferred
degree of neutralization is in the range from 50 to 100 mol%, more preferably
55-80
mol%, especially from 60 to 75 mol%. Preferably, the crosslinker solution in
pure
acrylic acid is mixed together with the acryiate solution just before the
polymerization to
set the degree of neutralization. The base is added in such a way that the
temperature
in the apparatus does not rise above 60°C and is preferably in the
range from 20 to
PF 55145 CA 02527362 2005-11-28
35°C, and the pH is 4-13, preferably 4.5-10. The heat of neutralization
is preferably
removed by cooling the vessel with the aid of internal cooling coils or via
jacketed
cooling.
5 The ratio of reaction mixture to neutralizing liquor is generally in the
range from 1:0.1 to
1:1, preferably in the range from 1:0.2 to 1:0.8 and more preferably in the
range from
1:0.3 to 1:0.7.
With regard to the apparatus, the above statements apply.
h) When a solvent is present in the reaction mixture, it may be substantially
removed
by distillation. Preferably, any solvent present is removed from the reaction
mixture
after washing and/or neutralization, but if desired this may also be done
prior to the
wash or neutralization.
For this, the reaction mixture is admixed with an amount of storage
stabilizer,
preferably hydroquinone monomethyl ether, such that, after removal of the
solvent,
100-500, preferably 200-500 and more preferably 200-400 ppm thereof are
present in
the target ester (residue). But instead of hydroquinone monomethyl ether it is
also
possible to use the above-described sterically hindered phenols preferably
alone or
mixed with other stabilizers.
The distiilative removal of the main amount of solvent is effected for example
in a
stirred tank with jacketed heating and/or internal heating coils under reduced
pressure,
for example at 20-700 mbar, preferably 30-500 mbar and more preferably 50-150
mbar
and 40-80°C.
It will be appreciated that the distillation can also be accomplished in a
falling-film or
thin-film evaporator. For this, the reaction mixture is recirculated,
preferably two or
more times, through the apparatus under reduced pressure, for example at 20-
700 mbar, preferably 30-500 mbar and more preferably 50-150 mbar and 40-
80°C.
An inert gas, preferably an oxygen-containing gas, more preferably air or a
mixture of
air and nitrogen (lean air) may preferably be introduced into the distillation
apparatus,
for example 0.1-1, preferably 0.2-0.8 and more preferably 0.3-0.7 m3/m'h,
based on the
volume of the reaction mixture.
The residual solvent content of the residue is generally below 5% by weight,
preferably
0.5-5% and more preferably 1-3% by weight after the distillation.
The removed solvent is condensed and preferably reused.
PF 55145
CA 02527362 2005-11-28
21
If necessary, a solvent stripping operation i) can be carried out in addition
to or in lieu
of the distillation.
For this, the target ester, which still contains small amounts of solvent, is
heated to 50-
90°C and preferably 80-90°C and the remaining amounts of solvent
are removed with
a suitable gas in a suitable apparatus. There are circumstances where a vacuum
can
be applied in support, if desired.
Examples of useful apparatuses include columns of conventional design which
contain
conventional internals, for example trays, dumped packing or structured
packing,
preferably dumped packing. Useful column internals include in principle all
common
internals, for example trays, arranged packing and/or random packing.
Preferred trays
include bubble trays, sieve trays, valve trays, Thormann trays and/or dual-
flow trays,
while preferred dumped packings are those of rings, coils, saddles, Raschig,
Intos or
Pall rings, barrel or Intalox saddles, Top-Pak, etc or braids.
Another possibility here is a falling-film, thin-film or wipe-film evaporator,
for example a
Luwa, Rotafilm or Sambay evaporator, which may be splash-guarded with a
demister
for example.
Useful gases include gases which are inert under the stripping conditions,
preferably
oxygen-containing gases, more preferably air or mixtures of air and nitrogen
(lean air)
or water vapor, especially such gases which have been preheated to 50-
100°C.
The stripping gas rate is for example in the range from 5 to 20, more
preferably in the
range from 10 to 20 and most preferably in the range from 10 to 15 m3/m3h,
based on
the volume of the reaction mixture.
If necessary, the ester can be subjected to a filtration j) at any stage of
the workup
process, preferably after washinglneutralization and any effected solvent
removal, in
order that precipitated traces of salts and any decolorizing agent may be
removed.
In a conceivable embodiment, the esterification a) of alkoxylated glycol with
(meth)acrylic acid in the presence of at least one esterification catalyst C
and of at least
one polymerization inhibitor D is carried out in a molar excess of at least
10:1, as
indicated above, without a solvent capable of forming an azeotrope with water.
In a preferred embodiment the excess (meth)acrylic acid is preferably
substantially not
removed, ie only that fraction of (meth)acrylic acid is removed from the
reaction mixture
that is determined by the volatility at the employed temperature, and beyond
that no
measures are carried out to remove the carboxylic acid, for example no
distillative,
rectificative, extractive (washing for example), absorptive (for example
passing through
PF 55145
CA 02527362 2005-11-28
22
activated carbon or through ion exchangers) and/or chemical steps such as
scavenging
of the carboxylic acid with epoxides are carried out.
The extent to which the (meth)acrylic acid in the reaction mixture is removed
from it is
preferably not more than 75% by weight, more preferably not more than 50% by
weight, even more preferably not more than 25% by weight, especially not more
than
10% by weight and most preferably not more than 5% by weight, based on the
(meth)acrylic acid in the reaction mixture after the reaction has ended. In a
particularly
preferred embodiment, stage b) can be omitted, so that only the fraction of
water of
reaction and (meth)acrylic acid is removed from the reaction mixture that is
determined
by the volatility at the employed temperature. This can preferably be
prevented by
substantially complete condensation.
Furthermore, the esterification catalyst C used is likewise substantially left
in the
reaction mixture.
The DIN EN 3682 acid number of the reaction mixture thus obtainable is
preferably at
least 25 mg of KOH/g of reaction mixture, more preferably at least 35 mg of
KOH/g,
even more preferably at least 45 mg of KOH/g. The acid number is more
preferably in
the range from 25 to 80 and most preferably in the range from 35 to 50 mg of
KOH/g.
Any pre- or afterwash e) or g) is preferably omitted; merely a filtration step
j) can be
sensible.
The reaction mixture can subsequently be diluted in step c), in which case it
is
preferably converted within 6 hours and more preferably within 3 hours to the
hydrogel.
It may preferably be neutralized in a step f).
The order of the steps c), j) and f) is arbitrary.
The present invention further provides a composition of matter comprising
- at least one ester F obtainable by one of the esterification processes
described
above,
- (meth)acrylic acid and
- diluent G.
The composition of matter of the present invention may further comprise
- esterification catalyst C in protonated or unprotonated form,
polymerization inhibitor D and also
- any solvent E if used in the esterification.
PF 55145
CA 02527362 2005-11-28
23
The composition of matter may have been neutralized and have a pH as cited
above
under f).
When the composition of matter has been neutralized, at least a portion of the
(meth)acrylic acid has been converted into their water-soluble alkali metal,
alkaline
earth metal or ammonium salts.
A preferred composition of matter comprises
- ester F in a fraction from 0.1 % to 40% by weight, more preferably from 0.5%
to
20%, even more preferably from 1 % to 10%, especially from 2% to 5% and
specifically from 2% to 4% by weight,
- monomer M at 0.5-99.9% by weight, more preferably 0.5-50% by weight, even
more preferably 1-25%, especially 2-15% and specifically from 3% to 8% or
4-5% by weight,
esterification catalyst C at 0-10% by weight, more preferably 0.02-5%, even
more preferably 0.05-2.5% by weight and especially 0.1-1 % by weight,
- polymerization inhibitor D at 0-5% by weight, more preferably 0.01-1.0%,
even
more preferably 0.02-0.75%, especially 0.05-0.5% and specifically 0.075-0.25%
by weight,
- solvent E at 0-10% by weight, more preferably 0-5% by weight, even more
preferably 0.05-1.5% by weight and especially 0.1-0.5% by weight, with the
proviso that the sum total is always 100% by weight, and also
- any diluent G ad 100% by weight.
The reaction mixtures obtainable by the above process and compositions of
matter
according to the present invention can find use
- as a free-radical crosslinker of water-absorbing hydrogels,
- as a starting material for producing polymer dispersions,
- as a starting material for producing polyacrylates (except hydrogels),
- as a paint raw material or
- as a cement additive.
Compositions of matter according to the present invention which are
particularly useful
as radical crosslinkers of water-absorbing hydrogels have a solubility in
distilled water
at 25°C of not less than 0.5% by weight, preferably not less than 1 %
by weight, more
preferably not less than 2% by weight, even more preferably not less than 5%
by
weight, particularly preferably not less than 10% by weight, even more
preferably not
less than 20% by weight and especially not less than 30% by weight.
PF 55145
CA 02527362 2005-11-28
24
k) The reaction mixture from the esterification, including workup steps
thereof, where
practiced, for example the reaction mixture from f) or, when f) is omitted,
from b) or,
when b) is omitted, the reaction mixture from a), can optionally be admixed
with
additional monoethylenically unsaturated compounds N which bear no acid groups
but
are copolymerizable with the hydrophilic monomers M and can then be
polymerized in
the presence of at least one radical initiator K and optionally at least one
grafting base
L to prepare water-absorbing hydrogels.
It may be preferable
I) to postcrosslink the reaction mixture of k).
Useful hydrophilic monomers M for preparing k) these highly swellable
hydrophilic
hydrogels include for example acids capable of addition polymerization, such
as acrylic
acid, methacrylic acid, ethacrylic acid, a-chloroacrylic acid, crotonic acid,
malefic acid,
malefic anhydride, vinylsulfonic acid, vinylphosphonic acid, malefic acid,
malefic
anhydride, fumaric acid, itaconic acid, citraconic acid, mesaconic acid,
glutaconic acid,
aconitic acid, allylsulfonic acid, sulfoethyl acrylate, sulfomethacrylate,
sulfopropyl
acrylate, sulfopropyl methacrylate, 2-hydroxy-3-acryloyloxypropylsulfonic
acid,
2-hydroxy-3-methacryloyloxypropylsulfonic acid, allylphosphonic acid,
styrenesulfonic
acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-acrylamido-2-methylpropane-
phosphonic acid and also their amides, hydroxyalkyl esters and amino- or
ammonio-
containing esters and amides. These monomers can be used alone or mixed with
each
other. Furthermore water-soluble N-vinylamides and also
diallyldimethylammonium
chloride. Preferred hydrophilic monomers are compounds of the formula V
Rs Rs
H Ra
where
R3 is hydrogen, methyl or ethyl,
R4 is -COOR6, a sulfonyl group, a phosphonyl group, a (C,-C4)-alkanol-
esterified
phosphonyl group or a group of the formula VI
~ H3C CH3
~ R'
~N~C~
H H2
RS is hydrogen, methyl, ethyl or a carboxyl group,
PF 55145
CA 02527362 2005-11-28
R6 is hydrogen, amino or hydroxy-(C,-C4)-alkyl and
R' is a sulfonyl group, a phosphonyl group or a carboxyl group.
Examples of (C,-C4)-alkanols are methanol, ethanol, n-propanol and n-butanol.
5
Particularly preferred hydrophilic monomers are acrylic acid and methacrylic
acid,
especially acrylic acid.
To optimize properties, it can be sensible to use additional monoethylenically
10 unsaturated compounds N which do not bear an acid group but are
copolymerizable
with the monomers bearing acid groups. Such compounds include for example the
amides and nitrites of monoethylenicaliy unsaturated carboxylic acid, for
example
acrylamide, methacrylamide and N-vinylformamide, N-vinylacetamide, N-
methylvinyl-
acetamide, acrylonitrile and methacrylonitrile. Examples of further suitable
compounds
15 are vinyl esters of saturated C~- to C4-carboxylic acids such as vinyl
formate, vinyl
acetate or vinyl propionate, alkyl vinyl ethers having at least 2 carbon atoms
in the alkyl
group, for example ethyl vinyl ether or butyl vinyl ether, esters of
monoethylenically
unsaturated C3- to C6-carboxylic acids, for example esters of monohydric C,-
to C,a-
alcohols and acrylic acid, methacrylic acid or malefic acid, monoesters of
malefic acid,
20 for example methyl hydrogen maleate, N-vinyllactams such as N-
vinylpyrrolidone or N-
vinylcaprolactam, acrylic and methacrylic esters of alkoxylated monohydric
saturated
alcohols, for example of alcohols having from 10 to 25 carbon atoms which have
been
reacted with from 2 to 200 mot of ethylene oxide and/or propylene oxide per
mole of
alcohol, and also monoacrylic esters and monomethacrylic esters of
polyethylene
25 glycol or polypropylene glycol, the molar masses (M~) of the polyalkylene
glycols being
up to 2000, for example. Further suitable monomers are styrene and alkyl-
substituted
styrenes such as ethylstyrene or tent-butylstyrene.
These monomers without acid groups may also be used in mixture with other
monomers, for example mixtures of vinyl acetate and 2-hydroxyethyl acrylate in
any
proportion. These monomers without acid groups are added to the reaction
mixture in
amounts within the range from 0 to 50% by weight, preferably less than
20°I° by weight.
The crosslinked (co)polymers preferably consist of acid-functional
monoethylenically
unsaturated monomers which have optionally been converted into their alkali
metal or
ammonium salts before or after polymerization and of 0-40% by weight based on
their
total weight of monoethylenically unsaturated monomers which do not bear acid
groups.
The production, testing and use of (meth)acrylic acid (co)polymers,
polyacrylic acids
and superabsorbents has been e;,~tensively described before and therefore is
well
known, see for example "Modern Superabsorbent Polymer Technology", F.L.
Buchholz
PF 55145
CA 02527362 2005-11-28
26
and A.T. Graham, Wiley-VCH, 1998 or Markus Frank "Superabsorbents" in
Ullmann's
Handbuch der technischen Chemie, Volume 35, 2003.
Preference is given to such hydrogels which are obtained by crosslinking
addition
polymerization or copolymerization of acid-functional monoethylenically
unsaturated
monomers M or salts thereof.
The polymers obtainable are notable for an improved saponification index
(VSI).
In the postcrosslinking process, the starting polymer is treated with a
postcrosslinker
and preferably during or after the treatment postcrosslinked and dried by
raising the
temperature, the crosslinker preferably being included in an inert solvent.
Inert solvents
are solvents which substantially do not react either with the starting polymer
or with the
postcrosslinker. Preference is given to such solvents which do not react
chemically with
the starting polymer or with the postcrosslinker to an extent of more than
90%,
preferably more than 95%, more preferably more than 99% and especially more
than
99.5%.
Postcrosslinking I) and drying m) is preferably carried out at from 30 to
250°C,
especially 50-200°C and most preferably at from 100 to 180°C.
The surface
postcrosslinking solution is preferably applied by spraying the polymer in
suitable spray
mixers. After spraying, the polymer powder is thermally dried, and the
crosslinking
reaction can take place not onl~~r before but also during the drying
operation. Preference
is given to spraying a solution of the crosslinker in reaction mixers or
mixing and drying
ranges such as for example Lodige mixers, BEPEX mixers, NAUTA mixers, SHUGGI
mixers or PROCESSALL. It is moreover also possible to use fluidized bed
dryers.
The drying operation can take place in the mixer itself, by heating of the
shell or by
blowing in hot air. Also suitable is a downstream dryer such as for example a
shelf
dryer, a rotary tube oven or a heatable screw. But it is also possible to
utilize an
azeotropic distillation as drying technique, for example. The preferred
residence time at
this temperature in the reaction mixer or dryer is below 60 min and more
preferably
below 30 min.
Preference is given to the above processes wherein the starting polymer is a
polymeric
acrylic acid or a polyacrylate, especially a polymeric acrylic acid or a
polyacrylate
obtained by free-radical polymerization using a polyfunctional ethylenically
unsaturated
radical crosslinker.
Preference is given to such processes wherein the composition of matter
containing
radical crosslinkers, ie the ester F, and diluents G in a ratio of 0.1-20% by
weight and
especially 0.5-10% by weight based on the mass of the starting polymer is
used.
PF 55145 CA 02527362 2005-11-28
27
Preference is given to such processes wherein the radical crosslinker is used
in a dose
of 0.01-5.0% by weight, preferably 0.02-3.0% by weight, more preferably 0.03-
2.5% by
weight, especially 0.05-1.0% and specifically from 0.1 % to 0.75% by weight
based on
the starting polymer.
The present invention also provides polymers prepared by one of the processes
mentioned above and for their use in hygiene articles, packaging materials and
nonwovens and also for the use of an abovementioned composition of matter for
producing crosslinked or thermally crosslinkable polymers, especially in
paints and
varnishes.
The highly swellable hydrophilic hydrogels to be used (starting polymers) are
in
particular polymers of (co)polymerized hydrophilic monomers M, graft
(co)polymers of
one or more hydrophilic monomers M on a suitable grafting base L, crosslinked
cellulose or starch ethers or natural products capable of swelling in aqueous
fluids, for
example guar derivatives. These hydrogels are known to one skilled in the art
and are
described for example in US-4 286 082, DE-C-27 06 135, US-4 340 706,
DE-C-37 13 601, DE-C-28 40 010, DE-A-43 44 548, DE-A-40 20 780, DE-A-40 15
085,
DE-A-39 17 846, DE-A-38 07 289, DE-A-35 33 337, DE-A-35 03 458, DE-A-42 44
548,
DE-A-42 19 607, DE-A-40 21 847, DE-A-38 31 261, DE-A-35 11 086, DE-A-31 18
172,
DE-A-30 28 043, DE-A-44 18 881, EP-A-0 801 483, EP-A-0 455 985, EP-A-0 467
073,
EP-A-0 312 952, EP-A-0 205 874, EP-A-0 499 774, DE-A 26 12 846, DE-A-40 20
780,
EP-A-0 20 5674, US-5 145 906, EP-A-0 530 438, EP-A-0 670 073, US-4 057 521,
US-4 062 817, US-4 525 527, US-4 295 987, US-5 011 892, US-4 076 663 or
US-4 931 497. Also of particular suitability are highly swellable hydrogels
from a
manufacturing operation as described in WO 01/38402 and also highly swellable
inorganiclorganic hybrid hydrogels as described in DE 198 54 575. The content
of the
aforementioned patent documents, especially the hydrogels obtained by the
processes,
is incorporated herein by reference.
Suitable grafting bases L for hydrophilic hydrogels obtainable by graft
copolymerization
of olefinically unsaturated acids can be of natural or synthetic origin.
Examples are
starch, cellulose, cellulose derivatives and also other polysaccharides and
oligosaccharides, polyalkylene oxides, especially polyethylene oxides and
polypropylene oxides, and also hydrophilic polyesters.
The water-absorbing polymer is obtainable by free-radical graft
copolymerization of
acrylic acid or acrylate onto a water-soluble polymer matrix. Nonlimiting
examples of
suitable water-soluble polymer matrices are alginates, polyvinyl alcohol and
polysaccharides such as starch for example. A graft copolymerization for the
purposes
PF 55145
CA 02527362 2005-11-28
28
of the present invention utilizes a polyfunctional ethylenically unsaturated
radical
crosslinker.
The water-absorbing polymer can be an organic/inorganic hybrid polymer formed
from
a polymeric acrylic acid or polyacrylate on the one hand and a silicate,
aluminate or
aluminosilicate on the other. More particularly, the polymeric acrylic acid or
polyacrylate
used may be obtained by free-radical polymerization using a polyfunctional
ethylenically unsaturated radical crosslinker and formed using a water-soluble
silicate
or soluble aluminate or mixture thereof.
Preferred hydrogels are in particular polyacrylates, polymethacrylates and
also the
US-4 931 497, US-5 011 892 and US-5 041 496 graft polymers. Very particularly
preferred hydrogels are the kneader polymers described in WO 01138402 and the
polyacrylate-based organic/inorganic hybrid hydrogels described in DE 198 545
75.
The substances prepared according to the present invention, which are useful
as
radical crosslinkers in hydrogels, can be used alone or in combination with
other
crosslinkers, for example internal or surface crosslinkers, for example the
following:
Suitable crosslinkers are in particular methylenebisacrylamide, methylene-
bismethacrylamide, esters of unsaturated mono- or polycarboxylic acids with
polyols,
such as diacrylate, triacrylate or tetraacrylate, for example butanediol
diacrylate,
butanediol dimethacrylate, ethylene glycol diacrylate, ethylene glycol
dimethacrylate,
and also trimethylolpropane triacrylate or glycerol diacrylate and glycerol
triacrylate or
pentaerythritol tetraacrylate and allyl compounds such as allyl
(meth)acrylate, triallyl
cyanurate, diallyl maleate, polyallyl esters, tetraallyloxyethane,
triallylamine,
tetraallylethylenediamine, allyl esters of phosphoric acid and also
vinylphosphonic acid
derivatives as described for example in EP-A-0 343 427. However, particular
preference for use in the process of the present invention is given to
hydrogels
prepared using polyallyl ethers as further crosslinkers and by acidic
homopolymerization of acrylic acid. Suitable crosslinkers are pentaerythritol
triallyl
ether, pentaerythritol tetraallyl ether, trimethylolpropane diallyl ether,
polyethylene
glycol diallyl ether, monoethylene glycol diallyl ether, glycerol diallyl
ether, glycerol
triallyl ether, polyallyl ethers based on sorbitol and also ethoxylated
variants thereof.
Particularly preferred crosslinkers further include polyethylene glycol
diacrylates,
ethoxylated derivatives of trimethylolpropane triacrylate, for example
Sartomer SR
9035, and also ethoxylated derivatives of glycerol diacrylate and glycerol
triacrylate. It
is obviously also possible to use mixtures of the above crosslinkers.
Particular preference is given to combinations of crosslinkers wherein further
crosslinkers can be dispersed in the inventive crosslinkers F. Examples of
such
crosslinker combinations are the inventive crosslinkers F together with di- or
PF 55145
CA 02527362 2005-11-28
29
tripropylene glycol diacrylate and propoxylated glycerol triacrylates. Further
examples
of such crosslinker combinations are the inventive crosslinkers together with
butanediol
diacrylate or trimethylolpropane triacrylate or pentaerythritol triallyl
ether.
Very particular preference is given to hydrogels prepared using an ester F
prepared
according to the present invention as a radical crosslinker.
The water-absorbing polymer is preferably a polymeric acrylic acid or a
polyacrylate.
This water-absorbing polymer can be prepared by a process known from the
literature.
Preference is given to polymers which contain crosslinking comonomers (0.001-
10 mol%), but very particular preference is given to polymers which were
obtained by
free-radical polymerization and where a polyfunctional ethylenically
unsaturated radical
crosslinker was used.
The highly swellable hydrophilic hydrogels are preparable by addition
polymerization
processes known per se. Preference is given to the addition polymerization in
aqueous
solution conducted as a gel polymerization. It involves, as stated above,
dilute,
preferably aqueous and more preferably 15-50% by weight aqueous, solutions of
one
or more hydrophilic monomers and optionally of a suitable grafting base L
being
polymerized in the presence of a free-radical initiator by utilizing the
Trommsdorff-
Norrish effect (Makromol. Chem. 1, 169 (1947)) preferably without mechanical
mixing.
The polymerization reaction may be carried out at from 0°C to
150°C, and preferably at
from 10°C to 100°C, not only at atmospheric pressure but also at
superatmospheric or
reduced pressure. Typically, the polymerization can also be carried out in a
protective
gas atmosphere, preferably under nitrogen. The addition polymerization may be
induced using high-energy electromagnetic rays or the customary chemical
polymerization initiators K, for example organic peroxides, such as benzoyl
peroxide,
tert-butyl hydroperoxide, methyl ethyl ketone peroxide, cumene hydroperoxide,
azo
compounds such as azobisisobutyronitrile and also inorganic peroxy compounds
such
as (NH4)ZS208, KZS208 or H202.
They can if desired be used in combination with reducing agents such as
ascorbic acid,
sodium hydrogensulfite and iron(II) sulfate or redox systems which comprise as
reducing component an aliphatic and aromatic sulfinic acid, such as
benzenesulfinic
acid and toluenesulfinic acid or derivatives thereof, for example Mannich
adducts of
sulfinic acids, aldehydes and amino compounds, as described in DE-C-1 301 566.
The
performance properties of the polymers can be further improved by postheating
the
polymer gels in the temperature range from 50° to 130°C and
preferably from 70° to
100°C for several hours.
The gels obtained are neutralized to the extent of 0-100 mol%, preferably 25-
100 mol%
and more preferably 50-85 mol% based on monomer used, for which the customary
PF 55145
CA 02527362 2005-11-28
neutralizing agents can be used, preferably alkali metal hydroxides, alkali
metal oxides
or the corresponding alkali metal carbonates, but more preferably sodium
hydroxide,
sodium carbonate and sodium bicarbonate. When sodium hydroxide is used, it is
particularly preferable to use the grade obtainable by membrane electrolysis.
5
Neutralization is typically achieved by mixing the neutralizing agent as an
aqueous
solution or else preferably as a solid into the gel. For this, the gel is
mechanically
comminuted, for example by means of a meat grinder, and the neutralizing agent
is
sprayed on, scattered on or poured on and then carefully mixed in. The gel
mass
10 obtained can then be repeatedly passed through the meat grinder for
homogenization.
The neutralized gel mass is then dried with a belt or can dryer until the
residual
moisture content is preferably below 10% by weight and especially below 5% by
weight.
15 The addition polymerization as such can also be carried out by any other
process
described in the literature. More particularly, the neutralization of the
acrylic acid can
also be carried out prior to the polymerization, as described above in step
f).
Irrespectively of whether neutralization takes place before, during or after
the
polymerization, it is particularly preferable to use acrylic acid having a
dimer content
20 below 2 000 ppm, more preferably below 1 000 ppm and most preferably below
500 ppm. Very particular preference is given to using sodium hydroxide from a
membrane electrolysis. This is notable for its high purity (for example low
chloride
content and absence of mercury traces) compared with other processes. It is of
course
also possible to use sodium hydroxide from the amalgam or diaphragm process.
The
25 polymerization can then be carried out in a conventional belt reactor or a
kneading
reactor continuously or else batchwise. When the polymerization is carried-out
in a belt
reactor, initiation by electromagnetic radiation and preferably by UV
radiation or
alternatively initiation by means of a redox initiator system is particularly
preferred. Very
particular preference is also given to a combination of the two methods of
initiation:
30 electromagnetic radiation and chemical redox initiator system
simultaneously.
n) The dried hydrogel can then be ground and sieved, in which case it is
customary to
use roll mills, pin mills or sieving mills for the grinding. The preferred
particle size of the
sieved hydrogel is preferably in the range 45-1000 Vim, more preferably at 45-
850 pm,
even more preferably at 200-850 Vim, and most preferably at 300-850 Vim. A
further
particularly preferred range is 150 - 850 Nm, especially 150 - 700 Nm and more
preferably 200 - 600 ~m and most preferably 150 - 550 pm. A further particular
range
is 200 - 800 um and a particularly preferred range is 250 - 650 Vim, a very
particularly
preferred range is 300 - 600 Vim. Particularly preferred ranges are 200 - 500
Vim,
100 - 450 ~m and also 150 - 400 Vim. The following ranges are further
preferrec: 100
Nm - 500 Nm , 100 pm - 600 Nm , 100 Nm - 700 Nm , 100 Nm - 800 Nm .These
ranges preferably cover 80% by vreight of the particles and especially 90% by
weight of
PF 55145 CA 02527362 2005-11-28
31
the particles. The size distribution can be determined using established
sieving
methods or else preferably using optical methods (photographs).
The present invention further provides crosslinked hydrogels which comprise at
least
one hydrophilic monomer M in copolymerized form and have been crosslinked
using an
ester F of alkoxylated glycol with (methacrylic) acid. The ester can be
prepared in a
manner according to the present invention or in a prior art manner and is
preferably
prepared in a manner according to the present invention.
Useful esters F include compounds as described above.
The CRC value [g/g] of the hydrogel-forming polymers according to the present
invention can be measured by the methods indicated in the description and is
preferably above 10, especially 11, 12, 13, 14, 15, 16, 18, 20, 22, 24, or
higher, more
preferably 25, especially 26, 27, 28, 29, even more preferably 30, 31, 32, 33,
34, 35,
36, 37, 38, 39, 40, 41, 42, 43, 44, 45 or higher.
The AUL 0.7 psi value [g/g] of the hydrogel-forming polymers according to the
present
invention can be measured by the methods indicated in the description part and
is
preferably above 8, especially 9, 10, 11, 12, 13, 14 or higher, more
preferably 15,
especially 16, 17, 18, 19, or higher, even more preferably above 20,
especially 21, 22,
23, 24, 25, 26, 27, 28, or higher.
The AUL 0.5 psi value [glg] of the hydrogel-forming polymers according to the
present
invention can be measured by the methods indicated in the description part and
is
preferably above 8, especially 9, 10, 11, 12, 13, 14 or higher, more
preferably 15,
especially 16, 17, 18, 19, or higher, even more preferably above 20,
especially 21, 22,
23, 24, 25, 26, 27, 28, or higher.
The saponification index VSI of the hydrogel-forming polymers according to the
present
invention can be measured by the methods indicated in the description part and
is
preferably less than 10, especially 9.5, 9 or 8.5 or lower, more preferably
less than 8,
especially 7.5, 7, 6.5, 6, 5.5 or lower, even more preferably less than 5,
especially 4.5,
4, 3.5 or lower.
The residual crosslinker content of the inventive hydrogel-forming polymers
can be
measured by the methods indicated in the description part and is preferably
less than
30 ppm, more preferably less than 20 ppm, most preferably less than 10 ppm,
especially 9.5 ppm, 9 ppm or 8.5 ppm or less, more preferably less than 8 ppm,
especially 7.5 ppm, 7 ppm, 6.5 ppm, 6 ppm, 5.5 ppm or less, even more
preferably less
than 5 ppm, especially 4.5 ppm, 4 ppm, 3.5 ppm or less. When a plurality of
PF 55145 CA 02527362 2005-11-28
32
crosslinkers are used in the mixture, these maximum values relate to each
individual
crosslinker in the mixture.
Deployment and use of the hydrogel-forming polymers according to the present
invention
The present invention further relates to the use of the abovementioned
hydrogel-
forming polymers in hygiene articles comprising
(P) a liquid-pervious topsheet
(Q) a substantially liquid-impervious backsheet
(R) a core positioned between (P) and (Q) and comprising
10-100% by weight of the hydrogel-forming polymer according to the present
invention
0-90% by weight of hydrophilic fiber material
preferably 20-100% by weight of the hydrogel-forming polymer according to the
present invention, 0-80% by weight of hydrophilic fiber material
more preferably 30-100% by weight of the hydrogel-forming polymer according to
the
present invention, 0-70% by weight of hydrophilic fiber material
even more preferably 40-100% by weight of the hydrogel-forming polymer
according to
the present invention, 0-60% by weight of hydrophilic fiber material
yet even more preferably 50-100% by weight of the hydrogel-forming polymer
according to the present invention, 0-50% by weight of hydrophilic fiber
material
particularly preferably 60-100% by weight of the hydrogel-forming polymer
according
to the present invention, 0-40% by weight of hydrophilic fiber material
especially preferably 70-100% by weight of the hydrogel-forming polymer
according to
the present invention, 0-30% by weight of hydrophilic fiber material
extremely preferably 80-100°,~o by weight of the hydrogel-forming
polymer according to
the present invention, 0-20% by weight of hydrophilic fiber material
most preferably 90-100% by weight of the hydrogel-forming polymer according to
the
present invention, 0-10% by weight of hydrophilic fiber material
(S) optionally a tissue layer positioned directly above and below said core
(R), and
(T) optionally an acquisition layer positioned between (P) and (R).
The percentages are to be understood so that in the case of 10-100% by weight,
11%,
12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% up to in each case 100% by weight of
hydrogel-forming polymer according to the present invention and all
intermediate % (for
example 12.2%) are possible and correspondingly hydrophilic fiber material
from 0% to
in each case 89%, 88%, 87%, 86%, 85%, 83%, 82%, 81 % by weight and
intermediate
percentages (for example 87.8%) are possible. When further materials are
present in
the core, the percentages of polymer and fiber decrease accordingly. The same
applies
to the preferred ranges, for example in the case of extremely preferable 81 %,
82%,
83%, 84%, 85%, 86%, 87%, t38%, 89% by weight can be present for the hydrogel-
PF 55145
CA 02527362 2005-11-28
33
forming polymer according to the present invention and correspondingly 19%,
18%,
17%, 16%, 15%, 14%, 13%, 12%, 11 % by weight for the fiber material. Thus,
20%,
21 %, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29% to 100% by weight of the hydrogel-
forming polymer according to the present invention can be present in the
preferred
range, 30%, 31 %, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39% to 100% by weight can
be present for the hydrogel-forming polymer according to the present
invention, in the
more preferred range, 40%, 41 %, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% to
100% by weight can be present for the hydrogel-forming polymer according to
the
present invention, in the even more preferred range, 50%, 51 %, 52%, 53%, 54%,
55%,
56%, 57%, 58%, 59% to 100% by weight can be present for the hydrogel-forming
polymer according to the present invention, in the yet even more preferred
range, 60%,
61 %, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69% to 100% by weight can be present
for the hydrogel-forming polymer according to the present invention, in the
particularly
preferred range, 70%, 71 %, 71 %, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79% to
100% by weight can be present for the hydrogel-forming polymer according to
the
present invention in the especially preferred range, and 90%, 91 %, 92%, 93%,
94%,
95%, 96%, 97%, 98%, 99% or 100% by weight can be present for the hydrogel-
forming
polymer according to the present invention in the most preferred range.
Hygiene articles for the purposes of the present invention include not only
incontinence
pads and incontinence briefs ~or adults but also diapers for infants.
The liquid-pervious topsheet (P) is the layer which is in direct contact with
the skin of
the wearer. Its material comprises customary synthetic or manufactured fibers
or films
of polyesters, polyolefins, rayon or natural fibers such as cotton. In the
case of non-
woven materials the fibers are generally joined together by binders such as
polyacrylates. Preferred materials are polyesters, rayon and blends thereof,
polyethylene and polypropylene. Examples of liquid-pervious layers are
described in
WO 99/57355 A1, EP 102 388 3 A2.
The liquid-impervious layer (Q) is generally a sheet of polyethylene or
polypropylene.
However, it is possible to use any other materials which can be processed into
liquid-
impervious sheets. Liquid impervious in this connection. means an
imperviousness to
condensed liquids. At the same time, however, the sheet can exhibit
perviousness to
the vapor of the liquid, and modern diaper constructions often combine a high
vapor
perviousness with maximum imperviousness to the underlying condensed liquid,
which
is generally water or urine.
The core (R) comprises not only the hydrogel-forming polymer according to the
present
invention but also hydrophilic fiber material. By hydrophilic is meant that
aqueous fluids
spread quickly over the fiber. The fiber material is usually cellulose,
modified cellulose,
rayon, polyester such as polyethylene terephthalate. Particular preference is
given to
PF 55145 CA 02527362 2005-11-28
34
cellulose fibers such as pulp. The fibers generally have a diameter of 1-200
~m and
preferably 10-100 Vim, and also have a minimum length of 1 mm.
Diaper construction and shape is common knowledge and described for example in
WO 95/26 209 page 66 line 34 to page 69 line 11, DE 196 04 601 A1, EP-A-0 316
518
and EP-A-0 202 127. Diapers and other hygiene articles are generally also
described in
WO 00165084, especially at pages 6-15, WO 00/65348, especially at pages 4-17,
WO 00/35502, especially pages 3-9, DE 19737434, WO 98/8439. Hygiene articles
for
feminine care are described in the following references. The subject hydrogel-
forming
polymers capable of absorbing aqueous fluids can be used there. Feminine care
references: WO 95/24173: Absorption Article for Controlling Odour, WO
91111977:
Body Fluid Odour Control, EP 389023: Absorbent Sanitary Articles, WO 94/25077:
Odour Control Material, WO 97/01317: Absorbent Hygienic Article, WO 99/18905,
EP 834297, US 5,762,644, US 5,895,381, WO 98/57609, WO 2000/065083,
WO 2000/069485, WO 2000/069484, WO 20001069481, US 6,123,693, EP 1104666,
WO 2001/024755, WO 2001/000115, EP 105373, WO 2001/041692, EP 1074233.
Tampons are described in the following references: WO 98!48753, WO 98/41179,
WO 97109022, WO 98/46182, WO 98/46181, WO 2001/043679, WO 2001/043680,
WO 2000/061052, EP 1108408, WO 2001/033962, DE 200020662, WO 2001/001910,
WO 2001/001908, WO 200'i/001909, WO 2001/001906, WO 2001/001905,
WO 2001/24729. Incontinence articles are described in the following
references:
Disposable Absorbent Article for Incontinent Individuals: EP 311344
description pages
3-9; Disposable Absorbent Article: EP 850623; Absorbent Article: WO 95!26207;
Absorbent Article: EP 894502; Dry Laid Fibrous Structure: EP 850 616; WO
98/22063;
WO 97/49365; EP 903134; EP 887060; EP 887059; EP 887058; EP 887057;
EP 887056; EP 931530; WO 99/25284; WO 98/48753. Feminine care and incontinence
articles are described in the following references: Catamenial Device: WO
93/22998
description pages 26-33; Absorbent Members for Body Fluids: WO 95/26209
description pages 36-69; Disposable Absorbent Article: WO 98120916 description
pages 13-24; Improved Composite Absorbent Structures: EP 306262 description
pages 3-14; Body Waste Absorbent Article: WO 99145973. These references and
the
references therein are hereby expressly incorporated herein.
The hydrogel-forming polymers according to the present invention are very
useful as
absorbents for water and aqueous fluids, so that they may be used with
advantage as
a water retainer in market gardening, as a filter aid and particularly as an
absorbent
component in hygiene articles such as diapers, tampons or sanitary napkins.
Incorporation and fixation of the highly swellable hydrogels according to the
present
invention
PF 55145 CA 02527362 2005-11-28
In addition to the above-described highly swellable hydrogels, the absorbent
composition of the present invention includes constructions which comprise
highly
swellable hydrogels or to which they are fixed. Any construction is suitable
that is
capable of accommodating highly swellable hydrogels and of being integrated
into the
5 absorption layer. A multiplicity of such compositions is already known and
described in
detail in the literature. A construction for installing the highly swellable
hydrogels can be
for example a fiber matrix consisting of a cellulose fiber mixture (air-laid
web, wet laid
web) or synthetic polymer fibers (meltblown web, spunbonded web) or else of a
fiber
blend of cellulose fibers and synthetic fibers. Possible fiber materials are
detailed in the
10 chapter which follows. The air-laid web process is described for example in
WO 98/28 478. Furthermore, open-celled foams or the like may be used to
install
highly swellable hydrogels.
Alternatively, such a construction can be the result of fusing two individual
layers to
15 form one or better a multiplicity of chambers which comprise the highly
swellable
hydrogels. Such a chamber system is described in detail in EP 0 615 736 A1
page 7
lines 26 et seq.
In this case, at least one of the two layers should be water pervious. The
second layer
20 may either be water pervious or water impervious. The layer material used
may be
tissues or other fabric, closed or open-celled foams, perforated films,
elastomers or
fabrics composed of fiber material. When the absorbent composition consists of
a
construction of layers, the layer material should have a pore structure whose
pore
dimensions are small enough to retain the highly swellable hydrogel particles.
The
25 above examples of the construction of the absorbent composition also
include
laminates composed of at least two layers between which the highly swellable
hydrogels are installed and fixed.
Generally it is possible to fix hydrogel particles within the absorbent core
to improve dry
30 and wet integrity. Dry and wet integrity describes the ability to install
highly swellable
hydrogels into the absorbent composition in such a way that they withstand
external
forces not only in the wet but also in the dry state and highly swellable
polymer does
not dislocate or spill out. The forces referred to are especially mechanical
stresses as
occur in the course of moving about while wearing the hygiene article or else
the
35 weight pressure on the hygiene article in the case of incontinence
especially. As to
fixation, one skilled in the art knows a multiplicity of possibilities.
Examples such as
fixation by heat treatment, addition of adhesives, thermoplastics, binder
materials are
noted in WO 95/26 209 page 37 line 36 to page 41 line 14. The cited passage is
thus
part of this invention. Methods for enhancing wet strength are also to be
found in
WO 2000136216 A1.
PF 55145 CA 02527362 2005-11-28
36
Furthermore, the absorbent composition may comprise a base material, for
example a
polymer film on which the highly swellable hydrogel particles are fixed. The
fixing may
be effected not only on one side but also on both sides. The base material can
be
water pervious or water impervious.
The above constructions of the absorbent composition incorporate the highly
swellable
hydrogels at a weight fraction of from 10-100% by weight, preferably 20-100%
by
weight, more preferably 30-100% by weight, even more preferably 40-100% by
weight,
much more preferably 50-100% by weight, particularly preferably 60-100% by
weight,
especially preferably 70-100% by weight, extremely preferably 80-100% by
weight and
most preferably 90-100% by weight, based on the total weight of the
construction and
of the highly swellable hydrogels.
Fiber materials of the absorbent composition
The structure of the present absorbent composition according to the invention
may be
based on various fiber materials, which are used as a fiber network or
matrices. The
present invention includes not only fibers of natural origin (modified or
unmodified) but
also synthetic fibers.
A detailed overview of examplAs of fibers which can be used in the present
invention is
given in WO 95/26 209 page 28 line 9 to page 36 line 8. The cited passage is
thus part
of this invention.
Examples of cellulose fibers include cellulose fibers which are customarily
used in
absorption products, such as fluff pulp and cellulose of the cotton type. The
materials
(soft- or hardwoods), production processes such as chemical pulp, semichemical
pulp,
chemothermomechanical pulp (CTMP) and bleaching processes are not particularly
restricted. For instance, natural cellulose fibers such as cotton, flax, silk,
wool, jute,
ethylcellulose and cellulose acetate are used.
Suitable synthetic fibers are produced from polyvinyl chloride, polyvinyl
fluoride,
polytetrafluoroethylene, polyvinylidene chloride, polyacrylic compounds such
as
ORLON~, polyvinyl acetate, polyethyl vinyl acetate, soluble or insoluble
polyvinyl
alcohol. Examples of synthetic fibers include thermoplastic polyolefin fibers,
such as
polyethylene fibers (PULPEX~), polypropylene fibers and polyethylene-
polypropylene
bicomponent fibers, polyester fibers, such as polyethylene terephthalate
fibers
(DACRON° or KODEL°), copolyesters, polyvinyl acetate, polyethyl
vinyl acetate,
polyvinyl chloride, polyvinylidene chloride, polyacrylics, polyamides,
copolyamides,
polystyrene and copolymers of the aforementioned polymers and also bicomponent
fibers composed of polyethylene terephthalate-polyethylene-isophthalate
copolymer,
polyethyl vinyl acetate/polypropylene, polyethylene/polyester,
polypropylenelpolyester,
PF 55145 CA 02527362 2005-11-28
37
copolyester/polyester, polyamide fibers (nylon), polyurethane fibers,
polystyrene fibers
and polyacrylonitrile fibers. Preference is given to polyolefin fibers,
polyester fibers and
their bicomponent fibers. Preference is further given to thermally adhesive
bicomponent fibers composed of polyolefin of the core-sheath type and side-by-
side
type on account of their excellent dimensional stability following fluid
absorption.
The synthetic fibers mentioned are preferably used in combination with
thermoplastic
fibers. In the course of the heat treatment, the latter migrate to some extent
into the
matrix of the fiber material present and so constitute bond sites and renewed
stiffening
elements on cooling. Additionally the addition of thermoplastic fibers means
that there
is an increase in the present pore dimensions after the heat treatment has
taken place.
This makes it possible, by continuous addition of thermoplastic fibers during
the
formation of the absorbent layer, to continuously increase the fraction of
thermoplastic
fibers in the direction of the topsheet, which results in a similarly
continuous increase in
the pore sizes. Thermoplastic fibers can be formed from a multiplicity of
thermoplastic
polymers which have a melting point of less than 190°C, preferably in
the range from
75°C to 175°C. These temperatures are too low for damage to the
cellulose fibers to be
likely.
Lengths and diameters of the above-described synthetic fibers are not
particularly
restricted, and generally any fiber from 1 to 200 mm in length and from 0.1 to
100 denier (gram per 9000 meters) in diameter may preferably be used.
Preferred
thermoplastic fibers are from 3 to 50 mm in length, particularly preferred
thermoplastic
fibers are from 6 to 12 mm in length. The preferred diameter for the
thermoplastic fiber
is in the range from 1.4 to 10 decitex, and the range from 1.7 to 3.3 decitex
(gram per
10 000 meters) is particularly preferred. The form of the fiber may vary;
examples
include woven types, narrow cylindrical types, cutlchopped yarn types, staple
fiber
types and continuous filament fiber types.
The fibers in tl~e absorbent composition of the present invention can be
hydrophilic
and/or hydrophobic. According to the definition of Robert F. Gould in the 1964
American Chemical Society publication "Contact angle, wettability and
adhesion", a
fiber is referred to as hydrophilic when the contact angle between the liquid
and the
fiber (or the fiber surface) is less than 90° or when the liquid tends
to spread
spontaneously on the same surface. The two processes are generally coexistent.
Conversely, a fiber is termed hydrophobic when a contact angle of greater than
90° is
formed and no spreading is observed.
Preference is given to using hydrophilic fiber material. Particular preference
is given to
using fiber material which is weakly hydrophilic on the body side and most
hydrophilic
in the region surrounding the highly swellable hydrogels. In the manufacturing
process,
PF 55145 CA 02527362 2005-11-28
38
layers having different hydrophilicities are used to create a gradient which
channels
impinging fluid to the hydrogel, where it is ultimately absorbed.
Suitable hydrophilic fibers for use in the absorbent composition of the
present invention
include for example cellulose fibers, modified cellulose fibers, rayon,
polyester fibers,
for example polyethylene terephthalate (DACRON°), and hydrophilic nylon
(HYDROFIL°). Suitable hydrophilic fibers may also be obtained by
hydrophilicizing
hydrophobic fibers, for example the treatment of thermoplastic fibers obtained
from
polyolefins (e.g. polyethylene or polypropylene, polyamides, polystyrenes,
polyurethanes, etc.) with surfactants or silica. However, for cost reasons and
ease of
availability, cellulosic fibers are preferred.
The highly swellable hydrogel particles are embedded into the fiber material
described.
This can be done in various ways, for example by using the hydrogel material
and the
fibers together to create an absorbent layer in the form of a matrix, or by
incorporating
highly swellable hydrogels into fiber mixture layers, where they are
ultimately fixed,
whether by means of adhesive or lamination of the layers.
The fluid-acquiring and -distributing fiber matrix may comprise synthetic
fiber or
cellulosic fiber or a mixture of synthetic fiber and cellulosic fiber, in
which case the
mixing ratio may vary from (100 to 0) synthetic fiber: (0 to 100) cellulosic
fiber. The
cellulosic fibers used may additionally have been chemically stiffened to
increase the
dimensional stability of the hygiene article.
The chemical stiffening of cellulosic fibers may be provided in different
ways. A first
way of providing fiber stiffening is by adding suitable coatings to the fiber
material.
Such additives include for example polyamide-epichlorohydrin coatings
(Kymene° 557
H, Hercules, Inc. Wilmington, Delaware), polyacrylamide coatings (described in
US-A-3,556,932 or as the Parez° 631 NC commercial product from
American
Cyanamid Co., Stamford, CT), melamine-formaldehyde coatings and
polyethyleneimine coatings.
CeNulosic fibers may also be chemically stiffened by chemical reaction. For
instance,
suitable crosslinker substances may be added to effect crosslinking taking
place within
the fiber. Suitable crosslinker substances are typical substances used for
crosslinking
monomers including but not limited to CZ-C8-dialdehydes, CZ-C8-monoaldehydes
having acid functionality and in particular C2-Cg-polycarboxylic acids.
Specific
substances from this series are for example glutaraldehyde, glyoxal, glyoxylic
acid,
formaldehyde and citric acid. These substances react with at least 2 hydroxyl
groups
within any one cellulose chain or between two adjacent cellulose chains within
any one
cellulose fiber. The crosslinking causes a stiffening of the fibers, to which
greater
dimensional stability is imparted as a result of this treatment. In addition
to their
PF 55145 CA 02527362 2005-11-28
39
hydrophilic character, these fibers exhibit uniform combinations of stiffening
and
elasticity. This physical property makes it possible to retain the capillary
structure even
under simultaneous contact with fluid and compressive forces and to prevent
premature collapse.
Chemically crosslinked cellulose fibers are known and described in WO
91/11162,
US 3,224,926, US 3,440,135, US 3,932,209, US 4,035,147, US 4,822,453,
US 4,888,093, US 4,898,642 and US 5,137,537. The chemical crosslinking imparts
stiffening to the fiber material, which is ultimately reflected in improved
dimensional
stability for the hygiene article as a whole. The individual layers are joined
together by
methods known to one skilled in the art, for example intermelting by heat
treatment,
addition of hot-melt adhesives, latex binders, etc.
Methods of making the absorbent composition
The absorbent composition is composed of constructions which comprise highly
swellable hydrogels and the highly swellable hydrogels which are present in
said
constructions or fixed thereto.
Examples of processes to obtain an absorbent composition comprising for
example a
base material to which highly swellable hydrogels are fixed on one or both
sides are
known and included by the invention but not limited thereto.
Examples of processes to obtain an absorbent composition comprising for
example a
fiber material blend of synthetic fibers (a) and cellulosic fibers (b)
embedded in highly
swellable hydrogels (c), the blend ratio varying from (100 to 0) synthetic
fiber: (0 to
100) cellulosic fiber, include (1 ) a process where (a), (b) and (c) are mixed
together at
one and the same time, (2) a process where a mixture of (a) and (b) is mixed
into (c),
(3) a process where a mixture of (b) and (c) is mixed with (a), (4) a process
where a
mixture of (a) and (c) is mixed into (b), (5) a process where (b) and (c) are
mixed and
(a) is continuously metered in, (6) a process where (a) and (c) are mixed and
(b) is
continuously metered in, and (7) a process where (b) and (c) are mixed
separately into
(a). Of these examples, processes (1 ) and (5) are preferred. The apparatus
used in this
process is not particularly restricted and any customary apparatus known to
one skilled
in the art can be used.
The absorbent composition obtained in this way can optionally be subjected to
a heat
treatment, so that an absorption layer having excellent dimensional stability
in the moist
state is obtained. The heat treatment process is not particularly restricted.
Examples
include heat treatment by feeding hot air or infrared irradiation. The
temperature of the
heat treatment is in the range from 60°C to 230°C; preferably
from 100°C to 200°C,
particularly preferably from 100°C to 180°C.
PF 55145
CA 02527362 2005-11-28
The duration of the heat treatment depends on the type of synthetic fiber, its
amount
and the hygiene article production rate. Generally the duration of the heat
treatment is
in the range from 0.5 second to 3 minutes, preferably from 1 second to 1
minute.
5
The absorbent composition is generally provided for example with a liquid-
pervious
topsheet and a liquid-impervious backsheet. Furthermore, leg cuffs and
adhesive tabs
are attached to finalize the hygiene article. The materials and types of
pervious
topsheet and impervious backsheet and of the leg cuffs and adhesive tabs are
known
10 to one skilled in the art and are not particularly restricted. Examples
thereof may be
found in WO 95126 209.
The present invention is advantageous in that the esters F, which are useful
as
crosslinkers, do not have to be purified after they have been formed and
particularly in
15 that the (meth)acrylic acid, preferably acrylic acid, does not have to be
removed, since
it is generally a monomer for forming the hydrogels.
Experimental part
20 Parts per million and perce,~tages are by weight, unless otherwise stated.
The example which follows illustrates the process of the present invention.
Examples
Production of crude acrylate esters useful as SAP-crosslinkers
SAP-crosslinkers are prepared in the examples by esterifying alkoxylated
glycol with
acrylic acid by removing water in an azeotropic distillation. The
esterification catalyst in
the examples is sulfuric acid. The reactants are introduced in the examples as
initial
charge in methylcyclohexane entrainer together with a stabilizer mixture
consisting of
hydroquinone monomethyl ether, triphenyl phosphite and hypophosphorous acid.
The
reaction mixture is then heated to about 98°C until the azeotropic
distillation starts.
During the azeotropic distillation, the temperature in the reaction mixture
rises. The
amount of water removed is determined. The distillation is discontinued once
at least
the theoretical amount of water has been removed. Subsequently the entrainer
is
removed in a vacuum distillation. The product is cooled and used as a
crosslinker in
SAP production.
Conversion and yield of the reaction is not precisely determined because the
water
removed in the esterification also comprises acrylic acid and acrylic acid is
also
PF 55145
CA 02527362 2005-11-28
41
removed during the vacuum distillation of the entrainer. Similarly, the crude
ester still
contains free acrylic acid which is titrated together with the catalyst (acid
number).
Parts are by weight, unless otherwise stated.
Production of ester
Acid numbers were determined in accordance with DIN EN 3682.
Example 1 Preparation of alkoxylated glycol as a basis for ester F
a) PO - EO6 -PO
124 g of glycol are placed with 0.5 g of KOH, 45% in water as an initial
charge in an
autoclave and dewatered together at 80°C and reduced pressure (about 20
mbar).
440 g of ethylene oxide are then added at 145 to 155°C and allowed to
react at this
temperature under elevated pressure. The reaction has ended when no further
change
in pressure is observed. The reaction mixture is then stirred for a further 30
min at
about 150°C. 232 g of propylene oxide are subsequently added at 120 to
130°C at
elevated pressure over a prolonged period and likewise allowed to react. After
purging
with inert gas and cooling at 60°C, the catalyst is separated off by
addition of sodium
pyrophosphite and subsequent filtration.
b) Tripropylene glycol is a commercially available diol component.
Example 2 Preparation of acrylic ester
a) PO - EO6 -PO diacrylate
506 parts of the propoxylated polyglycol (as per Example 1 b) are esterified
with
200 parts of acrylic acid and 5 parts of sulfuric acid in 345 parts of
methylcyclohexane.
The assistants used are 2 parts of hydroquinone monomethyl ether, 2 parts of
a-tocopherol and also 1 part of hypophosphorous acid. 36 parts of water are
removed
before the entrainer is removed by vacuum distillation. The product is
purified through
K300 filter. The acid number is determined. The viscosity of the minimally
colored
product (APH,4 < 100) is further reduced by addition of 40 parts of acrylic
acid.
b) Tripropylene glycol diacrylate is commercially obtainable as Laromer TPGDA
(BASF
AG). But it can also be prepared in a manner completely analogous to the above
examples.
PF 55145 CA 02527362 2005-11-28
42
Making of hydrogels
To determine the quality of surface crosslinking, the dried hydrogel can be
investigated
using the following test methods.
Test methods
a) Centrifuge Retention Capacity (CRC)
This method measures the free swellability of the hydrogel in a teabag. 0.2000
+/-
0.0050 g of dried hydrogel (particle size fraction 106-850 Vim) are weighed
into a
teabag 60 x 85 mm in size which is subsequently sealed. The teabag is placed
for
30 minutes in an excess of 0.9% by weight sodium chloride solution (at least
0.83 I of
sodium chloride solution/1 g of polymer powder). The teabag is then
centrifuged for
3 minutes at 250 g. The amount of liquid is determined by weighing back the
centrifuged teabag.
b) Absorbency Under Load (AUL) (0.7 psi)
The measuring cell for determining AUL 0.7 psi is a Plexiglass cylinder 60 mm
in
internal diameter and 50 mm in height. Adhesively attached to its underside is
a
stainless steel sieve bottom having a mesh size of 36 Vim. The measuring cell
further
includes a plastic plate having a diameter of 59 mm and a weight which can be
placed
in the measuring cell together with the plastic plate. The plastic plate and
the weight
together weigh 1345 g. AUL 0.7 psi is determined by determining the weight of
the
empty Plexiglass cylinder and of the plastic plate and recording it as Wo.
0.900 +1-
0.005 g of hydrogel-forming polymer (particle size distribution 150-800 Vim)
is then
weighed into the Plexiglass cylinder and distributed very uniformly over the
stainless
steel sieve bottom. The plastic plate is then carefully placed in the
Plexiglass cylinder,
the entire unit is weighed and the weight is recorded as Wa. The weight is
then placed
on the plastic plate in the Plexiglass cylinder. A ceramic filter plate 120 mm
in diameter,
10 mm in height and 0 in porosity (Duran, from Schott) is then placed in the
middle of a
Petri dish 200 mm in diameter and 30 mm in height and sufficient 0.9% by
weight
sodium chloride solution is introduced for the surface of the liquid to be
level with the
filter plate surface without the surface of the filter plate being wetted. A
round filter
paper 90 mm in diameter and < 20 pm in pore size (S8~S 589 Schwarzband from
Schleicher 8~ Schull) is subsequently placed on the ceramic plate. The
Plexiglass
cylinder comprising hydrogel-forming polymer is then placed with plastic plate
and
weight on top of the filter paper and left there for 60 minutes. At the end of
this period,
the complete unit is removed from the filter paper and the Petri dish and
subsequently
the weight is removed from the Plexiglass cylinder. The Plexiglass cylinder
comprising
PF 55145 CA 02527362 2005-11-28
43
swollen hydrogel is weighed together with the plastic plate and the weight
recorded as
Wb~
AUL was calculated by the following equation:
AUL 0.7 psi (g/gj = (Wb-W~ / (Vlla-Wo~
AUL 0.5 psi is measured in similar fashion at a lower pressure.
c) The 16 h extractables value is determined similarly to the description in
EP-A1 811 636 at page 13 line 1 to line 19.
d) Method for determining residual levels of crosslinkers in hydrogels
To determine the level of residual, unconverted crosslinker, this residual
crosslinker is
initially extracted from the dried hydrogel by a double extraction. To this
end, 0.400 g of
dry hydrogel and 40 g of 0.9% by weight sodium chloride solution are weighed
into a
sealable and centrifugable ampoule. 8 ml of dichloromethane are added, the
ampoule
is sealed and is then shaken for 60 min. The ampoule is thereafter immediately
centrifuged at 1500 rpm for 5 min, so that the organic phase is cleanly
separated from
the aqueous phase.
50 u1 of monoethylene glycol are weighed into a second ampoule, about 5 - 6 ml
of the
dichloromethane extract are added, the weight of the extract is measured
accurately to
0.001 g. The dichloromethane is then evaporated off at 50-55°C and the
residue after
cooling is taken up with 2 ml of methanol-water mixture (50 parts by volume of
each).
This is followed by shaking for 10 min before filtration through a PTFE 0.45
~m filter.
The sample thus obtained is separated by means of liquid phase chromatography
and
analyzed by mass spectrometry. Quantification is against a dilution series of
the same
crosslinker used.
The chromatography column used is a Zorbax Eclipse XDB C-8 (150 x 4.6 mm - 5
Vim)
and the precolumn used is a Zorbax Eclipse XDB C-8 (12.5 x 4.6 mm - 5 Vim).
The
mobile phase used is a 75/25 methanol/water mixture.
The gradient course is as follows:
Time (min)% Methanol % Water
0 75 25
3 75 25
PF 55145 CA 02527362 2005-11-28
44
4 98 2
8 98 2
9 75 25
14 75 25
Flow is 1 ml/min at 1600 psi pressure.
The injection volume is 20 ~I.
Typical analysis time is 5-30 min for the samples.
Detection is by mass spectrometry, for example in the range 800 - 1300 m/z
(full scan,
positive). The instrument utilizes APCI (atmospheric pressure chemical
ionization,
positive ionization). For optimization, the capillary temperature is set to
180°C, the
APCI vaporizer temperature to 450°C, source current to 5.0 E.tA and gas
flow to
80 ml/min.
The individual settings have to be done separately for each crosslinker. To
this end, a
suitable calibrating solution of the crosslinker is used to determine the
characteristic
peaks which are later relevant for evaluation. The main peak is generally
chosen.
The residual crosslinker concentration is then calculated as follows:
CONCProbe - robe x ~%ONCStd x VF ~ Astd
CONCProbe : is wanted residual crosslinker concentration in dry hydrogel in
mg/kg
CONCs,d : is wanted residual crosslinker concentration in calibrating solution
in mg/kg
AProbe : is peak area of extract sample of dried hydrogel
Astd : is peak area of calibrating solution
VF is the dilution factor:
VF = MpcM x Nlson / (MProbe x MExtract)
MocM is weight of dichloromethane for extraction
MProbe is weight of dry hydrogel
Mson is weight of methanol-water mixture + monoethylene glycol
PF 55145 CA 02527362 2005-11-28
ME,~,a~ is weight of dichloromethane extract
A calibration has to be carried out (involving a plurality of points in the
range 0 -
ppm for example) to ensure that the determination is carried out in the linear
range.
5
e) Saponification index VSI
The comminuted gel is then further treated in two different ways:
Workup method 1:
The comminuted gel is evenly spread out in a thin layer on sieve-bottomed
trays and
then dried at 80°C under reduced pressure for 24 h. This form of drying
is very gentle
on the product and therefore represents the best standard for comparison.
The dried hydrogel is then ground and the sieve fraction of 300 - 600
micrometers is
isolated.
Workup method 2:
The comminuted gel is initially heat-treated at 90°C in a sealed
plastic bag for 24 h. It is
then spread out evenly in a thin layer on sieve-bottomed trays and dried at
80°C under
reduced pressure for 24 h. This drying simulates the drying conditions which
occur in
typical manufacturing plants and which customarily limit the drying
performance and
the throughput because of the reduced quality associated therewith.
The dried hydrogel is ground and the sieve fraction of 300 - 600 micrometers
is
isolated.
The hydrogels obtained according to the two workup methods are characterized
by
determination of teabag capacity (CRC) and also of the extractables content
after 16 h
and with regard to the level of unreacted, residual crosslinker. In addition,
the moisture
content is determined and if found to be above 1% by weight it is
arithmetically allowed
for when determining these properties. Typically, the moisture content will be
about 5%
by weight.
The measured values are then used to determine the saponification index (VSI)
of the
crosslinker in the gel, which computes as follows:
VSI = 0.5 x (CRCZ - CRC,) + 0.5 x (extractables2 - extractables,)
The subscripted indices here indicate workup method 1 and workup method 2, as
the
case may be. Thus, the saponification index increases when teabag capacity
increases
PF 55145
CA 02527362 2005-11-28
46
as a result of plant drying and when the fraction of extractables increases in
the
process. The two contributions are given equal weight.
It is generally advantageous to use crosslinkers whose saponification index is
very
small. The ideal crosslinker has a VSI of zero. The use of such crosslinkers
makes it
possible to increase the performance of the plant dryers to the technically
achievable
maximum without loss of quality. The reason for this is that the degree of
crosslinking
achieved during the polymerization - and hence the properties of the end
product -
does not change any more by hydrolysis in the course of drying.
Example 3: Preparation of superabsorbent using the acrylic ester of example 2
and
other internal crosslinkers
Example A (comparative)
305 g of acrylic acid and 3204 g of a 37.3% by weight sodium acrylate solution
are
dissolved in 1465 g of distilled water in an acid-resistant plastics tub. 9.7
g of Sartomer
SR 344 (polyethylene glycol-400 diacrylate) are added as a crosslinker and
also 0.61 g
of V-50 (2,2'-azobisamidinopropane dihydrochloride) and 3.05 g of sodium
persulfate
as initiators. The initiators are advantageously predissolved in a portion of
the batch
water. The batch is thoroughly stirred for some minutes.
Then nitrogen gas is bubbled through the plastics film covered solution in the
tub for
about 30 min in order that oxygen may be removed and a homogeneous
distribution
may be achieved for the crosslinker. Finally, 0.244 g of hydrogen peroxide
dissolved in
5 g of water and also 0.244 g of ascorbic acid dissolved in 5 g of water are-
added. The
temperature at the start of the reaction should be 11 -13°C. The
reaction solution is
about 6 cm deep. The reaction starts after a few minutes and is allowed to
proceed
under adiabatic conditions and the thermally insulated tub is allowed to stand
for not
longer than 30 min before the gel is worked up.
To work up the gel, the gel block is initially broken into pieces and then
comminuted
through a meat grinder equipped with a 6 mm breaker plate.
The comminuted gel is then further treated in two different ways:
Workup method 1:
The comminuted gel is evenly spread out in a thin layer on sieve-bottomed
trays and
then dried at 80°C under reduced pressure for 24 h. This form of drying
is very gentle
on the product and therefore represents the best standard for comparison.
PF 55145
CA 02527362 2005-11-28
47
The dried hydrogel is then ground and the sieve fraction of 300 - 600
micrometers is
isolated.
Workup method 2:
The comminuted gel is initially heat-treated at 90°C in a sealed
plastic bag for 24 h. It is
then spread out evenly in a thin layer on sieve-bottomed trays and dried at
80°C under
reduced pressure for 24 h. This drying simulates the drying conditions which
occur in
typical manufacturing plants and which customarily limit the drying
performance and
the throughput because of the reduced quality associated therewith.
The dried hydrogel is ground and the sieve fraction of 300 - 600 micrometers
is
isolated.
The following further examples are prepared similarly to example A:
Tab. 1
Ex. Crosslinker type Amount used Amount
No. based on acrylicused
acid monomer in g
A Sartomer SR 344 (Cray Valley) 0.80% by weight9.7
g
B Laromer TPGDA (BASF) 0.47% by weight5.7
g
C Acrylate PO-EO6-PO acrylate 0.80% by weight9.7
g
The properties achied for these hydrogels are summarized in Tab. 2:
Extract- Extract-Residual
Ex. CRC ables CRC ables crosslinkerVSI
1 2
16h 16h content
1 2 2
~9~91 f9~9] ~PPm]
weig weight]
t]
A Sartomer SR 35.0 10.2 39.7 16.7 27 6
344
B Laromer TPGDA 30.3 4.9 32.1 5.6 5 1
crylate PO-EOs-PO
C 35.7 10.9 37.6 14.1 < 10 3
acrylate
Postcrosslinking:
PF 55145 CA 02527362 2005-11-28
48
The gel ground after the polymerization is dried, ground and comminuted by
workup
method 1.
The dry normal base polymer powder is sprayed homogeneous (while stirring)
with a
solution of 0.12% by weight of N-hydroxyethyl-2-oxazolidinone, 3.35% by weight
of
water and 1.65% by weight of 1,2-propanediol, all percentages being based on
polymer
used.
For comparison, some completely analogous batches were carried out using
water/isopropanol and waterl1,3-propanediol as a solvent. The amounts used are
identical to those described above.
The batch size is in each case 1.2 kg, and spraying is through a two-material
nozzle by
atomizing the solution with nitrogen. A plowshare mixer from Lodige is used
which has
a 5 I working capacity.
In those cases where a special sieve section is reported, it is produced by
sieving
before the postcrosslinking solution is sprayed on.
The moist powder is then heat treated in a drying cabinet from 180°C
for 60 min. It is
then sieved once more at 850 micrometers in order that agglomerates may be
removed.
Only about 100 g of moist polymer are needed far drying.
The properties of this postcrosslinked polymer are determined.
Ex. Crosslinker Base polymer CRC AUL 0.7
sieve section psi
pm
A Sartomer SR 344 100 - 800 28.3 24.0
A1 Sartomer SR 344 100 - 500 26.9 23.7
A2 Sartomer SR 344 300 - 850 30.0 25.0
B Laromer TPGDA 100 - 800 27.0 23.0
B1 Laromer TPGDA 100 - 600 25.9 22.1
B2 Laromer TPGDA 300 - 600 27.5 23.3
C Acrylate PO-EO6-PO acrylate100 - 800 29.0 24.7
C1 Acrylate PO-EO6-PO acrylate100 - 500 25.4 21.3
And for comparison, in an analogous manner, the properties using isopropanol
or
1,3-propanediol as a solvent:
PF 55145
CA 02527362 2005-11-28
49
Ex. Crosslinker Base polymerSolvent CRC AUL 0.7
sieve section psi
~m
A3 Sartomer SR 100 -800 Isopropanol 29.8 25.1
344
A4 Sartomer SR 100 -800 1,3-Propanediol27.0 23.9
344
B3 Laromer TPGDA 100 -800 Isopropanol 27.8 23.4
B4 Laromer TPGDA 100 -800 1,3-Propanediol26.5 23.2
