U.S. patent application number 09/376177 was filed with the patent office on 2002-03-21 for acrylic acid-maleic acid copolymer (or its salt), its production process and use, and production process for aqueous maleic salt solution with low impurity content.
Invention is credited to ISHIDA, TAMAO, MAEDA, YOSHIHIRO, YAMAGUCHI, SHIGERU.
Application Number | 20020035224 09/376177 |
Document ID | / |
Family ID | 27477311 |
Filed Date | 2002-03-21 |
United States Patent
Application |
20020035224 |
Kind Code |
A1 |
YAMAGUCHI, SHIGERU ; et
al. |
March 21, 2002 |
ACRYLIC ACID-MALEIC ACID COPOLYMER (OR ITS SALT), ITS PRODUCTION
PROCESS AND USE, AND PRODUCTION PROCESS FOR AQUEOUS MALEIC SALT
SOLUTION WITH LOW IMPURITY CONTENT
Abstract
The present invention provides: an acrylic acid-maleic acid
copolymer (or its salt) which is excellent in performances, such as
Mg.sup.2+ scavengeability, clay dispersibility in the presence of
Mg.sup.2+, inhibitability upon Mg(OH).sub.2 scale, and
inhibitability upon CaCO.sub.3 scale; and a production process for
such a copolymer (or its salt). The present invention further
provides a production process for an aqueous maleic salt solution
with a low impurity content which has the advantage of easily
giving the above copolymer (or its salt). The present invention
still further provides uses of the above copolymer (or its salt)
having the above excellent properties.
Inventors: |
YAMAGUCHI, SHIGERU; (OSAKA,
JP) ; MAEDA, YOSHIHIRO; (OSAKA, JP) ; ISHIDA,
TAMAO; (OSAKA, JP) |
Correspondence
Address: |
ROBERT J JACOBSON PA
650 BRIMHALL STREET SOUTH
ST PAUL
MN
551161511
|
Family ID: |
27477311 |
Appl. No.: |
09/376177 |
Filed: |
August 17, 1999 |
Current U.S.
Class: |
526/271 ;
526/317.1; 526/318.2; 526/79; 526/80; 526/81; 562/590 |
Current CPC
Class: |
C08F 220/06 20130101;
C08F 222/02 20130101; C11D 3/3757 20130101; C08F 222/06
20130101 |
Class at
Publication: |
526/271 ; 526/79;
526/80; 526/81; 526/317.1; 526/318.2; 562/590 |
International
Class: |
C08F 122/04 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 8, 1998 |
JP |
10-254334 |
Dec 28, 1998 |
JP |
10-373894 |
Aug 11, 1999 |
JP |
11-228035 |
Aug 11, 1999 |
JP |
11-228036 |
Claims
What is claimed is:
1. An acrylic acid-maleic acid copolymer (or its salt),
characterized by having a magnesium ion scavengeability of 210 mg
(in terms of Mg(OH).sub.2)/g or more and a magnesium hydroxide
scale inhibitability of 30 % or more.
2. An acrylic acid-maleic acid copolymer (or its salt) according to
claim 1, which further has a clay dispersibility of 60% or more in
the presence of magnesium ion.
3. An acrylic acid-maleic acid copolymer (or its salt) according to
claim 1, which further has a molecular weight distribution of 3.5
or less and low-molecular fractions with a molecular weight of
1,000 or less in the ratio of 9 wt % or less to the total of the
copolymer (or its salt).
4. An acrylic acid-maleic acid copolymer (or its salt) according to
claim 2, which further has a molecular weight distribution of 3.5
or less and low-molecular fractions with a molecular weight of
1,000 or less in the ratio of 9 wt % or less to the total of the
copolymer (or its salt).
5. An acrylic acid-maleic acid copolymer (or its salt), having a
magnesium ion scavengeability of 210 mg (in terms of
Mg(OH).sub.2)/g or more, a molecular weight distribution of 3.5 or
less, and low-molecular fractions with a molecular weight of 1,000
or less in the ratio of 9 wt % or less to the total of the
copolymer (or its salt).
6. A production process for an acrylic acid-maleic acid copolymer
(or its salt), comprising the step of copolymerizing ethylenically
unsaturated monomers including acrylic acid and maleic acid in the
presence of a polymerization initiator, with the production process
being characterized in that: 50 wt % or more of the maleic acid is
initially charged; the maleic acid has a neutralization degree of
70.about.95 mol % before the polymerization initiator is charged;
and the resultant acrylic acid-maleic acid copolymer (or its salt)
has a neutralization degree of 50.about.70 mol % and a solid
component concentration of 45 wt % or more at the end of the
polymerization.
7. A production process according to claim 6, further comprising
the step in which hydrogen peroxide is used as the polymerization
initiator, and the charging of this hydrogen peroxide is finished
earlier than the charging end of all the monomers.
8. A detergent composition, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 1 and a surfactant.
9. A detergent composition, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 2 and a surfactant.
10. A detergent composition, comprising the acrylic acid-maleic
acid copolymer (or its salt) as recited in claim 3 and a
surfactant.
11. A detergent composition, comprising the acrylic acid-maleic
acid copolymer (or its salt) as recited in claim 4 and a
surfactant.
12. A detergent composition, comprising the acrylic acid-maleic
acid copolymer (or its salt) as recited in claim 5 and a
surfactant.
13. A detergent builder, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 1.
14. A detergent builder, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 2.
15. A detergent builder, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 3.
16. A detergent builder, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 4.
17. A detergent builder, comprising the acrylic acid-maleic acid
copolymer (or its salt) as recited in claim 5.
18. A production process for an aqueous maleic salt solution,
characterized by comprising the steps of: charging 80% or less of
the required amount of a basic substance to produce the aqueous
maleic salt solution and 80% or less of the required amount of
maleic acid (or its salt) and/or maleic anhydride to produce the
aqueous maleic salt solution into a reaction vessel; and then
adding thereto the respective balances of water, the basic
substance, and the maleic acid (or its salt) and/or maleic
anhydride under conditions where the highest value of the reaction
temperature will be 80.degree. C. or higher; thus obtaining the
aqueous maleic salt solution with a formed malic acid content of
not more than 10,000 ppm.
19. A production process according to claim 18, wherein the molar
ratio of the maleic acid (or its salt) and/or maleic anhydride to
the basic substance in the reaction system is maintained in the
range of 1:4.about.4:1 for 90% or more of a period of time when the
reaction temperature is 100.degree. C. or higher.
20. A maleic acid/acrylic acid copolymer (or its salt), which
comprises maleic acid (or its salt) of 30.about.70 mol % and
acrylic acid (or its salt) of 70.about.30 mol %, and has a
weight-average molecular weight of 2,000.about.50,000, a calcium
ion scavengeability of 400 mg CaCO.sub.3/g or more, a clay
dispersibility of 0.6 or more, and a malic acid content of not more
than 9 wt % in the solid content of the copolymer (or its salt).
Description
BACKGROUND OF THE INVENTION
[0001] A. Technical Field
[0002] The present invention relates to: an acrylic acid-maleic
acid copolymer (or its salt) which is excellent in performances
such as metal ion scavengeability, clay dispersibility, and scale
inhibitability, and has a high random degree; a production process
therefor; and uses of this copolymer (or its salt) for such as
detergent builders.
[0003] The present invention further relates to a production
process for an aqueous maleic salt solution with a low impurity
content which has the advantage of giving the above copolymer (or
its salt) more excellent performance.
[0004] B. Background Art
[0005] Generally, copolymers (or their salts), as used for
detergent builders, water-treating agents, various chelating
agents, and so on, are required to be high both in the metal ion
scavengeability and the clay dispersibility in the presence of
metal ions. Thus, various maleic acid copolymers (or their salts)
have been developed to satisfy these performances. Furthermore, in
water-treating processes, the alkaline earth metal ion scale
inhibitability is demanded as an important performance, and the use
of conventionally known maleic acid copolymers (or their salts)
have been recognized to improve the scale inhibitability upon
calcium ion that is the main component of the scale. However, in
the case where such polymers (or their salts) as improved in the
metal ion scavengeability, the clay dispersibility, and the scale
inhibitability upon calcium are used for detergent builders,
excellent deterging effects are exhibited according to expectation
in some regions, while the hygroscopicity and touch of washed
clothes are bad in other regions. In addition, there are problems
in that the performances, such as the detergency or the softness of
fibers after washing, vary with regions where the above polymers
(or their salts) are used.
[0006] The present inventors diligently studied to pursue causes of
the above problems. As a result, the present inventors have found
that the cause is the formation of scale due to the generation of
an inactive salt (magnesium hydroxide) from magnesium ion. That is
to say, they have found that the generation and deposition of
magnesium hydroxide scale have a bad influence upon the
hygroscopicity and touch of clothes especially in regions where the
magnesium ion content in water is high. Thus, the present inventors
have further found out a copolymer (or its salt) which does not
only maintain conventional performance levels of the metal ion
scavengeability, the clay dispersibility, and the scale
inhibitability upon calcium ion, but is also at high level in the
scale inhibitability upon magnesium ion as has never been
studied.
[0007] By the way, the production of the maleic acid copolymer (or
its salt) involves the production of an aqueous maleic salt
solution which is an aqueous solution of a monomer of the maleic
acid copolymer (or its salt), but the production process for the
aqueous maleic salt solution has never been studied.
[0008] The present inventors considered the production process for
the aqueous maleic salt solution to be particularly important, and
thus studied it. As a result, the present inventors found that a
specific production process can give an aqueous maleic salt
solution which contains only a small amount of formed impurities
such as malic acid and therefore has high purity, and further that
the resultant maleic acid copolymer (or its salt) from such an
aqueous maleic salt solution also contains only a small amount of
impurities such as malic acid and is therefore a copolymer (or its
salt) which exhibits high calcium ion scavengeability and high clay
dispersibility.
SUMMARY OF THE INVENTION
OBJECTS OF THE INVENTION
[0009] Thus, a first object of the present invention is to provide:
an acrylic acid-maleic acid copolymer (or its salt) which is
excellent with good balance in performances such as metal ion
scavengeability, clay dispersibility, calcium carbonate scale
inhibitability, and magnesium hydroxide scale inhibitability; a
production process therefor; and uses of this copolymer (or its
salt) for such as detergent builders.
[0010] A second object of the present invention is to provide a
production process for an aqueous maleic salt solution which
contains only a small amount of formed impurities such as malic
acid and therefore has high purity.
DISCLOSURE OF THE INVENTION
[0011] An acrylic acid-maleic acid copolymer (or its salt),
according to the present invention, is characterized by having a
magnesium ion scavengeability of 210 mg (in terms of
Mg(OH).sub.2)/g or more and a magnesium hydroxide scale
inhibitability of 30% or more. Preferably, this copolymer (or its
salt) further has a clay dispersibility of 60% or more in the
presence of magnesium ion.
[0012] Another acrylic acid-maleic acid copolymer (or its salt),
according to the present invention, has a magnesium ion
scavengeability of 210 mg (in terms of Mg(OH).sub.2)/g or more, a
molecular weight distribution of 3.5 or less, and low-molecular
fractions with a molecular weight of 1,000 or less in the ratio of
9 wt % or less to the total of the copolymer (or its salt).
[0013] A production process for an acrylic acid-maleic acid
copolymer (or its salt), according to the present invention,
comprises the step of copolymerizing ethylenically unsaturated
monomers including acrylic acid and maleic acid in the presence of
a polymerization initiator, and is characterized in that: 50 wt %
or more of the maleic acid is initially charged; the maleic acid
has a neutralization degree of 70.about.95 mol % before the
polymerization initiator is charged; and the resultant acrylic
acid-maleic acid copolymer (or its salt) has a neutralization
degree of 50.about.70 mol % and a solid component concentration of
45 wt % or more at the end of the polymerization.
[0014] A detergent composition, according to the present invention,
comprises the above present invention acrylic acid-maleic acid
copolymer (or its salt) and a surfactant.
[0015] A detergent builder, according to the present invention,
comprises the above present invention acrylic acid-maleic acid
copolymer (or its salt).
[0016] A production process for an aqueous maleic salt solution,
according to the present invention, is characterized by comprising
the steps of: charging 80% or less of the required amount of a
basic substance to produce the aqueous maleic salt solution and 80%
or less of the required amount of maleic acid (or its salt) and/or
maleic anhydride to produce the aqueous maleic salt solution into a
reaction vessel; and then adding thereto the respective balances of
water, the basic substance, and the maleic acid (or its salt)
and/or maleic anhydride under conditions where the highest value of
the reaction temperature will be 80.degree. C. or higher; and this
process can give an aqueous maleic salt solution with a formed
malic acid content of not more than 10,000 ppm.
[0017] The present invention can provide a maleic acid/acrylic acid
copolymer (or its salt), which comprises maleic acid (or its salt)
of 30-70 mol % and acrylic acid (or its salt) of 70.about.30 mol %,
and has a weight-average molecular weight of 2,000.about.50,000, a
calcium ion scavengeability of 400 mg CaCO.sub.3/g or more, a clay
dispersibility of 0.6 or more, and a malic acid content of not more
than 9 wt % in the solid content of the copolymer (or its
salt).
[0018] These and other objects and the advantages of the present
invention will be more fully apparent from the following detailed
disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Part I
[0019] In this part I, detailed descriptions are given on the
present invention acrylic acid-maleic acid copolymer (or its salt)
and its production process and use.
Acrylic Acid-maleic Acid Copolymer (or its salt)
[0020] The magnesium ion scavengeability of the present invention
acrylic acid-maleic acid copolymer (or its salt) is defined as the
mg number, in terms of magnesium hydroxide (Mg(OH).sub.2), of
magnesium ion as scavenged by 1 g of the copolymer (or its salt),
and, for example, can be measured by the method as described in the
below-mentioned examples of some preferred embodiments. The
magnesium ion scavengeability is an index to show how much
magnesium ion in water the acrylic acid-maleic acid copolymer (or
its salt) scavenges. The surfactant, as used for detergents,
becomes insoluble upon bonding to magnesium ion in water, so that
the detergency deteriorates. However, if, even when the fiber is
treated with magnesium-ion-containing water, the present invention
acrylic acid-maleic acid copolymer (or its salt) having high
magnesium ion scavengeability is used together with the surfactant,
then the surfactant is prevented from becoming insoluble, so that
the detergency upon dirt such as oil dirt can be prevented from
deteriorating, and further, the magnesium scale can be prevented
from deposition to fibers. Such effects can lessen the variation of
the performance of detergent materials, such as detergent
compositions and detergent builders, with regions.
[0021] The magnesium ion scavengeability of the present invention
acrylic acid-maleic acid copolymer (or its salt) is usually 210
mg/g or more (in terms of Mg(OH).sub.2 as scavenged by 1 g of the
acrylic acid-maleic acid copolymer (or its salt)), preferably 220
mg (in terms of Mg(OH).sub.2)/g or more, more preferably 230 mg (in
terms of Mg(OH).sub.2)/g or more, still more preferably 240 mg (in
terms of Mg(OH).sub.2)/g or more. The increase in the magnesium ion
scavengeability enhances the ability of the acrylic acid-maleic
acid copolymer (or its salt) as the detergent builder in the
presence of magnesium ion.
[0022] The clay dispersibility of the present invention acrylic
acid-maleic acid copolymer (or its salt) in the presence of
magnesium ion is defined as the value (%) of the absorbance as
measured by the method as described in the below-mentioned examples
of some preferred embodiments.
[0023] The clay dispersibility in the presence of magnesium ion is
an index for evaluation of effects upon removing and uniformly
dispersing the dirt such as mud dirt, thereby preventing the clay
from precipitating, in the case where water, as used for washing,
contains magnesium ion. To sufficiently obtain such effects, the
above clay dispersibility is preferably 60 % or more, and further,
to prevent the deposition of mud dirt, the clay dispersibility is
more preferably 70% or more, still more preferably 73% or more,
most preferably 75% or more.
[0024] The clay dispersibility in the presence of magnesium ion is
a numerical value to evaluate the dispersion extent of the clay in
the presence of magnesium ion and the copolymer (or its salt) on
the basis of the turbidity of a supernatant as produced by allowing
a suspension of dispersed clay to stand stationary for a certain
time. The larger numerical value shows higher clay
dispersibility.
[0025] The magnesium hydroxide scale inhibitability and the calcium
carbonate scale inhibitability of the present invention acrylic
acid-maleic acid copolymer (or its salt) are defined as the
magnesium hydroxide inhibition rate (%) and the calcium carbonate
inhibition rate (%) respectively as measured by the methods as
described in the below-mentioned examples of some preferred
embodiments, and are indices to show how much the acrylic
acid-maleic acid copolymer (or its salt) prevents the generation
and deposition of the magnesium hydroxide scale and calcium
carbonate scale in water systems. The larger numerical values of
the above scale inhibition rates (%) show that their respective
scale inhibitabilities are higher. In the case where the magnesium
hydroxide scale or calcium carbonate scale is generated and
deposited in water systems, bad influences are produced, for
example, as follows: piping is clogged, or the detergency of
detergents is lowered, or clothes are blacked (especially, the
deposition of magnesium hydroxide scale to clothes will overstarch
the clothes to deteriorate their hygroscopicity and touch).
However, if the present invention acrylic acid-maleic acid
copolymer (or its salt) having high magnesium hydroxide scale
inhibitability and high calcium carbonate scale inhibitability is
used, then the generation and deposition of the magnesium hydroxide
scale and calcium carbonate scale can be prevented to avoid the
above bad influences.
[0026] The magnesium hydroxide scale inhibitability of the present
invention acrylic acid-maleic acid copolymer (or its salt) is
usually 30% or more, preferably 33% or more, more preferably 35% or
more, still more preferably 37% or more, to sufficiently obtain the
above effects.
[0027] The calcium carbonate scale inhibitability of the present
invention acrylic acid-maleic acid copolymer (or its salt) is
usually 60% or more, preferably 70% or more, more preferably 75% or
more, still more preferably 78% or more, yet still more preferably
80% or more, to sufficiently obtain the above effects.
[0028] The weight-average molecular weight of the present invention
acrylic acid-maleic acid copolymer (or its salt) is preferably in
the range of 2,000.about.100,000, more preferably
3,000.about.50,000, still more preferably 5,000.about.20,000, most
preferably 6,000.about.15,000. In the case where the weight-average
molecular weight is less than 2,000, the magnesium ion
scavengeability tends to be so low as to deteriorate the
detergency. In the case where the weight-average molecular weight
exceeds 100,000, the clay dispersibility in the presence of
magnesium ion or the magnesium hydroxide scale inhibitability tends
to be low.
[0029] Furthermore, for more enhancing the magnesium ion
scavengeability, it is very preferable that the molecular weight
distribution, namely, Mw/Mn as given by dividing the weight-average
molecular weight (Mw) by the number-average molecular weight (Mn),
of the present invention acrylic acid-maleic acid copolymer (or its
salt) is 3.5 or less, more preferably 3.0 or less, and further that
the present invention acrylic acid-maleic acid copolymer (or its
salt) has low-molecular fractions with a molecular weight of 1,000
or less in the ratio of 9 wt % or less, more preferably 6 wt % or
less, to the total of the copolymer (or its salt).
[0030] The production process for the present invention acrylic
acid-maleic acid copolymer (or its salt) is not especially limited.
However, for example, the below-mentioned production process
according to the present invention is preferable.
Production Process for Acrylic Acid-maleic Acid Copolymer (or its
salt)
[0031] The production process according to the present invention is
a process comprising the step of copolymerizing ethylenically
unsaturated monomers including acrylic acid and maleic acid in the
presence of a polymerization initiator, thereby obtaining the
acrylic acid-maleic acid copolymer (or its salt).
[0032] In this process, the amount of maleic acid, as initially
charged, is usually 50 wt % or more, preferably 80 wt % or more,
most preferably 100 wt % (initially charging the entirety), of the
entirety of maleic acid as used. In the case where the amount of
maleic acid, as initially charged, is smaller than 50 wt %, the
amount of unreacted maleic acid is so large in the latter half of
the polymerization that maleic acid cannot uniformly be introduced
into the resultant copolymer (or its salt), therefore the resultant
magnesium ion scavengeability is low, and the resultant magnesium
hydroxide scale inhibitability is also low.
[0033] The neutralization degree of maleic acid is usually in the
range of 70.about.95 mol %, preferably 75.about.90 mol %, more
preferably 80.about.87 mol %, before the polymerization initiator
is charged. In the case where this neutralization degree is less
than 70 mol %, maleic acid is polymerized in the block form, so the
resultant clay dispersibility in the presence of magnesium ion is
low. In the case where the above neutralization degree exceeds 95
mol %, the introducing efficiency of maleic acid is so bad that the
resultant magnesium ion scavengeability is so low as to deteriorate
not only the detergency, but also the magnesium hydroxide scale
inhibitability.
[0034] The initial solid component concentration of maleic acid is
preferably 48 wt % or more, more preferably 50 wt % or more, still
more preferably 53 wt % or more, of the entirety of the initial
reaction liquid. In the case where the initial solid component
concentration of maleic acid is less than 48 wt %, the introducing
efficiency of maleic acid tends to be so bad that the resultant
magnesium ion scavengeability is so low as to deteriorate not only
the detergency, but also the magnesium hydroxide scale
inhibitability.
[0035] The form of maleic acid, as used, may be any of maleic
anhydride, maleic acid, and maleic salt, and any mixture thereof is
also available. In addition, when used, maleic anhydride or maleic
acid is fitly partially neutralized to a predetermined
neutralization degree with an alkaline substance, if necessary. The
above alkaline substance is not especially limited, but examples
thereof include: alkaline metal hydroxides, such as sodium
hydroxide and potassium hydroxide; ammonia; and organic amines,
such as monoethanolamine. These may be used either alone
respectively or in combinations with each other.
[0036] Acrylic acid is added to the reaction system by dropping
preferably 70 wt % or more, more preferably 90 wt % or more, most
preferably 100 wt %, of the entirety thereof as used. In the case
where the ratio of acrylic acid, as dropped, is less than 70 wt %,
initial acrylic acid is polymerized in the block form, so the
resultant magnesium hydroxide scale inhibitability tends to be
low.
[0037] The dropping duration of acrylic acid is preferably in the
range of 30.about.240 minutes, more preferably 90.about.150
minutes, still more preferably 100.about.140 minutes. In the case
where the dropping duration of acrylic acid is shorter than 30
minutes, acrylic acid is polymerized in the block form, so the
resultant magnesium hydroxide scale inhibitability tends to be low.
In the case where the dropping duration of acrylic acid exceeds 240
minutes, maleic acid is polymerized in the block form, so the
resultant clay dispersibility in the presence of magnesium ion
tends to be low.
[0038] The form of acrylic acid, as used, is, especially
preferably, acrylic add. An acrylic salt may be used by adding it
to acrylic acid, if necessary. But the ratio of the acrylic salt,
as added, is set to such that the neutralization degree of the
acrylic acid-maleic acid copolymer (or its salt) will be in the
below-mentioned range. The above acrylic salt is not especially
limited, but examples thereof include: alkaline metal acrylates,
such as sodium acrylate and potassium acrylate; ammonium acrylate;
and organic amine salts of acrylic acid. These may be used either
alone respectively or in combinations with each other.
[0039] The ratio between acrylic acid and maleic acid as used for
copolymerization (acrylic acid/maleic acid (molar ratio)) is
preferably in the range of 30/70.about.70/30, more preferably
35/65.about.65/35, still more preferably 40/60.about.60/40. In the
case where the ratio of acrylic acid, as used, is less than 30/70,
the resultant magnesium ion scavengeability tends to be so low as
to deteriorate the magnesium hydroxide scale inhibitability. In the
case where the ratio of acrylic acid, as used, exceeds 70/30, the
resultant magnesium ion scavengeability tends to be low, and the
resultant clay dispersibility in the presence of magnesium ion also
tends to be low.
[0040] Acrylic acid and maleic acid are essentially used as the
ethylenically unsaturated monomers. However, if necessary, another
ethylenically unsaturated monomer may be used jointly with acrylic
acid and maleic acid within the range where the effect of the
present invention is not damaged.
[0041] The above other ethylenically unsaturated monomer, which can
be used jointly, is not especially limited if it is copolymerizable
with acrylic acid and maleic acid. But examples thereof include:
unsaturated monocarboxylic acid monomers, such as methacrylic acid
and crotonic acid; unsaturated dicarboxylic acid monomers and
unsaturated polycarboxylic acid monomers, such as fumaric acid,
itaconic acid, citraconic acid, and aconitic acid; amide monomers,
such as (meth)acrylamide and t-butyl(meth)acrylamide; hydrophobic
monomers, such as (meth)acrylic esters, styrene, 2-methylstyrene,
and vinyl acetate; unsaturated sulfonic acid monomers, such as
vinylsulfonic acid, allylsulfonic acid, methallylsulfonic acid,
styrenesulfonic acid, 2-acrylamido-2-methylpropan- esulfonic acid,
3-allyloxy-2-hydroxypropanesulfonic acid, sulfoethyl
(meth)acrylate, sulfopropyl (meth)acrylate, 2-hydroxysulfopropyl
(meth)acrylate, and sulfoethylmaleimide; neutralized products as
formed by partially or entirely neutralizing the above unsaturated
monocarboxylic acid monomers, the above unsaturated dicarboxylic
acid monomers, the above unsaturated polycarboxylic acid monomers,
or the above unsaturated sulfonic acid monomers with, for example,
monovalent metals, divalent metals, ammonia, or organic amines;
hydroxyl-group-containing unsaturated monomers, such as
3-methyl-2-buten-1-ol (which might be referred to as "prenol"),
3-methyl-3-buten-1-ol (which might be referred to as "isoprenol"),
2-methyl-3-buten-2-ol (which might be referred to as "isoprene
alcohol"), 2-hydroxyethyl (meth)acrylate, polyethylene glycol
mono(meth)acrylate, polypropylene glycol mono(meth)acrylate,
polyethylene glycol monoisoprenol ether, polypropylene glycol
monoisoprenol ether, polyethylene glycol monoallyl ether,
polypropylene glycol monoallyl ether, glycerol monoallyl ether,
.alpha.-hydroxyacrylic acid, N-methylol(meth)acrylamide, glycerol
mono(meth)acrylate, vinyl alcohol, and .alpha.-hydroxyalkyl
acrylates; cationic monomers, such as dimethylaminoethyl
(meth)acrylate and dimethylaminopropyl(meth)acrylamide- ; nitrile
monomers, such as (meth)acrylonitrile; phosphorus-containing
monomers, such as (meth)acrylamidomethane phosphonic acid, methyl
(meth)acrylamidomethanephosphonate, and
2-(meth)acrylamido-2-methylpropan- ephosphonic acid; alkyl vinyl
ethers, such as methyl vinyl ether and ethyl vinyl ether; and
vinylpyrrolidone. These monomers may be used either alone
respectively or in combinations with each other.
[0042] The polymerization initiator is not especially limited, but
examples thereof include: hydrogen peroxide; persulfuric acid
salts, such as ammonium persulfate, sodium persulfate and potassium
persulfate; azo compounds, such as 2,2'-azobis(2-amidinopropane)
dihydrochloride, 4,4'-azobis-(4-cyanovaleric acid),
2,2'-azobisisobutyronitrile and
2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile); organic
peroxides, such as benzoyl peroxide, lauroyl peroxide, peracetic
acid, persuccinic acid, di-tertiary-butyl peroxide,
di-tertiary-butyl hydroperoxide and cumene hydroperoxide. These may
be used either alone respectively or in combinations with each
other. Among them, the use of hydrogen peroxide or persulfuric acid
salt is preferable, and the joint use of hydrogen peroxide and
persulfuric acid salt is more preferable.
[0043] In the case where hydrogen peroxide is used as the
polymerization initiator, it is preferable to finish charging
hydrogen peroxide earlier than the charging end of all the
monomers, more preferably, by 10 minutes or more, considering the
simplification of production facilities, the cost saving, and
effects of lessening the amount of hydrogen peroxide remaining at
the end of the polymerization. In other words, it is preferable to
finish charging hydrogen peroxide in a state where polymerizable
raw monomers still remain in the reaction system.
[0044] The amount of the polymerization initiator, as used, is not
especially limited, but is, for example, preferably in the range of
1.about.20 wt %, more preferably 3.about.15 wt %, still more
preferably 5.about.12 wt %, of the total weight of the monomers as
used. In the case where the amount of the polymerization initiator,
as used, is smaller than 1 wt %, maleic acid tends not to
efficiently be introduced into the resultant copolymer (or its
salt). In the case where the amount exceeds 20 wt %, the resultant
magnesium ion scavengeability tends to be low because of low
molecular weight of the resultant copolymer (or its salt).
[0045] As to the polymerization solvent, aqueous solvents are used.
Particularly preferably, water is used alone. However, a
hydrophilic organic solvent may be used by fitly adding it to
water, if necessary.
[0046] The above hydrophilic organic solvent is not especially
limited, but examples thereof include: lower alcohols, such as
methanol and ethanol; amides, such as dimethylformamide; and
ethers, such as diethyl ether. These may be used either alone
respectively or in combinations with each other.
[0047] The ratio of the hydrophilic organic solvent, as used, is
preferably 20 wt % or less, more preferably 10 wt % or less, still
more preferably 1 wt % or less, of the total amount of a mixed
solvent with water. In the case where this ratio exceeds 20 wt %,
maleic acid has a tendency not to efficiently be introduced into
the resultant copolymer (or its salt).
[0048] The polymerization temperature is not especially limited,
but is preferably 80.degree. C. or higher, more preferably
100.degree. C. or higher or a temperature near the boiling point of
the polymerization solvent, for example, in view of efficient
introduction of maleic acid into the resultant copolymer (or its
salt).
[0049] The polymerization pressure is not especially limited, but
any of normal pressure (atmospheric pressure), an increased
pressure, and a reduced pressure is available.
[0050] The neutralization degree of the resultant acrylic
acid-maleic acid copolymer (or its salt) is set to be usually in
the range of 50.about.70 mol %, preferably 52.about.68 mol %, more
preferably 55.about.65 mol %, at the end of the polymerization. In
the case where this neutralization degree is less than 50 mol %,
maleic acid is introduced into the resultant copolymer (or its
salt) in the block form, resulting in the deterioration of the clay
dispersibility in the presence of magnesium ion. In the case where
the above neutralization degree exceeds 70 mol %, the ratio of
maleic acid as introduced is so low that the resultant magnesium
ion scavengeability is low, and that the amount of residual maleic
acid is large.
[0051] The neutralization degree of the resultant acrylic
acid-maleic acid copolymer (or its salt) is in the above specific
range at the end of the polymerization, but, after the end of the
polymerization, the neutralization degree may be changed to any
value by conventional methods, if necessary.
[0052] The solid component concentration of the resultant acrylic
acid-maleic acid copolymer (or its salt) is set to be preferably 45
wt % or higher, more preferably 48 wt % or higher, still more
preferably 49 wt % or higher, yet still more preferably 50 wt % or
higher, of the entirety of the reaction liquid at the end of the
polymerization. In the case where this solid component
concentration is lower than 45 wt %, the resultant magnesium ion
scavengeability tends to be low because of low molecular weight of
the resultant copolymer (or its salt).
[0053] The acrylic acid-maleic acid copolymer (or its salt),
according to the present invention, can favorably be used, for
example, for detergent compositions, detergent builders,
water-treating agents (e.g. scale inhibitors for industries, scale
inhibitors for oil fields, and scale inhibitors for pulp
digesters), pigment dispersants, fiber-treating agents (e.g.
bleaching assistants, fiber-scouring assistants, and dyeing
assistants), and soil dispersants (e.g. adjusting agents for
bentonite muddy water, ground-improving dispersants for high
pressure jet processing methods). Hereinafter, explanations are
specifically made on detergent compositions, detergent builders,
water-treating agents, pigment dispersants, and fiber-treating
agents as particularly preferable uses, as selected from among the
above various uses, of the present invention acrylic acid-maleic
acid copolymer (or its salt).
Detergent Composition
[0054] The detergent composition, according to the present
invention, comprises the present invention acrylic acid-maleic acid
copolymer (or its salt) and a surfactant.
[0055] In the detergent composition of the present invention, the
ratio of the present invention acrylic acid-maleic acid copolymer
(or its salt) and the surfactant as mixed is not especially
limited. However, for example, in view of scavenging the magnesium
ion from tap water, dispersing the clay, and preventing the
deposition of magnesium hydroxide scale, the ratio to the entirety
of the detergent composition is preferably such that: the present
invention acrylic acid-maleic acid copolymer (or its salt) is in
the range of 1.about.20 wt %, and the surfactant is in the range of
5.about.60 wt %, and more preferably, the present invention acrylic
acid-maleic acid copolymer (or its salt) is in the range of
2.about.18 wt %, and the surfactant is in the range of 10.about.55
wt %.
[0056] In addition, the present invention detergent composition may
comprise the present invention acrylic acid-maleic acid copolymer
(or its salt) and the surfactant, or may further comprise acrylic
acid-maleic acid copolymers (or their salts) other than the present
invention acrylic acid-maleic acid copolymer (or its salt), or yet
other polymers or copolymers (or their salts), for specific
example, conventional polymer builders such as glyoxylic acid
polymers (or their salts) and polyaspartic acid polymers (or their
salts), if they do not hinder the performance or effects of the
present invention detergent composition.
[0057] As to the surfactant, at least one member selected from the
group consisting of anionic surfactants, nonionic surfactants,
amphoteric surfactants and cationic surfactants can preferably be
used.
[0058] The anionic surfactant is not especially limited, but
examples thereof include alkylbenzenesulfonic acid salts, alkyl or
alkenyl ether sulfuric acid salts, alkyl or alkenyl sulfuric acid
salts, .alpha.-olefinsulfonic acid salts, .alpha.-sulfofatty acids
or any ester salt thereof, alkanesulfonic acid salts, saturated or
unsaturated fatty acid salts, alkyl or alkenyl ether carboxylic
acid salts, amino acid surfactants, N-acylamino acid surfactants,
and alkyl or alkenyl phosphoric acid esters or any salt thereof.
One or more kinds can be fitly selected from among these
surfactants and used.
[0059] The nonionic surfactant is not especially limited, but
examples thereof include polyoxyalkylene alkyl ethers,
polyoxyalkylene alkenyl ethers, polyoxyethylene alkyl phenyl
ethers, higher fatty acid alkanolamide or any alkylene oxide
addition product thereof, sucrose fatty acid esters, alkyl
glycoxides, fatty acid glycerol monoesters, and alkylamine oxides.
One or more kinds can be fitly selected from among these
surfactants and used.
[0060] The amphoteric surfactant is not especially limited, but,
for example, one or more of carboxy or sulfobetaine amphoteric
surfactants are usable.
[0061] The cationic surfactant is not especially limited, but, for
example, one or more of quaternary ammonium salts are usable.
[0062] The detergent composition of the present invention may
further comprise an enzyme in order to enhance the detergency, if
necessary.
[0063] The enzyme, as can be mixed, is not especially limited, but
examples of usable enzymes include protease, lipase, and cellulase.
Particularly preferred are protease, alkaline lipase, and alkaline
cellulase, all of which are highly active in alkaline washing
liquids. The amount of the enzyme, as mixed, is preferably within
the range of 0.01 to 1 wt % of the entirety of the detergent
composition. In the case where the amount deviates from this range,
the balance with the surfactant is lost, so the enhancement of the
detergency tends to be impossible.
[0064] The detergent composition of the present invention, if
necessary, may further comprise components which are usually used
for conventional detergent compositions, such as alkaline builders,
chelate builders, re-attachment inhibitors, fluorescent agents,
bleachers and perfumes. In addition, zeolite may also be added. The
addition of zeolite is preferable for greatly enhancing the
detergency. Examples of usable alkaline builders include silicic
acid salts, carbonic acid salts, and sulfuric acid salts. Examples
of the chelate builder, as can be used if necessary, include HIDS
(hydroxyiminodisuccinic acid salts), IDS (iminodisuccinic acid
salts), CMOS (carboxymethyloxysuccinates), diglycolic acid,
oxycarboxylic acid salts, EDTA (ethylenediaminetetraacet- ic acid),
DTPA (diethylenetriaminehexaacetic acid), citric acid, and ss-EDDS
(ss-ethylenediaminesuccinates). In addition, substances, such as
products by addition reaction of EO (ethylene oxide) to
polyethylenimine, may further be used as soil releasing agents in
order to enhance the detergency.
[0065] The detergent composition of the present invention is
favorably used as a detergent for clothes. Particularly, this
composition, having high scavengeability upon metal ions including
magnesium ion, is very effective for inhibiting the yellowing due
to a slight amount of metals, which are present in washing liquids,
such as iron ions and zinc ions.
[0066] Because the detergent composition of the present invention
contains the present invention acrylic acid-maleic acid copolymer
(or its salt) which has excellent clay dispersibility in the
presence of magnesium ion and excellent magnesium ion
scavengeability, this detergent composition is well balanced
between (1) an effect to disperse mud dirt and (2) an effect to
remove oil dirt by inhibiting the insolubilization of the
surfactant in the detergent composition by scavenging metal ions,
including magnesium ion, even if the magnesium ion is present in
water as used for washing. Thus, the detergent composition of the
present invention is a high performance detergent composition.
(Detergent builder):
[0067] The detergent builder, according to the present invention,
comprises the present invention acrylic acid-maleic acid copolymer
(or its salt).
[0068] The detergent builder of the present invention may comprise
the present invention acrylic acid-maleic acid copolymer (or its
salt), or may comprise the joint use of this acrylic acid-maleic
acid copolymer (or its salt) with conventional detergent builders,
such as alkaline builders, chelate builders, glyoxylic acid
polymers (or their salts), and polyaspartic acid polymers (or their
salts), or with other polymers (or their salts). The amount of
these materials, jointly usable with the present invention acrylic
acid-maleic acid copolymer (or its salt), is not especially limited
if those materials do not hinder the performance or effects of the
present invention detergent builder. The content of the present
invention acrylic acid-maleic acid copolymer (or its salt) in the
present invention detergent builder is preferably in the range of
1.about.100 wt %, more preferably 5.about.100 wt %, of the entirety
of the detergent builder. Specific examples of the alkaline builder
and the chelate builder include the same as exemplified above as
those which can be added to the detergent composition of the
present invention.
Water-treating Agent
[0069] The water-treating agent, comprising the present invention
acrylic acid-maleic acid copolymer (or its salt), is excellent in
dispersibility and other performances, such as chelating ability
and scale inhibitability, even in regions where the magnesium ion
content in water is high. Therefore, this water-treating agent is
useful for inhibiting the formation of magnesium hydroxide scale
and calcium carbonate scale in systems such as cooling water
circulation systems, boiler water circulation systems, seawater
desalination plants, pulp digesters, and black liquor evaporators.
Not only may the acrylic acid-maleic acid copolymer (or its salt)
be used alone as the water-treating agent, but it may be used as
the water-treating agent in the form of a composition which further
comprises additives such as polymeric phosphoric acid salts,
phosphonic acid salts, anticorrosive agents, slime controlling
agents, and chelating agents. In addition, the water-treating agent
may further comprise polymers (or their salts) other than the
present invention acrylic acid-maleic acid copolymer (or its salt)
if they do not hinder the performance or effects of the
water-treating agent.
[0070] In the water-treating agent comprising the present invention
acrylic acid-maleic acid copolymer (or its salt), the content of
this copolymer (or its salt) is preferably in the range of
5.about.100 wt %, more preferably 10.about.99 wt %, most preferably
20.about.80 wt %, of the solid content of the water-treating
agent.
[0071] The amount of the water-treating agent, which comprises the
present invention acrylic acid-maleic acid copolymer (or its salt)
and is added to the water system, is not especially limited, but is
preferably in the range of 0.1.about.100 ppm, more preferably
0.5.about.50 ppm, most preferably 1.about.20 ppm, in the water
system.
Pigment Dispersant
[0072] The pigment dispersant, comprising the present invention
acrylic acid-maleic acid copolymer (or its salt), is excellent in
pigment dispersibility even in regions where the magnesium ion
content in water is high. Therefore, this pigment dispersant
exhibits good performance as a dispersant for pigments, for
example, inorganic pigments, such as heavy or light calcium
carbonate (as used for paper coating), clay, titanium oxide,
magnesium hydroxide, iron oxide, and alumina, and organic pigments,
such as carbon black and phthalocyanine.
[0073] The above pigment dispersant may comprise the present
invention acrylic acid-maleic acid copolymer (or its salt), but may
further comprise other components such as polymeric phosphoric acid
and any salt thereof, phosphonic acid and any salt thereof, and
polyvinyl alcohol, or may further comprise polymers (or their
salts) other than the present invention acrylic acid-maleic acid
copolymer (or its salt) if they do not hinder the performance or
effects of the pigment dispersant.
[0074] If a small amount of the pigment dispersant comprising the
present invention acrylic acid-maleic acid copolymer (or its salt)
is added to a pigment instead of conventional pigment dispersants
and dispersed into water along with the pigment, then high
concentration pigment slurries such as high concentration calcium
carbonate slurries can be produced wherein the high concentration
pigment slurries have a low viscosity and a high fluidity, and
further, a good stability of these properties over a period of
time.
[0075] The amount of the pigment dispersant, as used, comprising
the present invention acrylic acid-maleic acid copolymer (or its
salt), is preferably in the range of 0.05.about.2 wt %, more
preferably 0.1.about.1.0 wt %, still more preferably 0.2.about.0.8
wt %, in terms of the ratio of the present invention acrylic
acid-maleic acid copolymer (or its salt) to the pigment. In the
case where the amount of the pigment dispersant, as used, is
smaller than 0.05 wt %, the dispersibility tends to be
insufficient. In the case where the amount exceeds 2 wt %, effects
rewarding the increase in the amount of addition tends to be
unexpectable. (Fiber-treating agent):
[0076] Even in regions where the magnesium ion content in water is
high, the fiber-treating agent comprising the present invention
acrylic acid-maleic acid copolymer (or its salt) exhibits high
dispersibility and high effects of improving the detergency, and
further, can prevent the magnesium hydroxide scale from being
deposited to fibers and thus deteriorating their hygroscopicity and
touch. Therefore, this fiber-treating agent can favorably be used
in the steps, such as scouring, dyeing, bleaching, and soaping
steps, in the treatment of fibers.
[0077] The acrylic acid-maleic acid copolymer (or its salt) may be
used alone as the fiber-treating agent, but also can be used in the
form of a composition further comprising additives such as dyeing
agents, peroxides, and surfactants. As to the above additive, those
which are usually used for conventional fiber-treating agents are
available. The ratio between the acrylic acid-maleic acid copolymer
(or its salt) and the above additive is such that the above
additive is added in the ratio of preferably 0.1.about.100 weight
parts, more preferably 0.2.about.80 weight parts, still more
preferably 1.about.50 weight parts, per 1 weight part of the
acrylic acid-maleic acid copolymer (or its salt), for example, in
order to improve the degree of whiteness, color evenness and degree
of dyed colorfastness of fibers. In the case where the amount of
the above additive is smaller than 0.1 weight part, the effect due
to the addition tends to be insufficient. In the case where the
amount exceeds 100 weight parts, the acrylic acid-maleic acid
copolymer (or its salt) tends to be unable to exhibit their
effects. The fiber-treating agent, comprising the present invention
acrylic acid-maleic acid copolymer (or its salt), may further
comprise acrylic acid-maleic acid copolymers (or their salts) other
than the present invention acrylic acid-maleic acid copolymer (or
its salt) if they do not hinder the performance or effects of the
fiber-treating agent. The content of the present invention acrylic
acid-maleic acid copolymer (or its salt) in the fiber-treating
agent is not especially limited, but is preferably in the range of
1.about.100 wt %, more preferably 5.about.100 wt %, of the entirety
of the fiber-treating agent.
[0078] The fiber for which the fiber-treating agent comprising the
present invention acrylic acid-maleic acid copolymer (or its salt)
can be used is not especially limited. However, examples thereof
include cellulose fibers, such as cotton and hemp; chemical fibers,
such as nylon and polyester; animal fibers, such as wool and silk;
semisynthetic fibers, such as rayon; and any fabric and blend
thereof.
[0079] In the case where the fiber-treating agent comprising the
present invention acrylic acid-maleic acid copolymer (or its salt)
is applied to the scouring step, it is preferable that the present
invention acrylic acid-maleic acid copolymer (or its salt) is mixed
with alkali agents and surfactants. For the bleaching step, it is
preferable that the present invention acrylic acid-maleic acid
copolymer (or its salt) is mixed with peroxides and with silicic
chemicals, which are used as inhibitors of alkaline bleachers from
decomposition, such as sodium silicate.
Part II
[0080] In this part II, detailed descriptions are given on the
present invention production process for the aqueous maleic salt
solution and on the present invention maleic acid copolymer (or its
salt) resultant from this aqueous solution.
[0081] First of all, the production process for the aqueous maleic
salt solution, according to the present invention, comprises the
steps of: charging 80% or less of the required amount of a basic
substance to produce the aqueous maleic salt solution and 80% or
less of the required amount of maleic acid (or its salt) and/or
maleic anhydride to produce the aqueous maleic salt solution into a
reaction vessel; and then adding thereto the respective balances of
water, the basic substance, and the maleic acid (or its salt)
and/or maleic anhydride under conditions where the highest value of
the reaction temperature will be 80.degree. C. or higher; thus
obtaining the aqueous maleic salt solution with a formed malic acid
content of not more than 10,000 ppm, therefore, with high
purity.
[0082] Examples of the basic substance, as initially charged,
include: alkaline metal hydroxides, such as sodium hydroxide and
potassium hydroxide; alkaline earth metal hydroxides, such as
calcium hydroxide and magnesium hydroxide; and ammonia water. These
may be used either alone respectively or in combinations with each
other. Preferable ones are alkaline metal salts, and the most
preferable one is sodium hydroxide.
[0083] As to the basic substance, 80% or less, preferably 60% or
less, most preferably 50% or less, of the required amount thereof
to produce the aqueous maleic salt solution is initially charged
into the reaction vessel. In the case where more than 80% of the
required amount is initially charged, a large amount of malic acid
is unfavorably formed.
[0084] In addition, the maleic acid (or its salt) and/or maleic
anhydride, as initially charged, may be in any form of melted
products of maleic anhydride, solids (e.g. powders or tablets) of
maleic anhydride, melted products of maleic acid (so-called hydrous
maleic acid), solids (e.g. powders or tablets) of maleic acid (the
same as above), and aqueous solutions of maleic acid (either of
anhydrous and hydrous ones). These may be used either alone
respectively or in combinations with each other. Particularly, the
melted products of maleic anhydride are preferable.
[0085] As to the maleic acid, 80% or less, preferably 60% or less,
most preferably 50% or less, of the required amount thereof to
produce the aqueous maleic salt solution is initially charged into
the reaction vessel. In the case where more than 80% of the
required amount is initially charged, there are disadvantages in
that the amount of fumaric acid being formed greatly increases. The
fumaric acid is an isomer of maleic acid and consumed in the
polymerization, but fumaric acid has the disadvantage of having
much lower polymerizability than maleic acid, therefore making it
very difficult to control the molecular weight and the molecular
weight distribution, and increasing the amount of residual
monomers.
[0086] Next, after initially charging the above materials under the
above conditions, the respective balances of water, the basic
substance, and the maleic acid (or its salt) and/or maleic
anhydride are added, when the highest value of the reaction
temperature needs to be 80.degree. C. or higher, and is preferably
100.degree. C. or higher, and is most preferably so high as to
produce a boiling point reflux state. In the case where the
reaction temperature is below 80.degree. C., the neutralization
will unfavorably need a very long time.
[0087] In addition, the molar ratio of the maleic acid (or its
salt) and/or maleic anhydride to the basic substance in the
reaction system is preferably maintained in the range of
1:4.about.4:1 for 90% or more of a period of time when the reaction
temperature is 100.degree. C. or higher. This ratio is more
preferably maintained in the range of 1:3.about.3:1, and most
preferably in the range of 1:2.about.2:1. Especially, when the
reaction temperature is 110.degree. C. or higher, the above ratio
is preferably maintained in the range of 1:3.about.3:1, and more
preferably in the range of 1:2.about.2:1. In the case where the
molar ratio of the basic substance is more than the above ranges,
there are disadvantages in that the amount of malic acid being
formed greatly increases. In the case where the molar ratio of the
maleic acid (or its salt) and/or maleic anhydride is more than the
above ranges, the amount of fumaric acid being formed greatly
increases, so there are disadvantages for the aforementioned
reason.
[0088] Furthermore, the aqueous maleic salt solution, as produced
by the initial charging and the dropping, has a solid component
concentration of preferably 40 wt % or higher, more preferably 45
wt % or higher, most preferably 50 wt % or higher, at the end of
the reaction. In the case where the solid component concentration
of the aqueous maleic salt solution is lower than 40 wt %, there
are disadvantages, for example, in that the polymerization using
such an aqueous maleic salt solution implies a low solid component
concentration in the polymerization and therefore greatly lowers
the productivity or greatly deteriorates the polymerizability of
maleic acid. In addition, as the solid component concentration
becomes higher, the productivity preferably becomes better.
However, in the case where the solid component concentration
exceeds 75 wt %, there are disadvantages in that the water
solubility and the stability of the resultant aqueous maleic salt
solution are deteriorated.
[0089] In the above way, the aqueous maleic salt solution with a
formed malic acid content of not more than 10,000 ppm, therefore,
with high purity can be obtained. Incidentally, the reason why
malic acid is chosen as the impurity is because malic acid is a
product by addition reaction of water to maleic acid, and is
presumed to be easily formed as a by-product, namely, an impurity,
during the neutralization, and is actually formed in the largest
quantity among the impurities. The malic acid content in this
aqueous maleic salt solution of high purity is preferably not more
than 7,000 ppm, more preferably not more than 5,000 ppm, still more
preferably not more than 4,000 ppm, most preferably not more than
2,000 ppm.
[0090] Next, explanations are made on the maleic acid copolymer (or
its salt) as obtained from this aqueous maleic salt solution of
high purity. However, the use of the present invention aqueous
maleic salt solution is not limited thereto.
[0091] The maleic acid copolymer (or its salt), according to the
present invention, is a maleic acid/acrylic acid copolymer (or its
salt), which comprises maleic acid (or its salt) of 30.about.70 mol
% and acrylic acid (or its salt) of 70.about.30 mol %, and has a
weight-average molecular weight of 2,000.about.50,000, a calcium
ion scavengeability of 400 mg CaCO.sub.3/g or more, a clay
dispersibility of 0.6 or more, and a malic acid content of not more
than 9 wt % in the solid content of the copolymer (or its
salt).
[0092] The calcium ion scavengeability is defined as the mg number,
in terms of calcium carbonate, of calcium ion as scavenged by 1 g
of copolymer (or its salt), and is an index to show how much
calcium ion in water the maleic acid scavenges. The surfactant
becomes insoluble upon bonding to calcium ion in water. However, if
the maleic acid copolymer (or its salt) having high calcium ion
scavengeability is used together with the surfactant, then the
surfactant is prevented from becoming insoluble, so that a great
effect upon improving the detergency is produced. The calcium ion
scavengeability of the present invention copolymer (or its salt) is
400 mg CaCO.sub.3/g or more, and preferably 420 mg CaCO.sub.3/g or
more. The increase in the calcium ion scavengeability has the
advantage of enhancing the ability of the maleic acid copolymer (or
its salt) as the detergent builder. However, an attempt to obtain a
copolymer (or its salt) having a calcium ion scavengeability more
than 490 mg CaCO.sub.3/g might lower the production efficiency or
involve high cost.
[0093] The clay dispersibility is an index for evaluation of
effects upon removing and uniformly dispersing the dirt such as mud
dirt, thereby preventing the clay from precipitating, in the course
of washing. To sufficiently obtain such effects, the clay
dispersibility of the present invention copolymer (or its salt) is
0.6 or more, and preferably 0.8 or more. The increase in the clay
dispersibility has the advantage of enhancing the ability of the
maleic acid copolymer (or its salt) as the detergent builder.
However, an attempt to obtain a copolymer (or its salt) having a
clay dispersibility more than 1.5 might lower the production
efficiency or involve high cost.
[0094] The malic acid content in the solid content of the copolymer
(or its salt) is an index to show how large amount of low-molecular
impurity is contained in the maleic acid copolymer (or its salt).
Incidentally, the reason why malic acid is chosen as the impurity
is not only such as aforementioned about the neutralization step,
but also that maleic acid is polymerized in the aqueous solution,
and further that, especially in the case where hydrogen peroxide is
used as the polymerization initiator, malic acid is presumed to be
easily formed, and is actually formed in the largest quantity among
the impurities. The ratio of the malic acid content to the solid
content of the present invention copolymer (or its salt) is not
more than 9 wt %, and preferably not more than 7 wt %, more
preferably not more than 5 wt %. The decrease in the malic acid
content has the advantage of enhancing the ability of the maleic
acid copolymer (or its salt) as the detergent builder. However, in
the case where hydrogen peroxide is used as the polymerization
initiator under the below-mentioned conditions, an attempt to
obtain a copolymer (or its salt) having a malic acid content of not
more than 3 wt % might lower the production efficiency or involve
high cost.
[0095] In addition, the monomer components of the present invention
maleic acid copolymer (or its salt) comprises maleic acid (or its
salt) of 30.about.70 mol % and acrylic acid (or its salt) of
70.about.30 mol %, and, if necessary, can further comprise another
water-soluble monoethylenic monomer of 5 mol % or less.
[0096] As to the maleic acid (or its salt), the aforementioned
aqueous maleic salt solution is preferably used, and, according to
cases, maleic acid and/or maleic anhydride may further be used
fitly. In the case where the ratio of the maleic acid (or its salt)
is less than 30 mol %, there are disadvantages in that the
copolymer (or its salt) having high calcium ion scavengeability is
extremely difficult to obtain. In addition, in the case where the
ratio of the maleic acid (or its salt) exceeds 70 mol %, there are
disadvantages in that the polymerizability tends to greatly be
deteriorated, and further that the resultant copolymer (or its
salt) tends to have a greatly deteriorated clay dispersibility.
[0097] As to the acrylic acid (or its salt), either of acrylic acid
and acrylic salt may be used, and any mixture thereof is also
available. The acrylic salt is obtainable by neutralization with
the aforementioned basic substance. In the case where the ratio of
the acrylic acid (or its salt) is less than 30 mol %, there are
disadvantages in that the polymerizability tends to greatly be
deteriorated, and further that the resultant copolymer (or its
salt) tends to have a greatly deteriorated clay dispersibility. In
addition, in the case where the ratio of the acrylic acid (or its
salt) exceeds 70 mol %, there are disadvantages in that the
copolymer (or its salt) having high calcium ion scavengeability is
extremely difficult to obtain.
[0098] Examples of the above other water-soluble monoethylenic
monomer, as used in the amount of 5 mol % or less if necessary,
include unsaturated monocarboxylic acid monomers, such as
methacrylic acid, .alpha.-hydroxyacrylic acid and crotonic acid,
and any salt thereof; unsaturated polycarboxylic acid monomers,
such as fumaric acid, itaconic acid, citraconic acid and aconitic
acid, and any salt thereof; vinyl acetate;
hydroxyl-group-containing unsaturated monomers, such as
3-methyl-3-buten-1-ol (isoprenol), 3-methyl-2-buten-1-ol (prenol),
2-methyl-3-buten-2-ol (isoprene alcohol), and monomers as formed
from addition reactions of 1.about.100 mol of ethylene oxide and/or
propylene oxide to 1 mol of the above monomers; (meth)allyl etheric
unsaturated monomers, such as glycerol monoallyl ether and monomers
as formed from addition reactions of 1.about.100 mol of ethylene
oxide and/or propylene oxide to 1 mol of glycerol monoallyl ether;
sulfonic-acid-group-containin- g unsaturated monomers, such as
3-allyloxy-2-hydroxypropanesulfonic acid, vinylsulfonic acid,
allylsulfonic acid, methallylsulfonic acid, styrenesulfonic acid,
2-acrylamido-2-methylpropanesulfonic acid, sulfoethyl
(meth)acrylate, sulfopropyl (meth)acrylate, 2-hydroxysulfopropyl
(meth)acrylate and sulfoethylmaleimide, and any salt thereof;
terminal-alkyl-group-containing esteric unsaturated monomers, such
as (i) monoesters, as formed from reactions of alcohols with
unsaturated monocarboxylic acid monomers (e.g. (meth)acrylic acid
and crotonic acid), or (ii) monoesters, any salt thereof, or
diesters, as formed from reactions of alcohols with unsaturated
polycarboxylic acid monomers (e.g. maleic acid, fumaric acid,
itaconic acid, citraconic acid, and aconitic acid), wherein the
alcohols are products from addition reactions of 0.about.100 mol of
ethylene oxide and/or propylene oxide to alkyl alcohols having
1.about.20 carbon atoms; esteric unsaturated monomers, such as
(iii) monoesteric monomers, as formed from addition reactions of
1.about.100 mol of ethylene oxide and/or propylene oxide to 1 mol
of unsaturated carboxylic acid monomers (e.g. (meth)acrylic acid
and crotonic acid), or (iv) monoesters, any salt thereof, or
diesteric monomers, as formed from addition reactions of
1.about.100 mol of ethylene oxide and/or propylene oxide to 1 mol
of unsaturated polycarboxylic acid monomers (e.g. maleic acid,
fumaric acid, itaconic acid, citraconic acid, and aconitic
acid).
[0099] Furthermore, the weight-average molecular weight of the
present invention copolymer (or its salt) is in the range of
2,000.about.50,000, preferably, 5,000.about.15,000. In the case
where the weight-average molecular weight is less than 2,000, there
are disadvantages in that the calcium ion scavengeability is
greatly deteriorated. In the case where the weight-average
molecular weight exceeds 50,000, there are disadvantages in that
the clay dispersibility is greatly deteriorated.
[0100] Next, explanations are made on the present invention
production process for the maleic acid copolymer (or its salt). The
present invention copolymer (or its salt) is obtainable by any
production process, but, particularly preferably, produced by the
below-mentioned process.
[0101] As to the maleic acid (or its salt), preferably 50 wt % or
more, more preferably 70 wt % or more, most preferably the
entirety, of the amount thereof as used is charged into the
reaction vessel prior to the reaction. In the case where the
charging amount prior to the reaction is smaller than 50 wt %,
there are disadvantages in that a large amount of maleic acid (or
its salt) might remain after the end of the polymerization. In
addition, the concentration of the maleic acid (or its salt) at the
initiation of the polymerization is usually 40 wt % or more,
preferably 45 wt % or more, more preferably 50 wt % or more. In the
case where the charging concentration is smaller than 40 wt %,
there are disadvantages in that a large amount of maleic acid (or
its salt) might remain after the end of the polymerization.
[0102] As to the acrylic acid (or its salt), preferably 50 wt % or
more, more preferably 70 wt % or more, most preferably the
entirety, of the amount thereof as used is dropwise supplied into
the reaction vessel after the initiation of the polymerization. In
the case where the amount exceeding 50 wt % is charged prior to the
reaction, there are disadvantages in that, because acrylic acid (or
its salt) has much higher polymerizability than maleic acid, it is
remarkably difficult to control the molecular weight and the
molecular weight distribution. The dropping period of time is in
the range of usually 30.about.300 minutes, preferably 60.about.180
minutes, after the initiation of the reaction. Such a dropping
period of time has the advantage of narrowing the molecular weight
distribution of the resultant maleic acid copolymer (or its salt)
and therefore enhancing the calcium ion scavengeability and the
clay dispersibility. Also for enhancing the productivity, it is
preferable to finish dropping the acrylic acid (or its salt) in a
short period of time. However, dropping shorter than 30 minutes has
the disadvantage of involving a large amount of residual maleic
acid after the end of the polymerization, or having a possibility
that much reaction heat might be generated in a short period of
time to make it difficult to remove the heat. In addition, dropping
longer than 300 minutes is unfavorable, because it greatly
deteriorates the productivity and is therefore economically
disadvantageous.
[0103] In addition, as to the aforementioned other water-soluble
monoethylenic monomer, the initially charging amount and the
dropping amount thereof may be determined optionally according to
the polymerizability thereof. The dropping period of time is also
optional, but it is preferable that the dropping end is earlier
than that of acrylic acid (or its salt).
[0104] As to the polymerization solvent, aqueous solvents are used.
Preferably 80 wt % or more, most preferably 100 wt %, thereof is
water. Examples of hydrophilic organic solvents, usable jointly
with water as the aqueous solvent, include: lower alcohols, such as
methanol, ethanol, and isopropyl alcohol; amides, such as
diethylformamide; and ethers, such as diethyl ether. These may be
used either alone respectively or in combinations with each
other.
[0105] In the present invention, hydrogen peroxide is preferably
used as a water-soluble polymerization initiator. The amount of
hydrogen peroxide, as used, is preferably within the range of
2.about.8 g, more preferably 3.about.5 g, per mol of the monomer
components. In the case where the amount of hydrogen peroxide, as
used, is smaller than 2 g, there are disadvantages in that a large
amount of maleic acid remains, and that the molecular weight of the
resulting copolymer (or its salt) is too high, thus resulting in
low clay dispersibility. In addition, in the case where more than 9
g of hydrogen peroxide is used, there are disadvantages in that the
amount of residual hydrogen peroxide is too large at the end of the
polymerization.
[0106] Considering the simplification of production facilities, the
cost saving, and effects of lessening the amount of hydrogen
peroxide remaining at the end of the polymerization, it is
preferable to finish dropping hydrogen peroxide earlier than the
dropping end of acrylic acid (or its salt) by 20 minutes or more.
The above production conditions can reduce the concentration of
hydrogen peroxide, remaining after the end of the polymerization,
to 2 wt % or lower, more preferably 1 wt % or lower, still more
preferably 0.5 wt % or lower, of the entirety of the reaction
liquid. In addition, the production conditions can reduce the
amount of maleic acid, remaining after the end of the
polymerization, to 3 wt % or smaller, more preferably 1 wt % or
smaller, of the entirety of the reaction liquid. In the case where
the amount of residual maleic acid is larger than 3 wt %,
unfavorably, there might be problems in that crystals of maleic
acid are deposited in places where it is cold in winter.
[0107] In the present invention production process, other
water-soluble polymerization initiators may further be used, if
necessary. Examples thereof include: persulfuric acid salts, such
as ammonium persulfate, sodium persulfate and potassium persulfate;
azo compounds, such as 2,2'-azobis(2-a midinopropane)
dihydrochloride, 4,4'-azobis-(4-cyanovaler- ic acid),
2,2'-azobisisobutyronitrile and 2,2'-azobis(4-methoxy-2,4-dimeth-
ylvaleronitrile); organic peroxides, such as benzoyl peroxide,
lauroyl peroxide, peracetic acid, persuccinic acid,
di-tertiary-butyl peroxide, di-tertiary-butyl hydroperoxide and
cumene hydroperoxide. It is also permissible to use any mixture of
at least two members selected from the group consisting of these
compounds. Particularly preferred ones are the persulfuric acid
salts such as ammonium persulfate, sodium persulfate and potassium
persulfate. Incidentally, the entirety of the water-soluble
polymerization initiator is, preferably, dropwise supplied into the
reaction vessel. The beginning and ending times of the dropping are
optional, but, preferably, the dropping end of the water-soluble
polymerization initiator is 10.about.20 minutes later than that of
acrylic acid (or its salt). If so, the amount of residual acrylic
acid can be reduced very much.
[0108] In addition, if necessary, polyvalent metals are usable to
raise the efficiency of the above initiator. Examples of usable
effective polyvalent metal ions include: iron ions,
vanadium-atom-containing ions, and copper ions. Among the
polyvalent metal ions, preferable ones are Fe.sup.3+, Fe.sup.2+,
Cu.sup.+, Cu.sup.2+, V.sup.2+, V.sup.3+ and VO.sup.2+, and more
preferable ones are Fe.sup.3+, Cu.sup.2+ and VO.sup.2+. These
polyvalent metal ions may be used either alone respectively or in
combinations with each other. The concentration of the polyvalent
metal ions is preferably in the range of 0.1 to 100 ppm of the
entirety of the reaction liquid. In the case where the
concentration is lower than 0.1 ppm, few effects are seen. In the
case where the concentration is higher than 100 ppm, the resulting
maleic acid copolymer (or its salt) is highly colored, and it might
therefore be impossible to use such a copolymer (or its salt) as a
component of detergent compositions.
[0109] The form in which the polyvalent metal ions are supplied is
not especially limited, and any metal compound and any metal can be
used if it becomes ionized in the polymerization reaction system.
Examples of such metal compounds and metals include: water-soluble
metal salts, such as vanadium oxytrichloride, vanadium trichloride,
vanadium oxalate, vanadium sulfate, vanadic anhydride, ammonium
metavanadate, ammonium hypo-vanadious
[(NH.sub.4).sub.2SO.sub.4.VSO.sub.4.6H.sub.2O], ammonium vanadious
[(NH.sub.4)V(SO.sub.4).sub.2.12H.sub.2O], copper(II) acetate,
copper(II) bromide, copper(II) acetylacetate, cupric chloride,
ammonium cuprous chloride, copper carbonate, copper(II) chloride,
copper(II) citrate, copper(II) formate, copper(II) hydroxide,
copper nitrate, copper naphthenate, copper(II) oleate, copper
maleate, copper phosphate, copper(II) sulfate, cuprous chloride,
copper(I) cyanide, copper iodide, copper(I) oxide, copper
thiocyanate, iron acetylacetonate, ammonium iron citrate, ammonium
ferric oxalate, ammonium ferrous sulfate, ammonium ferric sulfate,
iron citrate, iron fumarate, iron maleate, ferrous lactate, ferric
nitrate, iron pentacarbonyl, ferric phosphate and ferric
pyrophosphate; metal oxides, such as vanadium pentaoxide,
copper(II) oxide, ferrous oxide and ferric oxide; metal sulfides,
such as copper(II) sulfide and iron sulfide; and copper powder and
iron powder.
[0110] The above metal compounds and metals may be charged into the
reaction vessel at any time before the end of the reaction, but is
preferably charged thereto before the initiation of the
reaction.
[0111] The pH value during the polymerization reaction can be
selected optionally. However, preferably for enhancing the
polymerizability of maleic acid, the pH is in the range of
5.about.13 at the initiation of the polymerization, and is then
decreased with the progress of the polymerization. Examples of
basic compounds for neutralization, as used to adjust the pH during
the polymerization, include: hydroxides and carbonates of alkaline
metals such as sodium, potassium and lithium; ammonia; alkylamines
such as monomethylamine, diethylamine, trimethylamine,
monoethylamine, dimethylamine and triethylamine; alkanolamines such
as monoethanolamine, diethanolamine, triethanolamine,
isopropanolamine and secondary-butanolamine; and pyridine. It is
also permissible to use any mixture of at least two members
selected from the group consisting of these compounds.
[0112] In the present invention, the monomer component, the
polymerization initiator, the aqueous solvent, and other raw
materials (usable if necessary), as mentioned above, need to be
used in amounts such that the theoretical solid component
concentration will be 40 wt % or more after the end of the
polymerization. In the case where the theoretical solid component
concentration is less than 40 wt %, bad influences are unfavorably
produced upon the calcium ion scavengeability and the clay
dispersibility, because the resultant molecular weight is low, and
because the resultant molecular weight distribution is broad.
[0113] As to other polymerization conditions, the polymerization
temperature is preferably 80.degree. C. or higher, and more
preferably near the boiling point of the polymerization solvent. In
the case where the polymerization temperature is lower than
80.degree. C., there are disadvantages in that the amount of
residual maleic acid is greatly increased. In addition, the
polymerization pressure is not especially limited, but any of
normal pressure (atmospheric pressure), an increased pressure, and
a reduced pressure is available.
[0114] By the above production process, the present invention
maleic acid copolymer (or its salt) is obtainable.
[0115] Next, explanations are made on uses of the present invention
maleic acid copolymer (or its salt). The present invention
copolymer (or its salt) is, for example, used for detergent
compositions, inorganic-pigment dispersants, water-treating agents,
and fiber-treating agents.
[0116] The above detergent composition comprises the present
invention copolymer (or its salt) and a surfactant. In the
detergent composition, the concentration of the copolymer (or its
salt) is preferably within the range of 0.1 to 20 wt %, more
preferably within the range of 0.5 to 15 wt %, and the
concentration of the surfactant is preferably within the range of 5
to 70 wt %, more preferably within the range of 20 to 60 wt %.
[0117] As to the surfactant, any of anionic surfactants, nonionic
surfactants, amphoteric surfactants and cationic surfactants is
usable.
[0118] Examples of the anionic surfactant include
alkylbenzenesulfonic acid salts, alkyl or alkenyl ether sulfuric
acid salts, alkyl or alkenyl sulfuric acid salts,
.alpha.-olefinsulfonic acid salts, .alpha.-sulfofatty acids or any
ester salt thereof, alkanesulfonic acid salts, saturated or
unsaturated fatty acid salts, alkyl or alkenyl ether carboxylic
acid salts, amino acid surfactants, N-acylamino acid surfactants,
and alkyl or alkenyl phosphoric acid esters or any salt
thereof.
[0119] Examples of the nonionic surfactant include polyoxyalkylene
alkyl ethers, polyoxyalkylene alkenyl ethers, polyoxyethylene alkyl
phenyl ethers, higher fatty acid alkanolamide or any alkylene oxide
addition product thereof, sucrose fatty acid esters, alkyl
glycoxides, fatty acid glycerol monoesters, and alkylamine
oxides.
[0120] Examples of the amphoteric surfactant include carboxy or
sulfobetaine amphoteric surfactants.
[0121] Examples of the cationic surfactant include quaternary
ammonium salts.
[0122] The detergent composition containing the present invention
copolymer (or its salt) may further comprise an enzyme, if
necessary. Examples of the enzyme, as can be mixed, include
protease, lipase, and cellulase. Particularly preferred are
protease, alkaline lipase, and alkaline cellulase, all of which are
highly active in alkaline washing liquids. The amount of the
enzyme, as mixed, is preferably within the range of 0.01 to 5 wt %
of the entirety of the detergent composition. In the case where the
amount deviates from this range, the balance with the surfactant is
lost, so the enhancement of the detergency is impossible. If
necessary, the detergent composition containing the present
invention copolymer (or its salt) may further comprise components
which are usually used for conventional detergent compositions,
such as alkaline builders, chelate builders, re-attachment
inhibitors, fluorescent agents, bleachers and perfumes. In
addition, zeolite may also be added. Examples of usable alkaline
builders include silicic acid salts, carbonic acid salts, and
sulfuric acid salts. Examples of the chelate builder, as can be
used if necessary, include diglycolic acid, oxycarboxylic acid
salts, EDTA (ethylenediaminetetraacetic acid), DTPA
(diethylenetriaminehexaacetic acid), and citric acid.
[0123] The above inorganic-pigment dispersant may comprise the
present invention copolymer (or its salt) only, or may further
comprise other components such as polymeric phosphoric acid and any
salt thereof, phosphonic acid and any salt thereof, and polyvinyl
alcohol. In either case, the inorganic-pigment dispersant exhibits
good performance as a dispersant for inorganic pigments, such as
heavy or light calcium carbonate (as used for paper coating) and
clay. If a small amount of the inorganic-pigment dispersant
comprising the present invention copolymer (or its salt) is added
to an inorganic pigment and dispersed into water along with the
pigment, then high concentration inorganic pigment slurries such as
high concentration calcium carbonate slurries can be produced
wherein the high concentration inorganic pigment slurries have a
low viscosity and a high fluidity, and further, a good stability of
these properties over a period of time. The amount of the
inorganic-pigment dispersant, as used, is preferably within the
range of 0.05 to 2.0 weight parts per 100 weight parts of the
inorganic pigment.
[0124] The copolymer (or its salt) of the present invention may be
used alone as the water-treating agent, or may be used as the
water-treating agent in the form of a composition which further
comprises additives such as polymeric phosphoric acid salts,
phosphonic acid salts, anticorrosive agents, slime controlling
agents, and chelating agents. Either case is useful for inhibiting
the formation of scale in systems such as cooling water circulation
systems, boiler water circulation systems, seawater desalination
plants, pulp digesters, and black liquor evaporators.
[0125] The above fiber-treating agent comprises the present
invention copolymer (or its salt) and at least one member selected
from the group consisting of dyeing agents, peroxides and
surfactants, and can be used in the steps, such as scouring,
dyeing, bleaching, and soaping steps, in the treatment of fibers.
As to the above dyeing agents, peroxides, and surfactants, those
which are usually used for conventional fiber-treating agents are
available. The ratio between the copolymer (or its salt) and the at
least one member selected from the group consisting of dyeing
agents, peroxides and surfactants is such that the at least one
member selected from the group consisting of dyeing agents,
peroxides and surfactants is added in the ratio of 0.1.about.100
weight parts per 1 weight part of the copolymer (or its salt), for
example, in order to improve the degree of whiteness, color
evenness and degree of dyed colorfastness of fibers. The fiber for
which the fiber-treating agent can be used is not especially
limited. However, examples thereof include cellulose fibers, such
as cotton and hemp; chemical fibers, such as nylon and polyester;
animal fibers, such as wool and silk; semisynthetic fibers, such as
rayon; and any fabric and blend thereof. In the case where the
fiber-treating agent is applied to the scouring step, it is
preferable that the present invention copolymer (or its salt) is
mixed with alkali agents and surfactants. For the bleaching step,
it is preferable that the present invention copolymer (or its salt)
is mixed with peroxides and with silicic chemicals, which are used
as inhibitors of alkaline bleachers from decomposition, such as
sodium silicate.
Effects and Advantages of the Invention
[0126] The acrylic acid-maleic acid copolymer (or its salt) of the
present invention does not only maintain conventional performance
levels of the metal ion scavengeability, the clay dispersibility,
and the scale inhibitability upon calcium ion, but is also at high
level in performances with regard to magnesium ion as have never
been studied, such as magnesium ion scavengeability, clay
dispersibility in the presence of magnesium ion, and scale
inhibitability upon magnesium ion. Thus, the acrylic acid-maleic
acid copolymer (or its salt) of the present invention is a
copolymer (or its salt) which is excellent with good balance in
performances, such as metal ion scavengeability, clay
dispersibility, calcium carbonate scale inhibitability, and
magnesium hydroxide scale inhibitability, even in regions where the
magnesium ion content in water is high.
[0127] The production process of the present invention can give the
above excellent acrylic acid-maleic acid copolymer (or its salt)
with ease and good efficiency, therefore, at a low cost, and
further, with a small amount of residual monomer at the end of the
polymerization, therefore, with high productivity. The reason why
the resultant acrylic acid-maleic acid copolymer (or its salt)
displays the above excellent performances is considered to be that
maleic acid and acrylic acid are introduced into the resultant
copolymer (or its salt) at high random. Especially, it is
considered that the good performances are displayed because the
resultant copolymer (or its salt) merely has a very low proportion
of moieties where maleic acid is polymerized in the block form.
[0128] Because the present invention detergent composition
comprises the above present invention acrylic acid-maleic acid
copolymer (or its salt) and because this copolymer (or its salt)
has high magnesium ion scavengeability as above, the present
invention detergent composition prevents the surfactant from
bonding to magnesium ion in water and thus becoming insoluble even
in regions where the magnesium ion content in water is high.
Therefore, the present invention detergent composition has a great
effect upon improving the detergency to oil dirt. In addition,
because the present invention acrylic acid-maleic acid copolymer
(or its salt), as contained in the present invention detergent
composition, is excellent also in the clay dispersibility in the
presence of magnesium ion, the present invention detergent
composition exhibits high detergency to mud dirt even in regions
where the magnesium ion content in water is high. Furthermore,
because the present invention acrylic acid-maleic acid copolymer
(or its salt), as contained in the present invention detergent
composition, is excellent also in the magnesium hydroxide scale
inhibitability, the present invention detergent composition can
prevent the magnesium hydroxide scale from being deposited to
clothes and thus deteriorating their hygroscopicity and touch even
in regions where the magnesium ion content in water is high.
[0129] Because of comprising the above present invention acrylic
acid-maleic acid copolymer (or its salt), the present invention
detergent builder is excellent in the dispersibility and the
chelating ability, and contributes to the enhancement of the
detergency of detergents, even in regions where the magnesium ion
content in water is high.
[0130] The present invention further can provide a production
process for an aqueous maleic salt solution which contains only a
small amount of formed impurities such as malic acid and therefore
has high purity. In addition, the present invention can provide a
maleic acid copolymer (or its salt) which is obtained from the
resultant aqueous solution and therefore also contains only a small
amount of impurities such as malic acid and therefore exhibits high
calcium ion scavengeability and high clay dispersibility.
Accordingly, if this copolymer (or its salt) is, for example, used
for detergent compositions, inorganic-pigment dispersants,
water-treating agents, and fiber-treating agents, then very
excellent performance is displayed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Part 1
[0131] In this part 1, the present invention is more specifically
illustrated by the following examples of some preferred embodiments
of the present invention acrylic acid-maleic acid copolymer (or its
salt) and its production process and use in comparison with
comparative examples not according to the invention. However, the
invention is not limited to these examples.
EXAMPLE 1-1
[0132] First of all, 310 g of ion-exchanged water and 400 g of
maleic anhydride (473.7 g as maleic acid) were charged into a
SUS-made separable flask of 5 liters in capacity as fitted with a
reflux condenser, a stirrer, and a thermometer. Thereto, 708.3 g of
48 wt % aqueous sodium hydroxide solution (hereinafter referred to
as 48%NaOHaq) was gradually added under stirring, so that the
initial neutralization degree was 85 mol %, and that the initial
solid component concentration was 50.9 wt %. Thereafter, while
being stirred, the aqueous solution in the flask was heated to its
boiling point under normal pressure. Next, under stirring, 450 g of
80 wt % aqueous acrylic acid solution (hereinafter referred to as
80%AAaq), 114.3 g of 35 wt % aqueous hydrogen peroxide solution
(hereinafter referred to as 35%H.sub.2O.sub.2aq), 166.7 g of 15 wt
% aqueous sodium persulfate solution (hereinafter referred to as
15%NaPSaq), and 33.3 g of ion-exchanged water were dropped from
different nozzles respectively as follows: 80%AAaq was dropped over
a period of 120 minutes; 35%H.sub.2O.sub.2aq was dropped over a
period of 50 minutes starting at the same time with the dropping of
80%AAaq; 15%NaPSaq and ion-exchanged water were dropped over a
period of 80 minutes since the dropping end of 35%H.sub.2O.sub.2aq,
namely, starting 50 minutes later than the dropping start of
80%AAaq, and ending 10 minutes later than the dropping end of
80%AAaq. After the dropping end of all components, the reaction
solution was kept in a boiling point reflux state for another 20
minutes to complete the polymerization, thus obtaining an acrylic
acid-maleic acid copolymer (salt) having a neutralization degree of
64.5 mol % and a solid component concentration of 50 wt % at the
end of the polymerization. Thereafter, the pH of this acrylic
acid-maleic acid copolymer (salt) was adjusted to 8 with a 48 wt %
aqueous NaOH solution.
EXAMPLES 1-2 to 1-5
[0133] Acrylic acid-maleic acid copolymers (salts) were obtained in
the same way as of Example 1-1 except that the initially charging
amount, the dropping amount, and the dropping period were as shown
in Table 1-1. Thereafter, the pH of these acrylic acid-maleic acid
copolymers (salts) were adjusted to 8 with a 48 wt % aqueous NaOH
solution.
[0134] Incidentally, the copolymer (salt), as obtained in Example
1-2, had a weight-average molecular weight of 10,000 and a
number-average molecular weight of 2,900 (the measurement method
for the weight-average and number-average molecular weights and the
measurement results of the weight-average molecular weights in the
other Examples are mentioned below). Thus, the molecular weight
distribution (Mw/Mn) was 3.45. In addition, the ratio of the
low-molecular fractions with a molecular weight of 1,000 or less to
the total of this copolymer (salt) was 8.9 wt %.
EXAMPLE 1-6
[0135] The low-molecular fractions of the copolymer (salt), as
obtained in Example 1-2, were removed with a dialyzate of the
differential molecular weight of 1,000 (RC Dialysis Tube Pore 6
MWCO1000; available from Ieda Trade Co., Ltd.) to obtain a purified
acrylic acid-maleic acid copolymer sodium salt, specifically, as
follows. The dialysis tube, which had been cut into the length of
about 50 cm and of which one opening end had been closed with an
exclusive use closer, was washed with ion-exchanged water.
Thereafter, about 50 g of the copolymer (salt), as obtained in
Example 1-2, was inserted into the washed dialysis tube from the
other opening end thereof, and this end was then closed with an
exclusive use closer. The resultant dialysis tube, containing the
copolymer (salt), was entirely immersed into about 2 kg of
ion-exchanged water in a beaker with a capacity of 2 liters to
carry out a dialysis for about 2 hours. Thereafter, the aqueous
solution within the dialyzate was collected into an
egg-plant-shaped flask for an evaporator and then concentrated with
the evaporator, and further, the solid content was then adjusted,
thus obtaining an acrylic acid-maleic acid copolymer (salt) of pH 8
with a solid component concentration of 30 wt %.
[0136] The resultant copolymer (salt) had a weight-average
molecular weight of 11,000 and a number-average molecular weight of
3,800, therefore, a molecular weight distribution (Mw/Mn) of 2.89.
In addition, the ratio of the low-molecular fractions with a
molecular weight of 1,000 or less to the total of this copolymer
(salt) was 5.4 wt %.
Comparative Examples 1-1 to 1-3
[0137] Comparative acrylic acid-maleic acid copolymers (salts) were
obtained in the same way as of Example 1-1 except that the
initially charging amount, the dropping amount, and the dropping
period were as shown in Table 1-2. Thereafter, the pH of these
comparative acrylic acid-maleic acid copolymers (salts) were
adjusted to 8 with a 48 wt % aqueous NaOH solution.
[0138] The acrylic acid-maleic acid copolymers (salts) of pH 8, as
obtained in the above Examples and Comparative Examples, were
evaluated with regard to the properties as detergent builders and
water-treating agents by the following methods. The results are
shown in Tables 1-3 to 1-4. Incidentally, in the following methods,
the reagents and water, as used to prepare the test liquids, are
all special grade ones and pure water respectively.
Quantification of Weight-average Molecular Weight, Number-average
Molecular Weight, Molecular Weight Distribution, and Low-molecular
Fractions
[0139] The weight-average molecular weight (Mw) and the
number-average molecular weight (Mn) were measured by GPC (gel
permeation chromatography) under the following conditions:
[0140] Column: GF-7MHQ (made by Showa Denko Co.).
[0141] Moving phase: an aqueous solution as prepared by adding pure
water to 34.5 g of disodium hydrogenphosphate dodecahydrate and
46.2 g of sodium dihydrogenphosphate dihydrate (both of which are
special grade reagents; hereinafter, the reagents as used for
measurement are all special grade ones) to adjust the entirety to
5,000 g, and then filtering the resultant mixture through a
membrane filter of 0.45 .mu.m.
[0142] Detector: UV 214 nm (Model 481 made by Nippon Waters Co.,
Ltd.).
[0143] Pump: L-7110 (made by Hitachi Co., Ltd.).
[0144] Flow rate: 0.5 ml/min.
[0145] Temperature: 35.degree. C.
[0146] Calibration curve: sodium polyacrylate standard sample (made
by Sowa Kagaku Co.).
[0147] Incidentally, the weight-average molecular weight and the
number-average molecular weight were determined by regarding the
area of the molecular weight of 300 or more on the resultant GPC
chart as the copolymer (or its salt). Then, the molecular weight
distribution was determined in terms of the resultant ratio,
Mw/Mn.
[0148] In addition, the area of the molecular weight of 1,000 or
less on the resultant GPC chart was regarded as the low-molecular
fractions, of which the ratio to the total of the resultant
copolymer (or its salt) was quantified by determining the
corresponding area ratio from the results of the measurement by
GPC.
Magnesium Ion Scavengeability Evaluation as Detergent Builder and
Water-treating Agent
[0149] (1) Magnesium standard solutions of the below-mentioned
concentrations are prepared to draw a calibration curve.
[0150] 0.01 M: as prepared by dissolving 2.033 g of magnesium
chloride hexahydrate into 1 kg of pure water.
[0151] 0.001 M: as prepared by adding pure water to 100 g of the
above 0.01 M magnesium standard solution to increase its weight to
1 kg.
[0152] 0.0001 M: as prepared by adding pure water to 10 g of the
above 0.001 M magnesium standard solution to increase its weight to
100 g.
[0153] (2)10 mg, in terms of solid content, of the acrylic
acid-maleic acid copolymer (or its salt) is weighed out, and
thereto 50 g of the above 0.001 M magnesium standard solution is
added.
[0154] (3) 50 g of each of the magnesium standard solutions, as
obtained in step (1) above, and the liquid, as obtained in step (2)
above, are stirred with a magnetic stirrer.
[0155] (4) Thereto, a 4.8 wt % aqueous NaOH solution is added to
adjust the pH to 9.about.11.
[0156] (5) Furthermore, 1 ml of aqueous 4M-KCL solution is
added.
[0157] (6) The resultant liquid is measured with an automatic
titration apparatus of which an electrode has been replaced with a
divalent cationic electrode.
[0158] (7) The amount of magnesium ion, as scavenged by the acrylic
acid-maleic acid copolymer (or its salt), is measured from the
calibration curve.
[0159] (8) The amount of magnesium ion, as scavenged by 1 g of the
acrylic acid-maleic acid copolymer (or its salt), is determined in
terms of magnesium hydroxide (mg), and the resultant value is
regarded as the magnesium ion scavengeability (mg
Mg(OH).sub.2/g).
Clay Dispersibility in the Presence of Magnesium Ion
[0160] (1) A glycine buffer is prepared by adding pure water to
67.56 g of glycine, 52.6 g of sodium chloride, and 60 ml of aqueous
1N-NaOH solution (or 2.4 g of sodium hydroxide) to adjust the total
weight to 600 g.
[0161] (2) A buffer is prepared by adding pure water to 0.1937 g of
magnesium chloride hexahydrate and 60 g of the glycine buffer, as
obtained above, to adjust the total weight to 1,000 g.
[0162] (3) About 10 g of 0.1 wt % (in terms of solid content)
aqueous acrylic acid-maleic acid copolymer (or its salt) solution
is prepared.
[0163] (4) A dispersion is prepared by adding 36 g of the buffer,
as obtained in step (2) above, to 4 g of the 0.1 wt % aqueous
acrylic acid-maleic acid copolymer (or its salt) solution, as
obtained above, and then stirring them.
[0164] (5) 0.3 g of clay of 8 types of JIS test dust I (Kanto loam,
fine particles; available from Japan Powder Industrial Technical
Society) and 30 g of the dispersion, as obtained in step (4) above,
are placed in sequence into a test tube, which is then sealed with
a parafilm (clay concentration=10,000 ppm, acrylic acid-maleic acid
copolymer (or its salt) concentration=100 ppm).
[0165] (6) The test tube is shaken. Then, after confirming that the
lumps of clay have disappeared from the bottom of the test tube,
the test tube is shaken up and down 20 times.
[0166] (7) The test tube is allowed to stand stationary for 20
hours in a place where the test tube is not exposed to direct
sunlight.
[0167] (8) After 20 hours, 5 g of supernatant of the dispersion is
sampled into a screw tube of 20 ml in capacity.
[0168] (9) The absorbance (%) is measured with a UW spectroscope as
started up beforehand (1 cm cell, wave length=380 nm).
Magnesium Hydroxide Scale Inhibitability Evaluation as Detergent
Builder and Water-treating Agent
[0169] (Test conditions):
[0170] mayonnaise bottle (prescription=200 cc)
[0171] temperature: 90.degree. C.
[0172] acrylic acid-maleic acid copolymer (or its salt)
[0173] concentration: 5 ppm
[0174] Mg.sup.2+ concentration: 100 ppm
[0175] (1) A solution is prepared by weighing out 0.881 g of
magnesium chloride hexahydrate and 0.459 g of sodium carbonate
anhydride and adding thereto pure water to adjust the total weight
to 1,000 g.
[0176] (2) 190 g of the solution, as obtained in step (1) above, is
placed into a mayonnaise bottle of 225 ml in capacity.
[0177] (3) Furthermore, 1 g of 0.1 wt % (in terms of solid content)
aqueous acrylic acid-maleic acid copolymer (or its salt) solution
is added.
[0178] (4) The pH is adjusted to 10.+-.0.2 with a 4.8 wt % aqueous
sodium hydroxide solution.
[0179] (5) Pure water is added to adjust the total weight to 200
g.
[0180] (6) The bottle is allowed to stand stationary for 20 hours
in a hot-air drying oven as set to 90.degree. C.
[0181] (7) After cooling the bottle under running water, the
contents of the bottle are filtrated with a 0.1 .mu.m membrane
filter.
[0182] (8) The filtrate is analyzed by ICP (inductively coupled
plasma) emission spectrometry to measure the Mg.sup.2+
concentration.
[0183] (9) The case of no acrylic acid-maleic acid copolymer (or no
salt thereof) is measured as the blank.
[0184] (10) The magnesium hydroxide scale inhibition rate is
calculated from the following equation:
Scale inhibition rate (%)-{(Z-Y)/(X-Y)}.times.100
[0185] wherein:
[0186] X is the Mg.sup.2+ concentration (ppm) in the solution
before the test, namely, 100 ppm;
[0187] Y is an Mg.sup.2+ concentration (ppm) in a filtrate free
from the acrylic acid-maleic acid copolymer (or its salt) (blank);
and
[0188] Z is an Mg.sup.2+ concentration (ppm) in a filtrate after
the test of the sample.
[0189] Incidentally, the Mg standard solution for drawing a
calibration curve is prepared in the following way.
[0190] a) 10 g of pure water is added to 190 g of the solution as
obtained in step (1) above, and the resultant mixture is regarded
as 100%.
[0191] b) The mixture, as obtained in step a) above, is diluted to
2 times by weight, and the resultant mixture is regarded as
50%.
[0192] c) Pure water is regarded as 0%.
Calcium Carbonate Scale Inhibitability Evaluation as Detergent
Builder and Water-treating Agent
[0193] Into a glass bottle having a capacity of 225 ml, there was
charged 170 g of water, into which 10 g of 1.56 wt % aqueous
calcium chloride dihydrate solution and 3 g of 0.02 wt % aqueous
solution of each acrylic acid-maleic acid copolymer (or its salt)
sample (3 ppm as based on the resulting supersaturated aqueous
solution) were then mixed. Moreover, 10 g of aqueous sodium
bicarbonate solution and 7 g of sodium chloride were added to
adjust the total weight to 200 g. The resultant supersaturated
aqueous solution of calcium carbonate having a concentration of 530
ppm was sealed and then heated at 70.degree. C. for 12 hours. After
cooling, the resultant precipitate was filtrated with a 0.1 .mu.m
membrane filter, and the filtrate was analyzed according to JIS K
0101.
[0194] The calcium carbonate scale inhibition rate (%) was
determined from the following equation:
Scale inhibition rate (%)-{(C-B)/(A-B)}/.times.100
[0195] wherein:
[0196] A is the concentration (%) of calcium which was dissolved in
the solution before the test;
[0197] B is a calcium concentration (%) in a filtrate free from the
acrylic acid-maleic acid copolymer (or its salt); and
[0198] C is a calcium concentration (%) in a filtrate after the
test.
[0199] In addition, the acrylic acid-maleic acid copolymers (salts)
of pH 8, as obtained in the above Examples and Comparative
Examples, were evaluated with regard to the performances as
fiber-treating agents, inorganic-pigment dispersants, and detergent
compositions by the following methods.
Evaluation as Fiber-treating Agent
[0200] The acrylic acid-maleic acid copolymer (or its salt) was
used in an amount of 2 g/L as a fiber-treating agent to bleach
plain-stitch-knitted, scoured cotton fabrics under the following
conditions. Results thereof are shown in Table 1-5.
Bleaching Conditions
[0201] Hardness of water as used: 35.DH
[0202] Bath ratio: 1:25
[0203] Temperature: 85.degree. C.
[0204] Period: 30 minutes
[0205] Chemicals as used:
[0206] Hydrogen peroxide: 10 g/L
[0207] Sodium hydroxide: 2 g/L
[0208] #3 Sodium silicate: 5 g/L
Evaluation
[0209] The feeling of the treated cloth was judged by a sensory
examination method.
[0210] The degree of whiteness was measured using a 3M color
computer SM-3 model, made by SUGA TEST MACHINE Co., to determine
the degree of whiteness (W) from the following whiteness degree
equation in the Lab system for evaluation.
W=100-{(100-L).sup.2+a.sup.2+b.sup.2}.sup.1/2
[0211] wherein:
[0212] L is a lightness as measured;
[0213] a is a chromatic index as measured; and
[0214] b is a chromatic index as measured.
[0215] The higher degree of whiteness is better.
[0216] The sewability was evaluated from the number of places where
base yarn of the cloth was broken in the case where 4 sheets of the
cloth were placed on each other to sew them by 30 cm with a needle
#11S using a main sewing machine, but with no sewing yarn. The
smaller number of the places where base yarn of the cloth was
broken is better.
Evaluation as Inorganic-pigment Dispersant
[0217] Into a beaker (material quality: SUS 304, inner diameter: 90
mm, height: 160 mm) having a capacity of 1 liter, there was placed
400 weight parts of filter-press-dehydrated cake (solid content:
65.3 wt %) of calcite type cubic light calcium carbonate (primary
particle diameter: 0.15 .mu.m). hereto, 3.26 weight parts of 40 wt
% aqueous solution of the acrylic acid-maleic acid copolymer (or
its salt) (the weight of this copolymer (or its salt) is 0.5 wt %
as based on the weight of the calcium carbonate) as the dispersant
and 6.9 weight parts of water for adjusting the solid component
concentration were added to mix them by kneading at a low speed for
3 minutes using a dissolver vane (50 mm .phi.). Then, an aqueous
dispersion having a solid component concentration of 64 wt % was
produced by a dispersing operation of the kneaded mixture at 3,000
rpm for 10 minutes. The viscosity of the resultant aqueous
dispersion was measured using a B-type viscometer at 25.degree. C.
both just after the aqueous dispersion had been produced and after
the resultant aqueous dispersion had been allowed to stand
stationary at room temperature for 1 week, whereby the stability
over a period of time was tested. The lower viscosity of the
dispersion is better. Results of the measurement are shown in Table
1-6.
Evaluation as Detergent Composition
[0218] Artificial grime of the composition of Table 1-7 was
dispersed into carbon tetrachloride to prepare an artificial grime
solution, and white cotton cloth was passed through this artificial
grime solution, and then dried, and then cut to make 10 cm.times.10
cm dirty cloth.
[0219] The detergent compositions of Table 1-8 were formulated to
wash the above dirty cloth under the conditions of Table 1-9. Water
for washing was prepared by adding calcium chloride and magnesium
chloride into ion-exchanged water. After being washed and rinsed,
the cloth was dried to measure its reflectivity.
[0220] The washing ratio of the dirty cloth was determined from its
reflectivity using the below-mentioned equation, thus evaluating
the detergency. Results are shown in Table 1-10.
Washing ratio=[{(reflectivity after washing)-(reflectivity before
washing)}/{(reflectivity of white cloth)-(reflectivity before
washing)}].times.100
[0221] In addition, the above dirty cloth was subjected to a
washing test (washing, rinsing, and drying) continuously 5 times
under the same washing conditions as above. Then, the touch of the
washed cloth was evaluated. The results are shown in Table
1-10.
1 TABLE 1-1 Example 1-1 Example 1-2 Example 1-3 Example 1-4 Example
1-5 Initially Anhydrous MA charging (g) 400 450 500 550 500 amount
(mol) 4.08 4.59 5.1 5.61 5.1 Ion-exchanged 310 310 100 200 200
water (g) 48% NaOHaq (g) 708.3 708.3 708.3 700 750 (mol) 8.5 8.5
8.5 8.4 9.0 Initial Neutralization 85 85 85 74.9 88.2 degree (mol
%) Solid 50.9 50.9 59.1 57.6 54.4 component concentration (wt %)
Dropping 80% AAaq 450 450 450 450 450 amount (g) (mol) 5 5 5 5 5
35% H.sub.2O.sub.2aq (g) 114.3 100 114.3 114.3 114.3 (g/mol) 4 3.5
4 4 4 15% NaPSaq (g) 166.7 200 166.7 166.7 166.7 (g/mol) 2.5 3 2.5
2.5 2.5 Ion-exchanged 33.3 30 200 100 100 water (g) Dropping 80%
AAaq 0.about.120 0.about.120 0.about.120 0.about.150 0.about.150
period 35% H.sub.2O.sub.2aq 0.about.50 0.about.50 0.about.50
0.about.80 0.about.80 (minutes) 15% NaPSaq 50.about.130
50.about.130 50.about.130 50.about.150 50.about.150 Ion-exchanged
50.about.130 50.about.130 50.about.130 50.about.150 50.about.150
water At end of Neutralization 64.5 60 55.9 51.8 59.2
polymerization degree (mol %) Solid 50 52.2 53.4 53.5 51.5
component concentration (wt %) MA: maleic acid AA: acrylic acid
[0222]
2 TABLE 1-2 Comparative Comparative Comparative Example 1-1 Example
1-2 Example 1-3 Initially Anhydrous MA charging (g) 100 200 300
amount (mol) 1.02 2.09 3.06 Ion-exchanged 300 200 169.2 water (g)
48% NaOHaq (g) 170 340 510 (mol) 2.04 4.08 6.12 Initial
Neutralization 100 100 100 degree (mol %) Solid 28.6 44.1 50
component concentration (wt %) Dropping 80% AAaq amount (g) 450 450
450 (mol) 5 5 5 35% H.sub.2O.sub.2aq (g) 114.3 114.3 114.3 (g/mol)
4 4 4 15% NaPSaq (g) 666.5 133.3 133.3 (g/mol) 10 2 2 Ion-exchanged
424 328.15 97.89 water (g) Dropping 80% AAaq 0.about.150
0.about.150 0.about.150 period 35% H.sub.2O.sub.2aq 0.about.80
0.about.80 0.about.80 (minutes) 15% NaPSaq 50.about.150
50.about.150 50.about.150 Ion-exchanged 50.about.150 50.about.150
50.about.150 water At end of Neutralization 29 45 55 polymer-
degree ization (mol %) Solid 28 40 49 component concentration (wt
%) MA: maleic acid AA: acrylic acid
[0223]
3 TABLE 1-3 Example Example Example Example Example Example 1-1 1-2
1-3 1-4 1-5 1-6 MA/AA (molar 45/55 48/52 50.5/ 52.9/ 50.5/ 48/52
ratio) 49.5 47.1 49.5 Weight-average 13,000 10,000 8,000 8,000
9,000 11,000 molecular weight Mg ion 240 235 230 235 235 250
scavengeability (mg Mg(OH).sub.2/g) Clay dispersibility 73.5 75 77
75 76 73 in presence of Mg ion (%) Magnesium 37 38 37 39 38 34
hydroxide scale inhibitability (%) Calcium carbonate 78 80 75 85 83
-- scale inhibitability (%) MA: maleic acid AA: acrylic acid
[0224]
4 TABLE 1-4 Comparative Comparative Comparative Example 1-1 Example
1-2 Example 1-3 MA/AA (molar 17/83 29/71 38/62 ratio)
Weight-average 10,000 55,000 9,000 molecular weight Mg ion 190 210
200 scavengeability (mg Mg(OH).sub.2/g) Clay dispersibility 65 49
69 in presence of Mg ion (%) Magnesium 20 25 28 hydroxide scale
inhibitability (%) Calcium carbonate 79 38 58 scale inhibitability
(%) MA: maleic acid AA: acrylic acid
[0225]
5TABLE 1-5 (Evaluation as fiber-treating agent) Sewability Degree
(number of of base whiteness yarn-broken Feeling* (W value) places)
Example 1-1 .smallcircle. 96.3 37 Example 1-2 .smallcircle. 95.8 38
Example 1-3 .smallcircle. 97.1 37 Example 1-4 .smallcircle. 97.3 36
Example 1-5 .smallcircle. 97.5 35 Comparative .DELTA. 85.3 69
Example 1-1 Comparative .DELTA. 89.2 72 Example 1-2 Comparative
.smallcircle. 93.1 42 Example 1-3 *Feeling: soft .smallcircle.
somewhat hard .DELTA. considerably hard X
[0226]
6TABLE 1-6 (Evaluation as inorganic-pigment dispersant) Viscosity
of aqueous dispersion (cP) Just after After being allowed to stand
production of stationary at room temperature for dispersion 1 week
Example 1-1 280 305 Example 1-2 270 290 Example 1-3 290 310 Example
1-4 310 330 Example 1-5 280 290 Comparative 890 1010 Example 1-1
Comparative 1200 1800 Example 1-2 Comparative 410 460 Example
1-3
[0227]
7TABLE 1-7 (Composition of grime) Components wt % Carbon black
(designated by JAPAN OIL 0.5 CHEMIST'S SOCIETY) Clay 49.75
Myristylic acid 8.3 Oleic acid 8.3 Tristearic acid 8.3 Triolein 8.3
Cholesterin 4.38 Cholesterin stearate 1.09 Paraffin wax (m.p.
50-52.degree. C.) 0.552 Squalene 0.552
[0228]
8TABLE 1-8 (Detergent composition) Components wt % Sodium salt of
linear chain alkylbenzenesulfonic 30 acid (C = 11.5)
Polyoxyethylene alkyl ether 15 (C = 12, EO = 8) Zeolite 10 Enzyme
(protease) 0.5 Acrylic acid-maleic acid copolymer (or its salt) 20
Sodium carbonate 15 #1 Sodium silicate 9.5
[0229]
9TABLE 1-9 Washing conditions Temperature 20.degree. C. Bath ratio
1/60 Detergent concentration 0.5 wt % Water quality Ca.sup.2+
concentration 50 ppm Mg.sup.2+ concentration 80 ppm Terg-O-Tometer
10 minutes Terg-O-Tometer: made by Ueshima Seisakusho Co., Ltd.
[0230]
10TABLE 1-10 (Evaluation as detergent composition) Washing ratio
(%) Touch after washing 5 times* Example 1-1 97 .smallcircle.
Example 1-2 98 .smallcircle. Example 1-3 96 .smallcircle. Example
1-4 98 .smallcircle. Example 1-5 97 .smallcircle. Comparative 83 x
Example 1-1 Comparative 85 .DELTA. Example 1-2 Comparative 87
.DELTA. Example 1-3 * Greatly starchy x Medium starchy .DELTA.
Little starchy .smallcircle.
Part 2
[0231] In this part 2, the present invention is also more
specifically illustrated by the following examples of some
preferred embodiments of the present invention production process
for the aqueous maleic salt solution and those of the present
invention maleic acid copolymer (or its salt) resultant from this
aqueous solution in comparison with comparative examples not
according to the invention. However, the invention is not limited
to these examples. Incidentally, in the examples, unless otherwise
noted, the units "%" and "part(s)" denote those by weight.
Methods to Measure Properties
Method to Measure Malic and Fumaric Acids Contents
[0232] As measured by GPC.
[0233] Column: G300OPWXL (made by TOSOH Corporation).
[0234] Column temperature: 35.degree. C.
[0235] Moving phase: 0.1% aqueous phosphoric acid solution.
[0236] Flow rate: 1.0 ml/min.
[0237] Detector: UV 200 nm (Model L-6000 made by Hitachi).
[0238] Calibration curves: as drawn with malic and fumaric acids
(both of which are special grade reagents), of which the contents
were calculated in terms of their respective sodium salts.
Weight-average Molecular Weight (hereinafter referred to as Mw)
[0239] As measured by GPC.
[0240] Column: GF-7MHQ (made by Showa Denko Co.).
[0241] Column temperature: 35.degree. C.
[0242] Moving phase: an aqueous solution as prepared by adding pure
water to 34.5 g of disodium hydrogenphosphate dodecahydrate and
46.2 g of sodium dihydrogenphosphate dihydrate (both of which are
special grade reagents; hereinafter, the reagents as used for
measurement are all special grade ones) to adjust the entirety to
5,000 g, and then filtering the resultant mixture through a
membrane filter of 0.45 .mu.m.
[0243] Detector: UV 214 nm (Model 481 made by Nippon Waters Co.,
Ltd.).
[0244] Flow rate: 0.5 ml/min.
[0245] Calibration curve: sodium polyacrylate standard sample (made
by Sowa Kagaku Co.).
Amounts of Residual Maleic and Acrylic Acids
[0246] These amounts were measured by the same method as the above
calibration curves were drawn with maleic anhydride and a 80%
aqueous acrylic acid solution as used respectively, and the amounts
of residual maleic and acrylic acids were determined in terms of
their respective sodium salts.
Calcium Ion Scavengeability
[0247] (1) First, aqueous calcium ion standard solutions (aqueous
solutions to draw a calibration curve) were prepared by the
following steps of preparing 50 cc each of aqueous solutions with
Ca.sup.2+ ion concentrations of 0.01 mol/l, 0.001 mol/l, and 0.0001
mol/l respectively, and then adjusting their pH to 9.about.11 with
a 4.8% aqueous sodium hydroxide solution, and then adding thereto 1
ml of 4 mol/l aqueous potassium chloride solution.
[0248] (2) Next, an aqueous solution of the sample to be measured
was prepared as follows. First, 10 g (in terms of solid content) of
copolymer (or its salt) (with pH adjusted to 7) was weighed out
into a 100 cc beaker, and thereto 50 cc of 0.001 mol/l aqueous
calcium ion solution (as prepared with sodium chloride dihydrate)
was added, and the resultant mixture was uniformly stirred with a
stirrer. Thereafter, the pH was adjusted to 9.about.11 with a 4.8%
aqueous sodium hydroxide solution, and further, 1 ml of 4 mol/l
aqueous potassium chloride solution was added.
[0249] (3) The measurement was carried out with a calcium ion
electrode 93-20 (made by OLION Co.) using an ion analyzer EA920
(made by OLION Co.).
[0250] (4) The amount of calcium ion, as scavenged by the sample,
was determined from the calibration curve and the measured value of
the sample (copolymer (or its salt)). Then, the determined amount
per g of the solid content of the copolymer (or its salt) was
denoted with the mg number in terms of calcium carbonate, and its
value was regarded as the calcium ion scavengeability value.
Clay Dispersibility
[0251] (1) First, a glycine buffer was prepared by adding
ion-exchanged water to 67.56 g of glycine, 52.6 g of sodium
chloride, and 60 ml of 1N-NaOH to adjust the total weight to 600
g.
[0252] (2) A dispersion was prepared by weighing out 0.0817 g of
calcium chloride dihydrate and 60 g of the glycine buffer, as
prepared in step (1) above, and adding thereto ion-exchanged water
to adjust the total weight to 1,000 g.
[0253] (3) Next, a 0.1% (in terms of solid content) aqueous
solution of copolymer (or its salt) (with pH adjusted to 7) was
prepared.
[0254] (4) 0.3 g of clay of 8 types of JIS test dust I (Kanto loam,
fine particles; available from Japan Powder Industrial Technical
Society) is placed into a test tube. Thereto, 27 g of the
dispersion, as prepared in step (2) above, and 3 g of the aqueous
solution, as prepared in step (3) above, are added, thus obtaining
a test liquid, of which the calcium ion concentration is 50 ppm in
terms of calcium carbonate,.
[0255] (5) The test tube was sealed with a parafilm, and then
shaken gently so that the clay would be dispersed into the entirety
of the test liquid. Thereafter, the test tube was further shaken up
and down 20 times.
[0256] (6) The test tube was allowed to stand stationary for 20
hours in a place where the test tube was not exposed to direct
sunlight. Thereafter, 5 ml of supernatant of the dispersion was
sampled with a whole pipet.
[0257] (7) The absorbance (ABS) of the sampled liquid was measured
with a 1-cm cell using a UV spectroscope (wave length=380 nm), and
the resultant value was regarded as the clay dispersibility.
EXAMPLE 2-1
[0258] First of all, 332 g of ion-exchanged water was charged into
a SUS-made separable flask of 2.5 liters in capacity as fitted with
a reflux condenser and a stirrer, and this ion-exchanged water was
then heated to 60.degree. C. while stirred. Thereafter, under
stirring, 588 g (6 mol) of melted maleic anhydride and a 48%
aqueous sodium hydroxide solution (12 mol in terms of sodium
hydroxide) were dropped from different dropping inlets over a
period of 60 minutes. On the way, the aqueous reaction solution
fell into a reflux state (110.degree. C. or higher) 8 minutes after
the initiation of the dropping, and this reflux state continued
till the end of the dropping.
[0259] Immediately after the end of the dropping, the reaction had
finished, thus obtaining a 100%-neutralized aqueous sodium maleate
solution with a solid component concentration of 50%. The amounts
of formed malic and fumaric acids in the resultant aqueous solution
were 1,800 ppm and 330 ppm respectively.
EXAMPLES 2-2 to 2-15
[0260] The neutralization reactions were carried out in the same
way as of Example 2-1 except that the initially charging amount and
the dropping amount were as shown in Tables 2-1 and 2-2.
Incidentally, in cases where the amount of the initially charged
48% aqueous sodium hydroxide solution is shown in the table, the
ion-exchanged water and the 48% aqueous sodium hydroxide solution
were initially charged in sequence and then heated to 60.degree. C.
to carry out the neutralization reactions.
[0261] As a result, aqueous sodium maleate solutions with the solid
component concentrations and the neutralization degrees as
similarly shown in Tables 2-1 and 2-2 were obtained, and the
amounts of formed malic and fumaric acids in the resultant aqueous
solutions were as shown in Tables 2-1 and 2-2.
Comparative Examples 2-1 to 2-2
[0262] The neutralization reactions were carried out in the same
way as of Example 2-1 except that the initially charging amount and
the dropping amount were as similarly shown in Table 2-2.
Incidentally, in Comparative Example 2-2, the ion-exchanged water
and tablets of maleic anhydride were initially charged in sequence
and then heated to carry out the neutralization reaction.
[0263] The results are shown in Tables 2-1 and 2-2. It is clear
that the amount of malic acid was increased in Comparative Example
2-1, and that the amount of fumaric acid w as increased in
Comparative Example 2-2.
EXAMPLE 2-16
[0264] Immediately after being prepared, 1,600 g (5 mol in terms of
sodium maleate) of the aqueous sodium maleate solution, as obtained
in Example 2-6, was charged into a SUS-made separable flask of 5
liters in capacity as fitted with a reflux condenser and a stirrer.
Then, this solution was heated again under stirring and thereby
caused to fall into a boiling point reflux state. Thereafter, while
this state was kept, 450 g (5 mol in terms of acrylic acid) of 80%
aqueous acrylic acid solution and 120 g of 35% aqueous hydrogen
peroxide solution began being dropped from different nozzles
simultaneously, wherein the 80% aqueous acrylic acid solution and
the 35% aqueous hydrogen peroxide solution were continuously and
uniformly dropped over periods of 120 minutes and 50 minutes
respectively. Furthermore, 160 g of 15% aqueous sodium persulfate
solution and 350 g of ion-exchanged water were continuously and
uniformly dropped from different nozzles over a period of 80
minutes starting 50 minutes later than the dropping start of the
80% aqueous acrylic acid solution, namely, starting at the dropping
end of the 35% aqueous hydrogen peroxide solution, accordingly,
ending 10 minutes later than the dropping end of the 80% aqueous
acrylic acid solution. After the dropping end of all components,
the boiling point reflux state was kept for another 20 minutes to
complete the polymerization.
[0265] After the end of the polymerization, the reaction mixture
was left cooled, and thereto 229.2 g (2.75 mol in terms of sodium
hydroxide) of 48 % aqueous sodium hydroxide solution was added, and
then the resultant mixture was diluted, thus obtaining an aqueous
maleic acid copolymer (salt) solution with a solid component
concentration of 45% and a pH of 7.5.
[0266] From the results of the property measurement by the
aforementioned methods, it was found that the resultant copolymer
(salt) had a weight-average molecular weight of 9,800, a calcium
ion scavengeability of 455, a clay dispersibility of 0.82, a malic
acid content of 7.6% in the solid content of the copolymer (salt),
an amount of residual maleic acid of 820 ppm, and an amount of
residual acrylic acid of 80 ppm, and further, a magnesium ion
scavengeability of 240 mg Mg(OH).sub.2/g, a clay dispersibility of
75% in the presence of magnesium ion, and a magnesium hydroxide
scale inhibitability of 34%.
EXAMPLE 2-17
[0267] An aqueous maleic acid copolymer (salt) solution with a
solid component concentration of 45% and a pH of 7.5 was obtained
by carrying out a polymerization reaction in the same way as of
Example 2-16 except that the aqueous sodium maleate solution, as
obtained in Example 2-6, was replaced with the aqueous sodium
maleate solution as obtained in Example 2-1. From the results of
the similar property measurement, it was found that the resultant
copolymer (salt) had a weight-average molecular weight of 9,500, a
calcium ion scavengeability of 460, a clay dispersibility of 0.86,
a malic acid content of 4.1% in the solid content of the copolymer
(salt), an amount of residual maleic acid of 1,500 ppm, and an
amount of residual acrylic acid of 120 ppm, and further, a
magnesium ion scavengeability of 245 mg Mg(OH).sub.2/g, a clay
dispersibility of 80% in the presence of magnesium ion, and a
magnesium hydroxide scale inhibitability of 37%.
Comparative Example 2-3
[0268] A comparative aqueous maleic acid copolymer (salt) solution
with a solid component concentration of 45% and a pH of 7.5 was
obtained by carrying out a polymerization reaction in the same way
as of Example 2-16 except that the aqueous sodium maleate solution,
as obtained in Example 2-6, was replaced with the comparative
aqueous sodium maleate solution as obtained in Comparative Example
2-1. From the results of the similar property measurement, it was
found that the resultant comparative copolymer (salt) had a
weight-average molecular weight of 9,600, a calcium ion
scavengeability of 415, a clay dispersibility of 0.62, a malic acid
content of 12.9% in the solid content of the copolymer (salt), an
amount of residual maleic acid of 780 ppm, and an amount of
residual acrylic acid of 80 ppm, and further, a magnesium ion
scavengeability of 210 mg Mg(OH).sub.2/g, a clay dispersibility of
60% in the presence of magnesium ion, and a magnesium hydroxide
scale inhibitability of 24%.
[0269] Thus, it is clear that the same copolymer (or its salt)
production process gave almost the same results with regard to the
weight-average molecular weight, the amount of residual maleic
acid, and the amount of residual acrylic acid, but that the malic
acid content was greatly increased in comparison with Example 2-16,
so the calcium ion scavengeability was greatly deteriorated, and
the day dispersibility was also deteriorated. The above results are
collectively shown in Tables 2-1 and 2-2.
11 TABLE 2-1 Example Example Example Example Example Example
Example Example Example 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9
Operational conditions Initially charged: Ion-exchanged water (g)
332 240.6 157.5 332 332 332 157.5 402.8 235.5 48% NaOH (g) -- -- --
100 200 400 400 -- -- (mol) -- -- -- 1.2 2.4 4.8 4.8 -- -- Dropped:
Anhydrous MA (g) 588 588 588 588 588 588 588 588 588 (mol) 6 6 6 6
6 6 6 6 6 48% NaOH (g) 1000 1000 1000 900 800 600 600 850 850 (mol)
12 12 12 10.8 9.6 7.2 7.2 10.2 10.2 Neutralization (%) 100 100 100
100 100 100 100 85 85 degree Solid component (%) 50 52.5 55 50 50
50 55 50 55 concentration MA dropping period (min) 0.about.60
0.about.60 0.about.60 0.about.60 0.about.60 0.about.60 0.about.60
0.about.60 0.about.60 NaOH dropping (min) 0.about.60 0.about.60
0.about.60 5.about.60 10.about.60 20.about.60 20.about.60
0.about.60 0.about.60 period Results Dropping initiation (.degree.
C.) 60 60 60 60 60 60 60 60 60 temperature Reflux initiation (min)
8 6 5 6 7 7 5 9 6 time Amount of formed (ppm) 1800 1700 1400 2200
2800 4100 3500 1700 1300 malic acid Amount of formed (ppm) 330 300
250 310 280 520 460 220 240 fumaric acid
[0270]
12 TABLE 2-2 Example Example Example Example Example Example
Comparative Comparative 2-10 2-11 2-12 2-13 2-14 2-15 Example 2-1
Example 2-2 Operational conditions Initially charged: Ion-exchanged
water (g) 402.8 402.8 402.8 473.6 332 332 332 332 Anhydrous MA (g)
-- -- -- -- -- -- -- 588 (mol) -- -- -- -- -- -- -- 6 48% NaOH (g)
200 300 425 -- 800 600 1000 -- (mol) 2.4 3.6 5.1 -- 9.6 7.2 1.2 --
Dropped: Anhydrous MA (g) 588 588 588 588 588 588 588 -- (mol) 6 6
6 6 6 6 6 -- 48% NaOH (g) 650 550 425 700 200 400 -- 1000 (mol) 7.8
6.6 5.1 8.4 2.4 4.8 -- 12 Neutralization (%) 85 85 85 70 100 100
100 100 degree Solid component (%) 50 50 50 50 50 50 50 50
concentration MA dropping period (min) 0.about.60 0.about.60
0.about.60 0.about.60 0.about.60 0.about.60 0.about.60 -- NaOH
dropping (min) 10.about.60 0.about.60 20.about.60 0.about.60
30.about.60 30.about.60 -- 0.about.60 period Results Dropping
initiation (.degree. C.) 60 60 60 60 60 60 60 60 temperature Reflux
initiation (min) 7 8 8 10 7 7 8 10 time Amount of formed (ppm) 2200
3100 4300 1400 35000 11000 45000 9800 malic acid Amount of formed
(ppm) 390 420 520 470 2800 950 5200 21000 fumaric acid
[0271] Various details of the invention may be changed without
departing from its spirit not its scope. Furthermore, the foregoing
description of the preferred embodiments according to the present
invention is provided for the purpose of illustration only, and not
for the purpose of limiting the invention as defined by the
appended claims and their equivalents.
* * * * *