Superabsorbent polymer with high permeability

1. A particulate superabsorbent polymer comprising:

a) from about 55 to about 99.9 wt. % of polymerizable unsaturated acid group containing monomers comprising acrylic acid neutralized with an alkali hydroxide to from 50 to 80 mol %;

b) from about 0.001 to about 5.0% by weight of internal crosslinking agent based on the weight of a);

wherein elements a) and b) are polymerized, dried to have a final product moisture content of less than 5 wt %, and comminuted into a particulate gel having a particle size of from 150 microns to about 850 microns; wherein the particulate superabsorbent polymer further comprise a crosslinked surface comprising:

c) from about 0.01 to about 3.0% by weight of surface crosslinking agent applied to the particle surface based on dry polymer powder weight; and

d) from about 0.01 to 0.5% by weight of a thermoplastic polymer based on dry polymer powder weight, wherein said thermoplastic polymer has a thermoplastic melt temperature wherein the thermoplastic polymer is applied on the particle surface coincident with, or followed by a temperature at least about the thermoplastic melt temperature, and wherein the thermoplastic polymer is either added to the particulate superabsorbent polymer with the surface crosslinking agent c) or applied to the particulate superabsorbent polymer before the surface crosslinking agent c) is added to the particulate superabsorbent polymer, wherein the thermoplastic polymer is part of the surface crosslinked portion of the particulate superabsorbent polymer wherein said particulate superabsorbent polymer has a gel bed permeability II of from about 300×10 −9 to about 1000×10 −9 cm 2 .

2. The particulate superabsorbent polymer of claim 1 having a Dust Value of about 4 or less.

3. The particulate superabsorbent polymer of claim 1 having a shear modulus of from about 4500 N/m 2 to about 9500 N/m 2 .

4. The particulate superabsorbent polymer according to claim 1 comprising from about 0.1 to about 5% by weight of a multivalent metal salt based on the dry polymer powder weight.

5. A method to make a particulate superabsorbent polymer comprising the steps of:

a) preparing a gel by the process of polymerizing from about 55 to about 99.9% weight of polymerizable unsaturated acid group containing monomers, and from about 0.001 to about 5% weight of internal crosslinking agent based on the polymerizable unsaturated acid group containing monomers, and a neutralization such that the gel has a degree of neutralization of more than about 25 mol %;

b) preparing particulate superabsorbent polymer from the gel;

c) treating the particulate superabsorbent polymer with surface additives including:

i) from about 0.01 to about 3.0% weight of a surface crosslinking agent based on dry polymer powder weight;

ii) from about 0.01 to about 10% weight of a penetration modifier based on dry polymer powder weight;

iii) from about 0.01 to about 5% weight of a multivalent metal salt based on dry polymer powder weight;

iv) from 0 to 2% weight of a surfactant based on dry polymer powder weight;

v) from about 0.01 to about 5% weight of fumed silica; and

vi) a thermoplastic polymer emulsion comprising from about 0.01 to 0.5% weight of a thermoplastic polymer based on dry polymer powder weight wherein the thermoplastic polymer emulsion is applied on the particle surface wherein the thermoplastic polymer emulsion is either added to the particulate superabsorbent polymer with the surface crosslinking agent c) or applied to the particulate superabsorbent polymer before the surface crosslinking agent c) is added to the particulate superabsorbent polymer,

heat treating the coated superabsorbent polymer particle at a temperature between 150° C. and 250° C. for from about 0.5 to about 60 minutes to effectuate the surface crosslinking of the superabsorbent polymer particle, wherein the thermoplastic polymer is part of the surface crosslinked portion of the particulate superabsorbent polymer;

wherein the superabsorbent polymer composition has the characteristics of centrifuge retention capacity of about 25 g/g or more; and a Dust Value of about 4 or less as determined by the test for Dust Values wherein said particulate superabsorbent polymer has a gel bed permeability II of from about 300×10 −9 to about 1000×10 −9 cm 2 .

6. The method of claim 5 wherein the internal crosslinking agent is from about 1.0 to about 3.0% weight based on the total amount of the polymerizable unsaturated acid group containing monomers.

7. A particulate superabsorbent polymer comprising:

a) from about 55 to about 99.9 wt. % of polymerizable unsaturated acid group containing monomers selected from acrylic acid, methacrylic acid or 2-acrylamido-2-methylpropanesulfonic acid, or mixtures of these monomers wherein the polymerizable unsaturated acid groups have a degree of neutralization of more than about 50 mol % and the polymerizable unsaturated acid groups are present as sodium, potassium, or ammonium salts;

b) from about 0.001 to about 5.0% by weight of internal crosslinking agent based on the weight of a);

wherein elements a) and b) are polymerized into a gel and the gel is prepared into particulate superabsorbent polymer; wherein the particulate superabsorbent polymer further comprise the following surface additives to form coated particulate superabsorbent polymer wherein the additives comprise;

c) from about 0.01 to about 3.0% by weight of a surface crosslinking agent comprising an alkylene carbonate applied to the particle surface based on dry polymer powder weight wherein the surface crosslinking agent is distributed evenly on the particulate superabsorbent polymer;

d) a thermoplastic polymer emulsion comprising from about 0.01 to 0.5% by weight of a thermoplastic polymer based on dry polymer powder weight, wherein the thermoplastic polymer is selected from polyethylene, polyesters, polyurethanes, linear low density polyethylene (LLDPE), ethylene acrylic acid copolymer (EAA), styrene copolymers, ethylene alkyl methacrylate copolymer (EMA), polypropylene (PP), ethylene vinyl acetate copolymer (EVA) or blends or copolymers thereof, and said thermoplastic polymer having a thermoplastic melt temperature wherein the thermoplastic polymer is applied on the particle surface coincident with or followed by a temperature at least about the thermoplastic melt temperature or greater wherein the thermoplastic polymer is either added to the particulate superabsorbent polymer with the surface crosslinking agent c) or applied to the particulate superabsorbent polymer before the surface crosslinking agent c) is added to the particulate superabsorbent polymer wherein the thermoplastic polymer is part of the surface crosslinked portion of the particulate superabsorbent polymer; and

e) from about 0.1 to about 5% by weight of fumed silica;

wherein the coated particulate superabsorbent polymer is thermally treated at a temperature between 150° C. and 250° C. for from about 0.5 to about 60 minutes to effectuate the surface crosslinking of the particulate superabsorbent polymer; and wherein the particulate superabsorbent polymer has a gel bed permeability II of from about 300×10 −9 cm 2 to about 1000×10 −9 cm 2 .

8. The particulate superabsorbent polymer of claim 7 wherein the internal crosslinking agent is selected from ethoxylated trimethylolpropanetriacrylate, ethoxylated allyl ether acrylate, polyethylene glycol diacrylate, methoxypolyethyleneglycol monomethacrylate, or ethoxylated trimethylolpropanetriacrylate.

9. The particulate superabsorbent polymer of claim 1 wherein the particulate superabsorbent polymer further comprise the following surface additives further comprises from about 0.1 to about 5% by weight of a multivalent metal salt based on the dry polymer powder weight.

10. The particulate superabsorbent polymer of claim 9 wherein the multivalent metal comprises aluminum sulfate.

11. The particulate superabsorbent polymer of claim 7 wherein the particulate superabsorbent polymer further comprise the following surface additives further comprises from about 0.01% to about 5 wt. % by weight of a penetration modifier immediately before, during or immediately after the surface crosslinking step based on dry polymer powder weight.

12. The particulate superabsorbent polymer of claim 7 having a Dust Value of about 4 or less.

13. The particulate superabsorbent polymer of claim 7 having a shear modulus of from about 4500 N/m 2 to about 9500 N/m 2 .

14. The particulate superabsorbent polymer according to claim 7 comprising from about 0.1 to about 5% by weight of aluminum sulfate based on the dry polymer powder weight.

15. A particulate superabsorbent polymer comprising:

a) from about 55 to about 99.9 wt. % of polymerizable unsaturated acid group containing monomers selected from acrylic acid, methacrylic acid, or mixtures of these monomers wherein the polymerizable unsaturated acid groups have a degree of neutralization of more than about 50% to about 80 mol % and the polymerizable unsaturated acid groups are present as sodium salts;

b) from about 0.001 to about 5.0% by weight of internal crosslinking agent based on the weight of a) wherein the internal crosslinker is selected from ethoxylated trimethylolpropanetriacrylate, ethoxylated allyl ether acrylate, polyethylene glycol diacrylate, methoxypolyethyleneglycol monomethacrylate, or ethoxylated trimethylolpropanetriacrylate;

wherein elements a) and b) are polymerized, dried to have a final product moisture content of less than 5 wt %, and comminuted into a particulate gel having a particle size of from 150 microns to about 850 microns; wherein the particulate superabsorbent polymer further comprise the following surface additives

c) from about 0.01 to about 3.0% by weight of surface crosslinking agent applied to the particle surface based on dry polymer powder weight;

d) from about 0.01 to about 0.5% by weight of fumed silica; and

e) a thermoplastic polymer emulsion comprising from about 0.01 to 0.5% by weight of a thermoplastic polymer based on dry polymer powder weight wherein the thermoplastic polymer emulsion is either added to the particulate superabsorbent polymer with the surface crosslinking agent c) or applied to the particulate superabsorbent polymer before the surface crosslinking agent c) is added to the particulate superabsorbent polymer, and said thermoplastic polymer selected from ethylene acrylic acid copolymer (EAA), polyethylene, polyesters, polyurethanes, linear low density polyethylene (LLDPE), polypropylene (PP), ethylene vinyl acetate copolymer (EVA) or blends thereof, or copolymers thereof, wherein the coated particulate superabsorbent polymer is thermally treated at a temperature between 150° C. and 250° C. for from about 0.5 to about 60 minutes to effectuate the surface crosslinking of the particulate superabsorbent polymer wherein the thermoplastic polymer is part of the surface crosslinked portion of the particulate superabsorbent polymer; and wherein the particulate superabsorbent polymer has a Centrifuge Retention Capacity of from about 25 g/g to about 35 g/g, a Gel Bed Permeability II of from about 300×10 −9 cm 2 to about 1000×10 −9 cm 2 , and a shear modulus of from about 4500 N/m 2 to about 9500 N/m 2 .

16. The particulate superabsorbent polymer of claim 1 , wherein the thermoplastic polymer is selected from polyethylene, polyesters, polyurethanes, linear low density polyethylene (LLDPE), ethylene acrylic acid copolymer (EAA), styrene copolymers, ethylene alkyl methacrylate copolymer (EMA), polypropylene (PP), ethylene vinyl acetate copolymer (EVA) or blends thereof, or copolymers thereof.

17. The particulate superabsorbent polymer of claim 1 , wherein the thermoplastic polymer is added to the particulate superabsorbent polymer with the surface crosslinking agent c).

18. The particulate superabsorbent polymer of claim 1 , wherein the thermoplastic polymer is added to the particulate superabsorbent polymer before the surface crosslinking agent c) is added to the particulate superabsorbent polymer.

19. The particulate superabsorbent polymer of claim 1 , wherein the particulate superabsorbent polymer further comprise the following surface additives:

e) from about 0.01% to about 5% by weight of a penetration modifier based on dry polymer powder weight; and

f) from about 0.01 to about 5% by weight of an insoluble, inorganic powder based on dry polymer powder weight.

20. The particulate superabsorbent polymer of claim 19 , wherein the insoluble, inorganic powder is silica, a silicate, titanium dioxide, aluminum oxide, magnesium oxide, zinc oxide, talc, calcium phosphate, clay, diatomaceous earth, a zeolite, bentonite, kaolin, hydrotalcite, or a mixture thereof.

21. The particulate superabsorbent polymer of claim 19 , wherein the insoluble, inorganic powder is silica.

22. The particulate superabsorbent polymer of claim 19 having a shear modulus of from about 4500 N/m 2 to about 9500 N/m 2 .

23. The particulate superabsorbent polymer of claim 19 having a centrifuge retention capacity of about 25 g/g or more.

24. The particulate superabsorbent polymer of claim 19 having a shear modulus of from about 4500 N/m 2 to about 9500 N/m 2 , and a centrifuge retention capacity of about 25 g/g or more.

25. The particulate superabsorbent polymer of claim 24 having a Dust Value of about 4 or less.

26. The particulate superabsorbent polymer of claim 1 , wherein the amount of internal crosslinking agent is from about 1.0 to about 3.0% by weight based on the weight of a).

27. The particulate superabsorbent polymer of claim 1 , wherein the internal crosslinking agent is ethoxylated trimethylolpropanetriacrylate, ethoxylated allyl ether acrylate, polyethylene glycol diacrylate, or ethoxylated trimethylolpropanetriacrylate.

28. The particulate superabsorbent polymer of claim 1 , wherein the surface crosslinking agent comprises an alkylene carbonate.