CA1212369A - Method for preparing absorbent fibrous fluff - Google Patents
Method for preparing absorbent fibrous fluffInfo
- Publication number
- CA1212369A CA1212369A CA000452171A CA452171A CA1212369A CA 1212369 A CA1212369 A CA 1212369A CA 000452171 A CA000452171 A CA 000452171A CA 452171 A CA452171 A CA 452171A CA 1212369 A CA1212369 A CA 1212369A
- Authority
- CA
- Canada
- Prior art keywords
- absorbent
- fluff
- polymer
- coated
- water
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
- A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
- A61L15/22—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
- A61L15/225—Mixtures of macromolecular compounds
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
- A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
- A61L15/42—Use of materials characterised by their function or physical properties
- A61L15/60—Liquid-swellable gel-forming materials, e.g. super-absorbents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C9/00—After-treatment of cellulose pulp, e.g. of wood pulp, or cotton linters ; Treatment of dilute or dewatered pulp or process improvement taking place after obtaining the raw cellulosic material and not provided for elsewhere
- D21C9/001—Modification of pulp properties
- D21C9/002—Modification of pulp properties by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives
- D21C9/005—Modification of pulp properties by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives organic compounds
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/20—Tampons, e.g. catamenial tampons; Accessories therefor
- A61F13/2002—Tampons, e.g. catamenial tampons; Accessories therefor characterised by the use
- A61F13/202—Catamenial tampons
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F13/537—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F2013/15008—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterized by the use
- A61F2013/15048—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterized by the use for protection against contamination, or protection in using body disinfecting wipes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F2013/15821—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
- A61F2013/51409—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material being a film
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F2013/530131—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium being made in fibre but being not pulp
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F2013/530481—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F2013/530802—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterized by the foam or sponge other than superabsorbent
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F13/537—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
- A61F13/53708—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer the layer having a promotional function on liquid propagation in at least one direction
- A61F2013/53721—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer the layer having a promotional function on liquid propagation in at least one direction with capillary means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2555/00—Personal care
- B32B2555/02—Diapers or napkins
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/913—Material designed to be responsive to temperature, light, moisture
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3707—Woven fabric including a nonwoven fabric layer other than paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3854—Woven fabric with a preformed polymeric film or sheet
- Y10T442/3886—Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
- Y10T442/651—Plural fabric layers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
Landscapes
- Health & Medical Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Veterinary Medicine (AREA)
- Epidemiology (AREA)
- Materials Engineering (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
- Public Health (AREA)
- Hematology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Wood Science & Technology (AREA)
- Textile Engineering (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Solid-Sorbent Or Filter-Aiding Compositions (AREA)
- Laminated Bodies (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Paper (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
This invention is directed to a method for preparing a fibrous fluff having improved absorbency, to the fibrous fluff prepared by the method, and to an absorbent device containing the fibrous fluff. The method comprises passing a base fluffing material through a zone wherein an aqueous solution of polymer which has been formulated into an absorbent composition is coated on the base fluffing material. The absorbent coated base fluffing material composite is then dried and finally disintegrated and worked by mechanical means into a plurality of absorbent fluff fibers. The absorbent device comprises the fibrous fluff, a water--impermeable bottom sheet and a water-permeable face sheet.
This invention is directed to a method for preparing a fibrous fluff having improved absorbency, to the fibrous fluff prepared by the method, and to an absorbent device containing the fibrous fluff. The method comprises passing a base fluffing material through a zone wherein an aqueous solution of polymer which has been formulated into an absorbent composition is coated on the base fluffing material. The absorbent coated base fluffing material composite is then dried and finally disintegrated and worked by mechanical means into a plurality of absorbent fluff fibers. The absorbent device comprises the fibrous fluff, a water--impermeable bottom sheet and a water-permeable face sheet.
Description
,, --1--A METHOD FOR PREPARING AN ABSORBENT FIBROUS FLUFF, THE FIBROUS FLUFF PREPARED BY l METHOD, AND AN
ABSORBENT DEVICE CONTAINING THE FIBROUS FLUFF
;
There are numerous disposable articles in the form of diapers, tampons and the like available on the market which contain a central matrix of absorbent fibrous fluff having varying degrees of absorbency.
5 There are, as well, a larye variety of disposable absorbent pads used in institutions such as hospitals including underpads as well as adult and junior diapers.
For egample, U.S. Patent No. 3,888,257 illustrates a disposable absorbent article utilizing a powdered ;10 polymer dispersed in a wicking substrate useful for the ;same general purposes as the articles which contain the absorbent hydrophilic fluff of this invention. Fiberized wood pulp alone is not highly efficient. In order to enhance the absorbency of the fiberized wood pulp, water-absorbent polymers have been proposed or distri-bution within the absorbent matrix.
The conventional fluff matrix construction of the prior known art was fibrous fluff which had been treated with finely divided powdered absorbent polymer.
.' 3~9 In this regard it has been found that application ox the powdered absorbent polymer presented special prob-lems of distribution within the cell matrix, as well as special problems in application. The finely divided powder is very difficult to maintain in anhydrous form while applying it to the fibrous fluff matrix. Pre-sently, the accepted industry practice is to construct a substantially closed system of application in order to minimize the particulate dust which would emanate from the application site. Elaborate systems have been designed for the purpose of containing the absorbent particle dust, yet even a small amount of absorbent powder escaping from the substantially closed system requires special clean-up and maintenance procedures.
When the powdered absorbent of the prior known art came in contact with moisture in the plant's atmosphere, it immediately began to swell, thereby yielding a gel which was not easily cleansed away due to its water-; absorbent properties. Thus, special solvents were required to maintain the equipment, and more signifi-cantly, the surrounding area in which the powdered absorbent dust settled.
The patent to R. E. Erickson et al., U.S.
Patent No. 4,117,184, discloses an absorbent polymer composition having a lightly crosslinked carboxylic polyelectrolyte which has an enhanced absorbent capa-city. The difficulty has been in winding a method of evenly distributing the absorbent polymer throughout the fluff matrix. One additional problem has been distributing a sufficient quantity of absorbent polymer into the fluff matrix in order to prepare resultant fluff products with improved absorbent qualities.
ABSORBENT DEVICE CONTAINING THE FIBROUS FLUFF
;
There are numerous disposable articles in the form of diapers, tampons and the like available on the market which contain a central matrix of absorbent fibrous fluff having varying degrees of absorbency.
5 There are, as well, a larye variety of disposable absorbent pads used in institutions such as hospitals including underpads as well as adult and junior diapers.
For egample, U.S. Patent No. 3,888,257 illustrates a disposable absorbent article utilizing a powdered ;10 polymer dispersed in a wicking substrate useful for the ;same general purposes as the articles which contain the absorbent hydrophilic fluff of this invention. Fiberized wood pulp alone is not highly efficient. In order to enhance the absorbency of the fiberized wood pulp, water-absorbent polymers have been proposed or distri-bution within the absorbent matrix.
The conventional fluff matrix construction of the prior known art was fibrous fluff which had been treated with finely divided powdered absorbent polymer.
.' 3~9 In this regard it has been found that application ox the powdered absorbent polymer presented special prob-lems of distribution within the cell matrix, as well as special problems in application. The finely divided powder is very difficult to maintain in anhydrous form while applying it to the fibrous fluff matrix. Pre-sently, the accepted industry practice is to construct a substantially closed system of application in order to minimize the particulate dust which would emanate from the application site. Elaborate systems have been designed for the purpose of containing the absorbent particle dust, yet even a small amount of absorbent powder escaping from the substantially closed system requires special clean-up and maintenance procedures.
When the powdered absorbent of the prior known art came in contact with moisture in the plant's atmosphere, it immediately began to swell, thereby yielding a gel which was not easily cleansed away due to its water-; absorbent properties. Thus, special solvents were required to maintain the equipment, and more signifi-cantly, the surrounding area in which the powdered absorbent dust settled.
The patent to R. E. Erickson et al., U.S.
Patent No. 4,117,184, discloses an absorbent polymer composition having a lightly crosslinked carboxylic polyelectrolyte which has an enhanced absorbent capa-city. The difficulty has been in winding a method of evenly distributing the absorbent polymer throughout the fluff matrix. One additional problem has been distributing a sufficient quantity of absorbent polymer into the fluff matrix in order to prepare resultant fluff products with improved absorbent qualities.
-2-6~
This invention is directed to a method for preparing a fibrous fluff having improved absorbency, said method comprising passing a base fluffing material through a zone wherein an aqueous solution of polymer which has been formulated into an absorbent composition is coated on the base fluffing material, the absorbent coated base fluffing material composite is then dried and finally disintegrated and worked by mechanical means into a plurality of absorbent fluff fibers. The present invention is also directed to the fibrous fluff of an absorbent polymer composition and a base fluffing material as prepared by the method described above.
The present invention is additionally directed to an absorbent device which comprises the fibrous fluff, a water-impermeable bottom sheet and water-permeable face sheet. The base fluffing material can be selected from a group of those articles which contain a fiber matrix capable of being mechanically disintegrated and worked into a fluff. The fluff base material may include the more common fluff pulp board which can be mechanicaly worked to prepare a fiberized wood pulp.
The hydrophilic absorbent fibrous fluff of this invention is characterized by being rapidly wetted and swelled by water.
For purposes of this invention, the following terms have the prescribed meaning.
By "luff" is meant any wicking substrate which has been mechanically worked and disintegrated into a matrix of discontinuous wicking fibers having a plurality of zones wherein the absence of fibrous matter imports air pockets with varying degrees of uniformity thus producing a loose, soft mass of fibers.
_4_ By "absorbent fluff" is meant any absorbent matrix which has been prepared by disintegration and mechanically working of the absorbent coated base fluffing material composite in accordance with the spirit and teachings of the present invention. More precisely, the absorbent fluff matrix contains an intimate dispersion of absorbent polymer, distributed within the fibrous fluff matrix by mechanical disinte-gration and working of the absorbent coated base fluffing material composite in a mechanical fluffing chamber.
By "base fluffing material" is meant a com-pacted mass of fibrous material which, when mechanically worked, is capable of forming a loose, soft mass of fibers herein described as fluff. Preferably, the base fluffing material is a wood cellulose pulp board.
Absorbent polymers useful in the practice of this invention generally may be any physiologically compatible, water-insoluble hydrophilic polymer which is capable of formulation into a coating solution. An embodiment of the present invention utilizes an aqueous solution of a lightly crosslinked alkali metal car-boxylic polyelectrolyte.
The preferred hydrophilic polymers useful in this invention are polyelectrolytes exemplary of which are ammonium or alkali metal salts of homopolymers of acrylic or methacrylic acid and copolymers with one or more ethylenically unsaturated comonomers.
Preferably, the polyelectrolyte is a partially saponified polyacrylate polymer. The polyrner before saponification is the result of reacting together a mixture of monomers which comprises (1) 30 to 92 per-cent by weight of an alkyl acrylate wherein the alkyl group has from 1 to 10 carbon atoms, an alkyl meth-acrylate wherein the alkyl group has from 4 to 10carbon atoms, or mixtures thereof; (2) 8 to 70 percent by weight of an olefinically unsaturated carboxylic acid; and (3) 0 to 15 percent by weight of an omega hydroxyalkyl acrylate wherein the hydroxyalkyl group has from 1 to 4 carbons.
Examples of useful alkyl acrylates include methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, and hexyl acrylate. Examples of useful alkyl methacrylates include methyl methacrylate, ethyl meth-acrylate, hexyl methacrylate, octyl methacryla~e anddecyl methacrylate. Examples of useful omega hydroxy-alkyl acrylates include 2-hydroxyethyl acrylate, hydroxy-methyl acrylate, 3-hydroxyethyl acrylate and 4-hydroxy-butyl acrylate.
The olefinically unsaturated carboxylic acids useful in this invention are mono- or polycarboxylic acids. Examples of monocarboxylic acids include acrylic acid, methacrylic acid, crotonic acid, and isocrotonic acid. Examples of polycarboxylic acids include maleic acid, fumaric acid, and itaconic acid.
The foregoing polyacrylates are then dis-solved in an aqueous alkali metal hydroxide solution.
The amount of hydroxide solution employed is sufficient to saponlfy some of the acrylate esters to alkali metal carboxylates and to neutralize the carboxylic groups of ; the polyacrylate to alkali metal carboxylates so that 1~23~9 the saponified polyacrylate polymer has from 30 to 70 weight percent alkali metal carboxylates.
The partially saponified polyacrylate polymer is employed as a solution containing from 5 to 60 per-cent by weight of the polymer.
A list of applicable polymers which could be prepared from readily available monomers and converted into their salt form is as follows: acrylic acid -acrylate copolymers; acrylic acid - acrylamide copoly-mers; acrylic acid - olefinic copolymers; polyacrylic acid; acrylic acid - vinyl aromatic copolymers; acrylic vinyl ether copolymers; acrylic acid - vinyl acetate copolymers; acrylic acid - vinyl alcohol copolymers and copolymers of methacrylic acid with all the above comonomers.
Illustrative examples of the polyfunctional crosslinking agents useful in this invention to convert the above polyelectrol~tes into water-swellable poly mers are set forth in U.S. Patent Nos. 2,929,154;
This invention is directed to a method for preparing a fibrous fluff having improved absorbency, said method comprising passing a base fluffing material through a zone wherein an aqueous solution of polymer which has been formulated into an absorbent composition is coated on the base fluffing material, the absorbent coated base fluffing material composite is then dried and finally disintegrated and worked by mechanical means into a plurality of absorbent fluff fibers. The present invention is also directed to the fibrous fluff of an absorbent polymer composition and a base fluffing material as prepared by the method described above.
The present invention is additionally directed to an absorbent device which comprises the fibrous fluff, a water-impermeable bottom sheet and water-permeable face sheet. The base fluffing material can be selected from a group of those articles which contain a fiber matrix capable of being mechanically disintegrated and worked into a fluff. The fluff base material may include the more common fluff pulp board which can be mechanicaly worked to prepare a fiberized wood pulp.
The hydrophilic absorbent fibrous fluff of this invention is characterized by being rapidly wetted and swelled by water.
For purposes of this invention, the following terms have the prescribed meaning.
By "luff" is meant any wicking substrate which has been mechanically worked and disintegrated into a matrix of discontinuous wicking fibers having a plurality of zones wherein the absence of fibrous matter imports air pockets with varying degrees of uniformity thus producing a loose, soft mass of fibers.
_4_ By "absorbent fluff" is meant any absorbent matrix which has been prepared by disintegration and mechanically working of the absorbent coated base fluffing material composite in accordance with the spirit and teachings of the present invention. More precisely, the absorbent fluff matrix contains an intimate dispersion of absorbent polymer, distributed within the fibrous fluff matrix by mechanical disinte-gration and working of the absorbent coated base fluffing material composite in a mechanical fluffing chamber.
By "base fluffing material" is meant a com-pacted mass of fibrous material which, when mechanically worked, is capable of forming a loose, soft mass of fibers herein described as fluff. Preferably, the base fluffing material is a wood cellulose pulp board.
Absorbent polymers useful in the practice of this invention generally may be any physiologically compatible, water-insoluble hydrophilic polymer which is capable of formulation into a coating solution. An embodiment of the present invention utilizes an aqueous solution of a lightly crosslinked alkali metal car-boxylic polyelectrolyte.
The preferred hydrophilic polymers useful in this invention are polyelectrolytes exemplary of which are ammonium or alkali metal salts of homopolymers of acrylic or methacrylic acid and copolymers with one or more ethylenically unsaturated comonomers.
Preferably, the polyelectrolyte is a partially saponified polyacrylate polymer. The polyrner before saponification is the result of reacting together a mixture of monomers which comprises (1) 30 to 92 per-cent by weight of an alkyl acrylate wherein the alkyl group has from 1 to 10 carbon atoms, an alkyl meth-acrylate wherein the alkyl group has from 4 to 10carbon atoms, or mixtures thereof; (2) 8 to 70 percent by weight of an olefinically unsaturated carboxylic acid; and (3) 0 to 15 percent by weight of an omega hydroxyalkyl acrylate wherein the hydroxyalkyl group has from 1 to 4 carbons.
Examples of useful alkyl acrylates include methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, and hexyl acrylate. Examples of useful alkyl methacrylates include methyl methacrylate, ethyl meth-acrylate, hexyl methacrylate, octyl methacryla~e anddecyl methacrylate. Examples of useful omega hydroxy-alkyl acrylates include 2-hydroxyethyl acrylate, hydroxy-methyl acrylate, 3-hydroxyethyl acrylate and 4-hydroxy-butyl acrylate.
The olefinically unsaturated carboxylic acids useful in this invention are mono- or polycarboxylic acids. Examples of monocarboxylic acids include acrylic acid, methacrylic acid, crotonic acid, and isocrotonic acid. Examples of polycarboxylic acids include maleic acid, fumaric acid, and itaconic acid.
The foregoing polyacrylates are then dis-solved in an aqueous alkali metal hydroxide solution.
The amount of hydroxide solution employed is sufficient to saponlfy some of the acrylate esters to alkali metal carboxylates and to neutralize the carboxylic groups of ; the polyacrylate to alkali metal carboxylates so that 1~23~9 the saponified polyacrylate polymer has from 30 to 70 weight percent alkali metal carboxylates.
The partially saponified polyacrylate polymer is employed as a solution containing from 5 to 60 per-cent by weight of the polymer.
A list of applicable polymers which could be prepared from readily available monomers and converted into their salt form is as follows: acrylic acid -acrylate copolymers; acrylic acid - acrylamide copoly-mers; acrylic acid - olefinic copolymers; polyacrylic acid; acrylic acid - vinyl aromatic copolymers; acrylic vinyl ether copolymers; acrylic acid - vinyl acetate copolymers; acrylic acid - vinyl alcohol copolymers and copolymers of methacrylic acid with all the above comonomers.
Illustrative examples of the polyfunctional crosslinking agents useful in this invention to convert the above polyelectrol~tes into water-swellable poly mers are set forth in U.S. Patent Nos. 2,929,154;
3,224,986; and 3,332,909. These polyfunctional cross-linking agents are generally known as polyamidepoly-amine epichlorohydrin adducts. Similar crosslinking agents are also commercially available from Hercules Incorporated as Kymene~ 557 and Polycup~ 172. The structure of these adducts has been discussed in an article by M. E. Coor et al., Journal of Applied Polymer Science, Vol. 17, pages 721-735 (1973).
Illustrative examples of the difunctional agents useful in this invention are polyhaloalkanols such as 1,3-dichloroisopropanol; 1,3-dibromoisopro-panol; sulfonium zwitterions suck as the tetrahydro-thiophene adduct of novolac resins; haloepoxyalkanes such as epichlorohydrin, epibromohydrin, 2-methyl epichlorohydrin and epiiodohydrin; polyglycidyl ethers such as 1,4-butanediol diglycidyl ether, glycerine-1,3-diglycidyl ether, ethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, diethylene glycol diglycidyl ether, neopentyl glycol diglycidyl ether, polypropylene glycol diglycidyl ethers having an epoxy equivalent weight range from 175 to 380, bisphenol A-epichlorohydrin epoxy resins having an epoxy equivalent weight range from 182 to about 975 and mixtures of the foregoing.
Also useful as crosslinking agents are mono-meric amine-epihalohydrin adducts prepaLed by reacting at least two moles of an epihalohydrin with one mole of various monoamines, di~mines and triamines at a temper-ature in the range from 0 to 90C for a time period of from 0~5 to 8 hours. The reaction is carried out in a reaction media containing from 20 to 90 percent water, lower alcohols such as methanol or ethanol, or in aqueous solutions of the lower alcohols. The amino--epihalohydrin adducts are used directly as made without separation or concentration. The preparation and use of amino-epihalohydrin adducts as crosslinking agents is further disclosed in U.S. Patent No. 4,310,593.
Sulfonium zwitterions are known from U.S. Patent Nos.
3,660,431; 3,749,737; and 3,749,738.
These crosslinking agents are used in an amount from 0.05 to 5.0 percent based on the weight of the polyelectrolyte used. This is generally sufficient to cause the polyelectrolyte to become lightly crosslinked.
~Z3~
Other hydrophilic polymers may also be employed, such as acrylic copolymer and starch/graft copolymers.
Composites containing such polymers with wicking sub-strates are available commercially as Permasorb~ Sheet Laminate from National Starch and Chemical Corporation, and Sanwet~ IM-300 from Sanyo Chemical Industry Company.
Also useful are the water-insoluble alkali salts of saponified, gelatinized starch/polyacrylonitrile graft polymers taught in U.S. Patent Nos. 3,997,484 and
Illustrative examples of the difunctional agents useful in this invention are polyhaloalkanols such as 1,3-dichloroisopropanol; 1,3-dibromoisopro-panol; sulfonium zwitterions suck as the tetrahydro-thiophene adduct of novolac resins; haloepoxyalkanes such as epichlorohydrin, epibromohydrin, 2-methyl epichlorohydrin and epiiodohydrin; polyglycidyl ethers such as 1,4-butanediol diglycidyl ether, glycerine-1,3-diglycidyl ether, ethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, diethylene glycol diglycidyl ether, neopentyl glycol diglycidyl ether, polypropylene glycol diglycidyl ethers having an epoxy equivalent weight range from 175 to 380, bisphenol A-epichlorohydrin epoxy resins having an epoxy equivalent weight range from 182 to about 975 and mixtures of the foregoing.
Also useful as crosslinking agents are mono-meric amine-epihalohydrin adducts prepaLed by reacting at least two moles of an epihalohydrin with one mole of various monoamines, di~mines and triamines at a temper-ature in the range from 0 to 90C for a time period of from 0~5 to 8 hours. The reaction is carried out in a reaction media containing from 20 to 90 percent water, lower alcohols such as methanol or ethanol, or in aqueous solutions of the lower alcohols. The amino--epihalohydrin adducts are used directly as made without separation or concentration. The preparation and use of amino-epihalohydrin adducts as crosslinking agents is further disclosed in U.S. Patent No. 4,310,593.
Sulfonium zwitterions are known from U.S. Patent Nos.
3,660,431; 3,749,737; and 3,749,738.
These crosslinking agents are used in an amount from 0.05 to 5.0 percent based on the weight of the polyelectrolyte used. This is generally sufficient to cause the polyelectrolyte to become lightly crosslinked.
~Z3~
Other hydrophilic polymers may also be employed, such as acrylic copolymer and starch/graft copolymers.
Composites containing such polymers with wicking sub-strates are available commercially as Permasorb~ Sheet Laminate from National Starch and Chemical Corporation, and Sanwet~ IM-300 from Sanyo Chemical Industry Company.
Also useful are the water-insoluble alkali salts of saponified, gelatinized starch/polyacrylonitrile graft polymers taught in U.S. Patent Nos. 3,997,484 and
4,405,387. Other such polymers are well known in the art.
For the purpose of this invention, a moisture absorbent or water-swellable polyelectrolyte or polymer is defined as one which adsorbs greater than 15 times its weight of synthetic or natural urine. Preferably, the absorbency should be in the range from 30 to 60 grams of urine per gram of polyelectrolyt~ or in the range from 90 to 250 grams of deionized water per gram of polyelectrolyte. The level of crosslinking agent used is a variable factor which is dependent upon the particular polyelectrolyte used and the molecular weight of the polyelectrolyte. Preferably, the amount used varies from 0.25 to 3.0 percent based on the weight of the polyelectrolyte. However, this range is varied for each polyelectrolyte in order to adjust the absorbency of the final crosslinked material.
It is sometimes desirable to add a small amount of a surfactant to the polyelectrolyte com-position to aid in flowing the solution onto the base fluffing material. A secondary benefit of using a surfactant is to increase the wettability of the final dry absorbent fluff. Either anionic or nonionic sur-factants may be used.
_9_ The aqueous polymer solution is coated on the base fluffing material by conventional means such as, for example, by spraying or reverse roll coating and prefexably doctored to uniform thickness with a drawbar, air knife or similar means. The coating is dried and the dried coated substrate then disintegrated into the absorbent fluff. The severity of the applied stress and the mechanical parameters are readily adjusted to optimum with simple preliminary experiments.
One method of increasing the amount of absor-bent polymer present in the fluff matrix is to increase the absorbent polymer film thickness on the base fluffing material. The thickness of the coating film can vary greatly, so long as the coated base fluffing material composite is still capable of being disintegrated and mechanically worked into an absorbent fibrous fluff.
; It can be seen that feeding coated base fluffing material composite having a specified thickness of polymer film coating and a known amount of base fluffing material, will yield an absorbent fibrous fluff having an absorbent polymer to wicking substxate fluff ratio which can be desirably tailored to the manufacturer's product specification. Exact amounts of absorbent polymer and base fluffing material needed can be determined by simple arithmetic calculation once the desired absorbent polymer content of the xesultant fluff has been determined.
An optional embodiment available with the method is the concurrent disintegration of an absorbent composite and a base fluffing material. In that instance, it is only necessary that the composite and base fluffing material be added to the disintegrator in whatever pre-_ g_ l~Z3~
determined ratio is desired in the resulting fluff.This option permits an easy adjustment of the amount of wicking substrate in the final fluff and can be achieved without shutting down the apparatus. The composite fluff exhibits a high absorption capacity, in economical fashion. In this regard, as indicated above, the distribution of hydrophilic absorbent polymer within the absorbent matrix, unlike that of the known prior art, is accomplished in a uniform, intimately dispersed manner.
The resulting fluff is well suited for use in known absorbent devices. The fluff may be blended with other fluff or may be employed in a layered structure with fibrous fluff.
Typical absorbent devices comprise a water--impermeable bottom sheet and a water-permeable face sheet. A suitable water-impermeable bottom sheet is a sheet of polyethylene film. Also suitable as a water--impermeable bottom sheet is a flexible hydrophilic absorbent laminate having a central, substantially continuous and uniform film consisting of a lightly crosslinked carboxylic polyelectrolyte and a layer of wicking substrate bonded to both sides of said film. A
suitable water-permeable face sheet is a nonwoven fiber mat. A preferred embodiment of these devices contains one or more layers of intermediate wicking sheets.
Suitable intermediate wicking sheets include, for example, woven fabrics, paper tissues, nonwoven fiber mats, polymeric foams, and flexible hydrophilic absorbent laminates.
The method of this invention permits produc-tion of fluff having an absorbent polymer bonded to fibers of the fluff and being uniformly distributed throughout the fluff. The method permits quick and easy adjustment of the ratio of absorbent polymer to fibrous fluff. The method minimizes the amount of polymer lost during preparation as is a common problem in the use of granular polymers added to a fluff. In this regard, it is noted that even that polymer which is flaked off during disintegration is in the form of platelets entrapped in the fibrous matrix. Much of the spherical granules ox the prior used dry powders would sift through the matrix and be lost. Because less polymer is lost during production, clean up operations are simplified.
The invention is illustrated in the following examples.
Example 1 A solution of acrylic polymer was formulated into the absorbent coating having Composition l as follows:
The acrylic polymer was the polymerizate of 52 mole percent ethyl acrylate, 28 mole percent sodium methacrylate, and 20 mole percent sodium acrylate having a pH between 6 and 8. The acrylic polymer was used as an aqueous solution containing 25 weight percent of the acrylic polymer.
94.0 Weight percent of that acrylic polymer was combined in solution with 5.0 weight percent poly-oxyethylene sorbitan monolaurate and 1.0 weight percent polyamide/epichlorohydrin resin. This composition was coated on 120 lb/1000 ft2 (0.59 kg/m2) fluff pulp board using a No. 70 Meyer rod (wire wound rod to a dry coating weight of 8.8 grams (dry weight)/ft.2 (95g/m2).
The coated board was dried for 10 minutes at 250F
(121.1C) in a hot air oven. The coated board was cut into small pieces and converted to a fluff using a commercial blender. The fluff containing this composi-tion was checked for absorbent capacity by placing 1 gram of fluff in 150 cubic centimeters of 1 percent sodium chloride solution, allowed to soak for 30 minutes, filtered through 150 mesh nylon screen, collected and then the filtrate was weighed. The result of this test is given in Table I.
Example 2 The aqueous solution of acrylic polymer of Example 1 was formulated into the absorbent coating having Composition 2 as follows:
94.4 Weight percent of acrylic polymer was combined with 5.0 weight percent of polyoxyethylene sorbitan monolaurate and 0.6 weight percent polyamide/-epichlorohydrin resin. This composition was processed and tested according to the procedures of Example 1.
The results of this test are given in Table I.
ExamPle 3 The aqueous solution of acrylic polymer of Example 1 is formulated into the absorbent coating having Composition 3 as follows:
71.5 Weight percent of acrylic polymer was combined with 1.0 weight percent polyoxyethylene sorbitan 3~
monolaurate, 0.5 weight percent polyamide/epichloroh~dri~
resin, and 27.0 weight percent glycerine. This composi-tion was processed and tested according to the procedures of Example 1. The result of this test is given in Table I.
TABLE I
Polymer Absorbency in Fluff CaPacity Composition 1 14% 20 grams/gram of fluff Composition 2 14% 25 grams/gram of fluff Composition 3 14% 19 grams/gram of fluff Uncoated Fluff -- 16 grams/gram of fluff Compositions 1, 2 an 3 were coated on a heavier weight fluff pulp board (154 lbs/1000 ft2 or 0.75 kg/m ) and the results were similar to those stated in Table I.
Example 4 A pilot coating run was made using a Keegan Coater. Fluff pulp board weighing 160 lbs/1000 ft (0.78 kg/m ) was coated with Composition 1 using a modified wire wound rod as the coating head. The oven temperature was 350F (176.7C3 and the coated board was exposed in the oven for from 3 to 5 minutes until it was dry. The dry weight of the absorbent polymer coating was approximately 10 grams/ft2 (108 g/m2).
The coated board was converted to fluff using a commercial blender. Samples of fluff containing absorbent polymer were compared to uncoated fibrous fluff for absorbent capacity in 1 percent sodium chlo-ride solution. Results are shown in Table II.
TABLE II
Polymer Absorbent in Fluff Capacity Pilot coated 5fluff board 13.7%19.2 grams/gram fluff Uncoated fluff -- 16.3 grams/gram fluff Both Tables I and II demonstrate the increased capacity of the cellulose fluff containing the absorbent polymer. An additional advantage of the absorbent polymer is its ability to retain the aqueous fluid under pressure to a greater extent than fluff in the prior art.
For purposes of this invention the absorbent composition can be varied considerably in degree of crosslinking, polymer content, surfactants, pigments and fillers, and other desired ingredients which the skilled artisan would include in conventional amounts.
In addition, a high molecular weight, slightly cross-linked salt form of acrylic acid could be used although associated with it would be the high cost of removing water. A drying step can be accomplished with conven-tional drying equipment such as a steam heated drying drum, microwave heaters, infrared heaters, or similar equipment. The preferred drying temperature is 250F
(121.1C) and for sufficient time to remove all of the moisture from the coated board. Temperature ranges from 150F (65.6C) to 350F (176.7C) can be used with appropriate time periods to remove the moisture.
For the purpose of this invention, a moisture absorbent or water-swellable polyelectrolyte or polymer is defined as one which adsorbs greater than 15 times its weight of synthetic or natural urine. Preferably, the absorbency should be in the range from 30 to 60 grams of urine per gram of polyelectrolyt~ or in the range from 90 to 250 grams of deionized water per gram of polyelectrolyte. The level of crosslinking agent used is a variable factor which is dependent upon the particular polyelectrolyte used and the molecular weight of the polyelectrolyte. Preferably, the amount used varies from 0.25 to 3.0 percent based on the weight of the polyelectrolyte. However, this range is varied for each polyelectrolyte in order to adjust the absorbency of the final crosslinked material.
It is sometimes desirable to add a small amount of a surfactant to the polyelectrolyte com-position to aid in flowing the solution onto the base fluffing material. A secondary benefit of using a surfactant is to increase the wettability of the final dry absorbent fluff. Either anionic or nonionic sur-factants may be used.
_9_ The aqueous polymer solution is coated on the base fluffing material by conventional means such as, for example, by spraying or reverse roll coating and prefexably doctored to uniform thickness with a drawbar, air knife or similar means. The coating is dried and the dried coated substrate then disintegrated into the absorbent fluff. The severity of the applied stress and the mechanical parameters are readily adjusted to optimum with simple preliminary experiments.
One method of increasing the amount of absor-bent polymer present in the fluff matrix is to increase the absorbent polymer film thickness on the base fluffing material. The thickness of the coating film can vary greatly, so long as the coated base fluffing material composite is still capable of being disintegrated and mechanically worked into an absorbent fibrous fluff.
; It can be seen that feeding coated base fluffing material composite having a specified thickness of polymer film coating and a known amount of base fluffing material, will yield an absorbent fibrous fluff having an absorbent polymer to wicking substxate fluff ratio which can be desirably tailored to the manufacturer's product specification. Exact amounts of absorbent polymer and base fluffing material needed can be determined by simple arithmetic calculation once the desired absorbent polymer content of the xesultant fluff has been determined.
An optional embodiment available with the method is the concurrent disintegration of an absorbent composite and a base fluffing material. In that instance, it is only necessary that the composite and base fluffing material be added to the disintegrator in whatever pre-_ g_ l~Z3~
determined ratio is desired in the resulting fluff.This option permits an easy adjustment of the amount of wicking substrate in the final fluff and can be achieved without shutting down the apparatus. The composite fluff exhibits a high absorption capacity, in economical fashion. In this regard, as indicated above, the distribution of hydrophilic absorbent polymer within the absorbent matrix, unlike that of the known prior art, is accomplished in a uniform, intimately dispersed manner.
The resulting fluff is well suited for use in known absorbent devices. The fluff may be blended with other fluff or may be employed in a layered structure with fibrous fluff.
Typical absorbent devices comprise a water--impermeable bottom sheet and a water-permeable face sheet. A suitable water-impermeable bottom sheet is a sheet of polyethylene film. Also suitable as a water--impermeable bottom sheet is a flexible hydrophilic absorbent laminate having a central, substantially continuous and uniform film consisting of a lightly crosslinked carboxylic polyelectrolyte and a layer of wicking substrate bonded to both sides of said film. A
suitable water-permeable face sheet is a nonwoven fiber mat. A preferred embodiment of these devices contains one or more layers of intermediate wicking sheets.
Suitable intermediate wicking sheets include, for example, woven fabrics, paper tissues, nonwoven fiber mats, polymeric foams, and flexible hydrophilic absorbent laminates.
The method of this invention permits produc-tion of fluff having an absorbent polymer bonded to fibers of the fluff and being uniformly distributed throughout the fluff. The method permits quick and easy adjustment of the ratio of absorbent polymer to fibrous fluff. The method minimizes the amount of polymer lost during preparation as is a common problem in the use of granular polymers added to a fluff. In this regard, it is noted that even that polymer which is flaked off during disintegration is in the form of platelets entrapped in the fibrous matrix. Much of the spherical granules ox the prior used dry powders would sift through the matrix and be lost. Because less polymer is lost during production, clean up operations are simplified.
The invention is illustrated in the following examples.
Example 1 A solution of acrylic polymer was formulated into the absorbent coating having Composition l as follows:
The acrylic polymer was the polymerizate of 52 mole percent ethyl acrylate, 28 mole percent sodium methacrylate, and 20 mole percent sodium acrylate having a pH between 6 and 8. The acrylic polymer was used as an aqueous solution containing 25 weight percent of the acrylic polymer.
94.0 Weight percent of that acrylic polymer was combined in solution with 5.0 weight percent poly-oxyethylene sorbitan monolaurate and 1.0 weight percent polyamide/epichlorohydrin resin. This composition was coated on 120 lb/1000 ft2 (0.59 kg/m2) fluff pulp board using a No. 70 Meyer rod (wire wound rod to a dry coating weight of 8.8 grams (dry weight)/ft.2 (95g/m2).
The coated board was dried for 10 minutes at 250F
(121.1C) in a hot air oven. The coated board was cut into small pieces and converted to a fluff using a commercial blender. The fluff containing this composi-tion was checked for absorbent capacity by placing 1 gram of fluff in 150 cubic centimeters of 1 percent sodium chloride solution, allowed to soak for 30 minutes, filtered through 150 mesh nylon screen, collected and then the filtrate was weighed. The result of this test is given in Table I.
Example 2 The aqueous solution of acrylic polymer of Example 1 was formulated into the absorbent coating having Composition 2 as follows:
94.4 Weight percent of acrylic polymer was combined with 5.0 weight percent of polyoxyethylene sorbitan monolaurate and 0.6 weight percent polyamide/-epichlorohydrin resin. This composition was processed and tested according to the procedures of Example 1.
The results of this test are given in Table I.
ExamPle 3 The aqueous solution of acrylic polymer of Example 1 is formulated into the absorbent coating having Composition 3 as follows:
71.5 Weight percent of acrylic polymer was combined with 1.0 weight percent polyoxyethylene sorbitan 3~
monolaurate, 0.5 weight percent polyamide/epichloroh~dri~
resin, and 27.0 weight percent glycerine. This composi-tion was processed and tested according to the procedures of Example 1. The result of this test is given in Table I.
TABLE I
Polymer Absorbency in Fluff CaPacity Composition 1 14% 20 grams/gram of fluff Composition 2 14% 25 grams/gram of fluff Composition 3 14% 19 grams/gram of fluff Uncoated Fluff -- 16 grams/gram of fluff Compositions 1, 2 an 3 were coated on a heavier weight fluff pulp board (154 lbs/1000 ft2 or 0.75 kg/m ) and the results were similar to those stated in Table I.
Example 4 A pilot coating run was made using a Keegan Coater. Fluff pulp board weighing 160 lbs/1000 ft (0.78 kg/m ) was coated with Composition 1 using a modified wire wound rod as the coating head. The oven temperature was 350F (176.7C3 and the coated board was exposed in the oven for from 3 to 5 minutes until it was dry. The dry weight of the absorbent polymer coating was approximately 10 grams/ft2 (108 g/m2).
The coated board was converted to fluff using a commercial blender. Samples of fluff containing absorbent polymer were compared to uncoated fibrous fluff for absorbent capacity in 1 percent sodium chlo-ride solution. Results are shown in Table II.
TABLE II
Polymer Absorbent in Fluff Capacity Pilot coated 5fluff board 13.7%19.2 grams/gram fluff Uncoated fluff -- 16.3 grams/gram fluff Both Tables I and II demonstrate the increased capacity of the cellulose fluff containing the absorbent polymer. An additional advantage of the absorbent polymer is its ability to retain the aqueous fluid under pressure to a greater extent than fluff in the prior art.
For purposes of this invention the absorbent composition can be varied considerably in degree of crosslinking, polymer content, surfactants, pigments and fillers, and other desired ingredients which the skilled artisan would include in conventional amounts.
In addition, a high molecular weight, slightly cross-linked salt form of acrylic acid could be used although associated with it would be the high cost of removing water. A drying step can be accomplished with conven-tional drying equipment such as a steam heated drying drum, microwave heaters, infrared heaters, or similar equipment. The preferred drying temperature is 250F
(121.1C) and for sufficient time to remove all of the moisture from the coated board. Temperature ranges from 150F (65.6C) to 350F (176.7C) can be used with appropriate time periods to remove the moisture.
Claims (8)
1. A method for preparing a fibrous fluff of improved absorbency, said method comprising passing a base fluffing material through a zone wherein an aqueous solution of polymer which has been formulated into an absorbent composition is coated on the base fluffing material, the absorbent coated base fluffing material composite is then dried and finally disintegrated and worked by mechanical means into a plurality of absorbent fluff fibers.
2. The method of Claim 1 wherein the absorbent composition comprises an aqueous solution of a lightly crosslinked alkali metal carboxylic polyelectrolyte.
3. The method of Claim 2 wherein the poly-electrolyte is crosslinked with a polyfunctional or difunctional crosslinking agent that is reactive with carboxylate groups.
4. The method of Claim 3 wherein the poly-functional crosslinking agent is a polyamide-polyamine epichlorohydrin adduct.
5. A method of Claim 1 wherein the drying temperature range is from 150°F (65.6°C) to 350°F
(176.7°C).
(176.7°C).
6. The absorbent fluff prepared according to the method of Claim 1.
7. An absorbent device which comprises the absorbent fluff of Claim 6, a water-impermeable bottom sheet and a water-permeable face sheet.
8. The absorbent device of Claim 7 which additionally contains one or more layers of intermediate wicking sheets.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/319,538 US4424247A (en) | 1981-11-09 | 1981-11-09 | Absorbent polymer-fiber composites and method for preparing the same |
US06/336,540 US4444830A (en) | 1981-11-09 | 1982-01-04 | Method for preparing absorbent fibrous fluff |
Publications (1)
Publication Number | Publication Date |
---|---|
CA1212369A true CA1212369A (en) | 1986-10-07 |
Family
ID=36809021
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000415045A Expired CA1194281A (en) | 1981-11-09 | 1982-11-08 | Absorbent polymer-fiber composites and method for preparing the same |
CA000452171A Expired CA1212369A (en) | 1981-11-09 | 1984-04-17 | Method for preparing absorbent fibrous fluff |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000415045A Expired CA1194281A (en) | 1981-11-09 | 1982-11-08 | Absorbent polymer-fiber composites and method for preparing the same |
Country Status (8)
Country | Link |
---|---|
US (2) | US4424247A (en) |
EP (2) | EP0093158B1 (en) |
JP (2) | JPS58501625A (en) |
AU (2) | AU558281B2 (en) |
BR (1) | BR8207934A (en) |
CA (2) | CA1194281A (en) |
DE (1) | DE3273617D1 (en) |
WO (1) | WO1983001598A1 (en) |
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-
1981
- 1981-11-09 US US06/319,538 patent/US4424247A/en not_active Expired - Fee Related
-
1982
- 1982-01-04 US US06/336,540 patent/US4444830A/en not_active Expired - Lifetime
- 1982-11-08 CA CA000415045A patent/CA1194281A/en not_active Expired
- 1982-11-08 EP EP19820903631 patent/EP0093158B1/en not_active Expired
- 1982-11-08 DE DE8282903631T patent/DE3273617D1/en not_active Expired
- 1982-11-08 WO PCT/US1982/001567 patent/WO1983001598A1/en active IP Right Grant
- 1982-11-08 AU AU10411/83A patent/AU558281B2/en not_active Ceased
- 1982-11-08 JP JP58500057A patent/JPS58501625A/en active Pending
- 1982-11-08 BR BR8207934A patent/BR8207934A/en unknown
-
1984
- 1984-04-17 AU AU27018/84A patent/AU563378B2/en not_active Ceased
- 1984-04-17 CA CA000452171A patent/CA1212369A/en not_active Expired
- 1984-04-21 EP EP19840104526 patent/EP0159371B1/en not_active Expired - Lifetime
- 1984-04-23 JP JP59081670A patent/JPS60224875A/en active Pending
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5509915A (en) | 1991-09-11 | 1996-04-23 | Kimberly-Clark Corporation | Thin absorbent article having rapid uptake of liquid |
Also Published As
Publication number | Publication date |
---|---|
JPS60224875A (en) | 1985-11-09 |
US4444830A (en) | 1984-04-24 |
WO1983001598A1 (en) | 1983-05-11 |
EP0093158A1 (en) | 1983-11-09 |
EP0093158B1 (en) | 1986-10-08 |
CA1194281A (en) | 1985-10-01 |
AU2701884A (en) | 1985-10-24 |
AU1041183A (en) | 1983-05-18 |
EP0159371A1 (en) | 1985-10-30 |
AU558281B2 (en) | 1987-01-22 |
EP0093158A4 (en) | 1984-04-06 |
EP0159371B1 (en) | 1990-04-04 |
US4424247A (en) | 1984-01-03 |
AU563378B2 (en) | 1987-07-09 |
DE3273617D1 (en) | 1986-11-13 |
JPS58501625A (en) | 1983-09-29 |
BR8207934A (en) | 1983-09-20 |
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