CA2049054A1

CA2049054A1 - Particulate absorbent material

Info

Publication number: CA2049054A1
Application number: CA002049054A
Authority: CA
Inventors: Donald F. H. Wallach; An-Cheng Chang
Original assignee: Individual
Current assignee: Micro Vesicular Systems Inc
Priority date: 1989-03-09
Filing date: 1990-03-08
Publication date: 1990-09-10
Also published as: CA2049055C; EP0462178A1; DE69003810D1; DE69003810T2; AU5284190A; EP0462178A4; EP0593421A1; KR920700020A; ZA901853B; CA2049055A1; US4959341A; WO1990010426A1; BR9007212A; JP2651952B2; AU627014B2; JPH0720547B2; AU5267690A; EP0462178B1; JPH04504978A; ZA901923B

Abstract

Abstract of the Invention The present invention features methods of making absorbent material which exhibit excellent absorption for saline and other liquids as well as being biodegradable. The methods of the invention form a particulate which can be stored in dry form and rehydrated at any time. The particulate can be used to replace the presently utilized polyacrylate superabsorbers. The base material used in the methods of the invention is a carboxylated cellulosic material such as carboxymethylcellulose, preferably, a carboxymethylcellulose having a DS, or Degree of Substitution, of 0.5 or greater. The carboxylated cellulose material is reacted with two distinct agents; a cross-linking agent and a hydrophobicity agent to make the final absorbent.

Description

~ o ~

PAR~ICUL~E AB~OR~ENS_~A~E~I

Reference tQ Relate~ ~ppl~ç~t~ns The present application ~ ~
continuation-~n-part of Unitea States Patent 5 Applic~tion ~erial No. 320,944, entitle~
~Biodeqradable Superabsorbing ~ponge,~ filed March 9, 1989, the disclosure of wh;~h i~ incorporate~ herein ,by reference. Th~ appli~ation ~s al~o rel~ted to United States Patent ~pplication Serial No. 371,210, 10 entitled ~Biodegradable Incsntinence Device,~ ~Eiled June 2~, 1989.

~ack~r~und of the Invçntion The present invention relates to absorbent particles which swell in the presence o~ aqueous lS solutions inclu~ing ~aline and urine to many times their own weight. These absorbent materials are biodegradable and have absorptive properties ~qual to or higher than those o present ~uperabsorbers.

B:iodegradability oE disposable produc~s is 20 no longer a preferred option; it has become a necessity. As the nu~ber of disposables in society has grown, the lan~ fill~ an~ others methods of treatment ~Eor these disposables bave been ~trained to the limit~. Plastic~ ~re just one form of the 25 problem of disposables while absorbent materials such as polyacrylates which are commonly used, e~g.~ in - 2 - 2049~4 dispo6sble diaper~, have ~egra~ation time~ ln the thousands of year~. Wh~le the ~uperabsorber such as the polyacrylates have advantages because of their high absorpt~ve capabilitie~ ~o that les~ i8 needed sto attract a large amount of liguid, the non-bio~egradability of these products make~ them unacceptable if alternative~ can be achieve~.

Particulate superabsorbers can be used either in lose or packed form or else can be lO,dispersed among fibers, e.g., cellulose fluff, to act as part of a liquid absorption system. However, if they are used in a packed form, the gel blocking problem must be ameliorated in order to provide optimum action.

Accordingly, an object of the invention is to provide a biodegradable superabsorbent particle which is competitive with the polyacrylate superabsorbers in terms of uptake for aqueous solutions and saline.

Another object of the invention ~s to provide methods of making biodegradable superabsorbers which use ineYpensive material and are rapid.

A further ob~ection of the invention i8 to 25provide a superabsorber wh~ch can act as a delivery system for a variety of materials, e.g., enzymes.

Shese and other object~ and features of the invention will be apparent from the follow~ng description.

The present invention features metho~s of makin~ absorbent materi~l which e~hibit eYcellent absorption for s~line an~ other l~Qui~ ~s well ~
5 beinQ biodegra~abl~. Th~ methoffs of the ~nven~ion form ~ particulate whi~h ~an be ~tore~ ~n dry form s~d rehydrate~ ~t ~ny t~me. The particulate can be use~ to replace the presently u~ilizea polyacrylate superabsorber6.
r The absorptive material made using the methods of the invention di~fers from acrylate absorbents in that ~t is biodegradable; and it i~
hydropho~ic which assists in limiting gel blocking and reduces clumping. The hydrophobic aspect of the 15 present particulates makes them distinct from earlier superabsGrber~ .

The base material used in the metho~s of the inve~tion is a carbosylated ~ellulosic material such as carbo~ymethylcelluloce. However, any cellulose 20 derivative which has substantial carbosylat~on ~an be use~. The preferrea carbo~ylated cellulose ~ a carbo~ymethylcellulose having a DS, or Degree of Substitution, of 0.5 or greater, most preferably greater than 0.7. Carbo~ymethylcellulo~e with this 25 high Degree of Substitution can have ~uch a large amount of ~ross-link~ng that it would form ~n unworkable, almost ~lue~ e material without the hydrophobicity tre~tment of th~ present invention.

The carbo~ylated cellulo~e mater~
reacte~ with two ~i~t~nct agents; ~ cro ~ nk~ng ayent and a hydrophobicity 3gent. The order of reaction can change the properties of the finzl 5 absorbent, wath the reaction ir~t w~t~ th~
cross-linking agent yiel~ing more o a ~hell-l~ke absorb~r an~, conse~uently, ~ f~rmer particle, wh~le their reaction with the hy~rophobicity agent ir~t will yi~l~ a particle having higher over~ll 10 absorptive capabilitie with absorpt~on thrsughout the body of the particle. The preferre~
cross-linking agents are those which are metal containing and include a metal with an e~fecta~e valence of at least three ~u~h as aluminum, chromium, 15 or iron. The most preferred cross-linking agents are acetates, alkoxides ~uch as isproposide~ ana hydro~ides, and chlorides. ~hese include materials such as aluminum acetate, aluminum i~opropoxide, aluminum hydro~ide, ferric chloride, and mixtures 20 thereo~.

Hydrophobicity aQents useful in the methods of the invention include monobasic and polybasic carboxylic acid~ or their ~alt~, chlorides or anhydrides, most preferably those with 2-16 carbon 25 atoms. Esamples of useful hydrophobicity agents include acetic aci~, proprionic acid, bu~yric a~id, i~obutyric acifl, acetyl chloride, 60dium acetate, so~ium proprionate, proprionyl chloride, ~odium butyrate, acetic anhydride, proprionyl anhydride, 30 ~uccinic acid, adipic acid, phthalic aci~, ~itric acid, ana mi~tures thereof~

20~90~

The reactions between the carbosylated cellulosic materlal and the cro~s-linking an~or hydrophobicity agent can be earrie~ out in either aqueous or organic solutions. If an aqueous ~olvent 5 i5 use~, a mo~erate concentration saline, e.g., 0.9%, is preferre~ to get a better charge 6eparation in the interior of the particle while organic solvent uch as neutral petroleum spirit~ may be use if the reactants chosen are not rea~ily ~oluble in aqueous 10 solution6. Sn one most preferred embo~iment to the invention, carbo~ymethylcellulose i8 first ,'pre-swollen in an aqueous solution which allows better access of the cross-linking ~nd hy~rophobicity aqents to the interior of the particle. In addition, 15 pre-treatment of the carbosymethylcellulose with a small quantity of an alcohol such as isopropyl alcohol may improve wetting and, accordingly, the reactions.

The following description will further 20 esplain the methods of the invention.

Des~ription of the Invent~oP

The preferre~ absorber6 of the present invention use a carbo-ymethylcellulose having a DS of 0.7 or above in order to provi~e sufficient 2scro6s-linking while allowing the hydrophobicity agent to eliminate the glue-like clumping problem.
Although it is not necessary for understanding the invention, it is theorire~ that the metal ion, e.g., aluminum, reacts with the carbo~yl groups on the 30ad~acent chains of carbo~ymethylcellulose, forming an - 6 - 2049 0~

ionic cross-link betweon the chains. The aluminum has a third group thereon, most normally a hydroside group although it could be an isopropyl or acetate group. The hydrophobic group, which most preferably 5 is a small group such a~ acetate or proprionate i~
linke~ to a carbosymethylcellulose residue by aluminum ions as already described for cross-linking. The reason that the shorter chain carbosylic acids are preferred, e.g., acetate or 10 proprionate i8 that with the 6ame Degree of Substitution using larger molecules such as bensoic or palmitic acid, the hydrophobicity is so great that the water is not as easily accessible to the interior of the molecule. To use the longer chain molecules 15 the deqree of hydrophobic substitution must be much lower.

The reason why the particulates of the present invention work 80 well as superabsorbers is not completely understood but is theorized that the 20 Donnan effect may be involved. The Donnan effect relstes to a charge separation whereby having a high concentration of net negative charge in the ~nterior of the particle will cause flow of saline. This type of effect is espected since the absorption for the 25 particulates made using the present methods 1~
improved for saline a~ compared with a ~alt free aqueous solution.

The following Esamples will further illustrate the methods of the invention.

_ 7 _ 2049 05~
E~Q~, In this E~ample, an organic methoa of making the particulate is describe~. In th~s, an~ all the following E~amples, similar carbo~ymethylcellulose S (CMC) was used. ~he carbosymethylcellulose had DS
of about 0.7 and was fir6t tieve~ to remov~ any particles smaller than 500 microns. The particular CMC used was CMC 7H obtained from Agualon.

Five q of CMC was d~ssolved in 4 ml of ,petroleum ether ha~ing a boiling point of 70-90-C.
The petroleum ether contained 1 9 of aluminum isoproposide (Manalo~ 130, Manchem, Princeton, New Jersey). The resulting slurry was stirred at 45-55-C. in a closed ~essel. After 2-4 hours 15 (determined by no further release of isoproponal), 0.4-0.8 g of anhydrous glacial acetic acid is added and stirring is continued for another 1-2 hours.
After completion of the reaction, the solvent is removed from the slurry by filtration, the slurry is 20 washed with other solvents such as petroleum ether and~or anhydride isopropl olcohol and air ~ried.

~ he resulting product was tested by uptake in capillary action with 0.15 N NaCl under applied load of 0.22 lbs.~in2 for si~ty minutes at room 25temperature. ~he mount of fluid uptake was then measured gravimetrically. ~he superabsorber absorbed 15 ml saline~g superabsorber.

- 8 ~ 9 a~3 E~ample 2.

In this E~ample, the same carbo~ymethylcellulose was forme~ into a particle using an aqueous procedure. Fir~t, appro~imately 1 g 5 of the cMe was pre-wet with 0.4 5 of an alcshol ~uch as isopropyl alcohol. The alcohol was remove~ an~
~hen 10 9 of ~aline ~ontaining ~luminum acetate (20 mq~g CMC) ~nd 40 mg glacial acet~c acid wa~
adde~. The reaction wa~ ~llowe~ tc procee~ for 4 10 hours at 50C. The ~wollen parti~les were then 'remove~ an~ drie~ under a hot air ~low~

Using the same test of ~eseribe~ in E~ample 1, the saline uptake under loa~ was approsimately 18 ml/g of superabsorber.

15 E~ampl~

In the Example, the carbo~ymethyleellulose was first allowed to swell for several hours in normal saline (0.9~) before the reactions described in Esample 2 were carried out. By ~llowing the 20 particles to swell to five times their initial weight before reaction, a value of approsimately 17 ml/g was obtained usinq the weight test. ~y allowing the particles to ~well to appro~imately ten times their ~nitial volume, a Yalue of 19 ml~g was cbtaine~. The 25 pre-swelled described herein was ~free~ swelliny, eOg.~ swelling without any applie~ load.

There are several fa~tors which can be modified in order to obtain optimum performance for a 2~l~9~r - g -particulnr ta~k. Fir~t, a more highly cro~ nke~
absorber will exhib~t a ~lower r~t~ o~ 6aline uptake that will be able to hold more tot~l E~line.
Further, ~ the reaction between the hydrophobi~
5agent and the carbosyl~tea cellulos~c mat~rial ~E
carr~e~ out before ~he ~os~ nkin~, ~ more absorbent material ~8 ~orme~. ~n ~ny ca~e, not ~11 of the carbo~yl ~roup~ were invol~e~ in the cross-linking. ~he highly cross-linked materials have 15-20 mole percent cross-linkea wh$1~ in ~ome materials, such as that describe~ in E~ample 2, only 'about 1 mole pPrcent cross-linking ~ use~.

Example 4.

In this E~ample, A low molecular weight 15carbo~ymethylcellulose (CMC) was used as a basis of the particulate superabsorber. Two ~istin~t hydrophobicity agents, a mono~asic acid ~nd a bibasic acid, were use~ to modulate the cross-linking 60 as to obtain a pro~uct having impr~ved properties.
20Without the use of both hydrophobicity aqents, the material becomes too heavily cross-linked to use.

One gram o~ low molecular weight CMC ~Akzo PL820) was mixed with 0. 5 9 of isopropanol. Thirty grams of ~ cross-linking/hydrophobicity agent 25solution was then ad~e~. ~his ~olution was made with 90 mg NaCl~ 20 mg ~lumi~um acet~te~borate, 40 mg glacial aceti~ acid, ana 50 mg fiuccinic acid in 2a ml water. The resulting ~olution ic ~tirrea continuously until a homogene~us 9el i~ ~orme~. The 30~el is then transferred into a 6yri~9e an~ injecte~

- lO_ 20~90~

into lS0 9 of an ~sopropyl alcohol ~olut~on through a 16 gauge nee~le. A white precipltate in the form of small fibers appear~ ~n the alcohol 601ution. She alcohol i8 removed by filtration and evaporation and sthe resulting fiber~ are air drie~.

Using the ~ame test as described in Esample 1, the material showe~ an absorption of lS ml saline~g ~uperabsorber under loa~. The particulate superabsorber also showed a free-~well (swelling lowithout any applie~ load) of 48 ml saline~g ,superabsorber.

A further te~t was conducted with this material by placing the free-swollen superabsorber in a ~tea-bag~ of a non-woven fabric with a 150 mm 15mesh. The tea-baqs were transferred to 50 ml centrifuge tubes and centrifuged to 3000 X g for 30 minutes. At the end of 30 minutes centrifugation, the free fluid was collected. The amount of liquid released was determined gravimetrically. The results 20show a liquid retention after centrifugation of approsimately 22 ml saline~g superabsorber.

In addition to those described above, other means of making a particulate could be used. For esample, a gel could be formed which i~ then 25dehydrated and groun~ to particulate form. Although thi~ procedure can be u~eful, see Esample 1 of the previously cited United ~tates Patent Application Serial No. 320,94~, i6 unlikely to yield particles of a ~ingle ~ize without significant waste of material.
30Further, tests of particulate made u~ing the grinding proc~dure withnut a~ing ad~itional ~ellulo~e (such as describe~ in the ~forementione~ E:~ample~ yiel~e~
an absorption un~er loa~ of 10-18 mlrmg. The values using the methods described herein ~re much mor~
5 consi~tent an~ simpler without yielding pro~lems of gel blocking.

Those skille~ the art will be able to determine other m~ficatiors of the E~ample procedure~ and ma~er~ al~ ~e~ forth herei~. ~;uch 10 other modificat;ons are within the scope of the ,followillg claims.

What is claimed ~s:

Claims

1. A method of making a particulate absorbent material comprising the steps of:

A. reacting a carboxylated cellulosic material with i. a cross-linking agent, and ii. a hydrophobicity agent;

B. separating the reaction product; and C. removing water from said reaction product until it is substantially dehydrated and a particulate is formed of said absorbent material.

2. The method of claim 1 wherein said carboxylated cellulosic compound is selected from the group consisting of carboxymethylcellulose with DS
valves of 0.5 or greater.

3. The method of claim 2 wherein said carboxymethylcellulose reacts with said cross-linking agent before the reaction of said carboxymethylcellulose with said hydrophobicity agent.

4. The method of claim 2 wherein said carboxymethylcellulose reacts with said hydrophobicity agent before the reaction of said carboxymethylcellulose with said cross-linking agent.

5. The method of claim 2 wherein said cross-linking agent is selected from the group consisting of cross-linking agents which include a metal having an effective valence of at least 3.

6. The method of claim 5 wherein said metal ion is selected from the group consisting of aluminum ions, chromium ions, and iron ions.

7. The method of claim 6 wherein said cross-linking agents are selected from the group consisting of aluminum acetate, aluminum isopropoxide, aluminum hydroxide, ferric chloride, and mixtures thereof.

8. The method of claim 2 wherein said hydrophobicity agent is selected from the group consisting of monobasic and polybasic carboxylic acids and salts, chlorides, and anhydrides thereof.

9. The method of claim 8 wherein said carboxylic acid is selected from the group consisting of monobasic and polybasic carboxylic acids having 2-16 carbon atoms, and salts, chlorides, and anhydrides thereof.

10. The method of claim 9 wherein said carboxylic acid agent is selected from the group consisting of acetic acid, proprionic acid, butyric acid, isobutyric acid, acetic chloride, sodium acetate, sodium propionate, proprionyl chloride, sodium butyrate, acetic anhydride, proprionyl anhydride, succinic acid, adipic acid, phthalic acid, citric acid, and mixtures thereof.

11. The method of claim 2 wherein said reactions of said carboxymethylcellulose with said cross-linking agent and said carboxymethylcellulose with said hydrophobicity agent are carried out in an organic solvent.

12. The method of claim 2 wherein said reactions of said carboxymethylcellulose with said cross-linking agent and said carboxymethylcellulose with said hydrophobicity agent are carried out in an aqueous solvent.

13. The method of claim 12 wherein said carboxymethylcellulose is pre-swollen in an aqueous solution before reaction with said cross-linking agent and said hydrophobicity agent.

14. A method of making a particulate absorbent comprising the steps of:

forming an emulsion of carboxymethylcellulose having a DS greater than 0.5 in an organic solvent;

reacting said carboxymethylcellulose with a cross-linking agent selected from the group consisting of primary and secondary chromium and aluminum alkoxides, ferric chloride, aluminum and chromium hydroxides, aluminum and chromium acetates, and mixtures thereof;

reacting the carboxymethylcellulose with a hydrophobicity agent selected from the group consisting of monobasic and polybasic carboxylic acids having 2-16 carbon atoms, and salts, chlorides, and anhydrides thereof; and removing said organic solvent.

15. The method of claim 14 wherein said reaction with said hydrophobicity agent takes place before the reaction with said cross-linking agent.

16. The method of claim 14 wherein said reaction with said cross-linking agent takes place before the reaction with said hydrophobicity agent.

17. A method of making a particulate absorbent comprising the steps of:

swelling particulates of carboxymethylcellulose having a DS greater than 0.5 in an aqueous solvent:

reacting said carboxymethylcellulose with a cross-linking agent selected from the group consisting of primary and secondary chromium and aluminum alkoxides, ferric chloride, aluminum and chromium hydrates, aluminum and chromium acetates, and mixtures thereof;

reacting the carboxymethylcellulose with a hydrophobicity agent selected from the group consisting of monobasic and polybasic carboxylic acids having 2-16 carbon atoms, and salts, chlorides, and anhydrides thereof; and removing said aqueous solvent.

18. The method of claim 17 wherein said reaction with said hydrophobicity agent is carried out before said reaction with said cross-linking agent.

19. The method of claim 17 wherein said reaction with said cross-linking agent is carried out before said reaction with said hydrophobicity agent.

20. The method of claim 17 wherein said carboxymethylcellulose is reacted with an alcohol before the reaction with said cross-linking agent and the reaction with said hydrophobicity agent.