CN102066467A - 香的水敏膜 - Google Patents

香的水敏膜 Download PDF

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CN102066467A
CN102066467A CN2009801239712A CN200980123971A CN102066467A CN 102066467 A CN102066467 A CN 102066467A CN 2009801239712 A CN2009801239712 A CN 2009801239712A CN 200980123971 A CN200980123971 A CN 200980123971A CN 102066467 A CN102066467 A CN 102066467A
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film
water
aforementioned
soluble polymers
weight
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CN102066467B (zh
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S·A·芬克
J·H·王
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Abstract

本发明提供由水溶性聚合物基体形成的膜，所述基体中含有至少一种香料。该膜是水敏性的(例如，可溶于水、可分散于水等)，从而在和足量水接触的情况下，聚合物基体随着时间而失去其完整性，逐渐将香料暴露于周围环境以释放其气味。在本发明中，通过控制膜结构的多个方面(包括香料的性质、水溶性聚合物的性质、熔融加工聚合物基体和香料的方式等)实现了能够将香料加入到聚合物基体中。例如，可将香料直接注入挤出机中并和水溶性聚合物熔融共混。按此方式，就不需要将香料加入母粒的昂贵且费时的预包囊或预混炼步骤。此外，为了获得香料在使用中能够释放出所需的气味与在熔融过程中将过早挥发的气味减少到最少之间的平衡，选择沸点(大气压下)在特定范围内的香料，例如从约125℃至约350℃。

Description

香的水敏膜
背景技术
膜用于品种众多的一次性商品中，如尿布、卫生棉、成人失禁衣物、绷带、包装等。在这点上，已进行多种尝试将香料加入到膜中从而它们能够释放所需的气味。例如，已将香料加入包装膜和包装袋中以消除和特定应用(例如，垃圾处理)有关的恶臭。例如，Van Gelder等人的美国专利申请No.2003/0204001中描述了一种用于生产具有香料的聚乙烯或聚丙烯膜的方法。该膜通过下述方法形成：将液体香料加入至聚乙烯或聚丙烯的多孔球粒，将混合物和保味剂(例如，二脂肪酸酰胺)共混，然后将该共混物挤出成粒以形成“母料”。随后可按100∶1至20∶1的比例(聚合物对母料的比例)将母料和聚乙烯或聚丙烯聚合物混合以形成膜。然而，不幸的是，这些技术过于复杂和昂贵，因为它们首先需要形成母料，它们也需要使用保味剂以防止香料的过早挥发。
也已尝试将添加剂加入到膜中使添加剂仅在膜分解时释放。例如，Dihel等人的美国专利申请公开No.2005/0186256中描述了用于释放封装于水溶性密封材料中的物质(例如，香料)的膜。被封装的物质喷洒或喷撒在可溶性膜上。然而，这些技术存在与上面所述的相同的问题。例如，该技术首先需要将物质预包襄，这为制造方法增添了不必要的复杂程度和成本。
因而，目前存在着对将香料加入到膜中的改进技术的需求。
发明概述
根据本发明的一个实施方案，公开了形成香的膜的方法，该方法包括将至少一种水溶性聚合物供给挤出机；将至少一种液体香料注入挤出机中，以形成包含所述水溶性聚合物和香料的共混物，其中，所述液体香料在大气压下的沸点为约125℃至约350℃；以及将共混物挤出到表面上以形成膜。
下面更详细地描述本发明的其它特征和方面。
附图的简要说明
在说明书的其余部分中，针对本领域普通技术人员结合附图对本发明充分的和可实施的公开内容(包括其最佳实施方式)进行更具体的阐述，附图包括：
图1是可用于本发明一个实施方案的挤出机的部分侧面剖视图；和
图2是本发明形成膜的方法的一个实施方案的示意图。
在本说明书和附图中重复使用的附图标记用于表示本发明的相同或相似特征或元件。
发明详述
现在将对本发明的各个实施方案进行详细说明，下面阐述其中的一个或多个实施例。各个实施例作为本发明的说明而提供，不是本发明的限制。事实上，在不脱离本发明范围或精神的情况下可对本发明作多种修改和变化对于本领域技术人员而言是显而易见的。例如，可将作为一个实施方案的一部分说明或描述的特征用于另一个实施方案以得到再一个实施方案。因此，本发明旨在覆盖落入权利要求及其等同方式范围内的这些修改和变化。
一般说来，本发明涉及由水溶性聚合物基体形成的膜，所述基体内含有至少一种香料。该膜是水敏性的(例如，可溶于水、可被水分散等)，从而在与足量水接触时，聚合物基体随着时间而失去其完整性，逐渐将香料暴露于周围环境以释放其气味。在本发明中，通过控制膜结构的多个方面(包括香料的性质、水溶性聚合物的性质、熔融加工聚合物基体和香料的方式等)实现了能够将香料加入到聚合物基体中。例如，可将香料直接注入挤出机中并与水溶性聚合物熔融共混。按此方式，就不需要将香料加入母粒的昂贵且费时的预包囊或预混炼步骤。此外，为了获得香料在使用中能够释放出所需的气味与在熔融加工过程中将过早挥发的气味减少到最少之间的平衡，选择沸点(大气压下)在特定范围内的香料，例如从约125℃至约350℃。
为此，下面将更详细地描述本发明的各个实施方案。
I.膜组分
A.香料
尽管通常任何种类的香料都可用于本发明的膜以产生所需的气味，但采用至少一种在环境温度和压力下处于液体形态的香料。一般选择沸点在一定范围内的液体香料，使得它的挥发性足以产生所需气味，但不至于达到香料的大部分在膜的熔融加工过程中释放的程度。为此，香料的沸点(大气压下)一般为约125℃至约350℃，在一些实施方案中为约150℃至约300℃，而在一些实施方案中为约175℃至约250℃。这样的香料的一些实例可包括：例如，苯甲醛、乙酸苯甲酯、樟脑、香芹酮、冰片、乙酸冰片酯、癸醇、桉油精、芳樟醇、乙酸己酯、乙酸异戊酯、麝香草酚、香芹酚、柠檬烯、薄荷醇、异戊醇、苯乙醇、α-蒎烯、α-萜品醇、香茅醇、α-侧柏酮、苯甲醇、β-γ-己烯醇、二甲基苯甲基甲醇、苯基乙基二甲基甲醇、阿道克醛、环己烷丙酸烯丙酯(allyl cyclohexane propionate)、β-蒎烯、柠檬醛、香茅醇乙酸酯、香茅腈、二氢月桂烯醇、香叶醇、乙酸香叶酯、香叶腈、氢醌二甲基醚、羟基香茅醛、乙酸芳樟酯、苯乙醛二甲缩醛、苯丙醇、乙酸异戊二烯酯、女贞醛、四氢化芳樟醇、乙酸邻叔丁基环己酯(verdox)、顺-3-己烯基乙酸酯等，以及它们的混合物。
当然，其它本领域公知的香料也可用于本发明。例如，这样的香料可包括茴香脑、庚炔羧酸甲酯、乙酰乙酸乙酯、对-伞花烃(para cymene)、橙花醇、癸醛、对甲酚、乙酸苏合香酯、α-紫罗酮、β-紫罗酮、十一烯醛、十一醛、2，6-壬二醛、壬醛、辛醛、苯乙醛、茴香醛、苯甲基丙酮、2-甲基丁酸乙酯、大马烯酮、α-大马酮、β-大马酮、氟乙酸酯(flor acetate)、芬美意(frutene)、苹果酮(fructone)、草质素(herbavert)、异环柠檬醛、甲基异丁烯基四氢吡喃、异丙基喹啉、2，6-壬二烯-1-醇、2-甲氧基-3-(2-甲基丙基)-吡嗪、甲基辛炔碳酸酯、十三烯-2-腈、戊基甘醇酸乙酸烯丙酯、环格逢酯、女贞醛(cyclal C)、甜瓜醛、γ-壬内酯、2-甲基-4-丙基-顺-1，3-氧硫杂环己烷(cis 1，3-oxathiane-2-methyl-4-propyl)等，以及它们的混合物。其它合适的香料描述于美国专利No.4,145,184；4,209,417；4,515,705；和4,152,272，在此出于所有目的将它们全部整体引入作为参考。
B.水溶性聚合物
本发明的膜也包含形成聚合物基体的一种或多种水溶性聚合物，在膜分解前，所述聚合物基体中含有香料。在一个具体的实施方案中，所述水溶性聚合物含有具有官能羟基的重复单元，比如乙烯醇均聚物(例如，“PVOH”)、乙烯醇共聚物(例如，乙烯乙烯醇共聚物、甲基丙烯酸甲酯乙烯醇共聚物等)等。例如，乙烯醇聚合物在分子中具有至少两个或更多个乙烯醇单元，且可以是乙烯醇的均聚物，或含有其它单体单元的共聚物。乙烯醇均聚物可通过乙烯基酯聚合物(如甲酸乙烯酯、乙酸乙烯酯、丙酸乙烯酯等)的水解而获得。乙烯醇共聚物可以由乙烯酯与含有2至30个碳原子的烯烃；含有3至30个碳原子的不饱和羧酸或其酯、盐、酸酐或酰胺；含有3至30个碳原子的不饱和腈；含有3至30个碳原子的乙烯醚等的共聚物水解得到，所述烯烃例如乙烯、丙烯、1-丁烯等；所述不饱和羧酸例如丙烯酸、甲基丙烯酸、巴豆酸、马来酸、富马酸等；所述不饱和腈例如丙烯腈、甲基丙烯腈等；，所述乙烯醚例如甲基乙烯醚、乙基乙烯醚等。
可选择水解度以使聚合物的溶解度等最佳。例如，水解度可为约60摩尔％至约95摩尔％，在一些实施方案中为约80摩尔％至约90摩尔％，而在一些实施方案中为约85摩尔％至约89摩尔％。合适的部分水解的聚乙烯醇聚合物的实例可从Celanese公司以CELVOLTM 203、205、502、504、508、513、518、523、530或540的名称购得。其它合适的部分水解的聚乙烯醇聚合物可从DuPont公司以ELVANOLTM 50-14、50-26、50-42、51-03、51-04、51-05、51-08、和52-22的名称购得。
除上述聚合物外，其它水溶性聚合物也可用于本发明。例如，水溶性聚合物也可由单体形成，所述单体如乙烯基吡咯烷酮、丙烯酸羟乙酯或甲基丙烯酸羟乙酯(例如，甲基丙烯酸2-羟乙酯)、丙烯酸羟丙酯或甲基丙烯酸羟丙酯、丙烯酸或甲基丙烯酸、丙烯酸酯或甲基丙烯酸酯或乙烯基吡啶、丙烯酰胺、乙酸乙烯酯、环氧乙烷以及它们的衍生物等。本发明也可以使用两种或更多种水溶性聚合物的混合物或共混物，以提供均衡的水溶性、熔融加工性、机械性能和或物理性能。水溶性聚合物的共混物的实例包括Wang等人的美国专利6,958,371中公开的聚乙烯醇和聚氧化乙烯的共混物。合适的单体的其它实例记载在James等人的美国专利No.4,499,154中，在此出于所有目的将这些专利整体引入作为参考。
也可使用经过化学改性(例如，酯化、醚化、氧化、酶水解等)以使其通常可溶于水的淀粉。特别希望的是淀粉醚和/或酯，如羟烷基淀粉、羧甲基淀粉等。羟烷基淀粉的羟烷基可含有，例如，2至10个碳原子，在一些实施方案中可含有2至6个碳原子，而在一些实施方案中可含有2至4个碳原子。代表性的羟烷基淀粉如羟乙基淀粉、羟丙基淀粉、羟丁基淀粉，以及它们的衍生物。淀粉酯，例如，可使用多种酐(例如，乙酸酐、丙酸酐、丁酸酐等)、有机酸、酰基氯或其它酯化试剂而制备。酯化度可根据需要而变，例如每糖苷单元的淀粉1至3个酯基。淀粉的来源可以变化，但代表性地包括谷粒的种子，如玉米、糯玉米、小麦、高粱、大米和糯米；块茎类，如马铃薯；根类，如木薯淀粉(即，木薯和树薯)、甘薯和竹芋；和西谷椰子瓤。
水溶性聚合物通常具有较低的粘度以提高它们和香料的熔融相容性。按此方式，得到的膜基本上没有多个明确的相，否则这些相会使香料成为屏障限制水溶性聚合物与水的接触而分散的能力。例如，所述水溶性聚合物的溶液粘度可为约50至约800毫帕斯卡秒(mPa·s)，在一些实施方案中为约100至约700mPa·s，而在一些实施方案中为约200至约600mPa·s。溶液粘度根据ASTM-D 1343-56第8部分，1958，486页通过Hoeppler落球法在20℃按4％水溶液测量。可以选择聚合物的分子量以实现所需粘度。例如，乙烯醇聚合物的数均分子量(“Mn”)一般为约1,000至约80,000克每摩尔，在一些实施方案中为约5,000至约60,000克每摩尔，而在一些实施方案中为约10,000至约40,000克每摩尔。同样，乙烯醇聚合物的重均分子量(“Mw”)也可为约10,000至约150,000克每摩尔，在一些实施方案中为约20,000至约100,000克每摩尔，而在一些实施方案中为约30,000至约75,000克每摩尔。另一方面，淀粉可具有较高的分子量，如数均分子量(“Mn”)为约50,000至约1,000,000克每摩尔，在一些实施方案中为约75,000至约800,000克每摩尔，而在一些实施方案中为约100,000至约600,000克每摩尔，以及重均分子量(“Mw”)为约5,000,000至约25,000,000克每摩尔，在一些实施方案中为约5,500,000至约15,000,000克每摩尔，而在一些实施方案中为约6,000,000至约12,000,000克每摩尔。
无论使用何种具体的聚合物，本发明也可使用增塑剂以使水溶性聚合物可熔融加工。合适的增塑剂可包括，例如，多元醇增塑剂，如糖(例如，葡萄糖、蔗糖、果糖、棉子糖、麦芽右旋糖、半乳糖、木糖、麦芽糖、乳糖、甘露糖和赤藓糖)、糖醇(例如，赤藓糖醇、木糖醇、麦芽糖醇、甘露糖醇和山梨糖醇)、多元醇(例如，乙二醇、甘油、丙二醇、二丙二醇、丁二醇、和己三醇)等。不具有羟基基团而由氢键形成的有机化合物也是合适的，包括尿素和尿素衍生物；糖醇的酐，如山梨糖醇的酐；动物蛋白，如明胶；植物蛋白，如向日葵蛋白、大豆蛋白、棉子蛋白；以及它们的混合物。其它合适的增塑剂以可包括：邻苯二甲酸酯、琥珀酸二甲酯和琥珀酸二乙酯以及相关的酯类、甘油三乙酸酯、甘油单乙酸酯和甘油二乙酸酯、甘油单丙酸酯、甘油二丙酸酯和甘油三丙酸酯、丁酸酯、硬脂酸酯、乳酸酯、柠檬酸酯、己二酸酯、硬脂酸酯、油酸脂和其它酸酯。也可以使用脂肪族酸，如乙烯和丙烯酸的共聚物、马来酸接枝的聚乙烯、聚丁二烯-共-丙烯酸、聚丁二烯-共-马来酸、聚丙烯-共-丙烯酸、聚丙烯-共-马来酸，和其它烃基酸。优选低分子量的增塑剂，如分子量小于约20,000克/摩尔，优选小于约5,000克/摩尔，更优选小于约1,000克/摩尔。
一般地，膜中的水溶性聚合物与增塑剂的重量比可以为约1至约50，在一些实施方案中为约2至约25，而在一些实施方案中为约3至约15。例如，增塑剂和水溶性聚合物的共混物(“增塑的水溶性聚合物”)可含有约1重量％至约40重量％的增塑剂，在一些实施方案中为约2重量％至约30重量％，而在一些实施方案中为约5重量％至约25重量％；还含有约60重量％至约99重量％的水溶性聚合物，在一些实施方案中为约70重量％至约98重量％，而在一些实施方案中为约75重量％至约95重量％。
通过选择性控制水溶性聚合物的性质(例如，分子量、粘度等)、增塑剂的性质和水溶性聚合物与增塑剂的相对量，增塑的水溶性聚合物可以实现与香料相符合的熔融粘度，这进一步有助于在膜形成过程中使相分离最小化。例如，增塑的水溶性聚合物在195℃的温度和1000秒-1的剪切速率下的表观熔融粘度可为约10至约400帕斯卡秒(Pa·s)，在一些实施方案中为约20至约200Pa·s，而在一些实施方案中为约30至约100Pa·s。
也可选择膜中使用的水溶性聚合物与香料的相对量以有助于进一步使相分离最小化。例如，水溶性聚合物和香料的重量比一般为约1至约500，在一些实施方案中为约10至约200，而在一些实施方案中为约20至约80。例如，香料可占膜的约0.1重量％至约15重量％，在一些实施方案中为约0.5重量％至约10重量％，而在一些实施方案中为约1重量％至约5重量％。水溶性聚合物可占膜的约40重量％至约99.9重量％，在一些实施方案中为约50重量％至约99.5重量％，而在一些实施方案中为约60重量％至约99重量％。同样，当使用时，增塑剂可占膜的约1重量％至约30重量％，在一些实施方案中为约2重量％至约25重量％，而在一些实施方案中为约5重量％至约20重量％。
C.其它组分
也可按本领域所公知将其它组分加入膜中。例如，所述膜可含有一种或多种可生物降解的聚酯。术语“可生物降解的”通常是指能在天然产生的微生物(如细菌、真菌和藻类)、环境热、水分或其它环境因素的作用下发生降解的物质，例如，可以根据ASTM测试法5338.92来测定。合适的可生物降解的聚酯的实例包括脂肪族聚酯(如聚己酸内酯)、聚酰胺酯、改性的聚对苯二甲酸乙二酯、聚乳酸(PLA)及其共聚物、基于聚乳酸的三聚物、聚乙醇酸、聚亚烷基碳酸酯(如聚亚乙基碳酸酯)、聚羟基烷酸酯(PHA)、聚3-羟基丁酸酯(PHB)、聚3-羟基戊酸酯(PHV)、聚3-羟基丁酸酯-共-4-羟基丁酸酯、聚3-羟基丁酸酯-共-3-羟基戊酸酯的共聚物(PHBV)、聚3-羟基丁酸酯-共-3-羟基己酸酯、聚3-羟基丁酸酯-共-3-羟基辛酸酯、聚3-羟基丁酸酯-共-3-羟基癸酸酯、聚3-羟基丁酸酯-共-3-羟基十八酸酯、和基于琥珀酸酯的脂肪族聚合物(例如，聚丁二酸丁二酯、聚丁二酸己二酸丁二酯、聚丁二酸乙二酯等)；芳香族聚酯和改性的芳香族聚酯；和脂肪族-芳香族共聚酯。例如，可生物降解的聚酯可以是具有如下结构的脂肪族-芳香族共聚酯：
Figure BPA00001279636900071
其中，
m为2到10的整数，在一些实施方案中为2到4，而在一个实施方案中为4；
n为0到18的整数，在一些实施方案中为2到4，而在一个实施方案中为4；
p为2到10的整数，在一些实施方案中为2到4，而在一个实施方案中为4；
x为大于1的整数；并且
y为大于1的整数。这样的共聚酯的一个实例是聚己二酸-对苯二甲酸-丁二醇酯，可从BASF公司以ECOFLEX
Figure BPA00001279636900072
F BX 7011的名称商购得到。。含有芳香族对苯二甲酸单体成分的合适的共聚酯的另一实例可从IREChemicals(韩国)以ENPOLTM 8060M的名称购得。其它合适的脂肪族-芳香族共聚酯可以为记载在美国专利No.5,292,783、5,446,079、5,559,171、5,580,911、5,599,858、5,817,721、5,900,322和6,258,924中的那些，在此出于所有目的将这些专利整体引入作为参考。当使用时，可生物降解的聚酯一般占膜的约1重量％至约40重量％，在一些实施方案中为约2重量％至约35重量％，而在一些实施方案中为约5重量％至约30重量％。
除上述组分外，也可将其它添加剂加入到本发明的膜中，如增滑添加剂(例如，脂肪酸盐、脂肪酸酰胺等)、增溶剂(例如，功能化的聚烯烃)、分散助剂、熔融稳定剂、加工稳定剂、热稳定剂、光稳定剂、抗氧化剂、热老化稳定剂、增白剂、抗粘连剂、粘合剂、润滑剂、填料等。例如，分散助剂也可以用于帮助使生物可降解聚合物与香料均匀分散以及延缓或防止其分离成多个成分相。同样，分散助剂也可改善膜的水分散性。当使用时，分散助剂通常占膜的约0.01重量％至约15重量％，在一些实施方案中为约0.1重量％至约10重量％，而在一些实施方案中为约0.5重量％至约5重量％。尽管本发明通常可使用任何分散助剂，但具有特定亲水/亲油平衡(“HLB”)的表面活性剂可改进组合物的长期稳定性。HLB系数在本领域是公知的，是衡量化合物在倾向亲水性溶液和倾向亲油性溶液之间的平衡的量度。HLB的数值范围为1至大约50数值越小表示亲油性倾向越大，数值越大表示亲水性倾向越大。。在本发明的一些实施方案中，表面活性剂的HLB值为约1至约20，在一些实施方案中为约1至约15，而在一些实施方案中为约2至约10。如果需要，可采用HLB值在所需值以下或以上的两种或更多种表面活性剂，但总的平均HLB值在所需范围内。
特别适合用于本发明的一类表面活性剂是非离子型表面活性剂，其一般具有疏水基(如长链烷基基团或烷基化的芳基基团)和亲水链(如含有乙氧基和/或丙氧基的链)。例如，可使用的一些合适的非离子型表面活性剂包括，但不限于，乙氧基化的烷基酚、乙氧基化的脂肪醇和丙氧基化的脂肪醇、甲基葡萄糖的聚乙二醇醚、山梨醇的聚乙二醇醚、氧化乙烯-氧化丙烯嵌段共聚物、乙氧基化的脂肪酸(C8-C18)的酯、氧化乙烯与长链胺或酰胺的缩合产物、氧化乙烯与醇的缩合产物、脂肪酸酯、长链醇的甘油单酯或甘油二酯以及它们的混合物。在一个特别的实施方案中，所述非离子表面活性剂可以是脂肪酸酯，如蔗糖脂肪酸酯、甘油脂肪酸酯、丙二醇脂肪酸酯、脱水山梨醇脂肪酸酯、季戊四醇脂肪酸酯、山梨醇脂肪酸酯等。用于形成这些酯的脂肪酸可以是饱和或不饱和的，取代或未取代的，并可含有6到22个碳原子，在一些实施方案中为8到18个碳原子，而在一些实施方案中为12到14个碳原子。在一个具体的实施方案中，可在本发明中使用脂肪酸的甘油单酯和甘油二酯。
也可在本发明中使用填料。填料为可以加入膜聚合物挤出共混物中且不会对挤出的膜产生化学干扰，但可以在整个膜中均匀分散的颗粒或其它形式的材料。填料可用作各种目的，包括增强膜的不透明度和/或透气性(如可透过蒸气和基本上不可透过液体)。例如，可以通过拉伸使填料从聚合物中脱离而产生微孔通道，从而使填充的膜变得透气。可透气的微孔弹性膜记载在，例如McCormack等人的美国专利No.5,997,981、6,015,764和6,111,163、Morman等人的5,932,497、Taylor等人的6,461,457中，此处出于所有目的将这些专利全部引入作为参考。此外，在膜的生产中常将受阻酚用作抗氧化剂。一些合适的受阻酚包括可从Ciba Specialty Chemicals以″Irganox
Figure BPA00001279636900091
”的名称购得的受阻酚，如Irganox
Figure BPA00001279636900092
1076、Irganox1010或IrganoxE 201。此外，也可将粘合剂加入膜中以促进膜与其它材料(例如，无纺网幅)的粘合。这样的粘合剂的实例包括氢化烃树脂。其它合适的粘合剂记载在Kieffer等人的美国专利No.4,789,699和McCormack的5,695,868中，在此处于所有目的将这些专利整体引入作为参考。
II.膜的制造
如上面指出的，一般直接将液态的香料注入挤出机中并与水溶性聚合物熔融共混。按此方式，不需要昂贵且耗时的香料的预包囊或预混炼步骤。例如，参照图1，说明了可为此目的使用的挤出机80的一个实施方案。如图所示，挤出机80包括壳体或料筒114和在一端可由合适的驱动器124(一般包括马达和变速箱)旋转驱动的螺杆120(例如，阻挡螺杆)。如果需要的话，可使用具有两个单独螺杆的双螺杆挤出机。挤出机80通常包括三个部分：进料段132，熔融段134和混合段136。进料段132是加入塑性材料的料筒114的输入部分。熔融段134是塑性材料由固体转变为液体的相变区域。混合段136与料筒114的输出端相邻，并且是将液体塑性材料完全混合的部分。虽然在制造挤出机时没有对这些段进行精确的划分，但是具有本领域普通技能的人能够鉴别出发生固体至液体相变的挤出机料筒114的熔融段134。
料斗40也位于驱动器124附近，用于通过料筒114的开口142将水溶性聚合物和/或其它材料(例如，增塑剂)供给进料段132。与驱动器124相对的是挤出机80的输出端144，挤出的塑料在这里输出，用于进一步加工成膜，下面将更详细地对它进行描述。液体香料供应站150也设置于挤出机料筒114上，包括至少一个料斗154，所述料斗与泵160相连以选择性地通过开口162将液体香料供给熔融段134。按此方式，可通过一致和均匀的方式将香料和水溶性聚合物混合。当然，除了将液体香料供给熔融段134之外或者代替将液体香料供给熔融段134，也应理解的是，可以将液体香料供给挤出机的其它区域，如进料段132和/或混合段136。
泵160可以是具有注射阀的高压泵(例如，容积式泵)以将稳定的选择量的香料量供给料筒114。如果需要，也可使用可编程逻辑控制器170将驱动器124和泵160相连，从而提供基于螺杆120的传动比的选定体积的香料。也就是说，控制器170可控制驱动器螺杆120和泵160的旋转速率以按照基于螺杆转速的速率注入香料。因此，如果增大螺杆120的转速以在给定的单位时间内驱动更大量的塑性材料通过料筒114，可同样增大泵160的泵速以相应地将更大量的香料泵入料筒114。
一旦注入挤出机80，可在高剪切/压力和热量下将香料和水溶性聚合物共混以保证充分混合。例如，熔融共混可在约75℃至约350℃的温度下进行，在一些实施方案中为约100℃至约300℃，而在一些实施方案中为约150℃至约250℃。同样地，在熔融混合过程中的表观剪切速率可以为约100秒钟-1至约10,000秒钟-1，在一些实施方案中为约500秒钟-1至约5000秒钟-1，而在一些实施方案中为约800秒钟-1至约1200秒钟-1。表观剪切速率等于4Q/πR3，其中Q为聚合物熔体的体积流速(“m3/s”)，R为聚合物熔体流经的毛细管(例如，挤出机模头)的半径(“m”)。
任何已知技术都可以用于由共混材料制成膜，包括吹制、流延、平模挤出等。在一个特别的实施方案中，膜可以通过吹制法形成，其中通过环形模口用气体(例如，空气)将挤出的聚合物共混物的气泡膨胀。然后该气泡塌陷并以平膜形态收集。生产吹制膜的方法记载在例如，Raley的美国专利No.3,354,506；Schippers的3,650,649；和Schrenk等人的3,801,429以及McCormack等人的美国专利申请公开No.2005/0245162和Bogqs等人的2003/0068951中，在此出于所有目的将这些专利整体引入作为参考。然而，在另一个实施方案中，用流延技术成膜。
例如，参考图2，显示了用于形成流延膜的方法的一个实施方案。在该实施方案中，按照上面所述和图1所示的方式将原料(未示出))供给挤出机80，然后流延到流延辊90上以形成单层的前体膜10a。如果要生产多层膜，将多层一起共挤出到流延辊90上。流延辊90可任选地具有压花元件以为膜提供图案。一般将流延辊90保持在足以使形成的片材10a固化和冷却的温度下，如约20℃到60℃。如果需要，可在流延辊90附近放置真空箱以助于保持前体膜10a靠近辊90的表面。另外，当前体膜10a绕着旋转辊移动时，气刀或静电栓可以有助于把前体膜10a压在铸造轧辊90上。气刀是本领域所公知的装置，它以非常高的流动速率集中一股空气流钉住膜的边缘。
一旦流延完成，然后可沿着一个或多个方向任选地使膜取向以进一步改进膜的均匀性和降低厚度。取向也可在含有填料的膜中形成微孔，由此为膜提供透气性。例如，可立即将膜再加热至低于膜的一种或多种聚合物的熔点，但足够高以使组合物被拉伸或延展的温度。在进行连续取向时，用以不同旋转速度旋转的辊拉伸“被软化的”膜，使膜片在纵向(机器方向)上被延展至期望的拉伸比。随后可以将该“单向”取向的膜层压为纤维状网。此外，还可以使单向拉升取向的膜在横向上进行取向，以形成“双取向的”膜。例如，可以用链夹(chain clip)夹紧膜的横向边缘后将其送入拉幅炉(tenter oven)中。膜在拉幅炉内被再次加热，并从横向被位于其拉伸方向上的链夹拉伸至期望的拉伸比。
例如，再次参考图2，显示了一种用于形成单向取向膜的方法。如图所示，使前体膜10a进入膜取向单元100或纵向取向器(“MDO”)，如商购自Providence，Rhode Island的Marshall and Willams公司的产品。MDO具有多个(如5-8个)沿着纵向逐渐将膜拉伸并减薄的拉伸辊，所述纵向为膜通过图2所示方法中的运动方向。尽管所示的MDO 100具有八个辊，但应理解辊的是，辊的数目可以更高或更低，取决于所需的拉伸水平和各个辊之间的拉伸程度。可以通过一个或多个独立的拉伸操作对膜进行拉伸。应当说明的是，MDO设备中的部分辊可能不能以逐渐提高的速度运行。如果需要，MDO 100的一些辊可充当预热辊。如果存在预热辊的话，先用这少数辊将膜10a加热至超过室温(例如，加热至125℉)。MDO中相邻辊的逐渐加快速度，用于拉伸膜10a。拉伸辊转速的选择决定膜的拉伸量和最终膜的重量。
然后可将得到的膜10b卷绕并保存在卷绕辊60上。尽管图中未示出，但在不脱离本发明的精神和范围的情况下可进行本领域公知的多种另外的可能处理和/或精加工步骤，如切缝、处理、钻孔、印刷图案或将膜与其它层(例如，无纺网幅材料)进行层压。
得到的水敏膜的厚度通常可根据所需用途而变化。不过，一般使膜的厚度最小化，以减少膜分散在水中所需的时间。因此，在本发明的大多数实施方案中，水敏膜的厚度为约50微米或以下，在一些实施方案中为约1至约100微米，在一些实施方案中为约5至约75微米，而在一些实施方案中为约10至约60微米。
虽然具有这样小的厚度和在水中良好的敏感性，不过本发明的膜能够在使用过程中保持良好的干燥机械性质。极限拉伸强度是能反映膜的相对干燥强度的一个参数，它等于应力-应变曲线中得到的峰值应力。如所预期的，本发明的膜表现出纵向(“MD”)的极限拉伸强度为约1至约50兆帕斯卡(Mpa)，在一些实施方案中为约5至约40MPa，而在一些实施方案中为约10至约30MPa；横向(“CD”)的极限拉伸强度为约1至约50兆帕(Mpa)，在一些实施方案中为约5至约40MPa，而在一些实施方案中为约10至约30MPa。尽管具有良好的强度，但该膜也不会过于僵硬。杨氏弹性模量是能反映膜的相对刚度(干燥时)的一个参数，它等于拉伸应力与拉伸应变的比值，由应力-应变曲线的斜率决定。例如，膜在纵向(“MD”)的杨氏模量一般为约100至约1500兆帕斯卡(“MPa”)，在一些实施方案中为约200至约1000MPa，而在一些实施方案中为约300至约900MPa；横向(“CD”)的杨氏模量为约75至约1200兆帕斯卡(“MPa”)，在一些实施方案中为约175至约900MPa，而在一些实施方案中为约250至约850MPa。
本发明的膜可以是单层的或多层的。多层膜可通过层的共挤出、挤压涂布或通过任何常规的形成层的方法制备。这样的多层膜通常包括至少一个基层和至少一个表层，也可以包括任意所需数量的层。例如，多层膜可以由一个基层和一个或多个表层形成，其中，所述基层由水溶性聚合物和香料的共混物形成。在大多数实施方案中，表层也由上述共混物形成。然而，应该理解其它聚合物也可用于表层。
III.制品
本发明的水敏层可用于多种应用。例如，如上所述，膜可用于吸收性制品。“吸收性制品”泛指任何能吸收水或其它流体的物品。一些吸收性制品的实例包括，但不限于，个人护理吸收性制品，如尿布、训练裤、吸收衬裤、防失禁用品、女性卫生用品(例如，卫生棉、卫生巾等)、泳装、婴儿拭巾等；医用吸收性制品，如服装、开窗术材料、内衬垫、床垫、绷带、吸收帘和医用拭巾；餐巾；衣着用品等。这样的吸收性制品的几个实例记载在DiPalma等人的美国专利No.5,649,916；Kielpikowski的6,110,158；Blaney等人的6,663,611中，在此出于所有目的将这些专利整体引入作为参考。其它合适的制品品记载在Fell等人的美国专利申请公开No.2004/0060112A1，以及Damico等人的美国专利No.4,886,512；Sherrod等人的5,558,659；Fell等人的6,888,044；Freiburger等人的6,511,465中，在此出于所有目的将这些专利整体引入作为参考。当用于吸收性制品时，本发明的膜可形成吸收性制品的底层、顶层、隔离衬里、腰带、侧板和/或本领域所公知的任何其它材料或组件。
当然，本发明的水敏膜是多用途的，也可用于制造其它种类的制品。例如，该膜可用作多种产品的包装膜，如食品、组织、医疗产品、衣服、吸收性制品(例如，尿布)等。该膜也可用作马桶的盖子、通马桶器等。
参照下列实施例可更好地理解本发明。
试验方法
拉伸性能：
基本上根据ASTM Standard D638-99测定条的拉伸强度。使用常速拉伸型的拉伸测定仪。拉伸测定系统是Sintech 1/D拉伸测定仪，可从北卡罗来纳州Cary的Sintech公司购得。拉伸测定仪上安装有MTS公司的TESTWORKS 4.08B软件以支持测试的进行。选择适当的载荷元件使得测试值落入满载荷的10-90％内。测试前，先将膜样品剪切成中心宽度为3.0mm的狗骨头形状。将样品固定在正面和反面为25.4毫米×76毫米的夹具之间。夹具的表面涂胶，使夹具的较长方向垂直于拉力方向。夹具的压力通过气动保持为每平方英寸40磅的。用长度为18.0毫米的标距长度、断裂灵敏度为40％来进行拉伸测试。在纵向方向施加测试载荷对五个样品进行测试，并在横向方向施加测试载荷对另五个样品进行测试。测试过程中，以每分钟约127毫米的十字头速度对样品十字方向进行延伸直到发生断裂。测量断裂时在纵向(“MD”)和横向(“CD”)上的模量、峰值应力和伸长量。
水分解测试：
在铰台上使用“溅泼箱”测试自来水中的膜分解速率，所述溅泼箱的物理尺寸为14″×18″×12″的高塑料箱。平台的一端连接往复式凸轮。通常振幅是±2″(4″范围)，溅泼按每秒0.5-1.5次溅泼进行。优选的作用是每秒0.9-1.3次溅泼。测试过程中，溅泼箱随着内部的水上下晃动，来回“溅泼”。该作用在易分散于水中的样品上产生波峰和间歇运动。为了不进行图像分析而定量测量样品膜在水中的分解，仅计时就足够了。将三升自来水加入到溅泼箱中并在箱中得到约5.5″深的水。选择3.5的频率进行测试。将各个膜样品切成1″×3″的尺寸。将三片投入溅泼箱中。在限定的条件下分解每种样品的时间均记录两次。然后记录样品分解时间的平均值。通常，在6小时的搅动时间内，不存在尺寸大于25mm2的片材时，膜达到可接受的分散点。
实施例1
制备一系列含有增塑的聚乙烯醇“PVOH”(Aqua-SolTM 116，从A.Schulman有限公司购得)和Firmenich 179132 Fresh Linen香料(瑞士Geneva的Firmenich)的共混物。使用Thermo Prism双螺杆挤出机(ThermoElectron公司)将PVOH树脂与香料熔融混炼。使用K-Tron(Pitman，NJ)的测重聚合物进料器将PVOH树脂球粒供入挤出机的窄口。Thermo Prism由十个区域组成，其中液体注入口在区4和区8。随着球粒的加入，用液体注射泵(由Eldex Laboratories股份有限公司，Napa，CA制造)将香料油注入到位于挤出机的区4的聚合物熔融物中。按基于聚合物进料速率的2％、4％和6％将香料加入到可分散于水的聚合物中，并用下面表1所示的条件。线股在离开挤出机时被冷却，并随后粒化用于膜流延。
还在Thermo Prism双螺杆挤出机上进行膜流延；然而，将线股模头换为膜模头。流延的条件列于下表2中。
Figure BPA00001279636900151
Figure BPA00001279636900161
实施例2
用从俄亥俄州Akron的A.Schulman购得的Aqua-SolTM 116 PVOH和从瑞士Geneva的Firmenich购得的Firmenich 447779香料(薄荷醇、桉树油和樟脑)制备共混物。通过测重进料器将基于淀粉的和PVOH树脂注入挤出机窄口并与在区4以液体注入挤出机中的香料熔融共混。代替挤出香的聚合物线股、粒化，然后膜流延地，用与双螺杆挤出机连接(区11)的流延膜模头在一个步骤中进行挤出和膜流延。挤出条件列于下表3中。
在膜的两个水平中很容易地检测到Fresh Linen香味(Firmenich 179132)。也检测到Firmenich 447779，但当膜是湿的并开始溶解时最为显著。
实施例3
制备多个轻香的基于淀粉的膜。
通过将70％的Cargill天然玉米淀粉和30％的Archer-Daniel-Midland公司，Decatur，IL的山梨醇和2％P40S表面活性剂(Kao公司，日本)干共混制备热塑性淀粉(“TPS”)。然后将百分之三十来自DuPont的ElvanolTM 51-05聚乙烯醇加入到玉米TPS中以制备总的70/30玉米TPS/PVOH共混物。通过K-Tron粉末进料器将该70/30共混物注入挤出机窄口。在区4将Firmenich 179132 Fresh Linen加入挤出机中并与热塑性熔融物混合。在膜流延前将得到的聚合物线股冷却并粒化。下表4列出了热塑性淀粉-香料加入转变加工过程中的挤出条件。
然后在吹膜流延前，将香的玉米TPS/PVOH树脂和ECOFLEX
Figure BPA00001279636900211
F BX 7011(BASF)干共混。制备三种共混物：1)56/24/20玉米TPS/PVOH/ECOFLEX
Figure BPA00001279636900212
(大部分为TPS共混物)，2)49/21/30玉米TPS/PVOH/ECOFLEX
Figure BPA00001279636900213
，和3)15/6/79玉米TPS/PVOH/ECOFLEX(大部分为ECOFLEX
Figure BPA00001279636900215
共混物)。吹膜加工的条件列于下表5中，膜的拉伸性能结果列于下表6中。
Figure BPA00001279636900221
如上所示，用大部分Ecoflex制成的膜比用大部分玉米TPS制成的膜具有更好的膜性能。两种膜都具有特征的Fresh Linen香味，不过在含有2％香料的膜中香味强得多。
虽然通过其具体实施方案详细描述了本发明，但本领域技术人员理解，在获得对上述内容的理解后，可容易想到这些实施方案的替换、变化和等价。因此，本发明的范围应被认为是所附的权利要求及其等同方式的范围。

Claims (19)

1.一种用于形成香的膜的方法，该方法包括：
将至少一种水溶性聚合物供给挤出机；
将至少一种液体香料注入到挤出机中，以形成包含所述水溶性聚合物和香料的共混物，其中所述液体香料在大气压下的沸点为约125℃至约350℃；和
将所述共混物挤出到表面上形成膜。
2.权利要求1所述的方法，其中，所述香料在大气压下的沸点为约175℃至约250℃。
3.权利要求1或2所述的方法，其中，所述水溶性聚合物包括乙烯基吡咯烷酮、丙烯酸羟乙酯或甲基丙烯酸羟乙酯、丙烯酸羟丙酯或甲基丙烯酸羟丙酯、丙烯酸或甲基丙烯酸、丙烯酸酯或甲基丙烯酸酯或乙烯基吡啶、丙烯酰胺、乙酸乙烯酯、乙烯醇、环氧乙烷、改性淀粉或它们的组合。
4.前述权利要求中任一项所述的方法，其中，所述水溶性聚合物包括乙烯醇聚合物。
5.前述权利要求中任一项所述的方法，其中，所述水溶性聚合物包括改性淀粉。
6.前述权利要求中任一项所述的方法，该方法还包括将增塑剂供给所述挤出机。
7.权利要求6所述的方法，其中，在将增塑剂供给挤出机前将其与所述水溶性聚合物混合。
8.权利要求6所述的方法，其中，所述增塑剂包括多元醇。
9.前述权利要求中任一项所述的方法，其中，所述香料占所述膜的约0.1重量％至约15重量％。
10.前述权利要求中任一项所述的方法，其中，所述香料占所述膜的约1重量％至约5重量％。
11.前述权利要求中任一项所述的方法，其中，所述膜中的水溶性聚合物与香料的重量比为约20至约80。
12.前述权利要求中任一项所述的方法，其中，在约75℃至约350℃的温度下进行挤出。
13.前述权利要求中任一项所述的方法，其中，将所述液体香料注入所述挤出机的熔融段。
14.前述权利要求中任一项所述的方法，其中，将所述水溶性聚合物供给所述挤出机的料斗。
15.前述权利要求中任一项所述的方法，该方法还包括将至少一种可生物降解的聚酯供给所述挤出机。
16.前述权利要求中任一项所述的方法，其中，所述可生物降解的聚酯包括脂肪族-芳香族共聚酯。
17.一种水敏性香膜，其由前述权利要求中任一项所述的方法形成。
18.一种吸收性制品，其包括权利要求17所述的膜，其中，所述吸收性制品包括主体部分，所述主体部分包括可透过液体的顶层、通常不可透过液体的底层，和位于所述底层和顶层之间的吸收芯。
19.一种包装，其包括权利要求17所述的膜。
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US8927617B2 (en) 2015-01-06
EP2294115A2 (en) 2011-03-16
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KR101676044B1 (ko) 2016-11-14
EP2294115A4 (en) 2013-09-04
WO2010001269A2 (en) 2010-01-07
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