CN102325828B - 亲水性有孔成形膜 - Google Patents

亲水性有孔成形膜 Download PDF

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CN102325828B
CN102325828B CN201080008857.8A CN201080008857A CN102325828B CN 102325828 B CN102325828 B CN 102325828B CN 201080008857 A CN201080008857 A CN 201080008857A CN 102325828 B CN102325828 B CN 102325828B
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fatty alcohol
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A·D·马斯奇诺
A·W·格罗斯
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Abstract

一种特别适合用作吸收制品中的面层或转移层的有孔成形膜，所述成形膜包含至少一种热塑性烯烃聚合物和足以增加所述膜的亲水性的足量的脂肪醇。

Description

亲水性有孔成形膜
背景技术
本发明涉及一次性吸收制品，更具体地涉及有孔真空成形的或液压成形的三维膜，所述膜具有对液体的亲合性。
有孔成形膜是对塑料膜进行加工在膜上产生孔或孔洞的塑料膜。有孔膜通常分为两类：三-维膜和平面膜。所有三维结构的膜具有额定厚度(norminalthickness)，但本发明的“三维膜”(本文中也称为“成形膜”)具有从膜表面延伸至孔穴终止的表面结构或突出物。这些突出物使得所述膜的厚度大于所述膜的额定厚度。这种膜通过厚度或高度(loft)进行表征，其厚度或高度定义为所述膜的基面和由突出物终端的孔限定的第二平面之间的距离。所述第二平面与所述膜的基面隔开并且基本平行。通常，这些突出物具有记忆效应，这样只要不超过膜的变形限度，这些突出物在被压力或张力变形之后能恢复形状。相反，平面有孔膜仅仅是带有孔洞的膜，缺少具有“三维膜”特征的三维记忆效应的表面结构。
本领域中有几种制造有孔膜的方法。可以用任意在膜中添加孔洞的方法制造平面膜。这些方法通常是使用销钉或其它模压的机械方法在前体膜中产生孔洞。对于三维膜，两种最常用的方法是真空成形和液压成形(hydroforming)。专利文献例如US 3939135和US 4324246中列举了一种真空成形方法，它使用真空在膜的一侧产生负压，在膜的相反一侧产生相应的正压。压差使得膜被吸入成形筛中的孔洞从而得到孔。如US4609518所述的液压成形方法使用高压喷水枪来产生冲击膜的液体流从而得到孔。
无论是液压成形法或是真空成形法，本领域已知要将膜支撑在穿孔结构上，本文中表示为成形筛。在直接浇注法中，熔融聚合物通过模头挤出到成形筛上，再进行真空处理。US 4456570描述了这种方法，其通过引用纳入本文。在再加热方法中，将前体膜加热至高于所述膜软化点但低于所述膜熔点的温度，再进行真空处理。所述前体膜可以是铸塑或吹塑膜。US 4151240描述了这种再加热方法，其通过引用纳入本文。
其它类型的有孔膜可以包括但不限于液压成形膜，如美国专利第4609518；4629643；4695422；4772444；4778644；4839216；和4637819号所述，这些都通过引用纳入本文。液压成形法与再加热方法类似，除了采用高压喷水迫使膜进入筛的开孔，从而形成有孔突出物。经常出现这样的情况，同时向膜施加真空以帮助去除并再循环水，但这在形成突出物方面不起作用。
这些年来，发现如果加入表面活性剂的话，可以提高三维膜用于吸收装置面层的功能性。“表面活性剂”是用作润湿剂的化学物质，以降低液体的表面张力并使得液体的“展开性”增加。聚合物膜产品的普通用途是用于防雾和防静电。由于膜由天然疏水的聚合物如热塑性聚烯烃制成，向膜中加入表面活性剂提高了膜的可浸润性，这反过来使得流体铺展在膜上。由于这使得使用者感觉膜较干燥并改进了孔中的流体流动，这在卫生应用中是有益的。众所周知的防雾剂是烷基酚乙氧基化物类、复杂的多元醇单酯类(complex polyol mono-esters)、油酸聚氧乙烯酯类、油酸聚氧乙烯脱水山梨糖醇酯类和脂肪酸脱水山梨糖醇酯类。
首先，常规的做法是向膜局部施用表面活性剂，但目前最好的做法是将表面活性剂加入树脂混合物，以制得具有对液体亲水性的膜。这种方法在前述US4456570中进行了描述。可以在用于卫生应用的成形膜中使用的现代表面活性剂在US 5520875中有所描述，它包括非离子表面活性剂如：醇乙氧基化物，烷基酚乙氧基化物，羧酸酯，甘油酯，脂肪酸聚氧乙烯酯，涉及松香酸的脂族羧酸聚氧乙烯酯，脱水山梨糖醇酯，乙氧基化脱水山梨糖醇酯，乙氧基化天然脂肪、油、和蜡，脂肪酸乙二醇酯，羧酸酰胺，二乙醇胺缩合物，单链醇胺缩合物，聚氧乙烯脂肪酸酰胺，聚环氧烷嵌段共聚物。这种表面活性剂会在膜形成之后迁移到膜的表面或“浮散(bloom)”，以使得膜表面具有亲水性。US6353149公开了选自乙氧基化脂肪醇、乙氧基化烷基酚、乙氧基化脂肪酸单酯、乙氧基化脂肪二酯及其混合物的表面活性剂能加速迁移。
在普遍使用醇和其它可燃溶剂的医院手术室中，避免任何能点燃这些溶剂的静电火花极为重要。抗静电剂是用来处理材料或其表面以降低或消除静电累积的化合物。它的作用是通过吸收空气中的湿气使自身变得导电，从而使表面或材料本身轻微导电。通常抗静电剂的分子同时具有亲水区和疏水区；疏水侧与材料表面相互作用，同时亲水侧与空气湿气相互作用并与水分子结合以形成水的薄层(与防雾表面活性剂相同)。然后该水的薄层向地面传导静电荷使其无法生长，从而排除静电火花。很多抗静电剂基于长链脂族胺(任选地被乙氧基化)、酰胺、磷酸酯、聚乙二醇酯或多元醇。
现有技术中脂肪醇和其它的脂肪成分被“乙氧基化”以用作表面活性剂。窄范围的乙氧基化物(“NRE”)是已知的非离子表面活性剂，其在合适的催化剂(经煅烧或用脂肪酸疏水化的层状化合物)存在下通过环氧乙烷在脂肪醇上的加成作用制得。这些表面活性剂化学性质是本领域众所周知的。
吸收装置现有技术中有对未改性脂肪醇的描述，但其是用于提高干燥度或促进皮肤健康的洗液(lotion)或涂料的混合物中的组分。示例性的现有技术文献包括US 6426444；US 6503526；和US 2008/0287896，这些文献都通过引用纳入本文。
虽然源自植物或动物的脂肪物质的多种组分在形成膜面层现有技术领域中作为表面活性剂和洗液是常见的，但在本发明之前脂肪醇未曾用作挤出树脂掺混物中的迁移表面活性剂。
发明内容
在一个实施方式中，本发明提供了一种三维有孔膜，所述三维有孔膜包含至少一种疏水性热塑性聚合物和足以使所述膜有亲水性的足量的脂肪醇。
在另一个实施方式中，本发明提供了一种包括面层和吸收芯的吸收制品，所述面层包括三维有孔膜，所述三维有孔膜包含至少一种疏水性热塑性聚合物和足以使所述膜有亲水性的足量的脂肪醇。
在另一个实施方式中，本发明提供了一种包括面层、吸收芯和位于所述面层和所述芯之间的转移层的吸收制品，所述面层和所述转移层中的至少一层包括三维有孔膜，所述三维有孔膜包含至少一种疏水性热塑性聚合物和足以使所述膜有亲水性的足量的脂肪醇。
本发明公开的这些和其它方面在参考附图和权利要求进一步阅读说明书后是显而易见的。
发明详述
脂肪醇是从天然脂肪和油衍生的脂族醇，主要指那些源于植物的脂族醇。脂肪醇通常具有偶数个碳原子。从脂肪酸制备得到正-链醇，或者另外表述为醇基(-OH)连接到末端碳原子。其它处理方法会得到醇基连接在碳链中间碳原子上的异醇。下表示出一系列具有相应碳原子数的脂肪醇。
表1
Figure BPA00001423540800041
随着碳原子数减少，脂肪醇的熔点也降低。例如，具有14个碳原子的脂肪醇在大约100℃熔化，具有12个碳原子的脂肪醇在大约24℃熔化(室温)。在设计有孔成形膜用于吸收制品特定用途时，应用的温度限制对设计者来说是显而易见的。如果悬浮在膜中的脂肪醇随着熔化变得粘度过低，脂肪醇可能无法在膜中保持所需的悬浮。随着碳原子数增加，脂肪醇可能变得过粘无法在挤出工艺中进行加工。优选的脂肪醇碳原子范围是8-24，更优选12-20，最优选16-18。
多种孔的形状和孔图案排列是有孔成形膜领域已知的。其设计目的是提高流体传动并赋予所述膜美学和触觉性质。例如，US 4324426公开了孔的等效液压直径如何影响液体传动；US 4342314公开了如何达到独特的纤维状美感；US 4463045公开了利用小的表面像差达到布状触感。这些文献和其它本领域已知的所有的形状和图案排列可以与本发明的实施方式结合使用。
仅出于描述目的，膜被制成具有五边形巢状侧边相接(nested side to side)的孔，这样所述孔通过窄纤维状元件分隔。所述膜每平方厘米包括大约90个孔，开放式区域约20-25％，高度(loft)约500-650微米。高度是成形膜的总厚度，包括孔和任意表面像差的高度。所述膜具有21.7克/m2的基重和随机的无光泽饰面。所述膜使用直接浇注真空成形法制备。所述膜使用通常疏水的聚烯烃掺混物(特别是聚乙烯)制成。在一种膜中，所述掺混物包含大约17,500ppm至20,000ppm的鲸蜡醇。
根据US 4456570所述的方法测定这些膜的溢出值(run off value)。在该文献的第6栏第10-16行描述了试验液体为蒸馏水、氯化钠和Triton X-100(来自陶氏化学公司(Dow Chemical Company)的非离子表面活性剂)的混合物。溢出值范围为0％-2.5％。较高浓度的鲸蜡醇能保证恒定的0％溢出。10,000ppm的浓度得到的溢出值为10-15％，可以认为是尿布面层的下限值。设计用于各种液体粘度和表面张力的其它应用的吸收装置时，添加量约低达500ppm的脂肪醇就足够了，这取决于将要通过面层传送的液体类型。
令人惊讶的是，重复使用硬脂醇的测试没有得到类似的结果。对照膜用不含表面活性剂添加剂的疏水性聚烯烃(聚乙烯)掺混物制得，其溢出值大于80％。仅向掺混物添加量约高达20,000ppm的硬脂醇没有得到小于78％的溢出值。但是，添加组合浓度为20,000ppm的硬脂醇与鲸蜡醇50％/50％的混合物时得到的溢出值为0％。由于鲸蜡醇是更有效的组分，不采用50％/50％比例的掺混物，优选鲸蜡醇作为混合物中的主要脂肪醇。
脂肪醇可以以纯的形式添加到挤出掺混物中或者作为加入预期产品的基础掺混物中任一种已知聚合物中的化合物。这种类型的混合是膜挤出工业中常见的。可以使用任一种相容的热塑性膜成形聚合物获益。特别优选聚烯烃，具体是聚乙烯和聚丙烯，用于卫生和个人护理应用的膜。

Claims (6)

1.一种在吸收装置中用作液体传输层的挤出亲水性有孔成形膜，所述成形膜由至少一种热塑性烯烃聚合物和脂肪醇的掺混物组成，所述脂肪醇的量为10,000-20,000ppm，是硬脂醇与鲸蜡醇的50%/50%的混合物。
2.如权利要求1所述的膜，其特征在于，所述脂肪醇的量至少为20,000ppm。
3.一种包括面层和吸收芯的吸收制品，所述面层包括挤出疏水性有孔成形膜，所述成形膜由至少一种热塑性烯烃聚合物和脂肪醇的掺混物组成，所述脂肪醇的量为10,000-20,000ppm，是硬脂醇与鲸蜡醇的50%/50%的混合物。
4.如权利要求3所述的膜，其特征在于，所述脂肪醇的量至少为20,000ppm。
5.一种吸收制品，它包括面层、吸收芯和位于所述面层和所述芯之间的转移层，所述转移层包括挤出的亲水性有孔成形膜，所述成形膜由至少一种热塑性烯烃聚合物和脂肪醇的掺混物组成，所述脂肪醇的量为10,000-20,000ppm，是硬脂醇与鲸蜡醇的50%/50%的混合物。
6.如权利要求5所述的制品，其特征在于，所述脂肪醇的量至少为20,000ppm。
CN201080008857.8A 2009-02-20 2010-02-19 亲水性有孔成形膜 Expired - Fee Related CN102325828B (zh)

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