CN1125391A - 高芯吸液体吸收剂复合材料 - Google Patents

高芯吸液体吸收剂复合材料 Download PDF

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Publication number
CN1125391A
CN1125391A CN94192426A CN94192426A CN1125391A CN 1125391 A CN1125391 A CN 1125391A CN 94192426 A CN94192426 A CN 94192426A CN 94192426 A CN94192426 A CN 94192426A CN 1125391 A CN1125391 A CN 1125391A
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Prior art keywords
composite
wettability
superabsorbents
liquid
fiber
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Granted
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CN94192426A
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CN1191802C (zh
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D·M·杰克逊
B·J·马修斯
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Kimberly Clark Corp
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Kimberly Clark Corp
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Abstract

公开了一种高芯吸的液体吸收剂复合材料，适于包括个人卫生产品在内的许多用途，也公开了该吸收剂复合材料的制备方法。吸收剂复合材料由约5-20％可湿性细纤维、约3-30％木浆纤维、约50-90％超吸收剂和约0-10％粘合剂的相对均匀的混合物制成，所有百分数均以干重计算，该混合物被压制成密度约0.1-0.5克/立方厘米、1小时垂直芯吸高度至少约10厘米的复合材料。制备方法包括形成50-90％可湿性细纤维和10-50％木浆纤维的片材，然后将片材在空气气流中纤维化成为许多单个的纤维，再混入超吸收剂并沉积在成型表面上形成复合材料，然后压制到所需的密度。

Description

高芯吸液体吸收剂复合材料
                   发明背景
本发明涉及一种超吸收剂(Superabsorbent)含量高的蓬松体/木浆吸收剂，特别涉及一种具有高含量超吸收剂的芯吸能力高的吸收剂。
人们已知的最老的液体吸收剂可能是得自棉花、木浆或蓬松体和其它天然物质的产品，这些材料惯常用于吸收液体、特别是与个人卫生有关的液体，其它的吸收剂制品有例如尿布、训练短裤(training pants)、失禁服、卫生巾、绷带等。随着这些产品开发的进步，对液体的保留容量提高的要求也在提高。一种提高此类产品液体保留容量的方法是加入超吸收剂。这种超吸收剂也称为水凝胶和水胶体(hydrocolloid)，特别是在尿布、训练短裤和失禁服中更是如此。随着这些产品变得愈来愈复杂，这些产品的制造商们已经减少了这些材料吸收层中木浆或蓬松体的量，而以不同量的超吸收剂代替之。
由于这些吸收剂结构中超吸收剂量增加，就产生了所谓凝胶封闭(gel-blocking)的问题。早期的超吸收剂制成颗粒状，并且它能吸收数倍于其自身重量的液体，如水和尿液。当它吸收了液体时，将不再保持其颗粒状或通常的球形，而是转变成糊状凝胶，这种凝胶溶胀，充满木浆纤维之间的空隙，并很快将这种结构转变成胶凝的杂乱体。此现象现在被称为凝胶封闭现象。由于这种凝胶封闭现象的出现，结果不再有输送更多量液体的孔洞或毛细管。结果，以尿布作为例子，尽管吸收剂的液体保留总容量很高，但因为凝胶封闭问题，只有很少的液体吸收容量可以被利用。在经第一次或第二次接受液体后，接受液体的区域将发生凝胶封闭，液体不会被吸收，并且有时会流出凝胶块的表面，甚至会从尿布渗漏出来。因此，只有有限量的超吸收剂可以加入吸收剂结构中。
随着超吸收剂工作的发展，开发了有高液体容量和高凝胶强度的超吸收剂颗粒，其意义是这种颗粒将吸收更大量的液体而仍旧保留其总体上的球形，其结果便增加了能够加入诸如尿布之类的个人卫生吸收剂产品中的吸收剂部分中的超吸收剂量，制造商因此便能撤出更多的木浆而代之以超吸收剂。此外，制造商发现他们能够将吸收剂进行高度压缩以制造薄得多的尿布。但是，这里又出现利用尿布中吸收剂整个容量的问题。
对于新的有高凝胶强度、高容量的超吸收剂，凝胶封闭问题减轻，但是又产生了一个新问题。当新的超吸收剂吸收液体膨胀时，其直径将大大地增加。高度压缩蓬松体/超吸收剂复合吸收材料有助于保持吸收剂的液体运送性质，但对于吸收剂容量的完全利用仍然是一个问题，这是因为当超吸收剂颗粒溶胀时，它们使吸收剂的结构分离开。在显微镜下观察，膨胀作用在吸收剂结构中产生了大的空隙，因而大大地降低了吸收剂中的毛细作用，并因此降低了吸收剂将液体从尿布的接受区(insult zone)运送和芯吸至吸收剂复合材料的其它区域因而能够更充分地利用尿布容量的能力。实质上，液体运送/芯吸问题是由凝胶封闭的吸收剂产生的，它实际上没有毛细管将液体运送至变得十分开放的吸收剂，因此没有足够的毛细作用将液体从接受区芯吸并运送出去。结果，使可以加入以蓬松体为主成分的吸收剂中的超吸收剂量存在上限，存在的木浆中每单位质量没有足够的表面积去补偿由于超吸收剂颗粒溶胀而破坏的毛细管的这一事实又加重了这一问题。
因此，本发明的目的是提供一种吸收剂结构，这种结构能利用有大量超吸收剂的木浆。
本发明的另一目的是生产一种木浆/超吸收剂复合材料，这种复合材料有提高了的毛细现象和芯吸作用，由此而制备能更有效地利用其液体保留容量的吸收剂结构。本发明的所有目的在进一步阅读了以下的说明和权利要求书后将会变得更加明显。
                   发明概述
本发明针对高芯吸的液体吸收剂复合材料和其制备方法以及所得到的几种产品。该方法包括在诸如水之类的溶剂中形成可湿性细纤维(fine wettable fiber)和木浆纤维(pulp fibers)的浆液，此浆液的固体含量为浆液总重量的约1-5％(重量)。固体含量和浆液由约10-50％的木浆纤维和约50-90％的可湿性细纤维组成(以干物质量计算)。然后在一小孔成型表面(foraminousforming surface)上由浆液形成片材，片材的重量为每平方米约350-720克，含湿量约为6-15％。
片材一经形成就将其在空气流中纤维化，形成许多纤维，并用超吸收剂和任选的粘合剂与之混合，在空气流中制成混合物。被夹带的材料然后在一成型表面上沉积，形成单位重量为每平方米约100-1000克的复合材料。然后将复合材料进行压制，使其密度为约0.1-0.5克/立方厘米。
高芯吸的液体吸收剂复合材料形成后，将成为约5-20％可湿性细纤维、约3-30％木浆纤维、约50-90％超吸收剂和约0-10％粘合剂(均以干重量计算)的较均匀的混合物。
由于本发明的复合材料有改进的芯吸能力，它能很好地适合于在许多应用上作为吸收材料而不只是个人卫生吸收产品。这些产品的例子包括尿布、训练短裤、失禁服、卫生巾、绷带等。另外，在需要时复合材料上可以形成含有更多或更少量可湿性细纤维的特定区域，以制成有特定需要的特殊的吸收剂复合材料。
               附图的简要说明
图1为形成本发明高芯吸的液体吸收剂复合材料的方法示意图。
图2为本发明的包括高芯吸液体吸收剂复合材料的个人卫生吸收剂制品的顶视图，其中部分切除。
               本发明的详细描述
本发明涉及合诸如木浆(蓬松体)的常规吸收剂和高浓度超吸收剂的高芯吸吸收剂复合材料。与易于凝胶封闭或阻止存留液体的芯吸的现有材料不同，本发明的材料因在超吸收剂/木浆组合之中加入了可湿性细纤维而增加了芯吸能力。本发明的材料具有作为尿布、训练短裤、失禁服、妇女卫生用品、绷带等的吸收剂的具体用处，但并无限制本发明范围之意。这些产品一般具有贯穿整个产品的吸收剂芯(adsorbent core)。为了提高这些产品的容量，在吸收剂芯中加入了称为“超吸收剂”、“水凝胶”或“水胶体”的高液体保留材料以增加吸收剂芯的液体处理和存留容量。遗憾的是，由于有许多因素存在，超吸收剂/木浆吸收剂芯不能充分地被利用。原因之一是吸收剂芯不能把液体从液体进入区或接受区芯吸出去。结果这种产品必须使用较实际需要更多的吸收剂材料制造，由此而增加了产品的厚度和总成本。本发明的材料由于有适合的吸收剂芯组分比例并且加入了称之为“可湿性细纤维”的材料以增加吸收剂芯的功能性利用而有助于解决此问题。
这种吸收剂芯的相对效率的一个指标是材料的垂直芯吸能力或垂直芯吸高度的测量值。如下所详细叙述，与常规超吸收剂/木浆吸收剂芯相比，本发明材料的液体垂直芯吸作用表现出明显的提高。以尿布为例，在会阴部分磨损的尿布面积中的更多的吸收剂芯能被利用来存留液体，由此便大大地减少了用于特定尿布结构中的吸收剂芯材料的总用量。本发明将主要叙述其在个人卫生产品(诸如尿布)中的应用，但无意对本发明进行限制。
本发明的高芯吸的液体吸收剂复合材料合有三种主要组分和一系列任选的添加剂或用以提高吸收剂复合材料性能的组分。这三种主要的组分包括吸收剂支承材料、超吸收剂和可湿性细纤维。它们的相对比例将在下面作详细叙述。将此三种主要组分相互紧密混合后，置于一成形表面，然后压制成所要求的密度，便得到了芯吸特性改进了的复合材料。
吸收剂支承材料最典型的是木浆或纤维素材料，诸如木浆纤维(常称作蓬松体)、棉花、棉绒纤维、蔗渣或人造纤维。另外，相应于前述材料的合成材料也被认为是在本发明的范围之内。这种吸收剂支承材料一般是纤维状，其纤维长度常在约2-10毫米，使用0.9％(重量)的盐溶液在每平方英寸0.5磅(3500帕)的负荷下的液体保留容量为每克材料约8克。木浆蓬松体例如包括CR2054蓬松木浆(由Kimberly-Clark Corp.of Neenah，Wisconsin生产)和NB 416蓬松木浆(由Weyerhauser Corp.of FederalWay，Washington生产)。
本发明的高芯吸的液体吸收剂复合材料的第二种组分是常称之为“水凝胶”或“水胶体”的超吸收剂材料，这种超吸收剂是熟知的并生产成至少三种形状，包括粒状、纤维状和片状。粒状是最常见的，典型的粒经在约50-1000微米范围，使用0.9％(重量)盐溶液在每平方英寸0.5磅(3500帕)的负荷下液体保留容量为每克超吸收剂10-40克范围。这种材料是天然的，但也可以是合成的。天然超吸收剂或水胶体的例子有阿拉伯胶、琼脂、瓜尔胶、各种淀粉、糊精和明胶。半合成体包括改性纤维素，诸如羧甲基纤维素和各种改性淀粉。合成吸收剂凝胶聚合物包括(但不限于)聚乙烯基吡咯烷酮和聚丙烯酸酯类。市售产品包括(但不限于)Hoechst-Celanese Corporation of Chalotte，North Carolina的Hoechs t-Celanese SANWETIM 5000和IM 3900、DowChemical company of Midland，Michigan的Dow Drytech534和Allied Colloids，Ltd.of Bradford，UK的Allied ColloidsSALSORB89。
纤维状超吸收剂也可购得，这些纤维直径一般在约10-50微米范围，长度在约3-60毫米范围，其吸收度在用0.9％(重量)的盐水溶液在每平方英寸0.5磅(3500帕)的负荷下每克超吸收剂在约10-40克范围。可以商品供应的超吸收剂纤维包括AlliedColloids/Courtalds FSA101和111，Arco Corporation ofPhiladelphia，Pennsylvania生产的ARCO FIBERSORB和ToyoBoseki KK of Osaka，Japan生产的TOYO BOSEKI KK Lanseal。
本发明高芯吸的液体吸收剂复合材料的第三种组分是可湿性细纤维。与常规蓬松体为基础的吸收剂芯材料的纤维和上述的超吸收剂纤维相比，此可湿性细纤维是直径很小的纤维。一般而言，它的长度小于约2毫米、直径小于约5微米，直径通常在约0.5-2.0微米之间。这种可湿性细纤维的比外表面积一般超过约每克纤维2平方米，通常大于每克纤维5平方米。这种纤维应具有固有的亲水性质或经处理后使其具有这种性质，结果在使用去离子水时这种可湿性细纤维将具有小于90°的前进(advancing)接触角，通常小于70°。Hoechst Celanese Corporation ofCharlotte，North Carolina的Hoechst Celanese Cellulose acetateFibrets纤维是这种可湿性细纤维的例子。Hoechst CelaneseFibrets纤维是高度纤维化的微细纤维，其长度在20-200微米之间、直径为0.5-5微米；它的总比表面积为每克20平方米，比重为1.32，软化温度在360-400°F之间，熔化温度为500°F。另一可湿性细纤维是American Cyanamid Company of Stanford，Connecticut的CFF细纤维化的纤维，它是一种性质类似于上述纤维的丙烯酸基纤维。
当与高溶胀的超吸收剂结合使用时，本发明的可湿性细纤维是特别有利的。在吸收液体时，某些超吸收剂的溶胀作用超过其它的超吸收剂。当这种高溶胀性的超吸收剂用于吸收剂复合材料时，它们将趋于膨大；当它们膨大时，颗粒间中心至中心的间距加大，因而增加了整个复合材料的空隙体积。如果间距变得太大并因此使空隙体积变得太大，结构的毛细作用将降低，结果吸收剂复合材料不能完全被利用。但是，可湿性细纤维将趋于桥连颗粒之间的间隙并提供运送液体的通路，因此维持了毛细作用，并且液体可被芯吸至吸收剂的更远的区域。
试验表明，上述三种组分应相互均匀混合以最大程度加大复合材料的芯吸作用和液体贮存能力。一般而言，复合材料包括约5-20％可湿性细纤维、约3-30％木浆纤维或其它吸收剂支承材料和约50-90％超吸收剂(均以干重为基础计算)的相对均匀的混合物。复合材料形成后即压制使其具有每立方厘米约0.1-0.5克的密度，并且一经形成，其60分钟的垂直芯吸高度至少为10厘米左右(均按下述试验方法)。
除了三种主要组分，也可加入其它组分以改变本发明的液体吸收剂复合材料的总体性质。这些添加剂例如包括(但不限于)粘合剂、润湿剂和抗静电剂。
粘合剂通过机械缠绕、粘合或这两种作用将本发明的组分结合在一起。粘合剂纤维可以是较短的人造短纤维或诸如熔喷纤维或纺粘纤维之类的长丝纤维，扯样长度纤维的细度在约6-40毫米范围，其纤度在1.5-6旦范围。人造短纤维例如包括由聚烯烃、耐纶或聚酯所生产的直丝或卷曲的单聚合物短纤维，如duPont de Nemours of Wilmington，Delaware的PLEXAFIL可熔性合成浆液也可用于粘合的目的，但其纤维细度一般超出上述范围。多组分纤维如二组分纤维也是可以使用的。这样的二组分纤维当其被加热以将它们的外皮部分与周围材料粘合时可以同时提供机械和粘胶性粘合作用。
除粘合剂纤维外，粘胶喷剂(adhesive spray)和粘胶粉剂可用来粘合本发明的材料，喷雾粘胶剂(spray adhesive)一般是溶剂基的，并可完全溶解或成乳状液，粉状粘胶剂通常是热活化的。水基粘胶剂也可使用。一般，本发明的高芯吸液体吸收剂复合材料含0-10％左右的粘合剂，以干重为基础计算。
在本发明的材料中可加入润湿剂以增加湿润性和液体渗透性。这种润湿剂的例子包括Rohm and Haas Company ofPhiladephia，Pennsylvania的TritonX和N型、GAFCorporation of Wayne，New Jersey的IgepalCO、Union CarbideCorporation of Danbury，Connecticut的Tergitol各种型号和American Cyanamide of Stanford，Connecticut的Aerosol各种类型。
抗静电剂可用于在形成网时阻止纤维附着在设备上。抗静电剂的例子是本领域普通技术人熟知的。
本发明的高芯吸液体吸收剂复合材料的形成取决于可湿性细纤维和超吸收剂的良好混合，从而当超吸收剂溶胀时可湿性细纤维能起运送机制的作用，将液体自最初的接受区运走。现在发现，细度小的可湿性细纤维的处理和加工困难。购买时某些可湿性细纤维是溶剂含量较高的湿砖或大包形状，溶剂通常是水(15-30％固体)，必须在进一步加工前将其除去。结果发现，若将它们首先与标准木浆纤维混合形成板，然后在与超吸收剂混合形成本发明的复合材料前进行再纤维化，可湿性细纤维是较容易加工的。
木浆板的形成是将可湿性细纤维与木浆纤维和水一起置于水浆机(hydropulper)中以形成约1-5％、一般约2％的在水中的固体浆料或浆液。可湿性细纤维与木浆的比率或百分数通常在约50％可湿性细纤维/50％木浆(1∶1)至90％可湿性细纤维/10％木浆(9∶1)之间，以干重量计用70％可湿性细纤维/30％木浆(2.33∶1)得到了好的结果。
浆液一经形成，可加入润湿剂、再润湿剂、抗静电剂和排水助剂，通常其总加入量为浆液中总固体重量的0.1-1.0％左右之间。然后将浆液形成板，通常是在细孔眼的金属成形网上，每令(ream)约200-350磅重(每平方米350-720克)，含湿量约为6-15％，以10-12％(重量)的效果较好。需要时，此板可以经辊辗和压制以使其更加均匀。
参考图1，木浆板形成后，就可将其送入一纤维化机(fiberizer)或纤维分离机10，诸如锤磨机。筛网型或非筛网型的纤维化机都可使用，非筛网型的堵塞较小。业已发现，在木浆板中加入抗静电剂能在木浆板纤维化时可有助于减少纤维附着在成形设备的表面上。参考图1中，随着木浆板12被粉碎，它由供给的空气夹带到小孔金属成形网14上。在金属成形网14的下方和纤维化机10的正下部是一真空箱16，调节真空箱16使约35-60英寸水(1.5-3.0磅/平方英寸)的真空通过金属网14以排除悬浮的或夹带的空气。
当木浆纤维和可湿性细纤维向下至成形表面14时，超吸收剂1 8被引入纤维化机10下部的导管22。超吸收剂可以是粒状、纤维状或片状，由于夹带空气的速度、体积和湍流，木浆纤维、可湿性细纤维和超吸收剂在落入成形表面14形成复合材料网20以前互相间紧密混合。复合材料网20的单位重量可按特定的终用途来设计，但一般是每平方米约100-1000克，以每平方米300-500克范围的复合材料为尿布和其它个人卫生品产品用的范围。
虽然希望使用空气成形设备达到组分的良好混合，但上述基本方法可被变动和修改。当复合材料网20形成后，它可能不具备充分的结构完整性，因此复合材料网20可通过一对压紧辊24以进一步压实并使网增加密度。用于个人卫生产品的网，其密度将在约0.1-0.35克/立方厘米。在某些应用中，复合材料网20可能没有足够的可湿性，因此可通过例如喷雾器25在网中加入更多的表面活性剂。表面活性剂可如图1所示在网20形成以前加入纤维中，或者可直接喷在形成的网上(未示出)，虽然此方法一般不能保证可以施于网中所有的纤维上。
如果需要结构上更加完整的复合材料网，可在复合材料网20完全形成前在夹带的纤维和超吸收剂流中加入粘合剂纤维。图1中示出一附加纤维源或源26，位于纤维化机10和成形网14之间。此纤维源26可适于导入一般长度在3-12毫米的较短的扯样长度纤维或诸如用熔喷法和纺粘法得到的较长的连续纤维。这些方法的例子可见USP 3,849,241、USP 3,692,618和USP 4,340,563，在此可作为一个整体供参考。粘合剂纤维一般与其它组分均匀混合，其存在量为复合材料网20总重量的约2-8％(重量)，前已述及，适合的粘合剂纤维是那些在直径方向上有均匀聚合物组成的纤维，它们也可以是非均匀的或者甚至有不同的区域，如二组分纤维。纤维也可具有规则和不规则的横截面形状，并且它们可以是亲水的或疏水的，虽然亲水纤维对液体运送更为理想。
如果使用热塑性或热熔性纤维，可在此方法中加入诸如热空气或红外加热之类的热源以将纤维熔化并粘接在一起。这样的热源30在图1中示意于压紧辊24之前。在运转时，当复合材料网20被压紧辊加压、粘合并使其密度增加时，热源一边将可熔性纤维加热至至少达到其软化点。网的加热时间取决于网的密度、网的线速度、粘合剂量和软化温度以及加热温度。用实施例中所述的材料时，在140℃的热空气中暴露15秒钟已足以活化粘合剂。根据所用的粘合剂纤维的类型，压紧辊可以加热和/或冷却或者只在环境温度下操作。另外，加热源30也可以置于下游，在压紧辊24压紧纤维以后(未示出)。再者，加热源可在无压紧辊的情况下操作。
如果复合材料网20中的粒状超吸收剂不能很好地在其上保留住，可将薄棉纸(未示出)之类的材料置于成形表面14上，再将复合材料置于薄棉纸上，薄棉纸即可将超吸收剂颗粒进一步托住。另外，也可将单独的纤维排(fiber bank)(未示出)置于本发明方法的上游以在沉积形成本发明复合材料网20的材料之前在金属成形网14上形成第一层纤维。
在复合材料网形成后，可将其保留在传送线上并在下游作进一步加工。也可将其卷在导出卷筒32上然后退卷以备切割、纵断和进一步加工。
也可以用第二种方法来制备本发明的高芯吸液体吸收剂复合材料。实施例3至7的材料是在Danwebforming InternationalLtd.(Aarhus，Denmark)在一圆网空气成形机上形成的。至少实施例1和2的材料，是首先由木浆纤维和可湿性细纤维形成木浆板，再将木浆板送入纤维分离机。在此纤维被分离后夹带在空气流中，空气流被送入一圆网空气成形机，同时将超吸收剂和粘合剂纤维导入空气流并在混合物以复合材料网的形式落在移动的成形表面上之前将其与木浆和可湿性细纤维紧密混合。复合材料网一经形成即令其通过一对压紧辊，然后，在加热至足以软化的温度并使粘合剂纤维自身和与复合物其它组分粘合。粘合后，将复合材料网冷却，然后卷在卷筒上。
本发明材料的一种用途是作为吸收剂芯料用于个人卫生产品，诸如尿布、训练短裤、失禁服、卫生巾、绷带等。这些个人卫生产品的例子是图2所示的尿布。在尿布的构造中，本发明的复合材料一般具有约0.1-0.35克/立方厘米的密度。对于大多数的个人卫生产品，最简单的尿布50的设计包括一尿布主体内衬(bodyside liner)52和外罩54，并有液体吸收芯料56置于其间。主体内衬52的目的是将液体或其它渗出物送入吸收剂芯56而被吸收芯吸收、分布和贮留。外罩54的目的是保持液体和其它渗出物，并且不让它们向不需要的方向扩散。
试验表明，复合材料网20(吸收剂芯56)显示出比常规超吸收剂/蓬松体复合材料更高的芯吸特性，但它常不能像常规吸收剂一样快地吸收如尿之类的液体，特别是在接受量大时，因此，尿布50的更优选的具体实施方案可包括一圈定的吸收剂芯56。如图2所示，吸收剂芯56有三个区域或部分，大致占尿布50中间的三分之一的中间部分58最接近穿戴者的会阴部分，因而是穿戴者体液流出的部分。这一部分的材料可以是常规的材料，因此基本上没有可湿性细纤维。“基本上没有”之意是中间部分所含的可湿性细纤维小于5％，基于此区域的材料总重计算。
相反，前区部分60和后区部分62总共约占吸附剂芯56其余的三分之二，它们是在中间部分58的相对的两边，由本发明的高芯吸液体吸收剂复合材料网组成。因此当液体浸入吸收剂芯56的中间部分58时，液体即被迅速吸取。液体被吸取后，前区部分60和后区部分62能将液体芯吸至接近穿戴者腰部的尿布50的区域，因而就增加了尿布50的总容量。尿布50的效用得到提高后，又有可能减少尿布中材料的量，由此可以有更薄更有效的尿布结构。从上述可知，58、60、62三部分的相互位置可以改变。例如，在男性尿布设计中，中间部分58可向尿布前方移动至比较靠近尿布的前方以比较更恰当地符合男性解剖学特征。另外，各部分的大小及形状是可以变化的，各部分的位置和数目是可以改变的。
垂直芯吸试验
为试验本发明以及其它材料的液体运送性质，进行垂直芯吸试验，测量方法是将材料样品的一端置于一恒定体积的合成尿液容器中，测定经一小时后被芯吸的高度。
将材料样品切成4×15英寸小块，每块样品将一块
Figure A9419242600191
英寸高×5英寸宽×1/4英寸厚的丙烯酸类树脂板沿底端和两面包裹起来，使样品的4英寸宽的两端在丙烯酸类的板的高度上的两面伸出相等距离(约
Figure A9419242600192
英寸)。用两个夹子沿板的侧边靠近样品的顶部夹住样品的侧边将样品保持在板上。板的侧边有1毫米距离的刻度以测量被芯吸的液体的垂直高度。
样品准备好以后，将其悬挂在一自由摆动的支撑板上，然后将样品下落至其底部对折边与试验液体贮液接触。在样品刚落入液体中时开始以秒为单位计时。当液体在样品材料上芯吸上移时，相对于时间监测液体前沿相对于恒定液体表面的垂直距离。记录一小时以后的液体前沿的垂直高度，作为芯吸高度的指标，由此得到样品材料的毛细作用吸力。
在垂直芯吸试验中，以使用表1中所述的化合物制备的合成尿液作为芯吸介质。试液的配制是在1000毫升的容量瓶中加入900毫升的蒸馏水。按表1的次序加入化合物，以避免由于溶液的高pH使二价阳离子沉淀。每一化合物在完全溶解后再加入第二种化合物。在加入了所有化合物后，将容量瓶稀释至1000毫升。
           表1化合物            浓度
              g/lKH2PO4          0.681F.W.＝136Ca(H2PO4)2H2O 0.309F.W.＝252.1MgSO47H2O       0.477
F.W.＝246.5K2SO4           1.333
F.W.＝174.3Na3PO4 12H2O   1.244
F.W.＝380.2NaCl              4.441
F.W.＝58.4KCl               3.161
F.W.＝74.5NaN3             0.400
E.W.＝65.0脲(NE2CONH2)    8.560
F.W.＝60.1Pluronic 10R8*    0.100
F.W.＝5000*湿润剂，BASF Corp.制造，(Parsippany，New York)
在每批试验液体中加入数滴染料以在芯吸试样时增进视觉观察效果。
实施例
实施例1
通过类似于图1所示的方法形成本发明的高芯吸材料。此材料包括62％(重量)的IM 5000P超吸收剂颗粒(HoechstCelanese Corp.of Richmond，Virginia生产)、16％(重量)的CR2054蓬松木浆(Kimberly-Clark Corp.of Neenah，Wisconsin生产)和16％(重量)的醋酸纤维素Fiberts纤维(Hoechst CelaneseCorp.of Charlotte，North Carolina生产)。该高芯吸材料还包括6％(重量)的平均直径约15微米的总体宏观连续熔喷法聚丙烯增强纤维(generally continuous macroscopic meltblownpolypropylene reinforcing fiber)。生产纤维的聚丙烯得自HimontPolymers of Norcross，Georgia，在纤维挤出前加入2％(重量)(以聚丙烯纤维总重量计算)的Mapeg 400DO添加剂，是一种PPGMazer Chemical Corp.of Pittsburgh，Pennsylvania生产的表面湿润性增强剂。此添加剂含分子量为400的聚乙二醇二油酸酯。将上述木浆纤维、超吸收剂、可湿性细纤维和增强纤维互相混合均匀，然后置于成形网上形成本发明的高芯吸吸收剂网。该网不需经过粘合或压制。网的单位重量约400克/平方米(gsm)、密度约0.2克/立方厘米(g/cc)。Mapeg 400 DO添加剂增加聚丙烯增强纤维的润湿性，增强纤维又用于增加总体结构的完整性。样品在80℃下加热30分钟以“活化”聚丙烯中的湿润体系。从表2可见，60分钟的样品芯吸高度为13厘米。
         表2
样品       垂直芯吸高度
1            13cm
2            10cm
3a(对照)     11cm
3b           14cm
4a(对照)      5cm
4b         10.5cm
5a(对照)      9cm
5b           13cm
6a(对照)      9cm
6b           14cm
7a(对照)      7cm
7b           11cm
实施例2
按类似于图1所示的方法形成实施例2的材料。该材料所用的组分同实施例1，但各组分的相对重量百分比不同。实施例2的材料包括80％(重量)的超吸收剂、3％(重量)的蓬松木浆、14％(重量)的醋酸纤维素Fibrets可湿性细纤维和3％(重量)聚丙烯增强纤维。材料单位重量为375克/平方米、密度约为0.2克/立方厘米。从表2可知，此材料的60分钟垂直芯吸高度为10厘米，低于实施例1中的值。无意为现有的假设所限制，可认为垂直芯吸高度降低是由于醋酸纤维可湿性细纤维的量减少和可湿性细纤维与超吸收剂的比率的减少。
实施例3
在实施例3中制备了两个样品(样品3a和3b)。样品3a实质上是对照样品，因为它不合任何可湿性细纤维，而样品3b是含可湿性细纤维的。两个样品都是按上述方法在DanwebformingInternational，Ltd.of Aarhus，Denmark制备的。
样品3a包括75％(重量)的实验高液体保留/高凝胶强度超吸收剂(Dow Chemical Corporation of Midland，Michigan生产)、19％(重量)CR 2054蓬松木浆(Kimberly-ClarkCorporation of Neenah，Wisconsin生产)和6％(重量)DanaklonES-C双组分聚烯烃粘合剂纤维(得自Danaklon a/s of Varde，Denmark)。粘合剂纤维是长6毫米的细度为3.3分特(dtex)的纤维。木浆和粘合剂纤维在加入空气成形混合物中前形成预混合物，预混合物形成木浆板，然后用小的锤磨机再进行纤维化。木浆和粘合剂纤维然后再于空气成形过程中与超吸收剂混合形成单位重量约400gsm、密度约0.2克/立方厘米的复合材料网。二组分粘合剂纤维用于将网熔合并增加其完整性。粘合剂纤维的粘合是在一通风炉(through-air oven)中于约140℃的温度将样品网加热约15秒钟完成的。样品3a(对照)的60分钟垂直芯吸高度为11.0厘米。
样品3a也用与样品3a相同的方法和组分制备，但再加入醋酸纤维素Fibrets纤维(一种可湿性细纤维)。样品3b包括75％(重量)的超吸收剂、14％(重量)的醋酸纤维素Fibrets可湿性细纤维、6％(重量)的蓬松木浆和5％(重量)的二组分聚烯烃粘合剂纤维。像实施例3a一样，先将木浆、可湿性细纤维和粘合剂纤维预混合，然后形成木浆板，木浆板再纤维化，并导入空气成形过程形成单位重量约400gsm、密度约0.2％克/立方厘米的复合材料，其中粘合剂纤维在一通风炉中于约140℃的温度下熔化。样品3b的60分钟垂直芯吸高度为14.0厘米。与对照样品3a的垂直芯吸高度11.0厘米相比，此垂直芯吸高度增加27％以上。
实施例4
在实施例4中制备了对照样品4a和本发明的样品4b。与样品3a和3b一样，4a和4b样品是用空气成形体系在Danwebforming International，Ltd.of Aarhus，Denmark制备的，样品4a包括70％(重量)的丙烯酸酯超吸收剂(10分特×6毫米)纤维“FSA-101”(Courtalds Fibers Ltd.of Coventry，UK和Allied Colloids，Ltd.of Bradford，UK合资企业生产)、23％(重量)的Weyerhauser NB-416缝松木浆(WeyerhauserCorporation of Federal Way，Washington生产)和7％(重量)的Danaklon二组分聚烯烃粘合剂纤维(与前述实施例的类型相同)。制成的复合材料的单位重量约为400gsm、密度约为0.2克/立方厘米。此材料于通风炉中在约140℃的温度下熔化，60分钟的垂直芯吸高度为5厘米。
样品4b使用75％(重量)的与样品4a相同的超吸收剂纤维，在空气成形法中将其与13％(重量)的醋酸纤维素Fibrets可湿性细纤维、5％(重量)的蓬松木浆和7％(重量)的Danaklon PE/PP偏心皮芯型二组分纤维紧密混合。可湿性细纤维、木浆和二组分纤维与前述实施例中使用的相同。将复合材料网通过温度接近140℃的一通风炉以熔化二组分纤维的外皮形成结构较完整的本发明复合材料网。得到的复合材料网的单位重量约为400gsm、密度约为0.2克/立方厘米、60分钟的芯吸高度为10.5厘米。与对照样品(4a)比较，本发明材料的垂直芯吸能力增加了110％。
实施例5
在实施例5中制备了样品5a和5b，5a是不合可湿性细纤维的对照样品。样品5a和5b均用与实施例3相同的成形方法成形。样品5a包括75％(重量)的与实施例4相同的丙烯酸酯超吸收剂(10分特×6毫米)FAS-101纤维、20％(重量)NB 416蓬松木浆(Weyerhauser Corporation of Federal Way，Washington生产)和5％(重量)的前述实施例中的二组分PE/PP粘合剂纤维(Danaklon a/s of Varde，Denmark生产)。得到的复合材料的单位重量为约400gsm、密度约为0.2克/立方厘米。材料形成后即在一通风炉中于接近140℃的温度下加热样品使其熔化并粘合二组分纤维。样品5a的60分钟垂直芯吸高度为9厘米。
样品5b使用与样品5a中相同的超吸收剂纤维和二组分纤维和与样品4a中相同的醋酸纤维素可湿性细纤维和蓬松木浆。样品5b含75％(重量)的超吸收剂纤维、16％(重量)的醋酸纤维素Fibrets可湿性细纤维、4％(重量)的蓬松木浆和5％(重量)的二组分聚烯烃粘合剂纤维。得到的样品的单位重量约为400gsm、密度约为0.2克/立方厘米。如样品5a一样，样品5b是在一通风炉中在约140℃的温度下熔化。其60分钟的垂直芯吸高度为13厘米。与对照样品5a相比，样品5b的垂直芯吸能力增加了44％。
实施例6
在实施例6中有两个样品(6a和6b)，样品6a是不合任何可湿性细纤维的对照样品。样品6a使用与样品5a相同的组分，但超吸收剂纤维的长度是12毫米，而不是6毫米。该样品包括75％(重量)的超吸收剂纤维、20％(重量)的蓬松木浆和5％(重量)的二组分PE/PP粘合剂纤维。样品6a和6b是用与实施例3所述的方法成形的。样品6a的单位重量约为400gsm、密度约为0.2克/立方厘米，其粘合剂纤维是在一通风炉中于约140℃的温度熔化的。对照样品6a的60分钟垂直芯吸高度为9厘米。
样品6b使用与样品5b相同的材料，它包括75％(重量)的超吸收剂纤维、16％(重量)的可湿性细纤维、4％(重量)的蓬松木浆和5％(重量)的二组分粘合剂纤维。如其它样品一样，所得到的复合材料的单位重量为约400gsm、密度为0.2克/立方厘米，其粘合剂纤维是在一通风炉中于约140℃的温度下熔化。本发明的样品6b的60分钟垂直芯吸高度为14厘米。与对照样品6a相比，其垂直芯吸能力增加了56％。
实施例7
在实施例7中制备了两个样品7a和7b，7a不合可湿性细纤维，用作对照样。二样品均按实施例3的方法制备。样品7a包括75％(重量)的丙烯酸酯超吸收剂(10分特×12毫米)纤维“FSA-111”(由Courtalds Fibers Ltd.of Coventry，UK和AlliedColloids，Ltd.of Bradford，UK合资企业生产)、20％(重量)CR2054蓬松木浆(得自Kimberly-Clark Corporation of Neenah，Wisconsin)和5％(重量)的二组分聚烯烃粘合剂纤维(DanaklonES-C 3.3分特×6毫米)纤维，得自Danakalon a/s of Varde，Denmark)。此材料的60分钟芯吸高度为7.0厘米。
样品7b使用与样品7a相同的材料，再加上样品6b中所述和使用的醋酸纤维素可湿性细纤维。样品7b包括75％(重量)的超吸收剂纤维、16％(重量)的可湿性纤维、4％(重量)的蓬松木浆和5％(重量)的粘合剂纤维。所得到的复合材料在一通风炉中于约140℃的温度下熔化。复合材料的单位重量约为400gsm、密度约为0.2克/立方厘米。复合材料的60分钟垂直芯吸高度的11.0厘米。与对照样品比较，其垂直芯吸高度增加了57％。
由上述各实施例可见，当使用高负荷的超吸收剂时，在本发明的吸收剂结构中通过加入可湿性细纤维，有助于分布液体，可以得到芯吸能力的戏剧性增加。使用可湿性细纤维时，吸收剂结构内的毛细作用得到了改进，因此液体可以从接受区运送到更远的区域，由此便增加了吸收剂结构的总容量并因而增加了其使用性。
本发明已经做了详细说明，但本发明可做各种修改和变化而不脱离下面权利要求书的精神和范围，这是很明显的。

Claims (23)

1.一种形成高芯吸的液体吸收剂复合材料的方法，该方法包括：
a)形成包括约50-90％可湿性细纤维和约10-50％木浆纤维(均以干重计算)的片；
b)在空气流中将所说的片纤维化成许多单个的纤维；
c)在所说的空气流中将超吸收剂与得自纤维化的片的所说纤维混合形成均匀的混合物；
d)将所说的均匀混合物沉积在成形表面上以形成复合材料；和
e)将所说的复合材料加压至所需密度。
2.按权利要求1的方法，其中所说的复合材料被压制到密度为约0.1-0.5克/立方厘米。
3.按权利要求1的方法，还包括在形成所说的复合材料之前在所说混合物中加入粘合剂的步骤。
4.按权利要求3的方法，还包括活化所说粘合剂以粘合所说复合材料的步骤。
5.一种形成高芯吸的液体吸收剂的方法，该方法包括：
a)在溶剂中形成可湿性细纤维和木浆纤维的浆液，该浆液的固体含量为总浆液重量的约1-5％，该固体含量包括约10-50％的木浆纤维和约50-90％的可湿性细纤维，均以干重计算；
b)所说的浆液形成重约350-720克/平方米和含湿量约6-15％的片材；
c)在空气流中将所说的片材纤维化成为许多纤维；
d)在所说空气流中将超吸收剂和粘合剂混入从纤维化的片材得到的纤维，以形成混合物；
e)将所说混合物沉积在成形表面上以形成单位重量约100-1000克/平方米范围的复合材料；
f)压制所说的复合材料使其密度达到约0.1-0.5克/立方厘米；和
g)活化所说的粘合剂以粘结所说的复合材料。
6.按权利要求5的方法，还包括向所说的复合材料中加入湿润剂的步骤。
7.按权利要求5的方法，还包括在混合步骤中向所说的复合材料中加入润湿剂的步骤。
8.按权利要求5的方法，还包括向所说的浆液中加入加工剂(processing agent)的步骤。
9.一种高芯吸的液体吸收剂复合材料，包括约5-20％可湿性细纤维、约3-30％木浆纤维、约50-90％超吸收剂和0-约10％粘合剂的相对均匀的混合物，所述百分数均以干重为基础计算，所述混合物被压制成密度为约0.1-0.5克/立方厘米、1小时垂直芯吸高度至少约10厘米的复合材料。
10.按权利要求9的复合材料，其中所述可湿性细纤维的纤维直径为约0.5-5.0微米之间。
11.按权利要求9的复合材料，其中所说的超吸收剂是纤维状的。
12.按权利要求9的复合材料，其中所说的超吸收剂是片状的。
13.按权利要求9的复合材料，其中所说的超吸收剂在3500帕的负载下于0.9％的盐水溶液中的液体保留容量为至少约10克/立方厘米。
14.按权利要求9的复合材料，其中所说的复合材料具有第一区和第二区，所说的第二区比所说的第一区具有更大量的可湿性细纤维，以干重为基础计算。
15.按权利要求10的复合材料，其中所说的可湿性细纤维的前进接触角(advancing contact angle)小于90°。
16.按权利要求10的复合材料，其中所说的可湿性细纤维的前进接触角(advancing contact angle)小于70°。
17.一种吸收剂制品，包括一透液体的上片(top sheet)和一不透液体的支持片(backing sheet)，二片间有液体吸收剂芯，所说的芯包括约5-20％可湿性纤维、约3-30％木浆、约50-90％超吸收剂和0-约10％粘合剂的相对均匀的混合物，所说的百分数均以干重计算，所说的混合物被压制成密度约0.1-0.35克/立方厘米的复合材料，所说的复合材料的1小时垂直芯吸高度至少为约10厘米。
18.按权利要求17的个人卫生吸收剂制品，其中所说的制品是尿布形式。
19.按权利要求17的个人卫生吸收剂制品，其中所说的制品是训练短裤(training pants)形式。
20.按权利要求17的个人卫生吸收剂制品，其中所说的制品是失禁服形式。
21.按权利要求17的个人卫生吸收剂制品，其中所说的制品是卫生巾形式。
22.按权利要求17的个人卫生吸收剂制品，其中所说的制品是绷带形式。
23.按权利要求17的个人卫生吸收剂制品，其中所说的芯有第一区和第二区，所说的第二区比第一区有更大量的可湿性细纤维。
CNB941924262A 1993-04-30 1994-04-19 高芯吸液体吸收剂复合材料及其形成方法和含该材料的吸收制品 Expired - Fee Related CN1191802C (zh)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102178581A (zh) * 2011-03-31 2011-09-14 黄新铧 一次性吸乳吸汗垫及其生产方法
CN105026638A (zh) * 2013-03-06 2015-11-04 科德宝两合公司 通气插件
US10161080B2 (en) 2013-03-06 2018-12-25 Carl Freudenberg Kg Ventilation insert
CN109953850A (zh) * 2017-12-22 2019-07-02 北京小鹿科技有限公司 一种不断层不起团吸收芯体的制备系统
CN111836606A (zh) * 2018-03-16 2020-10-27 日绊株式会社 创伤敷料

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US5350370A (en) 1994-09-27
AU6637994A (en) 1994-11-21
TW316230B (zh) 1997-09-21
FR2704563B1 (fr) 1995-10-27
EP0703764B1 (en) 1999-09-29
CN1191802C (zh) 2005-03-09
AU674413B2 (en) 1996-12-19
CA2101835A1 (en) 1994-10-31
FR2704563A1 (fr) 1994-11-04
WO1994024975A1 (en) 1994-11-10
KR100331901B1 (ko) 2002-11-23
DE69420963D1 (de) 1999-11-04
KR960701622A (ko) 1996-03-28
DE69420963T2 (de) 2000-05-31
EP0703764A1 (en) 1996-04-03

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