CN85109071A - 吸水性无纺织品 - Google Patents

吸水性无纺织品 Download PDF

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CN85109071A
CN85109071A CN198585109071A CN85109071A CN85109071A CN 85109071 A CN85109071 A CN 85109071A CN 198585109071 A CN198585109071 A CN 198585109071A CN 85109071 A CN85109071 A CN 85109071A CN 85109071 A CN85109071 A CN 85109071A
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fabric
absorbent
fiber
water imbibition
described water
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利·A·格曼
索马斯·I·英斯利
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3M Co
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Minnesota Mining and Manufacturing Co
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Abstract

用已有的无纺材料制成的高级吸水性无纺织品。本发明透露，无纺织品的每根纤维由一种超吸水性聚电解质聚合吸收剂涂覆。聚合吸收剂涂层可在织品空隙截留液体最少的情况下吸收液体。

Description

本发明涉及用现有的无纺材料和一种超吸水性聚电解质聚合物组成的高吸水性无纺织品。
通过将吸水性聚合物与各种载体基底物相结合已制得了吸水性薄片材料。这些材料大多数是用载体基底物为那些本身机械强度很差或没有机械强度的吸水部分提供机械支撑。有各种制做吸收剂载体复合材料的方法;经常是将超吸水性聚合物膜层或颗粒层制成夹层或叠层结构（参见美国专利4，008，353和4，190，562）。
在某些这类结构中，超吸水性聚合物高度定域集中，夹在两层底层中，最终构成的产品中至少有一面是可渗水的。还有其它一些已知的结构，其中吸收剂是涂在无纺织品的上面、或下面、或上、下两面。尽管这些复合物含有相当数量的吸水性材料，然而，它们确有其固有的缺点，在某些特殊应用中，这些缺点尤为明显。因此，当需要快速吸收液体成为一项关键的性能标准时，尤其是当超吸水性聚合物是主要的吸水成分时，超吸水性聚合物的高度定域（平面）集中致使这些复合物受到超吸水性聚合物的凝胶现象的影响。超吸水性聚合物就其本质来说，遇水膨胀，但并不溶解。正是这种机理使这些材料得以吸入并保留大量的液体。虽然在水的负载量方面超吸水性聚合物是极好的材料（通过渗透效应产生膨胀），但是，液体穿过凝胶主要是通过扩散进行的，而且必然在速率上受到限制。如果使用几层平面分散的超吸水性聚合物，那么，将最靠近液体源的表层润湿所产生的凝胶层本质上起一个液体阻挡层的作用。这些效应已被广泛承认，并且在某些情况下可产生理想的效果。美国专利No.3，888，256透露了一种尿布结构，其中一种颗粒状膨胀物质被安置在紧靠婴儿皮肤的层中。颗粒是这样分布的：颗粒间间隔是允许液体（尿）的初始通道，但当颗粒因湿而膨胀时，它们就将织品的孔隙开口部分关闭，最终形成一个阻止液体回流的阻挡层。
当不希望有阻挡层效应（当超吸水性聚合物为主要吸水成分时可能出现这种情况）时，则须使用另外的分散方法。在开网系统中使超吸水性聚合物近乎均匀分散的方法是采用液体载体方法和空气载体的方法使遇水膨胀但不溶解的超吸水性聚合物与开网结为一体。在液体载体方法中，水悬浮液中膨胀的超吸水性聚合物颗粒沉积在基底物表面上，液体载体被蒸发，以产生固定的超吸水性聚合物复合物（美国专利4，235，235和3，686，024）。
在水溶液中膨胀的凝胶颗粒，既使是中等浓度，它也是非常粘滞的悬浮液，从加工的角度来讲，本来就难以处理。如果用较低的悬浮浓度来减少粘性效应，则在蒸发工艺步骤中必需将大量的液体载体去除掉。沉积控制的其它方法是用空气作超吸水性聚合物的载体（美国专利4，429，001）。尽管这种方法克服了湿法沉积工艺的许多缺点，然而由于机械截持，这些复合物会使粒状超吸水性聚合物残留在织品中，从而造成超吸水性聚合物成分的部分损失（由于飞尘）。
本发明涉及一种改进了的开网吸水剂织品，其中，在无纺载体基底的单个纤维上有一层薄薄的超吸水性聚合物的薄膜涂层。本发明的复合无纺织品尤其适用于吸收及保留液体，并且适用于尿布、卫生巾、失控用品，并可作为绷带。
本发明的高吸水性无纺织品是用下述方法制得的：把超吸水性预聚合物浸渍剂就地固化（交联），例如使浸有预聚合物水溶液的无纺织品干燥。预聚合物可以是一种皂化羧基聚电解质，如丙烯酸-丙烯酸盐共聚物、丙烯酸-丙烯酰胺共聚物，丙烯酸-烯烃共聚物，聚丙烯酸，丙烯酸-乙烯基芳族共聚物，丙烯酸-苯乙烯磺酸共聚物，丙烯酸-乙烯基醚共聚物，丙烯酸-烯基醋酸乙烯酯共聚物，丙烯酸-乙烯醇共聚物，甲基丙烯酸与所有上述共聚单体的共聚物;马来酸、富马酸及其酯与所有上述共聚单体的共聚物;顺丁烯二酸酐与上述所有共聚单体的共聚物;或含凝胶化淀粉和皂化聚丙烯腈或聚甲基丙烯腈的接枝聚合物。
本发明中所用的交联剂有多卤代烷醇（如1，3-二氯异丙醇、1，3-二溴异丙醇）;两性磺离子（如酚醛树脂的四氢噻吩加合物）;环氧卤代烷（如3-氯1，2环氧丙烷、表溴醇、2-甲基表氯醇和表碘醇）;聚甘油醇醚类（如1，4-丁二醇双甘油醚、甘油-1，3-双甘油醚、甘醇双甘油醚、丙二醇双甘油醚、二甘醇双甘油醚、新戊基二醇双甘油醚、环氧当量为175-380聚丙二醇二甘油醚，环氧当量为182-975双酚A-表氯醇环氧树脂类，以及上述交联剂的混合物）
可以预期，含有上述交联剂的双或多官能团的化合物同样是有用的;另外，当聚电解质在加热和干燥条件下形成的这些官能团母体也是有用的。
两性磺离子可从美国专利3，660，431、美国专利3，749，737和美国专利3，749，738中得知。
所获得的含聚合物的无纺产品有非常有用的吸收并保留液体的性质。这样，吸水性多孔织品就是人造短纤维织成的无纺纤维三维网，在各个纤维上有一层薄的但为连续的超吸水性聚合物吸收剂涂层，纤维网只在纤维的交叉点由聚合物涂层合为一体，这样一旦吸附上液体，聚合物涂层便会在织品空隙截留最小的条件下吸液膨胀。聚合物吸收剂在织品的空隙内很不容易看到，既使在显微镜观察下也是如此。
这种开网吸收剂系统的空隙体积可在60-99+之间。空隙体积是用空气比较比重计（Beckman型9030，采用标准操作方式）测定的。
本发明的较好实施方案是用三维开网结构作载体基底物，这种结构是由许多纤维彼此以无规点相接触而形成的。用Rando    Webber机或梳棉机织成的无纺织品是适宜的基底物。无纺织品用吸收剂预聚合物复合物浸透;然后把大块的吸收剂预聚合物复合物除去，把织品置于烤箱中干燥使预聚物就地固化。所得到的复合物是各个纤维被超吸水性聚合物封装、纤维的交叉点被固化的聚电解质相互粘接在一起。这样，载体织品保留着它的开网结构，同时不仅为超吸水性聚合物提供了结构支撑，而且还提供了最佳吸收剂表面积和最适超吸水性聚合物的分布，这种结构可使整个织物的凝胶阻挡效应降低至最低限度。
用于评价本发明织品吸收率的试验以及织物在压力下保留吸收的液体的能力的测试方法概括如下：
规定的吸收率试验
将一个直径为1.75吋（4.45cm）织品试样置于过滤漏斗中的一个25-50μ的多孔盘上。用一个可在漏斗筒中自由移动的圆柱向样品施加1.0kPa的压力;处于静水压头为零的试验流体由储水池经虹吸管原理对多孔盘的上表面施加压力试样在多孔盘上吸收液体。然后，测量试样从容器中吸出的流体量，以测定试样吸入的流体量。
离心保留试验
将1g织品试样放在离心过滤篮中，装有样品的篮在试验溶液中浸至三个小时。把装有样品的篮取出，滴干2-3分钟，然后置于离心管中。离心管放在离心机内，置于180G的离心力下10分钟。取出样品，测量残留的试验溶液量。
在规定的吸收率试验和离心保留试验中，用合成尿作试验液体（S.U.），合成尿的配方如下：
0.06%    氯化钙
0.10%    硫酸镁
0.83%    氯化钠
1.94%    尿素
97.07%    去离子水
合成尿溶液的导电系数为15.7mΩ。
下述实例将更加充分的说明本发明。很明显，可以使用不同的基底物来实施本发明。
实施例1-6
吸收剂预聚合物复合物按下述方法制备：
将300.9克皂化的丙烯酸乙酯/甲基丙烯酸分散剂（大约12%固体）（Dow    XD-8587.01，道化学公司）与等量的去离子水和4.2克非离子型表面活化剂（Triton    X-100，Rohm    &    Haas）相混合。
反应混合物在搅拌下在热盘上于低温下加热，并加入6.0克的交联剂（CX-100，Polyvinyl    Chemical    Industries）。
用基础重量为190g/m2（日本Chisso公司）的6dpf×64mm Chisso织品在Rando Webber机上织成干燥、蓬松的纤维织品。纤维经热固化使织品成为一体。然后用三种重量：48、60和66重量%的吸收剂（织物总重量加上吸收剂）预聚合物复合物施于基底物上。每种重量的吸收剂-预聚物复合物选四块作样品用下述方法浸渍。
圆形的1.75吋（4.45cm）模切的干燥、蓬松试样片浸泡在吸收剂预聚合物复合物中。然后用离心法除去基底物空隙中的大部分吸收剂预聚物。样品经不同时间的离心后，得到不同涂覆量的纤维膜。试样在烤箱中于150°F（65℃）下固化12小时。
三种用量（即48，60和66重量百分比）的每一用量都是用四个试样，它们均按美国专利3，686，024所描述方法“涂层”。
之后，用规定的吸收率试验和离心保留试验对样品进液体吸收和保留测试。吸收剂用量不同的吸收和保留值在表Ⅰ和表Ⅱ中示出。
Figure 85109071_IMG1
表Ⅱ
在示出时间内所吸收的液体重量（l/m2）
实例    5分钟    10分钟    15分钟    20分钟    25分钟    30分钟
1    2.5    4.9    6.7    7.7    8.1    -
2    2.6    5.4    7.5    9.1    10.1    10.5
3    2.5    5.5    7.9    9.7    10.8    11.5
4    1.4    2.3    2.5    2.7    2.8    -
5    1.1    2.6    3.2    3.4    3.6    3.8
6    0.8    2.4    3.6    4.1    4.4    4.5
正如两种吸收剂使用方法的对比（表Ⅰ和表Ⅱ）数据所表明的那样，本发明浸渍过的开网系统优越的吸收特性是很明显的。浸渍过的开网系统能更加有效地利用吸收剂，从而其吸收率几乎是美国专利3，686，024的“涂层”法的三倍，其保留性能也很优越。从表Ⅱ所示出的吸收速度数据可以看出，本发明的开网织品由于其流体输送性能加强了（即不受凝胶阻挡效应的影响）故其吸收流体的速度几乎是涂层材料的两倍。
实施例7-10
圆形的、1.75吋（4.45cm）试样从一个热固化纤维织品上模切下来，该织品重量为50%的4    dpf×51mm全聚脂封装的纤维和重量为50%的聚脂人造短纤维（15dpf×31.5mm，431型、近无光的、发皱的）（Eastman化学品公司），其基础重量为128g/m2。曾认为全聚酯封装纤维含有聚对苯二甲酸乙二醇酯芯和一层聚脂树脂壳，该聚脂树脂壳是由68%对苯二甲酸单元和32%间苯二甲酸单元同乙二醇共聚所得到的无规共聚聚酯混合物。市场上可得到的全聚酯封装纤维有日本大阪的Unitika有限公司的4080型Melty纤维。
实例1-3的吸收剂预聚合物混合物已被制得，并根据实例1-3中的步骤对样品进行加工及测试。其吸收及保留数据在表Ⅲ和表Ⅳ中示出。
Figure 85109071_IMG2
对表Ⅲ和表Ⅳ进行考察表明，纤维基底物有一个最佳吸收剂封装量。对本基底物来说，吸收剂的重量百分数约为60%是最佳量。超过这一重量，吸收剂的效率会因凝胶阻挡而显著下降。
实施例11-14
根据示出的基础重量、由下列纤维成分按照实施例1-3示出的步骤可形成干燥、蓬松的织品。
实施例11含氯乙烯共聚物乳胶粘合剂（Union Wadding）的15dpf×1 1/2 ″（38.1mm）聚酯人造短纤维;基础重量为120g/m2。
实施例12 6dpf×64mm聚烯烃热粘结双成分人造短纤维，ES型（日本Chisso公司）;基础重量为225g/m2。
实施例13 重量为43%的5.5dpf×1 1/4 ″（31.75mm）聚酯人造短纤维，Kodel 435型、近无光的、牵伸、带皱的（Eastman化学品公司）;
重量为43%的50dpf×2 1/2 ″（63.5mm）聚酯人造短纤维（起皱的、3M Co.）;重量为14%的3dpf×1 1/2 ″（38.1mm），未牵伸的（热粘结）聚酯人造短纤维，近无光的（Celanese 纤维公司）;基础重量为330g/m2。
实施例14 9dpf×1 3/4 ″（44.45mm）聚丙烯人造短纤维，Herculon（Hercules公司）（用针钉住），基础重量为240g/m2。
圆形的1.75吋（4.45cm）的每个织品的模切试样用实施例1-3列出的配方中的吸收剂预聚物复合物浸渍，并按照实施例1-3中的步骤对其进行加工及测试。液体吸收和保留数据在表Ⅴ和表Ⅵ中给出。
Figure 85109071_IMG3
实施例11-14表示本发明中可有效地使用各种纤维基底物。
实施例15
含有90%的1.5dpf×1 1/2 ″（38.1mm）聚酯人造短纤维（杜邦）和10%的4dpf×51mm全封装聚酯（Melty 纤维4080型）的干而薄的纤维织品在吸收剂预聚物复合物中浸透，该复合物含有48%聚合物（Dow XD-8587.01）、0.64%表面活性剂（Triton X-100）、50%DIW和1.2%交联剂（CX100），然后用20 lbs.的压力挤压织品，以挤出多余的成分。将织品送入290°F（145℃）的烤箱中（两个道次）。吸收和保留数据示于表Ⅶ和表Ⅷ。
Figure 85109071_IMG4
本实施例十分清楚地表明，在固化前，利用压力将多余的预聚物浸渍剂从织品中去除可以制得适宜的吸水性织品。

Claims (9)

1、一种由人造短纤维制成的无纺纤维三维网的吸水性多孔织品，所说的纤维上面有一层薄而连续性的超吸水聚合吸收剂涂层，所说的纤维网由所述聚合涂层主要只在所述纤维的交叉点成为一体，这样在吸入液体时，所述聚合涂层便在织品空隙截留液体最少的情况下膨胀。
2、按照权利要求1所述的吸水性多孔织品，其中，所说的纤维上的聚合涂层占织品总重量的35%-80%。
3、按照权利要求1所述的吸水性多孔织品，其中，所说的纤维上的所述聚合涂层是织品总重量的60%。
4、按照权利要求1所述的吸水性多孔织品，其吸水能力是每克聚合吸收剂至少吸收20克的合成尿。
5、按照权利要求3所述的吸水性多孔织品，其吸水能力是每克聚合吸收剂至少吸收40克合成尿。
6、含有权利要求1所述的吸水性多孔织品的尿布。
7、含有权利要求1所述的吸水性多孔织品的妇女卫生用品。
8、含有权利要求1所述的吸水性多孔织品的失控用品。
9、含有权利要求1所述的吸水性多孔织品的绷带。
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