MXPA01002211A - Nonwoven polyolefin fabrics having hydrophilicity - Google Patents

Abstract

A nonwoven web having durable hydrophilic properties is prepared from an initially hydrophobic polymer chemically reacted with a polar material to form a polar-modified polymer, and further chemically reacted with a hydrophilic material to impart the hydrophilic properties. The hydrophilic polymer reaction product thus prepared can be formed into a nonwoven web using conventional melt spinning techniques. Alternatively, a nonwoven web can be formed from the hydrophobic polymer or its polar-modified intermediate, and the remaining reaction or reactions accomplished by surface grafting.

Description

NON-WOVEN POLIOFEINE FABRICS THAT HAVE INCREASED HYDROPHILIC PROPERTIES FIELD OF THE INVENTION This invention relates to non-woven fabrics based on chemically modified polyolefin having increased hydrophilic properties.

BACKGROUND OF THE INVENTION Maleated polyolefins (including, for example, maleated polypropylene and polyutyrene maleate are typically hydrophobic) These resins are commonly used as compatibilizers and / or as adhesives between polar materials, such as nylon or vinyletylene alcohol, and polyolefins. , an anhydride such as the maleic anhydride is chemically reacted (for example isfruited) on the polyolefin column chain using heat and / or a catalyst.When exposed to a polar material in the presence of heat, the grafted polyolefin forms a bond chemical for the polar material resulting in a union and compatibilization.

Some uses for maleated polyolefins are described in the patent of the United States of America numbers 5,721,315 granted to Evans and Others. These uses include engineering plastics which are materiale for structural members in the fields of transport machines (automobiles, boats and the like), tools, accessories, sporting goods, rest articles, connectors and tubes.

One use of polyolefins is in the manufacture of protected nonwoven fibrous fabrics for various applications. Non-woven fabrics may include fabrics bonded with yarn, fabrics blown with melt and fabrics which are cut and attached, for example, the laminates thereof. These fabrics are used in a wide variety of absorbent materials and clothing including diapers, tampons, medical garments, surgical gloves, caps, aprons and sterilization wraps. When used in absorbent materials, non-woven fabrics to form part of the topsheet, backing or similar structural material and a breathable film laminated to the fabric can provide a liquid barrier and a moisture vapor transmission . When used in medical clothing, specific laminates of non-woven fabrics can provide structural integrity and breathability as well as barriers to liquids, bacteria and viruses.

Polyolefins used to be non-woven fabrics are typically hydrophobic. When a non-woven fabric is intended to transmit or channel a liquid, such as on a topsheet of an absorbent structure, the hydrophobic nature of the material may act as an obstacle. Various surface treatments of non-woven fabrics are known to improve their hydrophilicity by making them more humid to aqueous liquids. These surface treatments have certain disadvantages, including a power to leave a non-woven fabric and escape to the user's skin or to the inner core of the absorbent article. There is a need or desire for a polyolefin-based non-woven fabric having hydrophilic properties which are more permanent and which do not require the use of mobile sulfates.

SYNTHESIS OF THE INVENTION The present invention is directed to a fibrous nonwoven fabric having a chemically impregnated hydrophilic surface. "Chemically taxed" means that the hydrophilic surface is formed by chemical reaction and bond between a hydrophilic moiety and an initially hydrofolic nonwoven fabric forming material. The chemical reaction the bond of the hydrophilic moiety is distinguishable from the prior art methods to which a non-woven fabric was made. hydrophilic by the surface recurrence of a hydrophilic compound, or by merely mixing (and not reacting) a hydrophilic compound with a nonwoven fabric forming polymer. The chemical reaction and the binding of the hydrophilic mit to the nonwoven fabric material causes the hydrophilic properties which are more permanent and less transient, than would occur without the chemical reaction.The starting material for the invention is a hydrophobic fibrous nonwoven fabric, or a hydrophobic nonwoven fabric forming polymer material. The non-woven fabric, or fabric-forming material, is chemically reacted with an anhydride and / or its carbonsylic acid derivative to form an intermediate hydrophobic material having polar functionality. The intermediate material is then further reacted with a hydrophilic compound having a reactive mit, such as a hydroxyl group or amino group, which forms a chemical bond with the polar functionality.

The resulting product is either a hydrophilic fibrous nonwoven fabric, or a hydrophilic polymer material which can be spun into a fibrous nonwoven fabric. The fabric or fabric former possesses all the desirable properties of the underlying polymeric base material, except for the hydrophilic addition. Hydrophilicity chemically imposed is durable meaning that it can not be washed out or physically removed.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a diagram showing the effect of different reaction-inducing levels of an anhydride of a polyglycol on the contact angle of the water of a polyolefin. The lower water contact angles, as measured by ASTM-D-5946-96, indicate a more hydrophilic material. In figure one, the polyglycol level is varied in three fixed levels of maleic anhydride.

Figure 2 is another diagram showing the effect of different levels that induce the reaction of an anhydride and a polyglycol on the water contact angle of a polyolefin. In figure two, the level of maleic anhydride is varied for three fixed levels of polyglycol.

Figure 3 is a diagram showing the effect of different reaction-inducing levels of a polyglycol having three molecular weights per weight of different weight, a constant level of maleic anhydride, on the water contact angle of a polyolefin.

Figure 4 is a diagram showing the effect of different reaction-inductive levels of a polyglycol, on the contact angle of the water of two polypropylene materials reacted with different levels of maleic anhydride.

Figure 5 is a bar graph showing the contact angles of the water of the poleolefins reacted using three different levels of polyglycol, and three different levels of maleic anhydride, before and after washing with distilled water.

Figure 6 is a diagram showing the reaction reproduction as reflected at water contact angles for a maleated poleolefin further reacted with different levels of a polyglycol.

Figures 7 and 8 are diagrams showing the water contact angles achieved after the reaction of different levels two polyglycol materials with the same maleated polypropylene.

DEFINITIONS "A non-woven fabric" means a fabric having a structure of individual fibers or threads which they are between placed, but not in a repetitive and identifiable way. Non-woven fabrics have been formed, in the past, through a variety of processes such as, for example, meltblowing processes, spinning processes and carding and bonding processes.

"Fusible blown fibers" means fibers formed by extruding a molten thermoplastic material through a plurality of thin, usually circular capillary vessels, such as strands or filaments fused into a gas (eg, air) stream at high temperatures. speed which attenuates the filaments of the molten thermoplastic material to reduce its diameter, possibly a microfiber diameter. Then, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form meltblown fiber fabric disbursed at random. Such a process is described, for example, in United States Patent 3,849,241 issued to Butin, the description of which is incorporated herein by reference.

"Microfibers" means small diameter fibers that have an average diameter of no more than about 100 microns, for example, which have an average diameter of about 0.5 microns about 50 microns, or more particularly an average diameter of about 4 microns around 40 microns.

"Yarn-bonded fibers" refer to small diameter fibers which are formed by extruding a molten thermoplastic material as filaments from a plurality of fine, usually circular capillary vessels of a spinner with the diameter of the extruded filaments then being rapidly reduced as, for example, by means of eductive pulling or other well-known splicing mechanisms. The production of non-woven fabrics bonded with yarn is illustrated in the patata as, for example, in the United States of America patent number 3,802,817 issued to Matsuki et al. And in the United States of America patent number 5,382,400 granted. to Pike and others. The descriptions of these patents are incorporated herein by reference.

"Polymer" generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, when using polymers and so on, to mixtures and modifications thereof. In addition, the term "Polymers" will include all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndromatic, and random symmetries.

"Bicomponent fibers" refer to fibers which have been formed from at least two extruded polymer from separate extruders but spun together to form a fiber. The polymers are arranged in different zones placed in simply constant shapes through the cross section of the bicomponent fibers extending continuously along the length of the bicomponent fibr. The configuration of such bicomponent fiber can be, for example, a pod / core arrangement where one polymer is surrounded by another or can be a side-by-side arrangement or an arrangement of "islands in the sea". The bicomponent fibers are taught in U.S. Patent No. 5,108,820 issued to Kaneko et al., In U.S. Patent No. 5,336,552 issued to Strack et al. And in European Patent No. 0586924. For fibers of two components, the polymers may be present in proportions of 75/25, 50/50, 25/75, any other desired proportions.

"Biconstituent fibers" refer to fibers which have been formed from at least two polymers extruded from the same extruder with a mixture. The term "mixture" is defined below. The biconstituent fibers do not have the various polymer components arranged in different zones placed relatively constant across of the cross-sectional area of the fiber. The various polymers are usually not continuous along the entire length of the fiber, but are instead in the form of fibrils which start and end at random. Fibers of biconstituents are sometimes also mentioned as multi-constituent fibers. Fibers of this type are discussed in, for example, U.S. Patent No. 5,108,827 issued to Gessner. The bicomponent and biconstituent fibers are also discussed in the textbook "Mixtures and Compounds of Polymer "by John A. Manson and Leslie H. Sperling, copyright 1976 by Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0-306-30831-2, pages 273 to 277.

The "mixture" means a combination of two or more polymers while the term "alloy" means a subclass of mixtures wherein the components are immutable but have been compatibilized. "Miscibility" and "immiscibility" are defined as mixtures that have positive and negative values, respectively, for the free energy of mixing. In addition, "compatilization" is defined as the process of modifying the interfacial properties of a mixture of immiscible polymer in order to be an alloy.

"Hydrophilic" refers to a material or surface that has an affinity for water, and is wettable by water. Some hydrophilic materials are capable of absorbing water, dissolving in water and / or being embedded in water. The hydrophilic material must have a water contact angle of about 80 degrees or less, as measured by ASTM D5946-96.

"Hydrophobic" refers to a surface or material that is poorly wetted by water, has little or no affinity with water, and tends to repel water. A hydrophobic material can have a contact angle in water of at least 80 degrees, sometimes of degrees or more.

"The chemically imposed hydrophilic surface" refers to a hydrophilic surface formed by the chemical reaction between a hydrophilic moiety and an initially hydrophobic nonwoven fabric or a polymer formed from cloth. Hydrophilic surfaces chemically imposed are generally durable, meaning that the fibers remain hydrophilic after washing with distilled water.

"Consisting essentially of" does not exclude the presence of additional materials which do not significantly affect the desired characteristics of a product or composition given. Examples of such materials include, without limitation, pigments, antioxidants, stabilizers, surfactants, waxes, flow promoters, particulate materials added to improve the processability of the composition.

THE DETAILED DESCRIPTION OF CURRENTLY PREFERRED INCORPORATIONS The starting material for the invention is a fibrous nonwoven fabric or a fabric forming material which is hydrophobic. The starting material includes a hydrophobic polymer. Exemplary hydrophobic polymers include, without limitation, polypropylene, polyethylene (high and low density) copolymers of ethylene with alpha-olefins sign, C3-C20, copolymers of propylene with ethylene or sign of C4-C20 alpha-olefins, copolymers of butene with ethylene, propylene, or sign of C3-C20 alpha-olefins, polyvinyl chloride, polyesters, polyflorocarbons, hydrophobic polyurethane, polystyrene, acrylic resins, and combinations thereof. Polyolefins are preferred, including polyethylenes, polypropylenes, copolymers thereof and mixtures thereof.

The non-woven fabric can be of any type of non-woven thermoplastic fabric. For example, the fabric can be a fabric linked to the side, a blown fabric with a merged and joined fabric or a combination that includes any of the above. The non-woven fabric can also be a bicomponent or biconstituent fabric, as well as a fabric containing one or more of the thermoplastic polymers indicated above. In the case of a bicomponent fabric, it is important only that the surface material includes a hydrophobic polymer which can be modified in accordance with the present invention to make it hydrophilic. The composition of a second material (interior) not exposed to the fiber surfaces, is the material for purposes of the invention and can be hydrophilic or hydrophobic. The non-woven fabric can have a basis weight of about 0.1-150 grams per square meter (gsm), preferably about 1-10 gsm, more preferably about 5-50 gsm.

The fibrous nonwoven fabric or the fabric formed material is chemically reacted with a polar material. The polar material may include an anhydride or an anhydride derivative (for example a carbonic acid derivative) and may be a monomer, a polymer or a compound. The reaction product is a hydrophobic polymer material having a polar functionality (here called a polar modified polymer). Preferably, the non-woven fabric is reacted with a maleic anhydride or a derivative thereof, such as fumaric acid or maleic acid. Other polar materials suitable include without limitation various anhydrides and their derivatives, particularly those having an unsaturated carbon-carbon double bond: HOOCCH = CHCOOH The polar material reacted with the hydrophobic polymer, either using heat or a catalyst (for example a peroxide catalyst) or a combination of heat and catalyst. When the heat is employed, the reaction can take place at a temperature near or above the melting point of the hydrophobic polymer. For example, the hydrophobic polymer and the polar material can be mixed together in a mixer, with the hydrophobic polymer in the molten state to essentially facilitate homogeneous mixing and reaction between the polar material and the hydrophobic polymer. When the hydrophobic polymer includes polypropylene, for example, the reaction can occur in a mixer at a temperature of about 160-225 ° C, preferably 175-200 ° C, with or without a peroxide catalyst, whereby the material polar is polyiminated from grafts on the hydrophobic polymer. Alternatively, the chemical reaction can occur at a much lower temperature in a solvent, with the graft reaction being aided by a peroxide catalyst.

Techniques for polymerizing a graft of a polar material, such as a maleic anhydride or a dicarboxylic acid derivative, on a hydrophobic polymer (for example polyolefin) are well known in the art, and do not constitute part of this invention. As an alternative to polymerize the polar material with the hydrophobic polymer, a suitable polar modified hydrophobic polymer can be purchased commercially. The commercially available modified hydrophobic-pore polymers include without limitation the following: EXXELOR registered trademark 1015, a maleated polypropylene available from Exxon Chemical, Co., having a melt flow rate (230 ° C) of 120 grams / 10 minutes and containing 0.4% by weight of grafted maleic anhydride; POLYBOND trademark 3150, a maleated polypropylene available from Uniroyal Chemical Co., which has a melt flow rate (230 ° C) of 50 grams / 10 minutes and which contains 0.7% by weight of grafted maleic anhydride; POLYBOND trademark 3200, a maleated polypropylene available from Uniroyal Chemical Co. , which has a molten flow rate (230 ° C) of 110 grams / 10 minutes and containing 1.0% by weight of grafted maleic anhydride: Maleated poleolefin (or other modified polar polymer) can itself be hydrophobic and non-wettable with water, or at the boundary line between hydrophobic and hydrophilic. The reaction with the polar material does not make a hydrophilic polymer column; rather, it provides a chemical bond for the subsequent reaction with the hydrophilic material. Generally, the polar modified polymer should contain about 0.1-3.0% by weight of the polar monomer, preferably about 0.4-1.0% by weight, more preferably about 0.6-0.08% by weight.

Preferably, the polar material is grafted onto the polyolefin resulting in a more favorable chemical stereo for an additional reaction. Maleated polypropylene, for example, has the following chemical stereo e which the functional anhydride group projects outwardly from the column chain.

CH, CH, -CH, CH, -CH - CH, C - C 0 = C 0 = C 0 According to the invention, the modified hydrophobic polar polymer is reacted with a hydrophilic material thereby increasing the hydrophilicity of the polymer to make it wettable to water. The hydrophilic material can be a hydrophilic monomer, a polymer, a compound, a mixture containing one or more of these. Suitable hydrophilic materials including organic alcohols, dialcohols, tertiary alcohols, polymers containing them and other hydrophilic materials having groups 1 which react with the polar group (eg half anhydride) on a modified polar hydrophobic polymer. Hydrophobic materials currently preferred include polyglycols and polyoxides, including polyolefin glycols and oxides such, such as polyethylene glycol, polyethylene oxide, polypropylene glycol, polypropylene oxide and copolymers and mixtures thereof. Presently preferred polyglycols include those monoamine and / or diamine linkages which further promote hydrophilicity. The JEFFAMINE series (trademark) of polyglycols, available from Hunstman Chemical Co., includes the monoamines and diamines of variable molecular weights. A typical monoamine structure JEFFAMINE (registered trademark) is as follows: CH, CH, CH, -0 - (C, H4 O). - (CH, CHO) - CH, CHNH, where a and b are integers Maleated poleolefins can be reacted with polyglycols in the presence of heat to form imides that have increased hydrophilic properties: CH3 - I) b -CH H H, CH3 CH3 I I -CH, -C-CH, -CH-CH, - "I C- C / \ O = C C = O \ / N CH, CH3 CH30 - (C2H40) a - (CH: CH0) b -CH, CH The reaction between a modified polar hydrophobic polymer and a hydrophilic material can be achieved by melt-mixing the ingredients together, with or without a peroxide catalyst to form a reaction product of hydrophilic polymer. The reaction mixture should contain about 1-35% by weight of the hydrophobic material, preferably about 4-25% by weight, more preferably about 8-20% by weight. The reaction preferably occurs with the polar polymer modified in the molten state; in order to facilitate an essentially homogeneous dispersion. When the maleated prolipolylene is the modified polar hydrophobic polymer, the reaction can occur at about 160-225 ° C, preferably at about 175-200 ° C.

The hydrophilic polymer reaction product is a polymer having an increased hydrophilicity compared to both the hydrophobic polymer and the hydrophobic polymer pol modified (which have the contact angles of water advancing greater than about 80 and sometimes about 90 or greater). Generally, the hydrophilic polymer reaction product has a water contact angle advancing from less than about 80, preferably from less to about 70, more preferably from less than about 60, and in some cases from less than about 50. The lower water contact angles for a material indicate a higher hydrophilicity, and a greater tendency for water to moisten the material.

It has also been found that, when the polyglycols are used as the reactive hydrophilic material, the polyglycols of higher molecular weight cause a greater increase in hydrophilicity. When the polyglycol is used, its weight average molecular weight should be at least about 500, preferably at least about 1000, more preferably at least about 150 and more preferably at least about 2000 The suitable JEFFAMINE (trademark) polyglycols, available from Huntsman Chemical Co., include those sold under the names M-600, M-1000, M-2005, ED-900 and ED-2003. These polyglycols differ in molecular weight and number of amine groups per molecule. The polyglycols of the JEFFAMINE series (registered trademark) "M" are monoamines, while the polyglycols of the "ED" series are diamines. The numbers after the "M" and "ED" annotations indicate a molecular weight by weight.

Once formed, the hydrophilic polymer reaction product can be converted to a fibrous nonwoven fabric using a conventional melt spinning process. The resulting non-woven fabric is of a durable hydrophilic character, meaning that hydrophilicity can not be washed out if it were otherwise to be easily removed. It is currently preferred to form the hydrophilic polymer reaction product, using the techniques described above, before forming the polymer in a non-woven fabric. However, it is also contemplated that the non-woven fabric can be formed before carrying out one or both reaction steps.

For example a non-woven fabric can be a modified polar hydrophobic polymer form, such as a maleated polypropylene after which the fabric can be surface reacted with a hydrophilic material using peroxide catalyst and a solution application. In similar fashion, a non-woven fabric can initially be formed of a hydrophobic polymer, after which the fabric is grafted to the surface with a polar monomer using a catalyst and a solution application., and then further react with a hydrophilic material. Other techniques for forming a hydrophilic nonwoven fabric by reacting hydrophobic polymer, a polar material and a hydrophilic material are also considered to be "within the scope of the invention. For example, a modified polar polymer such as a maleated polypropylene or a polyethylene can be mixed with a hydrophilic material such as polyethylene glycol or amine-terminated polyethylene oxide. The mixture is then spun into a non-woven fabric, with the spinning conditions being controlled to ensure a sufficient level of reaction between the hydrophilic material and the polar modified hydrophobic polymer, especially on the fiber surfaces.

In another embodiment, the hydrophilic polymer reaction product can be mixed with an unmodified hydrophobic polymer amount (for example an unmodified poleolifine such as polypropylene or polyethylene to produce a mixture having improved (mixed) hydrophilic properties. then be spun into a non-woven fabric.The blend composition can contain any from about 2-100% of the hydrophilic polymer reaction product, depending on the level of hydrophilicity needed.

EXAMPLES 1-74 In the following examples, several poleolefin maleates were chemically reacted with the glycol material of polyolefin using a Haake Rheocord 9000 loading blender as the reaction chamber. The mixer was equipped with twin blades and electric heating. For each example, a mixture of the maleated poleolefin and the glycol of poleolefin totaling 50 grams were placed in the loading mixer. the maleated poleolefin was added to the mixer in pellet form. If the polyglycols were in the liquid form, a syringe was used to add them. If the polyglycols were solid, they were aggregates together with the maleated poleolefin. The charge mixer was set at 190 ° C, and the action mixer was allowed to proceed for 10 minutes to form a hydrophilic polymer reaction product. After 10 minutes, samples of the reaction product were collected from the load mixer for analysis.

Of the samples, the films were pressed. Two separate films were pressed from each sample. The Mylar sheets were used to prevent the resin mixture from sticking to the film press. The film press was set at 190 ° C and 10,000 pounds per square inch for one minute. Then, the water contact angle measurements of those films were carried out with the contact angle goniometer NRL, model 100-00, available from Rame-Hart Inc.

The contact angle goniometer NRL is a device of small optical banking type incorporating an internal transporter-reader calibrated in increments of one degree. His low force microscope produces a sharply defined image of the water drop specimen, which is observed, like a silhouette. A specimen support phase allows the specimen to be easily aligned with the two transverse hairs independently rotatable within the microscope and calibrated on both horizontal and vertical axes. vertical in divisions of 0.02mm. The variable intensity illuminator can be adjusted to allow optimal illumination to be achieved. For these examples, a video camera was used to capture the image to display a 14-inch monitor, allowing easy reading.

Three drops of water were placed on each film sample, at the contact angles on both sides of the water droplets were recorded. These values were then averaged to give an average unwashed film contact angle. After measuring the contact angles, the films were carefully washed with distilled water, and the contact angles were measured again by the same method. This presumably washes away any excess residues or unreacted polyglycols on the surface of the resin that may not affect the measurement of the contact angle.

Below is a list of the maleated poleolefins and the polyglycols used for these experiments, as well as other ingredients.

Maleated Poleolefins 1. EXXELOR trademark 1015, previously described, polypropylene with 0.4% by weight of maleic anhydride. 2. POLYBOND trademark 3150, previously described, polypropylene with 0.7% by weight of maleic acid. 3. POLYBOND registered trademark 3200, previously described, polypropylene with 1.0% by weight of maleic anhydride. 4. POLYBOND trademark 3009, a maleated polyethylene available from Uniroyal having a melt flow rate (190 ° C) of 5 grams / 10 minutes and containing 1.0% by weight of grafted maleic anhydride.

. POLYBOND trademark 3002, a maleated polyethylene available from Uniroyal that has a melt flow rate (230 ° C) of 7 grams / 10 minutes and containing 0.2% by weight of grafted maleic anhydride. 6. DOW S-1775, a maleated polyethylene available from Dow Chemical Co. containing 1.2% by weight of maleic anhydride. 7. MP 660, a maleated polypropylene available from Aristech Chemical Co. containing 0.4% by weight of maleic anhydride.

Polyglycols 1. JEFFAMINE trademark M-600, previously described, a monoamine polyglycol having a molecular weight of 600. 2. JEFFAMINE registered trademark M-1000, previously described, a polyglycol monoamine having a molecular weight of 1000. 3. JEFFAMINE trademark M-2005, previously described, a polyglycol monoamine that has a molecular weight of 2005. 4. JEFFAMINE trademark ED-900, previously described, a diamine polyglycol having a molecular weight of 900.

. JEFFAMINE trademark Ed-2003, previously described, a diamine polyglycol having a molecular weight of 2003. 6. Polyethylene glycol having a molecular weight of 2000, available from Aldrich Chemical Co. 7. Polyethylene glycol having a molecular weight of 900, available from Aldrich Chemical Col.

Other Ingredients 1. EXXON 3445, a homopolymer of polypropylene (not maleated or otherwise modified) in some of the control examples. 2. Masil SF-19, an internal ethoxylated ditriloxane sulfactant available from PPG Industries, used in some of the control examples. 3. PEG 400 MO, an internal distearate sulfactant available from PPG Industries, used in some of the control examples. 4. Titanium propoxide, an esterification catalyst available from Aldrich Chemical Co., which can be used to assist the reaction between a polar functional poleolefin and a hydrophilic modifier.

The maleated poleolefins were reacted with various amounts of the different polyglycols. The following Table 1 summarizes the contact angles obtained pa -v, each example: "* i Table 1: Measurements of contact angles (degrees) The results of examples 1-74 are compared in several ways by the graphs (figures 1 8). Figures 1 and 2 illustrate the different effects of maleic anhydride on polypropylene and different levels of polyglycol for a polyglycol of JEFF7AMINE (registered trademark) M-2005, after washing. For the three levels of maleic anhydride (0.4%, 0.7% and 1.0%), the higher levels of polyglycol (20% and 24% by weight) resulted in lower contact angles. In general, polypropylene with 0.7% by weight of maleic anhydride resulted in better hydrophilicity (lower contact angles) than propylenes with 0.4% and 1.0% by weight of maleic anhydride.

Figure 3 illustrates the effects of using polyglycols of different molecular weight and different percentage levels for maleated polypropylene containing 0.4% by weight of maleic anhydride. The contact angles were lowered (indicating a higher hydrophilicity) as 1) the molecular weight of the polyglycol was high and 2) the amount of polyglycol was increased.

Figure 4 illustrates the effects of using the lower molecular weight polyglycol (M-600) in different amounts, with two levels of anhydride-grafted polypropylene (0.4% and 1% by weight). The best contact angles were achieved with the highest level of modification of anhydride. Even there there was little change in the contact angles when polyglycol levels varied by 4% and 16% by weight.

Figure 5 illustrates the effect of washing on samples made using all three polyglycols of the JEFFAMINE "M" series, at three levels of polyglycol, and of polypropylene grafted with 0.7% by weight of maleic anhydride. Washing made the angles of contact would increase, but n was sufficient to make the samples hydrophobic. The washing could have removed the unreacted monomer and the impurities, but did not remove the chemically impregnated hydrophilicity resulting from the chemical reaction between the maleated polypropylene and the hydrophilic materials.

Figure 6 illustrates that the contact angles on the reaction products of different tests are very reproducible for different samples prepared in the same way, using the same ingredients.

Figure 7 illustrates the effect of reacting the different levels of polyglycol monoamine with molecular weight of 2005, maleated polypropylene containing 0.7% by weight of maleic anhydride. In general, the contact angles decreased when the polyglycol level was raised. However, Figure 8 illustrates that the contact angle is approximately dependent on the level of polyglycol when a polyglycol diamine having a molecular weight of 900 is used E-JTEMPLO 75 A maleated polyethylene manufactured by Dow Chemical Co. under the name S-1775, attributically having 1.2 wt% maleic anhydride content was mixed with 5% by weight of poly (ethylene glycol), molecular weight 2000, in the aforementioned mixer at 190 ° C for 10 minutes. The contact angle of the pressed films of this compound was measured as 48 ° before washing, and 59 ° after washing the film with ample water and drying. The original resin S 1775 had a contact angle of 84 °.

EXAMPLE 76 A maleated polypropylene, manufactured by Exxon Chemical Co. under the name Exxelor 1015, having a claimed maleic anhydride content of 0.4% by weight was mixed with 4% by weight of poly (ethylene glycol), molecular weight of 2000 in the aforementioned mixer at 200 ° C for 10 minutes. The contact angle of the pressed films of this compuest it was measured as 51 ° before washing and 69 ° after washing the film with ample water and drying.

EXAMPLE 77 A maleated polypropylene manufactured by Aristech Chemical Co. under the name MP660, having a claimed maleic anhydride content of 0.4% was mixed with 4% by weight of poly (ethylene glycol), molecular weight 900 jun with 0.2% by weight of titanium propoxide catalyst with esterification obtained from Aldrich Chemical Co ., in the aforementioned mixer at 200 ° C for 10 minutes. The contact angle of the pressed films of this compound was measured as 38 ° before washing and 56 ° after washing the film with ample water and drying.

EXAMPLES 78-91 Using the techniques of Examples 75-77, fourteen additional compositions were prepared and tested. The results are summarized in Table 2 below.

Table 2 Contact angles (degrees)

Claims (49)

Although the embodiments of the invention described herein are currently considered to be preferred, various modifications and improvements can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated by the appended claims, and all changes that fall within the meaning and range of equivalent are intended to be encompassed here. CLAIMS

1. A non-woven fabric of fibers, the fibers formed of a polymer or polymer mixture comprising a hydrophilic polymer reaction product which is the reaction product: A hydrophobic polymer material having a contact angle with water of at least 80 °, measured using ASTM D5946-96; a polar material chemically reacted with the hydrophobic polymer to form a modified polymer containing at least about 0.1% by weight of the polar material; and a hydrophilic material mixed and chemically reacted with the modified polymer to form the hydrophilic polymer reaction product having a contact angle with water lower than that of the hydrophobic polymer both before and after the reaction product of hydrophilic polymer is washed with distilled water

2. The non-woven fabric as claimed in clause 1, characterized in that the hydrophobic polymer comprises a material selected from the group consisting of polypropylene, polyethylene, ethylene copolymer with sign of C3-C20 alpha-olefins, copolymers of propylene with ethylene or sign of alpha-olefins, C4-C20, copolymers of butene with ethylene, propylene, or sign of C5-C20 alpha-olefins, polyvinyl chloride, polyesters, polyfluorocarbons, polyurethane hydrofdbic, polystyrene, acrylic resins, and combinations thereof .

3. The non-woven fabric as claimed in clause 1, characterized in that the hydrophobic polymer comprises a polyolefin.

4. The non-woven fabric as claimed in clause 3, characterized in that the polyolefin comprises the material selected from the group consisting of polyethylenes, polypropylenes, copolymers thereof and mixtures thereof.

5. The non-woven fabric as claimed in clause 4, characterized in that the polyolefin comprises polypropylene.

6. The non-woven fabric as claimed in clause 4, characterized in that the polyolefin comprises polyethylene.

7. The non-woven fabric as claimed in clause 1, characterized in that the polar material comprises a material selected from the group consisting of anhydrides, carbosyl acid derivatives thereof, and combinations of the foregoing.

8. The non-woven fabric as claimed in clause 1, characterized in that the polar material comprises a material selected from the group consisting of maleic anhydride, carbosyl acid derivatives thereof, and combinations of the foregoing.

9. The non-woven fabric as claimed in clause 1, characterized in that the hydrophilic material comprises a material selected from the group consisting of polyglycols, polyoxides and combinations thereof.

10. The non-woven fabric as claimed in clause 9, characterized in that the hydrophilic material comprises a material selected from the group consisting of polyolefin glycols, polyolefin oxides, and combinations thereof.

11. The non-woven fabric as claimed in clause 10, characterized in that the hydrophilic material comprises a material selected from the group consisting of polyethylene glycol, polyethylene oxide, and combinations thereof.

12. The non-woven fabric as claimed in clause 10, characterized in that the hydrophilic material comprises a material selected from the group consisting of polypropylene glycol, polypropylene oxide, and combinations thereof.

13. The non-woven fabric as claimed in clause 10, characterized in that the hydrophilic material comprises a glycol of polyolefin having an amine bond.

14. The non-woven fabric as claimed in clause 13, characterized in that the amine bond comprises a monoamine.

15. The non-woven fabric as claimed in clause 13, characterized in that the amine linkage comprises a diamine.

16. The non-woven fabric as claimed in clause 1, characterized in that the modified polymer comprises about 0.1-3.0% by weight of the polar material

17. The non-woven fabric as claimed in clause 1, characterized in that the modified polymer comprises about 0.4-1.0% by weight of the polar material.

18. The non-woven fabric as claimed in clause 1, characterized in that the modified polymer comprises about 0.6-0.8% by weight of the polar material.

19. The non-woven fabric as claimed in clause 1, characterized in that the hydrophilic material comprises about 1-35% by weight of the reaction product of the hydrophilic polymer having increased hydrophilic properties.

20. The non-woven fabric as claimed in clause 19, characterized in that the hydrophilic material comprises about 4.25% by weight of the reaction product of the hydrophilic polymer.

21. The non-woven fabric as claimed in clause 19, characterized by the hydrophilic material comprises about 8.20% by weight of the hydrophilic polymer reaction product.

22. A non-woven fabric of fibers, the fibers formed of a polymer or a polymer mixture comprising a hydrophilic polymer reaction product which is the reaction product: a hydrophobic polymer material having a contact angle in water greater than about 80 °, measured using ASTM D5946-96; a polar material chemically reacted with the hydrophobic polymer to form a modified polymer containing at least about 0.1% by weight of polar material; Y a hydrophilic material mixed and chemically reacted with the modified polymer to form the hydrophilic polymer reaction product having a contact angle with water of less than about 80 ° both before and after the hydrophilic polymer reaction product is washed with distilled water.

23. The non-woven fabric as claimed in clause 22, characterized in that the hydrophobic polymer has an initial contact angle in water of at least about 90 °.

24. The non-woven fabric as claimed in clause 22, characterized in that the reaction product of the hydrophilic polymer has a contact angle in water of less than about 70 °.

25. The non-woven fabric as claimed in clause 22, characterized in that the reaction product of the hydrophilic polymer has a contact angle in water of less than about 60 °.

26. The non-woven fabric as claimed in clause 22, characterized in that the reaction product of the hydrophilic polymer has a contact angle in water of less than about 50 °.

27. The non-woven fabric as claimed in clause 22, characterized in that it comprises a fabric bonded with yarn.

28. The non-woven fabric as claimed in clause 22, characterized in that it comprises a meltblown fabric.

29. The non-woven fabric as claimed in clause 22, characterized in that it comprises a carded and bonded fabric.

30. A non-woven fabric of fibers, the fibers formed of a polymer or a polymer mixture comprising a maleated polyol olefin material blended and chemically reacted with a hydrophilic material to impart durable hydrophilic properties to the non-woven fabric that supports washing with water distilled

31. The non-woven fabric as claimed in clause 30, characterized in that the maleated poleolefin comprises a polyolefin reacted with maleic anhydride.

32. The non-woven fabric as claimed in clause 30, characterized in that the maleated polyolefin comprises an ethylene polymer.

33. The non-woven fabric as claimed in clause 30, characterized in that the maleated polyolefin comprises a propylene polymer.

34. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic polymer comprises a polyglycol or a polydide.

35. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic polymer comprises a glycol of polyolefin.

36. The non-woven fabric as claimed in clause 35, characterized in that the glycol of polyolefin includes at least one amine group.

37. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic material has a weight average molecular weight of at least about 500.

38. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic material has a weight average molecular weight of at least about 1000.

39. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic material has a weight average molecular weight of at least about 1500.

40. The non-woven fabric as claimed in clause 30, characterized in that the hydrophilic material has a weight average molecular weight of at least about 2000.

41. An absorbent product comprising the non-woven fabric as claimed in clause 1.

42. A garment comprising the non-woven fabric t and as claimed in clause 1.

43. A diaper comprising the nonwoven fabric ta and as claimed in clause 1.

44. A stopper comprising the non-woven fabric ta and as claimed in clause 1.

45. A medical garment comprising the non-woven fabric as claimed in clause 1.

46. A surgical glove comprising the non-woven fabric as claimed in clause 1.

47. A cap comprising the non-woven fabric as claimed in clause 1.

48. An apron comprising the non-woven fabric as claimed in clause 1.

49. A sterilization wrap comprising the non-woven fabric as claimed in clause 1.