RU2190713C2 - Stable treatment composition, method of treating substance by this composition, and cloth obtained therefrom - Google Patents

Abstract

FIELD: textile industry. SUBSTANCE: nonwoven materials are treated to impart stability properties, in particular wettability, which can by applicable in medicine, veterinary, and agriculture. Stable treatment composition in the form of aqueous emulsion with viscosity below ca. 100 VPa.s at 25 C contains, as viscosity modifier, 5-80% of alkylpolyglycoside with 8-10 carbon atoms in alkyl chain. Composition can contain a surfactant in the form of ethoxylated hydrogenised oil and sorbitan monooleate with less than 20% of solids. Composition is applied onto substrate in the form of 5-80-% aqueous solution emulsion by spraying or immersion in bath. EFFECT: prolonged utilization period (at least to cycles) when tested for drainage and increased wettability. 16 cl, 2 dwg, 7 tbl, 80 ex

Description

 This application claims priority based on provisional patent application US 60/025621, filed September 4, 1996

BACKGROUND OF THE INVENTION
The production of nonwoven fabrics is systematically expanding, resulting in a variety of materials for numerous applications. For example, nonwovens with a low surface density and an open structure are used in personal care products, such as disposable diapers, as lining fabrics that provide dry contact with the skin, but easily pass liquids to materials with a higher absorption capacity, which can be nonwovens different composition and / or different structure. Heavier non-woven materials can be made with a porous structure, which allows them to be used for filtration, absorption and protection, for example, in packaging for products that must be sterile, including napkins or protective clothing used in medicine, veterinary medicine or in industry . Heavier non-woven materials are designed for use in land reclamation, agriculture and construction. Here are a few examples from an almost unlimited number of examples of non-woven materials and their applications known to specialists in this field of technology, it should be borne in mind that new non-woven materials are constantly appearing and the scope of their application is expanding. In addition, various methods and equipment have been developed for the manufacture of nonwoven materials having an appropriate structure and composition that make them suitable for such applications. Examples of such methods are spinning, melt spinning, carding, and others, which will be described in more detail below. The present invention is generally applicable to non-woven materials, as should be obvious to specialists in this field of technology, but is not limited to references or examples relating to specific non-woven materials and are only illustrative.

 It is not always possible to produce a non-woven material having all the necessary properties immediately after molding, and it is often necessary to process the non-woven material in order to improve or change its properties, such as wettability by one or more liquids, impermeability to one or more liquids, electrostatic characteristics, electrical conductivity and ductility, not to mention other characteristics. Known processing methods include such steps as immersing the nonwoven material in the treatment bath, coating the nonwoven material with the treatment composition or spraying the composition thereon, and printing the nonwoven fabric with the treatment composition. Due to cost and other reasons, it is usually desirable to use the processing composition in a minimum amount that provides the desired effect with an acceptable degree of uniformity. It is known, for example, that the heat in the additional drying step necessary to remove the water introduced together with the processing composition can degrade the strength of the nonwoven material and also increase the cost of processing. Therefore, there is a need to create an improved processing method and / or composition for nonwoven materials that can be economically and effectively applied during processing without adversely affecting the physical characteristics of the nonwoven material to achieve the desired results.

 It is also known that most of the usual surfactants dispersible in water are not prone to the formation of high solids content (more than 10% by weight), low viscosity (less than 100 mPa • s), stable mixtures with water. Therefore, there is an additional need to create a treatment bath that is stable without phase separation for a long period of time and which has a low viscosity profile at room temperature, as well as means for effectively treating with a surfactant in order to impart stable hydrophilic properties to the non-woven substrate material.

The present invention relates to a stable machining composition in the form of an aqueous emulsion for increasing the service life of the material, having a viscosity of less than about 100 MPa • s at a temperature of about 25 ^o C and containing 5-80% alkylpolyglycoside with 8-10 carbon atoms in the alkyl chain as a modifier viscosity.

 According to preferred embodiments, the stable processing composition according to the invention further comprises a surfactant, and the solids concentration is at least 20% by weight; a surfactant contains a mixture of ethoxylated hydrogenated oil and sorbitan monooleate; the composition according to the invention additionally contains a surfactant, and the concentration of solids is less than 20 wt.%; the composition according to the invention is intended for processing the substrate as a material; the composition according to the invention is intended for processing material for the manufacture of personal care products.

In addition, the invention relates to a method for efficiently and economically processing nonwoven materials in order to impart one or more desired properties, for example, stable wettability, and thereby produce improved nonwoven materials. This problem is solved in a method for processing a substrate, comprising the step of applying to the substrate a treatment composition having a viscosity of less than 100 mPa s at a temperature of about 25 ^{° C.} , wherein the treatment composition contains an alkyl polyglycoside with 8-10 carbon atoms in an alkyl chain in the form of 5-80% aqueous emulsion as a viscosity modifier and a surfactant at a ratio of 1: 1 to 1:20, respectively.

 According to preferred embodiments, the method according to the invention is characterized in that the treatment means is applied by spraying means; spray means comprises one or more rotating spray heads; at the stage of applying the processing composition use a bath for processing and, in addition, the method includes a stage of drying; moreover, the processing composition is applied on both sides of the substrate; the substrate is a non-woven fabric, and the processing composition has a solids concentration of at least about 20 wt.% and furthermore contains a mixture of ethoxylated hydrogenated castor oil and sorbitan monooleate.

 In addition, the above problem is also solved by obtaining a material having a duration of use of at least 2 cycles when measured by the run test described in the application, and treated with a processing composition containing an alkylpolyglycoside having from 8 to 10 carbon atoms in the alkyl chain, as well as a mixture of ethoxylated hydrogenated castor oil and sorbitan monooleate.

 According to a preferred embodiment, the material treated with the processing composition according to the invention may be a foam or film.

 As will be shown below, the resulting processed fabrics turn out to be uniformly, stably and efficiently processed with reduced consumption of the working composition and with minimal negative consequences or without them. Preferred treatment compositions include a combination of a surfactant, which itself is a mixture of ethoxylated hydrogenated castor oil with sorbitan monooleate, and a viscosity modifier, alkyl polyglycoside. These types of processing of nonwoven materials are used, in particular, for personal care products, in medicine and in other fields, for example, wipes, protective clothing, applicators, etc., where it is desirable that the compositions applied to the substrate have a high solids content.

Below the invention is explained in more detail on the example of specific options for its implementation with reference to the accompanying drawings, in which:
Figure 1 schematically shows a processing method according to the invention, suitable for coating one or both sides of a nonwoven substrate;
figure 2 is a similar schematic version of a processing system.

As used herein, the term "nonwoven fabric or nonwoven fabric" means a nonwoven fabric having a structure of individual fibers or threads that are intertwined, but not in a regular or specific manner, like a knitted fabric. It also covers foamed materials and films that are fibrillated, provided with holes or otherwise processed to give them properties similar to those of fabrics. Non-woven fabrics or non-woven materials are obtained in a variety of ways, for example, such as melt spinning, spinning and combing with bonding. The surface density of non-woven materials is usually expressed in grams of material per square meter, and the used fiber diameters are usually expressed in micrometers. As used herein, the term “microfibers” means small diameter fibers having an average diameter of not more than 75 microns, for example, having an average diameter of from about 0.5 microns to about 50 microns, in particular microfibers can have an average diameter of from about 2 microns to about 40 microns. Another commonly used unit of fiber diameter is denier, which is defined in grams per 9000 m of fiber and can be calculated by taking the square of the fiber diameter in square micrometers, multiplying by the density in grams per centimeter cubic and multiplying by 0.00707. A lower denier indicates a thinner fiber, and a higher denier indicates a thicker or heavier fiber. For example, a polypropylene fiber diameter of 15 μm can be converted in denier by squaring, multiplying the result by 0.89 g / cm ³ and multiplying by 0.00707. Therefore, polypropylene fiber with a diameter of 15 microns has a denier value of about 1.42; (15 ² • 0.89 • 0.00707 = 1.415). Outside the US, the most common unit of measure is tex, which has a gram dimension per kilometer of fiber. Tex can be calculated as denier / 9.

 As used herein, the term "spinning fibers" ("staple fibers") refers to fibers of small diameter that are formed by extruding molten thermoplastic material in the form of monofilaments from a number of thin, usually round capillaries of a spinneret, followed by quick drawing, as, for example, in US Pat. 4,340,563 (Eppel et al.), In US Pat. No. 3,692,618 (Dorschner et al.), In US Pat. No. 3,802,817 (Matsuki et al.), In US Pat. Nos. 3,338,992 and 3,341,394 (Kinney), in US Pat. US 3502538 (Levy) and US Pat. No. 3,542,615 ( Dobo et al.). Staple fibers are chilled and usually not sticky when they are deposited on the receiving surface. Staple fibers are usually continuous and have an average diameter of 7 microns, and more particularly between about 10 microns and about 20 microns.

 As used herein, the term “melt-formed fibers” refers to fibers formed by extruding molten thermoplastic material through a number of thin, typically round capillaries of a spinneret in the form of molten filaments or monofilaments in converging high-speed gas flows (eg, air) that reduce the thickness of monofilaments from molten thermoplastic material in order to reduce their diameter, which may be equal to the diameter of microfiber. After this, the fibers formed by molding are transferred by a high-speed gas stream and deposited on the receiving surface to form a nonwoven material from randomly arranged fibers obtained by melt molding. Such a method is disclosed, for example, in US Pat. No. 3,849,241 (Butin). Fibers obtained from melt spinning are microfibers that can be continuous or intermittent and typically have an average diameter of less than 10 microns and are typically sticky when deposited on a receiving surface.

 As used herein, the term “polymer” usually encompasses, but is not limited to, homopolymers, copolymers such as block copolymers, grafted, random and random copolymers, ternary copolymers, etc., as well as mixtures and modifications thereof. In addition, unless otherwise specified, the term "polymer" covers all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and random symmetries.

 Used here, the term "direction of movement during processing" refers to the length of the fabric in the direction in which it is produced. The term "across the direction of movement during processing" refers to the width of the fabric, i.e. to the direction, usually perpendicular to the direction of processing.

 As used herein, the term “monocomponent” fiber refers to a fiber formed from one or more extruders using only one polymer. This does not mean the exclusion of fibers formed from one polymer, in which additives are added in small amounts with the aim of dyeing, imparting antistatic properties, oiling, ensuring hydrophilicity, etc. These additives, for example titanium dioxide for coloring, are usually present in an amount of less than 5% by weight, and more typically in an amount of about 2% by weight.

 Used herein, the term "combined fibers" refers to fibers that are formed from at least two polymers extruded from separate extruders, but spun together to form one fiber. Combined fibers are sometimes also referred to as multicomponent or bicomponent fibers. Typically, the polymers are different from each other, although the combined fibers can be monocomponent fibers. The polymers are located in essentially unchanged separate zones in the cross section of the combined fibers and are stretched continuously throughout the length of the combined fibers. Such a combined fiber may have, for example, a core-shell structure, where one polymer is surrounded by another, or a structure with spaced polymers, or an island-in-sea structure. Combined fibers are disclosed in US Pat. No. 5,108,820 (Kaneko et al.), US Pat. No. 5,336,552 (Streck et al.) And US Pat. No. 5,382,400 (Pike et al.) In bicomponent fibers, polymers can be present in proportions 75/25, 50 / 50, 25/75 or in any other necessary proportions.

As used herein, the term "bicomponent fibers" refers to fibers that are formed from at least two polymers extruded as a mixture from the same extruder. The term “mixture” is defined below. Two-ingredient fibers do not have different polymer components located in relatively invariably located separate zones in the cross-sectional area of the fiber, and different polymers are usually not continuous throughout the length of the fiber, but instead form fibrils or protofibrils that start and end at random places . Two-ingredient fibers are sometimes also referred to as multi-ingredient fibers. Fibers of this general form are discussed, for example, in US Pat. No. 5,108,827 (Gessner). Bicomponent and bicomponent fibers are also discussed in Polymer blends and composites, authors: Manson John A. and Sperling Leslie H., Plenum Press ^c , 1976, division of Plenum Publishing Corporation of New York, IBSN 0-306-30831-2, p. 273-277.

 As used herein, the term “mixture” as applied to polymers means a mixture of two or more polymers, while the term “alloy” means a subclass of mixtures in which the components are not miscible, but their mutual miscibility can be ensured. “Miscibility” and “immiscibility” refer to mixtures having respectively negative and positive values of the free energy of mixing. In addition, "ensuring miscibility" means the process of modifying the boundary properties of an immiscible polymer mixture in order to produce an alloy.

 As used herein, “air-bond” means a process for bonding a non-woven fabric, such as a non-woven fabric of bicomponent fibers, in which air hot enough to melt one of the polymers forming the fibers of the non-woven fabric is passed through the non-woven fabric. The speed is chosen, as a rule, between 30 and 152 m / min, and the time delay up to 6 s. Bonding is provided by melting and re-hardening of the polymer. When bonding by air permeability, the possibilities of change are limited, and it usually refers to the second stage of the bonding process. Since bonding by air passage requires the melting of at least one component to form a bond, its use is limited to nonwoven materials with two components, such as nonwoven materials from bicomponent fibers or nonwoven materials containing adhesive fibers or powder.

As used herein, “thermal dot bonding” encompasses the passage of a fabric or nonwoven fabric of fibers to be bonded between the heated calender roll and the support shaft. The calender roll is usually, although not always, embossed in such a way that the fabric taken as a whole does not bond along its entire surface. As a result, for functional or aesthetic reasons, various reliefs have been developed for calender rolls. One sample of the Hansen and Pennings relief has sharp protrusions, providing a bond area of about 30% and about 31 adhesion / cm ² , as presented in US Pat. No. 3,855,046 (Hansen, Pennings). The relief of Hansen and Pennings has square areas for bonding in the form of sharp protrusions or spikes, with the side size of each spike being 0.965 mm, the spacing between the spikes is 1.778 mm, and the depth of the bonding provided is 0.584 mm. The resulting relief provides a bond area of approximately 29.5%. Another typical point bonding relief is the sparse bonding relief of Hansen and Pennings, with which the bonding area is 15%, while the square spike has a side with a size of 0.94 mm, the gap between the spikes is 2.464 mm, and the depth is 0.991 mm. Another typical dot bonding relief, designated “714”, has bonding pads in the form of square spikes, each spike having a side with a size of 0.584 mm, the spacing between the spikes is 1.575 mm, and the bonding depth is 0.838 mm. The resulting relief provides a bond area of approximately 15%. Another common relief is the "C-star" relief, which provides a bond area of approximately 16.9%. The relief of a C-star has a structure in the form of transversely directed stripes or a “ribbed velveteen” structure interrupted by protruding stars. Other common reliefs include a diamond-shaped relief with the repetition of rhombs at a small offset, and a wire-weave relief that looks, as its name suggests, like a window binding. Typically, the percentage of bonded area ranges from about 10% to about 30% of the area of the nonwoven laminate. As is well known in the art, pin bonding fixes the layers to each other and also gives integrity to each individual layer by bonding monofilaments and / or fibers within each layer.

 As used herein, the term "personal care product" means diapers, training pants, absorbent elements of underwear, products for use in incontinence in the elderly, and feminine hygiene products.

 As used herein, the term “long-term wettability” or “long-term wettable” means the ability to withstand at least two, and with achieving a benefit, at least three liquid discharges during the runoff test described below.

 As used herein, the term "hydrophilic" means that the polymer composition has such free surface energy that the polymer material can be wetted by an aqueous medium, i.e. liquid medium in which water is the main component. That is, the aqueous medium wets the non-woven fabric treated in the bath with a surfactant. The surfactant bath contains at least 10% by weight of a surfactant or mixture of surfactants and not more than 90% of a solvent such as water.

Test methods
The water runoff (exposure) test and the wetting / drying procedure are described in US Pat. No. 5,258,221 (Meirovich et al.), Which is incorporated herein by reference in its entirety. In a typical case, as a rule, a rectangular sample with a size of 20 cm by 38 cm from a fibrous material, for example non-woven material, is fixed on the upper layer of an absorbent filler consisting of polypropylene, wood pulp fibers and / or superabsorbent material. The resulting test structure is placed in the center of the inclined surface and held in place with adhesive tape at each corner of the structure. The angle of inclination of the surface is chosen 45 ^o instead of the angle of 30 ^o shown in the patent. The funnel is placed at a distance of about 200 mm from the bottom or bottom edge of the test structure. The funnel valve is located above the upper surface of the test structure at a distance of approximately 10 mm. 100 ml of water having a temperature of 35 ^° C is poured into the funnel. The funnel valve is opened to release water over a period of about 15 seconds. Determine and record the amount of water (in grams) that drains and collects in the collection. Typically, the fibrous material is considered to have passed a modified water runoff test if the amount of water collected in the collector is less than the expected amount for this type of fibrous material. For example, when the fibrous material is a light (with a surface density of about 20 g / m ² ) non-woven material obtained by spinning and bonding, the amount of collected water should be less than 20 ml.

The wetting / drying cycle was modified by using water at room temperature (approximately 23 ^{° C.} ) in an amount of 500 ml instead of 1 liter. Typically, a rectangular sample in the form of a porous substrate with the coating described above is placed in water in an amount of 500 ml. The sample is kept in water for one minute with stirring with a frequency of 15-20 min ^-1 using a mechanical mixer. The sample is removed from the water, and the excess liquid is squeezed back into the vessel with wash water. The sample is dried in the air in the evening and all night or dried in an oven (Blue M model OV-475A-3 from General Signal, Blue Island, Illinois) at a temperature of 80 ^o C for 20 minutes and then subjected to a modified test for water flow described above. This process is repeated as many times as necessary.

 A tensile test of a strip is a measurement of the breaking strength and elongation or deformation of a fabric when it is subjected to unidirectional stress. This test is a modified version of the standard test method D882 of the American society for testing materials (test method for evaluating the tensile characteristics of thin plastic sheet material).

To measure the peak force in relation to the objectives of the present invention, the standard procedure has been amended:
The separation rate using the gripping element of the test setup was kept at 50 mm / min for all samples.

 The initial interval between the gripping elements varied from 25.4 to 76.2 mm, depending on the type of test sample. The initial interval for testing materials with a tape substrate was 38.1 mm, and the initial interval for testing materials with an outer coating was 76.2 mm.

 The peak force was calculated by dividing the maximum load by the value of the curve of the load moving in the transverse direction along the width of the sample.

 The results were expressed in kilograms for the gap and in percent stretch to break. Higher values indicate stronger, more stretchable fabric. The term "load" means the maximum load or force, expressed in units of mass, required to rupture or break the specimen during a tensile test. The term "deformation" or "total energy" means the total energy at load, depending on the value of the elongation curve, expressed in units of mass-length. The term “elongation” means an increase in the length of a specimen during its tensile test. The values of tensile strength during gripping and elongation during gripping were obtained using a fabric of precisely specified width, usually 102 mm, a certain width of the clamp and a constant speed of drawing. If the specimen is wider than the clamping device, then results are obtained that represent the effective strength of the fibers at the clamped width together with the additional strength introduced by adjacent fibers into the fabric. A sample clamped, for example, in an Instrom device of a TM model, can be obtained from Instrom Corporation, 2500 Washington Street. Canton, Massachusetts 02021, and the Intellect II Twing-Albert device can be obtained from Twing-Albert Instruments Co., 10960 Dutton Road, Philadelphia, PA 19154, these devices having seventy-six millimeter long parallel clamps. These devices fully simulate tissue stress states in real use.

 The passage of fluid versus time. This test is referred to as EDANA 150.1-90 and involves the measurement of the time required for a known volume of fluid (simulating urine) applied to the surface of the test sample of nonwoven material in contact with the underlying absorbent pad to pass through the nonwoven material. In the general case, a burette with a capacity of 50 ml is placed on the ring bracket, while the nozzle is placed inside the funnel. A standard absorbent pad made of five layers of a specific filter paper (with an absorption capacity of 482%) is placed under the funnel on an acrylic glass plate, and a non-woven sample is placed on top of the absorber. A passage plate made of acrylic glass with a thickness of 25 mm and a mass of 500 g is placed on top of the sample, while its hole is placed in the center 5 mm below the funnel. The burette is filled with liquid, keeping the funnel closed, and then 10 ml is poured into the funnel. After the release of liquid in an amount of 10 ml, a countdown begins, which is stopped when the liquid penetrates the gasket and falls down onto a number of electrodes, and the time spent on it is recorded. For each sample, this test is repeated 5 times using the same sections at each repetition, and the time values are averaged.

 Other materials similar to flame retardants can also be mixed with the polymer used to make the nonwoven fabric of the invention to increase fire resistance and / or pigments to give different layers the same or different colors. You can also use additives to create aromas, control odors, antibacterial substances, lubricants, etc. Such components for melt spinning and spinning thermoplastic polymers are well known in the art and are often referred to as internal additives. Pigment, if used, is usually present in an amount of less than 5% by weight, while other materials may be present, for example, in an aggregate amount of less than about 25% by weight.

 The fibers of which the fabric is made according to the invention can be obtained, for example, by using melt spinning or spinning processes, which are well known in the art. In these processes, an extruder is typically used to feed the molten thermoplastic polymer to a die, where the polymer is converted into fibers with a fiber exit that can have a staple type fiber length or greater. The fibers are then drawn, usually pneumatically, and deposited on a moving perforated litter or tape to form a non-woven fabric. As indicated above, the fibers obtained by spinning and spinning from a melt are microfibers.

 The manufacture of nonwoven materials from melt in a general form is discussed above and described in the references.

The fabric according to the invention may be a multilayer material. An example of a multilayer material is an embodiment in which some of the layers are obtained by spinning and some by melt spinning, for example, a layered yarn / melt stretch / yarn laminate disclosed in US Pat. No. 4,041,203 (Brock et al.) In US Pat. No. 5,169,706 (Collier et al.), In US Pat. No. 5,540,979 (Yahya et al.) And in US Pat. No. 4,374,888 (Bomsleger). Such a layered material can be made by sequentially depositing on a moving forming tape a first spun fabric layer, then obtained by melt-forming a fabric layer and, finally, another spun fabric layer, and then by bonding the laminate in the manner described below. Alternatively, fabric layers can be manufactured separately, assembled on rollers, and combined in a separate bonding step. Typically, such fabrics have a surface density of from about 3.4 to 400 g / cm ² or, more preferably, from about 25.4 g / cm ² to about 101.7 g / cm ² .

 Non-woven yarn fabrics are usually bonded in some way during production to give them some structural integrity to withstand the harsh conditions of subsequent processing into the final product. Bonding can be done in a number of ways, for example, by hydro-entangling, needle-piercing, ultrasonic welding, stitch welding, air transmission and thermal bonding.

As indicated above, a significant characteristic of processed non-woven fabrics in many applications is the duration of use with wetting or the ability to withstand multiple fluid secretions. For example, if used as a diaper lining, the ability to maintain wettability after exposure to three or more secretions of liquid is highly desirable. Some available formulations for processing, for example a mixture of ethoxylated hydrogenated castor oil and sorbitan monooleate (called Ahcovel N-62, may be obtained from ICC; it is also known simply as “Ahcovel”), presumably, should be used for a long time. compliance with this norm. However, the composition for processing is very viscous and difficult to apply due to the high density in the case of using conventional processing methods. Traditional viscosity modifying additives can reduce the viscosity of this composition for processing, but they adversely affect the duration of use of the treated fabric, as discussed below with reference to tables 3 and 4. In the framework of the invention it was found that the use of specific alkylpolyglycosides not only reduces the viscosity of this composition , but also saves the necessary duration of use. For best results, an alkylpolyglycoside is selected with 8-10 carbon atoms in the alkyl chain (e.g., glucopone 220UP) and is administered in an amount of about 5% to about 80%, and with a gain of about 5% to about 10%, calculated relative to the total the mass of the composition, while the mass of the composition with an alkylpolyglycoside, which may be aqueous, contains, for example, 40% water. Table 1 below shows the effect of adding glucopone 220UP in the form of a solution of 60% alkipolyglycoside and 40% water by weight, which can be obtained from Henkel Corporation (also called simply “glucopone”), on the viscosity of the base material Ahkobel N-62. Viscosity was determined for compositions containing a total of 20% solids at a shear rate of 20 s ^-1 using in each case a Brookfield DV II + viscometer with a CP-41 spindle.

 To solve the problems according to the invention, the preferred viscosity is a viscosity of less than about 100 MPa • s in the case of coating at room temperature in order to be able to use conventional systems and methods for applying sufficiently thick coatings, for example the VEKO roller system, which can be obtained from VEKO . As is apparent to those skilled in the art, other systems can be used, such as brush spraying devices and coating and printing devices. As shown above, the surfactant alone does not meet the requirements, but a small addition of 1 part per 20 parts of an alkyl polyglycoside such as glucopone 220UP drastically reduces its viscosity.

 The invention is applicable for processing with reduced viscosity and using a variety of compositions, although a combination with surfactant compositions, such as a number of Ahkovels, is highly preferred due to the long-term stability of such impregnations. However, when the duration of use indicator is not critical, it is only important that the composition contains, in effective amounts, a combination of a surfactant and a viscosity modifier to enable processing of the nonwoven material. To establish suitability, the composition can be checked using a Brookfield viscometer. Formulations with a viscosity of about 2000 mPa • s or less are preferred. Specific examples include Triton X-102, alkyl phenol ethoxylate, a surfactant that can be obtained from Union Carbide, Y12488 and Y12734, related to a number of ethoxylated polydimethylsiloxanes, which can be obtained from OS, Masil SF-19, grafted trisiloxane polyethylene glycol, which can be obtained from Pi-Pi-Gi, PEG 200, 400 and 600, belonging to the series of polyethylene glycol monostearates, distearates and monolaurates, from Pi-Pi-Gi, GEMTEX series SM-33 and SC75, dialkyl sulfosuccinates from Fiitex as well as water edible polymers such as polyvinyl pyrrolinone, polyvinyl alcohol, ethyl hydrohydrocellulose, carboxymethyl cellulose, hydroxypropyl cellulose, starch, agar-agar and other natural water-soluble polymers. Examples of a viscosity modifier include glucopone 220 or 225, both are alkyl polyglycosides with 8-10 carbon atoms in the alkyl chain and can be obtained from Henkel Corporation. The resulting mixture may have a viscosity, preferably as an emulsion, i.e. less than 100 mPa • s, and a viscosity of less than 50 mPa • s in all applications is more desirable.

Although the present invention is applicable to the processing of a wide range of nonwoven materials, it is most effective and therefore preferred for nonwoven materials that have properties that facilitate fast and efficient processing. These properties include surface density, for example, from 5 to 500 g / cm ² thickness, for example, from 0.2 to 10 mm and the like.

 In order to maximize the benefits of the present invention, it is desirable to select a non-woven material and composition for processing so that the composition can be applied using preferably not more than 80% water.

 Turning to FIG. 1, a process for coating one or both sides of a moving nonwoven fabric will be described. Specialists in the art should understand that the invention is equally applicable for processing as part of a system or for performing a separate processing step. Non-woven material 12, for example, non-woven fabric obtained by spinning or melt-forming, is sent to a processing station including rotating spray heads 22 for coating one side 14 of the non-woven material. In addition, an optional processing station 18 (shown by dashed lines), which may include rotating spray heads (not shown), can be used to coat the opposite side 23 of the nonwoven fabric 12 guided along the upper support rollers 17, 19. Each processing station receives an inflow processing solution 30 from the tank (not shown). After that, if necessary, the treated non-woven material can be dried by passing through drying drums (not shown) or through other drying means, followed by passing under the support roller 25 and winding it into a roll or converting as intended. Alternative drying means include ovens, air dryers, radiation dryers, blowers, and the like.

 In FIG. 2 shows an alternative apparatus in which the immersion and spin steps are carried out. As shown, the nonwoven material 100 extends over the guide roller 102 into the bath 104. In this case, the processing time is controlled by the guide rollers 106. When compressed between the squeeze shafts 108, the excess processing compound is removed and returned to the bath through the tray 109. In drying drums 110, the residual moisture.

 It is also understood that in the hydrophilic treatment method through the important application of the surfactants of this invention, not only numerous surfactants can be used to achieve improved wettability with respect to aqueous solutions (eg, urine) or to facilitate the handling of other body excretions (blood , menstrual fluid, feces, etc.), but also biologically active compounds and macromolecules that can give biofunctional signs to processing surfaces according to this invention (for example, antibacterial activity, odor control, skin protection, etc.).

 The invention is further illustrated by the following examples, which represent the invention, although other modifications are possible, obvious to experts and covered by the following claims.

In this case, the following compositions are used, indicated under their trademarks:
DOU 2210 (Dow Corning) - silicone antifoaming agent
Pluronic L 101 (BASF) - polyethylene oxide copolymer
Mazavet 77 (BASF) - fatty alcohol ethoxylate
G109 (ICI) - Fatty Acid Ester Ethoxylate
G1282 (ICI) - Ethoxylated Castor Oil (or Glyceride)
TL2119 (ICI) - a mixture of fatty alcohol and fatty acid ester ethoxylates
SF19 (BASF) - Ethoxylated Siloxane
Y-12488 (Osi) - Ethoxylated Polydimethylsiloxane
Triton X-102 - (Union nonylphenol ethoxylate)
PEG400ML (henkel) Carbide - polyethylene glycol-400 monolaurate
Examples
Examples 1-43
The compositions of surfactants with low viscosity and high solids content.

 Numerous hydrophilic methods for treating nonwovens with surfactants from low solids solutions are known and commonly used. However, due to the high solvent content, a drying step is necessary. It is known that thermal effects during the drying process adversely affect the mechanical properties of nonwoven materials after surface treatment (table 2). Therefore, the use of a solution with a high dry matter content can minimize or reduce the need for drying and thereby maintain the fabric's own tensile strength. Other obvious advantages of the high dry solids processing method include the lower cost of the composition of the surfactant, the simplification of transportation and storage, the saving of energy and the reduction of the processing cost, as well as the achievement of better processing uniformity. As used herein, the term “high solids content” means a solids concentration of at least about 10%, and with the achievement of the benefits, such compositions have at least about 20% solids.

 On the other hand, treatment surfactant compositions having a higher solids content also have disadvantages such as poor rheology, emulsion instability, gelation and variability of the processing parameters. Another objective related to the discussed use of a surfactant for processing nonwoven materials is to provide the required duration of use or the ability to maintain the wettability characteristics of water under repeated exposure to solutions.

 Therefore, the objective of this invention is threefold: 1) to create compositions for processing, having a low viscosity and high solids content, 2) to create compositions for processing, having a high dry matter content and not requiring (or requiring minimal) drying, 3) to create compositions for treatments that give non-woven fabrics long-lasting wettability.

 The following procedure is typical of a general process using the treatment compositions of the present invention having a high solids content and low viscosity.

Non woven fabric
An ordinary roll of 35.6 cm wide staple fabric with a surface density of 20.3 g / cm ² made of polypropylene fibers (approximately 2.2 denier) was used.

The composition of surfactants
Typically, an aqueous treatment solution was prepared containing 0.075% anti-foaming agent (Dow 2210 from Dow Corning) and 20% by weight of the composition of surfactants (table 3). After thoroughly stirring at room temperature, the composition of surfactants was poured into a treatment bath, where stirring was continued at room temperature, unless otherwise indicated (table 3).

Coating process
The processing compositions of this invention, including surfactants and having a high dry matter content and low viscosity, were applied using the VEKO installation (VEKO, Biel AG, Switzerland). By configuration, the VEKO installation is a wetting centrifuge using one or two rotating supports shown in FIG. 1. The composition of the surfactant was pumped into the collector of the VEKO installation using a gear pump, after which it was supplied to the wetting rotors through restriction tubes. The experimental equipment of the VEKO installation used in this invention was equipped with six rotors that rotated at a frequency of approximately 4500 min ^-1 . Under the influence of the centrifugal force created by the rotating rotors, the chemicals fell on the non-woven fabric in the form of small drops.

 The throughput (g / min) was regulated and set using restriction tubes of different diameters, manifold pressure and solution parameters (temperature and viscosity). Smoother bandwidth adjustments can be achieved by introducing optional needle valves in the manifold outlets.

Drying
For all fabrics treated according to examples 1-43, no drying was required.

Weight gain value
The value of tissue mass gain was measured by low resolution nuclear magnetic resonance spectroscopy in a solid using a Brookker Minispec 120 pulsed nuclear magnetic resonance spectroscope (Brucker Spectrospin, Canada, Ltd.). Further information regarding calculation methods can also be found in the following link, "Wide line nuclear magnetic resonance in measurements of finish-on-fiber of textile products", Rodgers JE, Spectroscopy, 9 (8), 40, 1994.

 The preferred processing composition of the surfactant is shown in examples 1 to 6. As can be seen from table 3, the fabrics of examples 1-6 were treated with an aqueous emulsion with a relatively very low viscosity and high dry matter content containing ahkover and glucopon in a ratio of 10 : 1 to 20: 1. It should be mentioned that the treated fabrics did not need any further drying after surface treatment according to the EECO process. The unusual nature of the data obtained in examples 1-6 compared with other processing results shown in table 3, lies in the duration of use provided by the processing of the surface-active substance and the viscosity modifier described here. The uniqueness of the processing composition lies in the fact that it simultaneously satisfies the following conditions: 1) it is a stable aqueous emulsion with a high dry matter content and low viscosity, applicable at room temperature; 2) does not require drying; 3) provides increased processing resistance, as established by the stock test described in the application.

 The runoff test clearly confirmed that stable processing is achieved in examples 1-11 and in examples 27-29 of table 3, and also in examples 44-46, 59-61 of table 4. The results of the run test suggest that a surfactant like Ahkovel type and only combined formulations of this surfactant with other surfactants can withstand the duration of use. The results of the duration of use test (from the runoff test) also suggest that there is a direct correlation between the mass gain value and the degree of stability (or the number of runoff cycles) only for a surfactant such as Ahkovel and some combined formulations such as Ahkovel / Glucopon , Akhkovel / glucopone / SF 19 and Akhkovel / glucopone / Y 12488. Such a correlation, in fact, does not exist for single surfactants of other types, as well as for some combined compounds such as Ahcovel / PEG 400 ML, Ahcovel / TL 2119, akhovel / G 2109. In the latter combination consisting of adding a second surfactant to Ahcovel appears in deterioration of processing stability.

 The EDANA fluid passage test data provide information on the rate of fluid intake from the treated tissue, as well as information on the processing resistance when the same tissue is exposed to 10 ml of saline 5 times. From the data presented in table 6, it is clearly seen that, although the initial time of fluid intake is approximately the same for all treated tissues, there is a difference in characteristics when the tissues are subjected to repeated exposure to liquid. For example, the fluid arrival time for tissues treated with the triton X-102 substance worsens at cycles 4 and 5, while the characteristics of Akhkovel and Akhkovel / glucopone, Akhkovel / glucopone / SF 19 are less affected after 5 exposures to saline. Consequently, the fluid passage data obtained during the EDANA test are consistent with the data on the processing resistance, and the test results coincide with the results of the run test.

Examples 44-76
Low solids saturation process
The following procedure is typical of the general process using a saturation process with a low solids content.

где Ww и Wd - масса во влажном и сухом состояниях соответственно куска ткани с размерами примерно 30, 48 на 30, 48 см. Например, измеренное значение 100% WPU для ткани, обработанной в ванне при содержании сухих веществ в количестве 0,3%, означает, что достигается прибавление 0,3% к массе ткани. Прирост массы определяется преимущественно концентрацией химикалий в ванне, скоростью движения линии и давлением отжима (таблица 5).Typically, an aqueous treatment solution was prepared containing 0.15% anti-foaming agent (Dow 2210 from Dow Corning), 0.5% hexanol and the required amount of surfactant or combination of surfactants added in the ratios shown in the table 4. After thorough mixing at room temperature, the composition was poured into the tank of the processing unit (Fig. 2). In a typical case, a roll of fabric with a width of 35.6 cm with a surface density of 20.3 g / cm ² made of polypropylene staple fibers (approximately 2.2 denier) was subjected to surface treatment with the compositions, as shown in table 4. The value of the mass gain was determined by measuring the percentage moisture absorption (% WPU) after saturation of the fabric and spin between two rubber rollers. To determine the% WPU value, weighed and calculated using the following formula:

where Ww and Wd are the mass in wet and dry conditions, respectively, of a piece of fabric with dimensions of about 30, 48 by 30, 48 cm. For example, the measured value of 100% WPU for tissue treated in the bath with a dry matter content of 0.3%, means that an addition of 0.3% to the mass of tissue is achieved. The mass gain is determined mainly by the concentration of chemicals in the bath, the speed of the line and the squeeze pressure (table 5).

 After controlling the value of the mass gain in the output, the treated fabric was passed through a series of steam-heated drying drums (figure 2). Then, the treated and dried tissue was tested on a bench to determine the duration of use (runoff / wetting / drying test) and the rate of fluid intake (fluid transit time in the EDANA test).

Example 77
A sheet of a metallocenic foam polyolefin (OPSEL LC31 from Sentinel Products Corp., Hyannis, Mass.) Was cut to a thickness of 0.635 mm. Samples of the foam were impregnated with a 1% solution of Ahkover / glucopone mixed in a ratio of 15: 1 by weight at 1% Triton X-102. Then, the processed foams were dried in an oven at a temperature of 60 ^° C for 30 minutes. The liquid absorption time of the treated foams was measured for a single liquid release by performing the EDANA fluid passage test described here, and the results are presented in Table 7.

Example 78
The same treatments as described in Example 77 were used for another metallocenic polyolefin foam (OPSEL LC 33 from Sentinel Products Corp.). The absorption rate of the liquid was measured as described in example 77, and the results are presented in table 7.

 The present invention is further described using the following examples.

Example 79
Example 79 used a staple non-woven fabric with a surface density of about 85 g / cm ² in which the bicomponent fibers were arranged in a row. The components, which were presented in approximately equal amounts, were polyethylene and polypropylene. The tissue was cut into pieces with dimensions of 20.32 by 25.4 cm. Tissue samples were immersed for about 30 s in a solution containing 3% by weight of Achkobel and glucopone in a ratio of 3: 1. The measured WPU value described here was about 200%, and therefore, due to the treatment of the tissue with a surfactant, the weight gain was 6% by weight. The treated fabric was tested for wettability by water by placing 10 drops of water (approximately 0.1 ml in volume) across the width of the fabric. All 10 drops were instantly absorbed by the fabric, indicating that the treatment used made the fabric uniform and highly hydrophilic. A control test of untreated tissue exposed to the same drops of water showed that none of the 10 drops of water penetrated or absorbed into the non-woven fabric.

Example 80
In Example 80, fabric obtained by combing and bonding was used, made of bicomponent polypropylene and polyethylene fibers with a fineness of 3 denier, respectively having a core-in-shell structure. The tissue was cut into pieces of 20.32 cm by 25.4 cm. Tissue samples were immersed for about 30 s in a solution containing 3% by weight of Achkobel and glucopone in a ratio of 3: 1. The measured value of the WPU described here was approximately 100%, and therefore, a consequence of the treatment of the tissue with a surfactant was an increase in the mass value of about 3 wt.%. The treated fabric was tested for wettability by water by placing 10 drops of water (approximately 0.1 ml in volume) across the width of the fabric. All 10 drops were instantly absorbed by the fabric, indicating that the treatment used imparted homogeneity and high hydrophilicity to the resulting combing and bonding of the fabric. A control test of untreated fabric (without finishing during spinning) exposed to the same drops of water showed that none of the 10 drops of water penetrated or absorbed into the non-woven fabric.

 Therefore, in accordance with the invention, an improved processing method is developed and processed non-woven materials are obtained that provide the advantages mentioned above. Although the invention has been illustrated by specific embodiments, it is not limited to them, and it is intended to cover all equivalents as being within the broad scope of the form of the invention.

Claims (17)

1. A stable treatment composition in the form of an aqueous emulsion to increase the service life of the material, having a viscosity of less than about 100 mPa • s at a temperature of about 25 ^o C and containing 5-80% alkylpolyglycoside with 8-10 carbon atoms in the alkyl chain as a viscosity modifier.  2. The stable processing composition according to claim 1, which additionally contains a surfactant, and the concentration of solids is at least 20 wt.%.  3. The stable treatment composition of claim 2, wherein the surfactant comprises a mixture of ethoxylated hydrogenated oil and sorbitan monooleate.  4. The stable processing composition according to claim 1, which additionally contains a surfactant, and the concentration of solids is less than 20 wt.%.  5. A stable processing composition according to any one of claims 1 to 3, which is designed to process the substrate as a material.  6. A stable processing composition according to any one of claims 1 to 3, which is intended for processing material for the manufacture of personal care products. 7. A method of processing a substrate, comprising the step of applying to the substrate a treatment composition having a viscosity of less than 100 mPa · s at a temperature of about 25 ^{° C.} , wherein the treatment composition contains an alkyl polyglycoside with 8-10 carbon atoms in the alkyl chain, in the form of 5-80% aqueous emulsion as a viscosity modifier and a surfactant at a ratio of 1: 1 to 1:20, respectively.  8. The method according to claim 7, in which the processing means is applied using a spray tool.  9. The method of claim 8, in which the spray means comprises one or more rotating spray heads.  10. The method according to claim 7, in which at the stage of applying the processing composition use a bath for processing, and the method includes a stage of drying.  11. The method according to claim 7, in which the processing composition is applied on both sides of the substrate.  12. The method according to claim 7, in which the substrate is a non-woven fabric, and the processing composition has a solids concentration of at least about 20 wt. % and in addition contains a mixture of ethoxylated hydrogenated castor oil and sorbitan monooleate.  13. A material having a duration of use of at least 2 cycles as measured by a run test and treated with a composition containing an alkyl polyglycoside having 8 to 10 carbon atoms in the alkyl chain, as well as a mixture of ethoxylated hydrogenated castor oil and sorbitan monooleate.  14. The material according to item 13, processed by the composition according to claim 2, representing the method of foam.  15. The material according to item 13, processed by the composition according to claim 3, which is a foam.  16. The material according to item 13, processed by the composition according to claim 2, which is a film.  17. The material according to item 13, processed by the composition according to claim 3, which is a film.

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