TWI432257B - 親水性多孔形成薄膜 - Google Patents

親水性多孔形成薄膜 Download PDF

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TWI432257B
TWI432257B TW099104996A TW99104996A TWI432257B TW I432257 B TWI432257 B TW I432257B TW 099104996 A TW099104996 A TW 099104996A TW 99104996 A TW99104996 A TW 99104996A TW I432257 B TWI432257 B TW I432257B
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film
alcohol
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fatty
fatty alcohol
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Andrew D Maschino
Alvin W Gross
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Tredegar Film Prod Corp
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Description

親水性多孔形成薄膜 發明領域
本揭示內容係有關於拋棄式吸收物件且，更詳細地，係有關於具有可以使薄膜對液體具親水性親和力之性質的多孔性真空形成或液壓成形之立體薄膜。
 發明背景
多孔形成薄膜為經處理可在薄膜內產生孔或洞之塑膠薄膜。多孔薄膜分為二概括種類：立體薄膜及扁平薄膜。雖然所有薄膜由於具有標稱厚度，所以具有立體結構，但是就本揭示內容而言，“立體薄膜”為具有自薄膜表面延伸並在孔內終止之表面結構或凸起部的薄膜。這些凸起部可以使該薄膜之厚度大於其標稱厚度。此等薄膜之特徵為一厚度或統層面(loft)之定義為該薄膜之基底面與藉位於凸起部之末端的該等細孔而界定之次級面(secondary plane)間的距離。該次級面係自薄膜之基底面分隔且通常與該基底面平行。一般而言，這些凸起部具有記憶力。因為在藉壓力或拉力而變形後，其等可恢復原來之形狀，其限制條件為該薄膜之變形極限尚未受損害。對照之下，扁平多孔薄膜僅為具有洞但缺乏具有可表示“立體薄膜”之特性之立體記憶的表面結構之薄膜。
本項技藝內有幾種用於製造多孔薄膜的方法。可藉其中係使薄膜具有洞之任何方法而製成扁平薄膜。一般而言，有利用銷或其它浮雕以在前驅薄膜內產生洞之機械方法。就立體薄膜而言，兩最常用的方法為真空成形法及液壓成形法。藉參考文獻(諸如美國專利US 3939135及US 4324246)而例示之真空形成法係利用真空以在薄膜之一側上產生負壓力並在該薄膜之反向側上產生對應正壓力。該壓差會導致薄膜被拉入該成形篩中之洞內以產生細孔。在如藉參考文獻US 4609518而例示之液壓成形法中，係使用高壓水噴射流產生液體流，其可撞擊該薄膜以產生細孔。
在該液壓成形或真空成形法中，該薄膜係承載在本項技藝中已知之多孔結構上，且以成形篩附加在文中作為參考資料。在直接鑄造方法中，熔態聚合物經由模具擠壓至該成形篩上，然後接受真空處理。此方法係藉US 4456570而例示，該專利在此併入本案以為參考資料。在再熱方法中，將前驅薄膜加熱至高於軟化點但低於該薄膜之熔數的溫度，然後接受真空處理。該前驅薄膜可以是鑄造或吹製薄膜。該再熱方法係藉US 4151240而例示，該專利在此併入本案以為參考資料。
多孔薄膜之其它類型可包括，但不限於：藉美國專利第4609518號、第4629643號、第4695422號、第4772444號、第4778644號、第4839216號、及第4637819號而例示之液壓成形薄膜，這等專利皆在此併入本案以為參考資料。除了使用高壓水噴射流以迫使該薄膜進入篩內之開口並因此形成多孔凸起部不同外，該液壓成形法與再熱法類似。情況通常為亦施加真空至該薄膜以協助水之移除及循環，除此之外，在凸起部之形成中並不起作用。
多年來，已發現若添加表面活化劑可增強立體薄膜作為用於吸收元件之頂層的機能性。“表面活化劑”為合併該名詞“表面活化藥劑”之字；亦即可作為濕潤劑以降低液體之表面張力並可增加擴展性的化學物種。在聚合物薄膜產物中之一般用途為防霧及抗靜電應用。由於該等薄膜係自天然疏水性聚合物(諸如熱塑性聚烯烴)製成，所以添加表面活化劑至該薄膜可改良薄膜之可濕性，其接著會致使流體遍佈該薄膜。在衛生應用上，由於其可以使該薄膜讓使用者感到更乾燥並改良流體進入細孔內之流動性所以很有利。已為吾人所熟知之防霧劑為烷基酚乙氧基化物、複合多元醇單酯、油酸之聚氧乙烯酯、油酸之聚氧乙烯山梨糖醇酐酯、及脂肪酸之山梨糖醇酐酯。
最初，慣用做法為局部施加表面活化劑至該薄膜，但是目前最近做法為將該表面活化劑併入樹脂混合物內以產生具有適於液體之親水性親和力的薄膜。此方法係藉上述US 4456570而例示。可用於適於衛生應用之成形薄膜的現代表面活化劑可在US 5520875內找到且包含非離子性表面活化劑，諸如：醇乙氧基化物、烷基酚乙氧基化物、羧酸酯、甘油酯、脂肪酸之聚氧乙烯酯、與松脂酸有關之脂肪族羧酸的聚氧乙烯酯、無水山梨糖醇酯、乙氧基化無水山梨糖醇酯、乙氧基化天然脂肪、油、及蠟、脂肪酸之乙二醇酯、羧酸醯胺、二乙醇胺縮合物、單烷醇胺縮合物、聚氧乙烯脂肪酸醯胺、聚氧化烯烴嵌段共聚物。此等表面活化劑可遷移至薄膜之表面或在該薄膜形成後“析出(bloom)”以使薄膜之表面獲得親水性親和力，US 6353149揭示選自由乙氧基化脂肪醇、乙氧基化烷基酚、乙氧基化單脂肪酸酯、乙氧基化二脂肪酯、及其等之混合物的表面活化劑顯示加速的遷移。
在普遍使用酒精及其它可燃溶劑之醫院手術房內，最重要的是需避免可引燃這些溶劑之任何靜電火花。抗靜電劑為用於處置材料或其等之表面以減少或消除靜電之積聚的化合物。其作用為藉自空氣吸收水份而使其本身變得具導電性因而致使該材料本身之表面具微導電性。抗靜電劑之分子通常兼具親水及疏水區域；該疏水側可以與材料之表面交互作用，而該親水側可以與空氣中之水份交互作用並結合該等水分子以形成水薄層(如同防霧表面活化劑的情況一樣)。然後本水薄層可將靜電荷傳導至地面，藉此其不會增加，因此可將靜電火花放電。許多抗靜電劑主要含脂肪族醯胺(其可選擇性經乙氧基化)、醯胺、磷酸之酯、聚乙二醇酯或多元醇。
為了作為表面活化劑，使先前技藝內之脂肪醇及其它脂肪元素經“乙氧基化”。窄範圍乙氧基化物(“NRE”)為已知非離子性表面活化劑，其係在合適催化劑(業經煅燒或經脂肪酸疏水化之層狀化合物)存在下藉添加環氧乙烷至脂肪醇上而製成。這些表面活化劑之化學性質在本項技藝內已為吾人所熟知。
未經改變的脂肪醇可在吸收元件之先前技藝內找到，但是其等係為用於洗劑及塗覆物以增強乾燥性或促進皮膚健康之混合物中的組份，作為例證的技藝包括US 6426444；US 6503526；及US 2008/0287896，其等皆在此併入本案以為參考資料。
雖然衍生自植物或動物之多種組份常用於該形成薄膜頂層先前技藝以作為表面活化劑及洗劑，但是在本發明該技藝之前，脂肪酯在先前並未作為擠製樹脂摻合物內之遷移性表面活化劑。
 發明概要
在一實施例中，本揭示內容提供一種立體多孔薄膜，其包含數量足以使該薄膜具親水性之至少一疏水熱塑性聚合物及一脂肪醇。
在另一實施例中，本揭示內容提供一種含頂層及吸收核心之吸收物件，其中該頂層包含一立體多孔薄膜，該立體多孔薄膜包含其數量足以使該薄膜具親水性之至少一疏水熱塑性聚合物及一脂肪醇。
在另一實施例中，本揭示內容提供含頂層、吸收核心、及位於該頂層與核心間之轉移層的吸收物件，其中該頂層及轉移層中之至少一者包含一立體多孔薄膜，該立體多孔薄膜包含其數量足以使該薄膜具親水性之至少一疏水熱塑性聚合物及一脂肪醇。
一旦進一步閱讀與圖式及附加申請專利範圍有關之專利說明書可瞭解本揭示內容之這些及其它方法。
 較佳實施例之詳細說明
脂肪醇為衍生自天然脂肪及油(主要為起源於植物)之脂肪族醇。脂肪醇通常具有偶數碳原子。自脂肪酸製造可得到直鏈醇，或不同的說法，該醇基(-OH)附著於末端碳。其它處理法可得到異醇，其中該醇基係附著於該碳鏈之內部中的一個碳。下表係表示具有對應碳原子數之一系列脂肪醇。
隨碳原子數減少，該脂肪醇之熔點亦降低。例如具有14個碳原子之脂肪醇可以於約100℃之溫度下熔化，而具有12個碳原子之脂肪醇可以於約24℃之溫度(室溫)下熔化。在設計用於特定用途之吸收物件的多孔形成薄膜時，設計者應瞭解該應用之溫度限制。若懸浮在薄膜內之該脂肪醇當熔化時黏度變得太低，若必要，其可不繼續懸浮在該薄膜內。隨著碳原子數減少，就以擠製法進行處理而言，其會變得太黏。脂肪醇之碳原子的較佳範圍為自8至24、更佳12至20、最佳16至18。
許多細孔形狀及細孔之圖式排列在多孔形成薄膜技藝中已為吾人所熟知。其等之設計目的為增強流體傳送性以及使該薄膜具有美觀及觸覺性質。例如US 4324426教示該細孔之等值水力直徑(Equivalent Hydraulic Diameter)可影響液體傳送性：US 4342314教示獲得獨特的似纖維美觀之方法；而US 4463045教示小表面像差用以提供似布觸感的用途。這些參考文獻及本項技藝中已知之其它參考文獻的所有形狀及圖式排列可以併用本發明實施例。
僅用於闡明，製成一具有並肩安置之五角形細孔(藉此該等細孔可藉窄似纖維元件而分離)的薄膜。該等薄膜之每平方厘米包含約90個細孔，且其開孔面積為約20-25%且統層面為約500-650微米。統層面為所形成薄膜之總厚度，其包括該等細孔及任何表面像差之高度。該薄膜具有21.7克/米2 之基礎重量及一無規不反光表面(matte finish)。使用直接鑄造真空成形法製成該等薄膜。
使用通常具疏水性之聚烯烴摻合物(明確地說，聚乙烯)製成該等薄膜。在一薄膜內，該摻合物含有約17,500ppm至20,000ppm鯨蠟醇。如根據US 4456570所測定，溢流(run off)值為0%至2.5%。較大濃度之鯨蠟醇可確保一致的0%溢流。10,000ppm之濃度可得到介於10與15%間之溢流值，且應該被視為尿布頂層之下限。當設計用於具有各種液體黏度及表面張力之其它應用的吸收元件，可根據欲經由該頂層傳送之液體的類型，添加其數量低如約500ppm之脂肪醇。
非可預期地，利用硬脂醇重複該測試並不能產生類似結果。自不含表面活化劑添加物之疏水性聚烯烴(聚乙烯)摻合物製成之對照薄膜具有大於80%之溢流值。僅添加其數量至高約20,000ppm之硬脂醇至該摻合物並未得到小於78%之溢流值。然而，當以20,000ppm之合併濃度添加至與鯨蠟醇呈50%至50%之混合物時可得到0%溢流值。由於該鯨蠟醇為更有效組份，違反該50%至50%比率之摻合物應該可進一步證實鯨蠟醇為該混合物內之主要脂肪醇。
該等脂肪醇可以純質或作為已知可於預期產物之基礎摻合物中的任何聚合物中之化合物形式，添加至擠製摻合物。此種混合類型常見於薄膜擠製工業。

Claims (6)

  1. 一種經擠製之親水性多孔形成薄膜，其係用於在吸收元件中輸送液體，該薄膜包括自薄膜表面延伸並在孔內終止之表面結構，該薄膜進一步包括一摻合物，該摻合物為至少一熱塑性烯烴聚合物及脂肪醇，其特徵在於，該脂肪醇為鯨蠟醇及硬脂醇之混合物。
  2. 如申請專利範圍第1項之薄膜，其中該脂肪醇係以至少約500ppm之量存在。
  3. 如申請專利範圍第1項之薄膜，其中該脂肪醇係以10,000-20,000ppm之含量存在。
  4. 如申請專利範圍第1項之薄膜，其中混合物包含至少50%鯨蠟醇。
  5. 一種吸收物件，其包含頂層、吸收核心，該頂層包含如申請專利範圍第1至4項中任一項之薄膜。
  6. 一種吸收物件，其包含頂層、吸收核心及位於該頂層與核心間之轉移層，其中該頂層及轉移層之至少一者包含如申請專利範圍第1至4項中任一項之薄膜。
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