US20030012928A1 - Absorbent structure and method for producing the same - Google Patents

Absorbent structure and method for producing the same Download PDF

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Publication number
US20030012928A1
US20030012928A1 US10/182,587 US18258702A US2003012928A1 US 20030012928 A1 US20030012928 A1 US 20030012928A1 US 18258702 A US18258702 A US 18258702A US 2003012928 A1 US2003012928 A1 US 2003012928A1
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United States
Prior art keywords
accordance
weight
absorbent structure
absorbent
superabsorbent polymer
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Abandoned
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US10/182,587
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English (en)
Inventor
Krzysztor Malowaniec
Rainer Mangold
Thomas Wurster
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PAUL-HARTMANN AG
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PAUL-HARTMANN AG
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=26004652&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20030012928(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from DE2000110269 external-priority patent/DE10010269C1/de
Priority claimed from DE2000110268 external-priority patent/DE10010268A1/de
Application filed by PAUL-HARTMANN AG filed Critical PAUL-HARTMANN AG
Assigned to PAUL-HARTMANN AG reassignment PAUL-HARTMANN AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MALOWANIEC, KRZYSZTOF D., WURSTER, THOMAS, MANGOLD, RAINER
Publication of US20030012928A1 publication Critical patent/US20030012928A1/en
Priority to US11/199,016 priority Critical patent/US7462754B2/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
    • A61F13/47—Sanitary towels, incontinence pads or napkins
    • A61F13/472—Sanitary towels, incontinence pads or napkins specially adapted for female use
    • A61F13/47218—Sanitary towels, incontinence pads or napkins specially adapted for female use with a raised crotch region, e.g. hump
    • A61F13/47227—Sanitary towels, incontinence pads or napkins specially adapted for female use with a raised crotch region, e.g. hump for interlabial use
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15617—Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
    • A61F13/532—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad
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    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A—HUMAN NECESSITIES
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    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A61F13/535—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A61F13/537—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
    • A61F13/53743—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer characterised by the position of the layer relative to the other layers
    • A61F13/53747—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer characterised by the position of the layer relative to the other layers the layer is facing the topsheet
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/22—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
    • A61L15/225—Mixtures of macromolecular compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/425—Porous materials, e.g. foams or sponges
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/60—Liquid-swellable gel-forming materials, e.g. super-absorbents
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203—Properties of the article, e.g. stiffness or absorbency
    • A61F2013/15284—Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
    • A61F2013/15422—Density
    • A61F2013/1543—Density with a density gradient in the horizontal plane
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F2013/530868—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterized by the liquid distribution or transport means other than wicking layer
    • A61F2013/530927—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterized by the liquid distribution or transport means other than wicking layer having longitudinal barriers
    • A61F2013/530934—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterized by the liquid distribution or transport means other than wicking layer having longitudinal barriers having a density gradient
    • A61F2013/530948—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterized by the liquid distribution or transport means other than wicking layer having longitudinal barriers having a density gradient along the length
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372—Particulate matter
    • Y10T428/24405—Polymer or resin [e.g., natural or synthetic rubber, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/2457—Parallel ribs and/or grooves

Definitions

  • the invention relates to an absorbent structure formed on the basis of particulate, superabsorbent polymer materials, where the superabsorbent polymer materials are bonded together by a lower-melting thermoplastic polymer.
  • the invention relates furthermore to a method for producing an absorbent structure of this kind and a hygiene article having such an absorbent structure as an absorbent core layer.
  • an absorbent structure on the basis of superabsorbent polymer materials is mentioned in what precedes, this is understood to mean a structure having an amount of more than 70% by weight of superabsorbent polymer materials. It is in line with established understanding and established practice in the sphere of interest here of absorbent structures that superabsorbent materials are meant to refer to such materials which by absorption or gel formation are able to absorb and permanently retain at least about ten times their own mass in fluid. The fluid is bonded into the molecular structure of these materials and not simply absorbed into pores in the materials, from which it could be squeezed out again.
  • Current superabsorbent materials are water-insoluble, cross-linked polymers which are capable of absorbing aqueous fluids and body exudates such as urine or blood by swelling and forming hydrogels and permanently retaining the quantity of fluid absorbed at least under a certain surrounding pressure.
  • thermoplastic foam The production of an extruded thermoplastic foam is also known from WO 98/56430.
  • the foam preferably has a structure consisting of cell walls and cavities.
  • the foam can be used, according to the description, as the container for a piece of meat or a layer in a diaper.
  • the object of the invention is to eliminate the aforementioned disadvantages in the case of an absorbent structure of the generic type named at the beginning having a high SAP content, that is, to achieve a flexible structure having good fluid absorption and retention characteristics, which can also be manufactured simply.
  • thermoplastic polymer and superabsorbent particulate polymer materials having a moisture content of at least 0.5% by weight relative to the total mass of the superabsorbent polymer materials and evaporating the fluid in the superabsorbent polymer materials and thereby inducing foaming in the structure.
  • the proposal is made to bond granular, particulate superabsorbent polymer material by means of at least partially molten thermoplastic polymer materials by extruding the mixture which is subject to pressure and temperature in the presence of a blowing agent which is formed from the moisture content of the superabsorbent materials. It is hereby possible on the one hand to immobilize, that is, fix in position the particulate superabsorbent polymer materials within the structure and on the other a structure is formed which can be extremely well penetrated by an impinging fluid, such as urine for example.
  • the fluid can penetrate very quickly into the open-pore foamed structure formed through extrusion of the mixture under expansion of the blowing agent, meaning evaporation of the fluid contained in the superabsorbent polymer materials, and can reach the superabsorbent polymer materials contained therein where it is then permanently retained.
  • the swellable, superabsorbent polymer materials in the structure under the invention to a far lesser degree cause the so-called gel blocking effect which proves to be problematic with higher weight percentages of swellable polymer materials in absorbent fiber structures because the polymer materials swelling in the fluid compress the interstices between fibers so that no capillarity is left to carry the fluid into still unutilized absorbent core areas.
  • the moisture content that is, the fluid which constitutes the at least 0.5% by weight moisture of the superabsorbent polymer material
  • the blowing agent during the extrusion of the mixture of superabsorbent polymer materials and thermoplastic polymer a critical effect is achieved for the absorption capability of the superabsorbent polymer materials in the finished structure:
  • the surface of these particles and the thermoplastic polymer settling on the surface of the particles is torn open in all directions.
  • the size of the particles of superabsorbent polymer materials is in the normal range and the mass median is preferably about 200-800 microns, where preferably no more than 20% by mass of the particles are smaller than 200 microns; in this respect reference is made to the disclosure in U.S. Pat. No. 5,061,259.
  • the inventive absorbent structure is manufactured using a superabsorbent polymer material having a moisture content of at least 1% by weight and especially preferably of at least 4% by weight. It is clear that moisture content as high as possible is striven for, whereby this is limited by the increasingly poor manageability of the particulate superabsorbent polymer materials as the moisture content increases.
  • the invention also does not preclude that in addition to the use of superabsorbent polymer materials with a moisture content in the range quoted a blowing agent, in the form of CO 2 for example, is additionally used. However, surprisingly as it turned out, this is not necessary to obtain adequate fluid retention capacities for the applications.
  • the extruded open-pored structure exhibits a retention capacity of at least 10 g fluid per gram of the extruded structure. Absorption capacity can be determined in a test procedure to be described in greater detail.
  • the percentage by mass of the thermoplastic polymer is less than 30% by weight, specifically 20% by weight, and specifically less than 10% by weight of the absorbent structure.
  • Corresponding copolymers, specifically ethylene vinyl acetate copolymers, as well as halogenated polyolefins can be used.
  • other thermoplastic polymers are suitable for the manufacture of the inventive absorbent structure, for example, those from the group of styrene polymers.
  • the degree of foaming is at least 20%, preferably it is higher, specifically 20%-50% or beyond.
  • the degree of foaming, or the term “foaming” of the structure respectively is defined or is understood as the increase in volume of a mass unit of the mixture in a state inside the extrusion apparatus on the one hand, or in the extruded state of the finished structure on the other hand.
  • the absorbent structure can comprise between 3% and 20%, preferably between 5% and 10% by weight fibers as additives.
  • They can be natural or synthetic fibers, preferably polyester fibers, but whose melting or degradation temperature is higher than the melting temperature of the related thermoplastic polymer inside the extrusion apparatus. The effect of the fibers is that during the extrusion process passages are formed which promote the penetration of aqueous fluid into the structure.
  • the invention allows absorbent structures to be formed whose basic weight varies in the longitudinal direction and/or in the transverse direction of the structure, where the longitudinal direction corresponds to the direction of extrusion.
  • an extrusion opening specifically an extrusion slit
  • any kind of cross-sectional structures can be achieved.
  • the thickness of the absorbent structure could be greater in the center and corresponding to the structure of the extrusion opening could decrease in any manner at all to the sides.
  • the structure can comprise in addition a surfactant substance, specifically a hydrophilizing agent in an amount of preferably 0.2%-10%.
  • a surfactant substance specifically a hydrophilizing agent in an amount of preferably 0.2%-10%.
  • This agent is fed to the extruder together with the remaining initial materials or injected into the already molten polymer mass, so it is already present commingled with the polymer melt before it is extruded.
  • Protection is also sought with this invention for a disposable, absorbent hygiene article, specifically a diaper, sanitary napkin or an incontinence pad, having a specifically multi-layer absorbent core which is characterized by an absorbent core layer of an absorbent structure of the previously described inventive type.
  • This absorbent core layer can be located on the side of a fluid distribution and intermediate retention layer facing outwardly from the body. It is also conceivable that the fluid distribution and intermediate retention layer which comprises fewer or no superabsorbent polymer materials, is also manufactured as an extruded, foamed structure, specifically with the addition of a blowing agent, such as CO 2 . In this case both absorbent cores could be produced inside the manufacturing machinery by extrusion and be placed one on top of the other to create the composite layer. Direct coextrusion of both layers, i.e. production by the same extrusion apparatus, is conceivable and advantageous.
  • a first layer facing outwardly from the body can be overlaid by a second body-facing layer.
  • the absorbent SAP-containing structure can, for example, be furnished with an advantageous SAP profile.
  • the first layer facing outwardly from the body can contain less SAP (in percent by weight relative to the first layer) than the second body-facing layer.
  • the surface extent, that is the width and/or length, of the first layer facing outwardly from the body is different from the surface extent of the second body-facing layer, specifically it can be advantageous to configure the first layer facing outwardly from the body larger, specifically wider with respect to its surface extent than the second body-facing/contacting layer.
  • This multi-layer construction of the absorbent SAP-containing structure itself can be produced simply, by direct coextrusion of the layers.
  • a fluid non-pervious layer facing outwardly from the body which is normally formed of a pre-manufactured plastic film is produced by coextrusion with the absorbent core.
  • a fixative means such as a hot melt adhesive for example, can then be advantageously omitted, since the extruded layers can be fixed in position among themselves but also with respect to additional layers and/or elements in the course of their manufacture.
  • the fluid distribution and intermediate retention layer which can contain very little or even no superabsorbent polymer materials, can be additionally configured and manufactured in the same way as the inventive absorbent structure or the aforementioned absorbent core. It can have additives in the form of fibers or surfactant substances and be configured manufactured with a varying thickness or varying basic weight respectively.
  • the absorbent core has a varying thickness in the longitudinal direction of the article or in the transverse direction, that is, if it is configured with a profiled shape.
  • the fluid absorption capacity available there can consequently be configured with any profile in and of itself, specifically bell-curve shaped or graduated.
  • the absorbent core has upwardly extending wall sections on both sides running in the longitudinal direction of the article and toward the wearer which form a leakage barrier. These wall sections assume the function of gatherings extending upwardly in the direction of the wearer which are normally formed in known hygiene articles from nonwoven materials with inserted means of elastification.
  • wall sections of this kind can also run in the transverse direction and can also exercise a blocking effect there, particularly for separating solid and liquid body excretions.
  • Subject of the present invention is also a method for producing an absorbent structure, specifically in accordance with claims 1 to 12 using the following process steps:
  • thermoplastic polymer introduction of a thermoplastic polymer into an extrusion apparatus
  • thermoplastic polymer material melting at temperatures below a melting or degradation temperature for the superabsorbent polymer material
  • the moisture contained in the superabsorbent polymer materials is thus used as a blowing agent during extrusion.
  • an additional blowing agent such as CO 2 would also be conceivable, although this is not necessary.
  • Saturated, unsaturated, cyclic hydrocarbons and halogenated hydrocarbons and noble gases such as argon, helium or nitrogen or a water/air mixture would also be conceivable.
  • CO 2 is used as an additional blowing agent, it is introduced in the so-called supercritical state at temperatures above about 31° C. and pressures above about 73.5 bar.
  • the blowing agent can be optimally mixed to prepare a physical foaming process with the superabsorbent polymer materials and with the molten thermoplastic polymer. If this mixture is then passed through an extrusion opening into an area of lower pressure, the blowing agent evaporates with decreasing temperature, and the foamed open-pore structure is created through an increase in volume.
  • thermoplastic polymer since not only sufficient pressure for the fluid, or respectively the moisture in the superabsorbent polymer materials, or respectively for the blowing agent, has to be attained, but the thermoplastic polymer must be at least partially melted, temperatures of 80° C. to 200° C. are created inside the extrusion apparatus.
  • the extrusion cross-section is changed during extrusion to produce varying thickness or shape in the longitudinal or transverse direction of the structure being produced. If a large quantity of correspondingly configured structures is to be extruded, it proves to be advantageous if the extrusion cross-section is changed in a correspondingly oscillating fashion. This takes place transversely to the direction of extrusion, specifically in the discharge direction, whereby the thickness of an extruded web is varied, or transversely to the discharge direction, whereby its width is varied.
  • Multistage rolling of the extruded structure is particularly advantageous. Multistage rolling enables the application of several temperature and/or pressure stages. In this way the extruded structure can be changed/optimized more selectively with respect to the requirements of its later use.
  • a temperature in the calendering stage of 40° C.-90° C., specifically 50° C.-60° C., has been shown to be suitable.
  • the extruded absorbent structure can be compressed advantageously cold in a second calendering stage, which is performed specifically at temperatures of 0° C.-30° C., specifically at 15° C.-25° C.
  • the inventive method is integrated into a production process for hygiene articles and thereby an absorbent core is extruded directly inside a machine.
  • fiber forming and discharge stations can be dispensed with in the manufacturing machinery (at least for the extruded absorbent core).
  • several absorbent cores which are to be positioned one above the other can be produced in the same machinery.
  • FIG. 1 shows a schematic view of an apparatus for producing an inventive absorbent structure
  • FIGS. 2 to 6 show different embodiments of inventive absorbent structures
  • FIG. 7 shows an additional embodiment of a multilayer inventive absorbent structure
  • FIG. 8 shows a schematic representation of a coextrusion apparatus.
  • FIG. 1 shows an apparatus for producing an inventive absorbent structure.
  • the apparatus comprises a funnel-shaped feed mechanism 2 through which a solid matter mixture, which preferably was produced in advance in accordance with the by-weight percentile composition of the individual components, can be fed into a cylindrical interior 4 of a high-pressure stable tubular housing 5 of the production apparatus.
  • a shaft 6 extends in this interior 4 having a helical screw 8 driven by an electric motor 6 .
  • Heating devices 12 are provided on the outer circumference of the tubular housing 5 .
  • An extrusion tool 16 can be mounted on the face of the tubular housing 5 at the end opposite the feed device 2 .
  • the extrusion tool 16 communicates through an opening 18 on the face 14 with the interior 4 of the tubular housing.
  • Injection devices 20 , 22 discharge into the interior 4 , whereby they discharge quasi inside the opening 18 .
  • a blowing agent under operating pressure can be introduced into the interior 4 through the injection devices 20 , 22 .
  • an operating pressure can be set and maintained in the interior 4 during the extrusion process, depending on the blowing agent employed in the extrusion process, generally above 70 bar.
  • operating pressure can be exerted on the mixture inside the apparatus by providing piston means or moveable wall sections.
  • a polyolefin specifically a polypropylene and/or polyethylene granulate can be used as an example of a thermoplastic polymer.
  • This granulate is mixed with swellable superabsorbent polymer materials, which are adequately known in combination with absorbent layers in hygiene articles and therefore do not need to be described in greater detail, whereby these superabsorbent polymer materials have a moisture content of at least 0.5% by weight.
  • the mixture obtained in this way is transported into the interior 4 by means of the conveying device 2 .
  • the mixture is brought up to an operating temperature by the heating devices 12 such that the thermoplastic polymer melts, but the particulate superabsorbent polymer materials are not affected in the slightest.
  • An operating pressure is created in the interior 4 which is suitable for extruding the partially molten mixture by means of the extrusion tool 16 using water as the blowing agent.
  • an additional blowing agent for example CO 2
  • CO 2 can be introduced into the interior 4 by means of the aforementioned injection devices 20 , 22 in the preferably supercritical state.
  • the fluid contained in the superabsorbent materials evaporates as result of the accompanying drop in pressure, along with any required additional blowing agent, and the mixture is foamed, that is to say pores or cavities which communicate with each other are formed by the expanding, evaporating fluid.
  • the particulate superabsorbent polymer materials are fixed in place inside this cavity structure formed by the hardening of the thermoplastic polymer. They are immobilized, but thereby their surface is exposed as a result of the expansion and escape of the moisture and the subsequently created cavities and is available to absorb fluid.
  • FIG. 2 shows a section of an extruded absorbent structure 30 which comprises 80% by weight a superabsorbent polymer material with a moisture content of at least 1% by weight (with respect to the mass of the superabsorbent polymer material) and 13% by weight a thermoplastic polymer, i.e. polyethylene (PE), and additionally 7% by weight polyester fibers (PES).
  • a superabsorbent polymer material with a moisture content of at least 1% by weight (with respect to the mass of the superabsorbent polymer material) and 13% by weight a thermoplastic polymer, i.e. polyethylene (PE), and additionally 7% by weight polyester fibers (PES).
  • PE polyethylene
  • the extrusion device is identified with the arrow 32 so that the end surface identified with the reference numeral 34 represents the plane perpendicular to the extrusion device 32 .
  • the absorbent structure 30 is shown exactly rectangular in FIG. 2; it must be pointed out that only a basically plane surface can be obtained by an extrusion process, and that even with a precisely rectangular extrusion opening rounded edges can be formed. However it would be possible to configure a continuous web in the extrusion device 32 by lengthwise and crosswise trimming with end surfaces 34 and longitudinal surfaces 36 exactly perpendicular to each other.
  • FIG. 3 shows an absorbent structure 38 which has a varying thickness d in the transverse direction 40 .
  • the structure runs along both of its longitudinal edges 42 in the longitudinal direction 44 the structure has a wall area 46 extending upwardly, that is in the thickness direction, which terminates in a point in the upward direction. From outside to inside, in the transverse direction 40 , this wall area 46 falls off asymptotically and transitions into a plane section with constant thickness d and then rises again toward the center in accordance with the profile seen in FIG. 3 to a section 48 of greater thickness.
  • a cross-sectional structure of this kind can be produced by shaping the extrusion slot correspondingly.
  • FIG. 4 shows a further embodiment of an inventive absorbent structure 50 having upwardly extending wall areas 46 on both sides running in the longitudinal direction 44 just as in FIG. 3.
  • the structure 50 has an area in the center also running in the longitudinal direction 44 essentially lozenge-shaped in cross-section and rising above a surface 52 . Because of its lozenge-shaped cross-section the area 54 forms undercuts 56 viewed in the direction perpendicular to the surface 52 .
  • the creation of structures which are round, elliptical or polygonal in cross section, with or without undercuts, would be conceivable.
  • Such absorbent core structures are intended for use in female hygiene products.
  • the raised area 54 whatever geometric form it may have, can extend at least partially into the vagina when it is worn and thus create a direct contact between the vagina and the absorbent hygiene product.
  • FIG. 5 shows in an appropriate view an absorbent structure 58 produced by extrusion having varying thickness d in the longitudinal direction of extrusion 44 . Furthermore, the absorbent structure shown 58 has a varying width b in the longitudinal direction 44 . The absorbent structure shown 58 would lend itself to the production of a diaper, whereby arcuate leg openings 60 are provided in the middle and in this area forming the crotch of the diaper an agglomeration of material is given by the greater thickness d provided there.
  • FIG. 6 shows schematically a suggested continuous extruded web 62 with varying width b in the longitudinal and extrusion direction 44 .
  • the broken lines 64 suggests the division of the continuous web by transverse cutting to create individual sections for the production of diapers.
  • FIG. 7 shows a continuous extruded absorbent structure 66 , which is produced by the coextrusion of three layers which is suitable for use in a hygiene article, in particular a diaper.
  • the structure comprises a first lower extruded film layer 68 of PE and/or PP.
  • a surface layer 72 on a polyester fiber (PES) base free firstly of superabsorbent polymer materials and secondly of polyethylene and/or polypropylene (PE/PP) is furnished on its upper side.
  • PES polyester fiber
  • All three layers 68 , 70 , 72 are produced in a coextrusion apparatus as shown schematically in FIG. 8, whereby to produce layer 72 a blowing agent under overpressure was used to create an open-pore foamed structure through expansion and evaporation of the blowing agent.
  • the structure 66 is configured in cross-section in accordance with FIG. 3; it has lateral upwardly extending wall areas 46 running in the longitudinal direction 44 , which can act as a leakage barrier in a hygiene article and perform the function of gatherings normally formed on the basis of nonwoven materials.
  • the agglomeration of material from a greater thickness of the absorbent layer 70 in a center area 48 makes available a greater fluid absorption capacity from greater quantities of superabsorbent polymer materials.
  • the upper layer 72 facing the body functions as a fluid distribution and intermediate retention layer. This means it captures a great volume of fluid through its greater volume of pores when suddenly impacted by fluid, then distributes this fluid with a time-delay in the direction of its thickness, but also in a horizontal direction, and releases it to the retention layer 70 located below it.
  • the fluid retention capability of an inventive extruded absorbent structure with a proportion of least 70% by weight of superabsorbent polymer materials is determined by the centrifuge test to be described in what follows by giving its retention value.
  • the absorbent structure to be tested is weighed in its dry state to determine its mass in grams.
  • a plurality of specimens are immersed completely for 30 minutes in a 1-percent aqueous solution of sodium chloride of demineralized water as the test solution and then centrifuged for 4 minutes at 276 times the force of gravity. Then the specimens are weighed again to determine their mass including the fluid bound in them.
  • the mass of the absorbed or bound fluid is therefore the difference between the mass determined after centrifuging and the dry mass of each of the specimens. If this difference m fl is divided by the dry mass m dry , the result is the retention value g fl /g dry , in the unit.

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  • Health & Medical Sciences (AREA)
  • Epidemiology (AREA)
  • Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Veterinary Medicine (AREA)
  • Public Health (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Vascular Medicine (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Biomedical Technology (AREA)
  • Chemical & Material Sciences (AREA)
  • Hematology (AREA)
  • Materials Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Materials For Medical Uses (AREA)
US10/182,587 2000-03-02 2001-03-02 Absorbent structure and method for producing the same Abandoned US20030012928A1 (en)

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DE2000110269 DE10010269C1 (de) 2000-03-02 2000-03-02 Absorbierender Hygieneartikel zum einmaligen Gebrauch und Verfahren zu seiner Herstellung
DE2000110268 DE10010268A1 (de) 2000-03-02 2000-03-02 Absorbierende Struktur sowie Verfahren zu deren Herstellung
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US7462754B2 (en) 2008-12-09
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WO2001064154A1 (de) 2001-09-07
AU2001244183A1 (en) 2001-09-12
JP4675020B2 (ja) 2011-04-20
JP2003524510A (ja) 2003-08-19
JP4902833B2 (ja) 2012-03-21
EP1259205B1 (de) 2004-11-17
AU2001252153A1 (en) 2001-09-12
WO2001064153A1 (de) 2001-09-07
EP1259205A1 (de) 2002-11-27
JP2003530149A (ja) 2003-10-14
DE50108543D1 (de) 2006-02-02
ATE314037T1 (de) 2006-01-15
ATE282386T1 (de) 2004-12-15
EP1259206B1 (de) 2005-12-28
JP4902832B2 (ja) 2012-03-21
EP1259207A1 (de) 2002-11-27
EP1259206A1 (de) 2002-11-27
DE50108460D1 (de) 2006-01-26
DE50104539D1 (de) 2004-12-23
US20030093051A1 (en) 2003-05-15
JP2003527895A (ja) 2003-09-24
US20050273067A1 (en) 2005-12-08
ATE313306T1 (de) 2006-01-15
PL354400A1 (en) 2004-01-12
AU2001250351A1 (en) 2001-09-12
WO2001064155A1 (de) 2001-09-07

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