WO2004011047A1 - Superabsorbent materials with low gel-bed friction angles and composites made from the same - Google Patents

Superabsorbent materials with low gel-bed friction angles and composites made from the same Download PDF

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Publication number
WO2004011047A1
WO2004011047A1 PCT/US2003/022425 US0322425W WO2004011047A1 WO 2004011047 A1 WO2004011047 A1 WO 2004011047A1 US 0322425 W US0322425 W US 0322425W WO 2004011047 A1 WO2004011047 A1 WO 2004011047A1
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WO
WIPO (PCT)
Prior art keywords
superabsorbent material
friction angle
gel
combinations
consisting essentially
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2003/022425
Other languages
English (en)
French (fr)
Inventor
Arvinder Pal Singh Kainth
Richard Norris Ii Dodge
Joseph Raymond Feldkamp
Stacy Averic Mundschau
Estelle Anne Ostgard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Priority to EP20030771651 priority Critical patent/EP1530488A1/en
Priority to KR1020057000636A priority patent/KR101047196B1/ko
Priority to JP2004524638A priority patent/JP2005534476A/ja
Priority to AU2003253987A priority patent/AU2003253987A1/en
Publication of WO2004011047A1 publication Critical patent/WO2004011047A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • A61F13/53—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
    • 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
    • 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
    • A61F2013/530481—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 superabsorbent materials, i.e. highly absorbent polymer gel materials
    • A61F2013/530708—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 superabsorbent materials, i.e. highly absorbent polymer gel materials characterized by the absorbency properties
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2311—Coating or impregnation is a lubricant or a surface friction reducing agent other than specified as improving the "hand" of the fabric or increasing the softness thereof
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2311—Coating or impregnation is a lubricant or a surface friction reducing agent other than specified as improving the "hand" of the fabric or increasing the softness thereof
    • Y10T442/2328—Organosilicon containing
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2311—Coating or impregnation is a lubricant or a surface friction reducing agent other than specified as improving the "hand" of the fabric or increasing the softness thereof
    • Y10T442/2336—Natural oil or wax containing
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2484—Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/699—Including particulate material other than strand or fiber material

Definitions

  • Absorbent articles including adult incontinence articles, feminine care articles, and diapers, are generally manufactured by combining a substantially liquid-permeable topsheet; a substantially liquid-impermeable backsheet attached to the topsheet; and an absorbent core located between the topsheet and the backsheet.
  • the liquid-permeable topsheet When the article is worn, the liquid-permeable topsheet is positioned next to the body of the wearer.
  • the topsheet allows passage of bodily fluids into the absorbent core.
  • the liquid-impermeable backsheet helps prevent leakage of fluids held in the absorbent core.
  • the absorbent core is designed to have desirable physical properties, e.g. a high absorbent capacity and high absorption rate, so that bodily fluids may be transported from the skin of the wearer into the disposable absorbent article.
  • the present invention relates to water swellable, water insoluble superabsorbent materials, which are often employed in an absorbent core (also referred to as an absorbent composite), in part to help "lock up" fluids entering the core. More specifically, the present invention pertains to superabsorbent materials having a modified friction angle measured in a gel-bed of the superabsorbent material. The gel-bed friction angle of the superabsorbent materials of the present invention is controllable and follows a predetermined pattern. The present invention also relates to use of the controlled gel-bed friction angle superabsorbent materials in absorbent composites and absorbent articles incorporating such absorbent composites.
  • Controlling the gel-bed friction angle of the superabsorbent materials may allow control of phenomena including, but not limited to: the swelling of the superabsorbent material; stresses experienced by the superabsorbent material and/or other ingredients (e.g., fibers) in an absorbent composite; the permeability of an absorbent composite containing the superabsorbent material; and/or, the absorbency, resiliency, and porosity of the absorbent composite.
  • the present invention relates to treatments for superabsorbent materials to manipulate gel-bed friction angle and new superabsorbent materials having the desired gel-bed friction angle characteristics.
  • Absorbent composites used in absorbent articles typically consist of an absorbent material, such as a superabsorbent material, mixed with a composite matrix containing natural and/or synthetic fibers. As fluids enter the absorbent composite, the superabsorbent material swells as it absorbs the fluids. The superabsorbent material contacts the surrounding matrix components and possibly other superabsorbent material as it swells.
  • an absorbent material such as a superabsorbent material
  • a composite matrix containing natural and/or synthetic fibers As fluids enter the absorbent composite, the superabsorbent material swells as it absorbs the fluids. The superabsorbent material contacts the surrounding matrix components and possibly other superabsorbent material as it swells.
  • the full swelling capacity of the superabsorbent material may be reduced due to stresses acting on the superabsorbent materials (e.g., stresses imposed by the matrix on superabsorbent material; external stresses acting on the absorbent composite that comprises a matrix and superabsorbent material, including, for example, stresses imposed on an absorbent composite by a wearer during use; stresses imposed by one portion of the superabsorbent material on another portion of the superabsorbent material, whether directly or indirectly; etc.).
  • stresses acting on the superabsorbent materials e.g., stresses imposed by the matrix on superabsorbent material; external stresses acting on the absorbent composite that comprises a matrix and superabsorbent material, including, for example, stresses imposed on an absorbent composite by a wearer during use; stresses imposed by one portion of the superabsorbent material on another portion of the superabsorbent material, whether directly or indirectly; etc.
  • stresses acting on an absorbent composite comprising the superabsorbent material may act to reduce interstitial pore volume, i.e., space between superabsorbent material, fibers, other ingredients, or some combination thereof (without being bound to a particular analogy, and for purposes of explanation only, think of a force acting on some unit area of a sponge-like material with pores, with the force per unit area - i.e., stress - acting to reduce the thickness of the sponge-like material, and, therefore, the volume of the pores).
  • the superabsorbent material As the superabsorbent material swells, it may rearrange into void spaces of the absorbent composite matrix as well as expand readily against the matrix to create additional void space. Also, as the superabsorbent material swells, stresses acting within and/or on the absorbent composite may increase due — at least in part — to expansion of the superabsorbent material, thereby reducing the pore volume between: fibers, superabsorbent material, other ingredients in the absorbent composite, or some combination there of.
  • the ability to rearrange within the composite matrix, and the magnitude and extent of the stresses acting within and on the composite matrix depend on several factors specifically including a gel-bed friction angle of the superabsorbent material.
  • the superabsorbent material may contact the components, such as fibers and binding materials, of the surrounding matrix.
  • the frictional properties of the superabsorbent material may influence the ability of the material to swell and rearrange or move within the matrix, as well as the magnitude and extent of the stresses acting within and on the composite matrix. It is often desired that the superabsorbent material be able to rotate and translate within the voids of the absorbent composite to allow the superabsorbent material to swell as close to full swelling capacity as is possible within the matrix. There is a need for a superabsorbent material which may more easily rearrange within the void space of the absorbent composite matrix.
  • the present invention is directed to superabsorbent materials having controlled gel-bed friction angles.
  • the superabsorbent materials of the present invention have gel-bed friction angles that follow controlled gel-bed friction angle patterns substantially different than gel-bed friction angle patterns followed by conventional superabsorbent materials.
  • the superabsorbent materials of the present invention may be produced using non-conventional manufacturing processes to obtain desired gel-bed friction angles or by treating with friction angle increasing additives and/or friction angle reducing additives to increase, decrease, or otherwise control the friction angle of the superabsorbent gel-bed during swelling.
  • Gel- bed friction angle is a property of a gel-bed or superabsorbent material coming from Mohr- Coulomb failure theory. A lower friction angle implies lower inter-particle friction.
  • the superabsorbent material of the present invention may be a water swellable, water insoluble superabsorbent material.
  • the water swellable, water insoluble superabsorbent material may have a first gel-bed friction angle at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material and gel-bed friction angles, at superabsorbent material swelling levels greater than about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material, substantially equal to or less than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less. In other embodiments, the gel-bed friction angles may be greater than the first gel-bed friction angle.
  • the superabsorbent material of the present invention may be utilized in an absorbent composite further comprising a plurality of wettable fibers.
  • FIGURE 1 shows an example of a response of a porous medium to a stress (i.e., a force per unit area) acting on the medium.
  • FIGURE 2 shows an example of the state of stress of an arbitrary element at equilibrium in a porous medium.
  • FIGURE 3 shows an example of an arbitrary element and the normal forces and shear forces acting on a plane passing through the arbitrary element.
  • FIGURE 4 shows an example of a Mohr Circle on a plot of shear stress (y axis) versus normal stress (x axis).
  • FIGURE 5 shows an example of a sequence of Mohr Circles corresponding to one possible stress path on a plot of shear stress (y axis) versus normal stress (x axis).
  • FIGURE 6 shows an example of Mohr Circles in relation to a Mohr-Coulomb failure envelope on a plot of shear stress (y axis) versus normal stress (x axis).
  • FIGURE 7 shows a specific example of Mohr Circles in relation to a Mohr-Coulomb failure envelope on a plot of shear stress (y axis) versus normal stress (x axis).
  • FIGURE 8 shows an example of a friction-angle measuring device, in this case a Jenike- Schulze Ring-Shear Tester, available in the U.S. from Jenike & Johanson, Inc., a business having offices in Westford, Massachusetts. DEFINITIONS
  • AUL Absorbency Under Load
  • “Absorbent article” includes, without limitation, diapers, training pants, swim wear, absorbent underpants, baby wipes, incontinence products, feminine hygiene products and medical absorbent products (for example, absorbent medical garments, underpads, bandages, drapes, and medical wipes).
  • Fiber and “Fibrous Matrix” includes, but is not limited to natural fibers, synthetic fibers and combinations thereof.
  • natural fibers include cellulosic fibers (e.g., wood pulp fibers), cotton fibers, wool fibers, silk fibers and the like, as well as combinations thereof.
  • Synthetic fibers can include rayon fibers, glass fibers, polyolefin fibers, polyester fibers, polyamide fibers, polypropylene. As used herein, it is understood that the term "fibrous matrix" includes a plurality of fibers.
  • Free Swell Capacity refers to the result of a test which measures the amount in grams of an aqueous 0.9% by weight sodium chloride solution that a gram of material may absorb in 1 hour under negligible applied load.
  • “Gel-bed friction angle” refers to the friction angle of a superabsorbent material in a gel-bed as measured with a Jenike-Shulze ring shear tester or other friction angle measuring technique. "Gradient” refers to a graded change in the magnitude of a physical quantity, such as the quantity of superabsorbent material present in various locations of an absorbent pad, or other pad characteristics such as mass, density, or the like.
  • “Gel-bed” refers to an amount of superabsorbent material within a container such as a ring shear cell.
  • “Homogeneously mixed” refers to the uniform mixing of two or more substances within a composition, such that the magnitude of a physical quantity of each of the substances remains substantially consistent throughout the composition.
  • “Incontinence products” includes, without limitation, absorbent underwear for children, absorbent garments for children or young adults with special needs such as autistic children or others with bladder/bowel control problems as a result of physical disabilities, as well as absorbent garments for incontinent older adults.
  • Meltblown fiber means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g., air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
  • heated gas e.g., air
  • Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than about 0.6 denier, and are generally self bonding when deposited onto a collecting surface. Meltblown fibers used in the present invention are suitably substantially continuous in length.
  • Mohr circle refers to a graphical representation of the state of stress within a material subjected to one or more forces. Mohr circles are described in more detail below.
  • Mohr failure envelope refers to the failure shear stress at the failure plane as a function of the normal stress on that failure or shear plane. Mohr failure envelopes are described in more detail below.
  • Polymers include, but are not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to isotactic, syndiotactic and atactic symmetries.
  • spunbonded fiber refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Patent No. 4,340,563 to Appel et al.; U.S. Patent No. 3,692,618 to Dorschner et al.; U.S. Patent No. 3,802,817 to Matsuki et al.; U.S. Patent Nos. 3,338,992 and 3,341 ,394 to Kinney; U.S. Patent No. 3,502,763 to Hartmann; U.S. Patent No.
  • FIG. 3 depicts a major principal stress ⁇ h 52 acting on a major principal plane 54, and a minor principal stress ⁇ v 56 acting on a minor principal plane 58.
  • a normal stress ⁇ na 60 and a shear stress ⁇ a 62 act on the imaginary or arbitrary plane 64 oriented at angle a 50 away from horizontal.
  • FIG. 4 shows a plot of shear stress (y-axis) 70 as a function of normal stress (x-axis) 72.
  • the principal stresses are assumed to be known (e.g., by calculation or measurement).
  • the x-y coordinates of the minor principal stress ⁇ v 74 and the major principal stress ⁇ h 76 lie on the x-axis (i.e., where the shear stress ⁇ 70 is equal to zero).
  • wood pulp fluff is identified with the trade designation CR1654, available from Bowater, Childersburg, Alabama, U.S.A., and is a bleached, highly absorbent wood pulp containing primarily soft wood fibers.
  • the cellulose fluff pulp may be homogeneously mixed with the superabsorbent material.
  • the homogeneously mixed fluff and superabsorbent material may be selectively placed into desired zones of higher concentration to better contain and absorb body exudates.
  • the mass of the homogeneously mixed fluff and superabsorbent materials may be controllably positioned such that more basis weight is present in a front portion of the pad than in a back portion of the pad.
  • a shear stress is placed on the superabsorbent material gel-bed 176 contacting the ring shear cell 172.
  • An instrument connected to the tie rods 182 measures the forces F1 and F2, which are used to determine the shear stress at failure (for a given applied normal stress) of the superabsorbent material gel-bed 176.
  • Superabsorbent material having a low gel-bed friction angle may be useful in absorbent composites.
  • the superabsorbent material gel-bed friction angle decreases upon swelling to about 20 degrees or less at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent aqueous sodium chloride solution/gram of superabsorbent material (gram/gram) and remains at about 20 degrees or less at swelling levels greater than 2.0 gram/gram.
  • emulsifiers and/or surfactants may be used in addition to the friction angle increasing additives, and friction angle increasing additive mixtures, may help increase the gel-bed friction angle of the superabsorbent materials.
  • the emulsifiers and surfactants may increase the miscibility between nonpolar friction angle increasing additives and polar friction angle increasing additives.
  • the emulsifiers and surfactants may also play an integral role in coating the swollen superabsorbent materials.
  • Various emulsifiers and/or surfactants may be used in the present invention depending on the friction angle increasing additive used. Examples of emulsifiers are phosphatidylcholine and lecithin.
  • the gel-bed friction angle of the superabsorbent material may be increased with a friction angle increasing additive located within the matrix of the absorbent composite.
  • the friction angle increasing additive is in combination with a matrix component, such as coated onto the wettable matrix fibers.
  • the friction angle increasing additive has a tendency to release from the fibers upon wetting and associate with the surface of the superabsorbent material to increase the gel-bed friction angle of the superabsorbent material.
  • the friction angle increasing additive debonds with the matrix component at a controlled rate upon wetting, and thereby gradually increases the gel-bed friction angle of the superabsorbent material over a desired time period.
  • the friction angle increasing additives may be organic and/or inorganic additives, natural and/or synthetic materials.
  • the additives such as the friction angle increasing additives and friction angle reducing additives, which may alter the friction angle of superabsorbent materials, may be delivered either directly or indirectly to the superabsorbent. Direct delivery could occur through release from the superabsorbent material itself while indirect delivery could occur from fiber or some other component positioned within or adjacent the superabsorbent material and/or the absorbent composite. Furthermore, friction angle altering additives may be delivered gradually over some time period through release from any of the existing components present in the absorbent composite or as the result of some chemical reaction devised to release the friction angle altering additive at the most desirable moment.
  • the friction angle altering additive may be attached to the surface of the superabsorbent material or embedded within its interior, or it may be loaded onto and/or into some other component present in the absorbent composite, including but not limited to the fibrous material.
  • the friction angle altering additive may be available immediately, leading to immediate alteration of the friction angle, or because of a chemical reaction or diffusion or some other mechanism, gradually alter the friction angle in the desired manner at some desired time.
  • the controlled gel-bed friction angle superabsorbent materials of the present invention may be incorporated into absorbent composites useful in absorbent articles.
  • the various controlled gel-bed friction angle superabsorbent materials of the present invention may be used in various composite structures known in the art, such as described above, including fibrous composites such as meltblown, airlaid, and spunbond composites and foam composites.
  • the superabsorbent materials of the present invention may be formed in various structures in absorbent composites, including particles, flakes, fibers, and spheres.
  • a superabsorbent material may comprise a water swellable, water insoluble superabsorbent material.
  • the superabsorbent material may have a first gel-bed friction angle at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material.
  • the superabsorbent material also may have gel-bed friction angles, at superabsorbent material swelling levels greater than about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material, substantially equal to or less than the first gel-bed friction angle.
  • the first gel- bed friction angle may be about 20 degrees or less.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of natural materials, modified natural materials, synthetic materials, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of silica gels, agar, pectin, guar gum, alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohols, ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropylcelluloses, polyvinyl morpholinones, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl pyridine, acrylonitrile grafted starch, acrylic acid grafted starch, isobutylene maleic anhydride copolymers, polyamines, and combinations thereof.
  • a superabsorbent material may comprise a water swellable, water insoluble superabsorbent material.
  • the superabsorbent material may have a first gel-bed friction angle at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material.
  • the superabsorbent also may have gel-bed friction angles, at superabsorbent material swelling levels greater than about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material, greater than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of natural materials, modified natural materials, synthetic materials, and combinations thereof.
  • the superabsorbent material may further comprise a structure selected from the group consisting of particles, fibers, flakes, spheres, and combinations thereof.
  • an absorbent composite may comprise a water swellable, water insoluble superabsorbent material and a plurality of wettable fibers.
  • the water swellable, water insoluble superabsorbent material in combination with the wettable fibers may have a first gel-bed friction angle at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material.
  • the superabsorbent material also may have gel-bed friction angles at superabsorbent material swelling levels greater than about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material, substantially equal to or less than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less.
  • the first gel-bed friction angle may be about 10 degrees or less.
  • the superabsorbent material may further comprise a structure selected from the group consisting of particles, fibers, flakes, spheres, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of natural materials, modified natural materials, synthetic materials, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of silica gels, agar, pectin, guar gum, alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohols, ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropylcelluloses, polyvinyl morpholinones, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl, pyridine, acrylonitrile grafted starch, acrylic acid grafted starch, isobutylene maleic anhydride copolymers, polyamines, and combinations thereof.
  • the present invention may further comprise a friction angle reducing additive in combination with the superabsorbent material.
  • the friction angle reducing additive may be selected from the group consisting essentially of glycerol, mineral oil, silicone oil, polysaccharides, polyethylene oxides, and combinations thereof.
  • the superabsorbent material may further comprise an emulsifier in combination with the superabsorbent material.
  • the emulsifier may be selected from the group consisting essentially of phosphatidylcholine, lecithin, and combinations thereof.
  • the superabsorbent material may further comprise a surfactant in combination with the superabsorbent material.
  • the surfactant may be selected from the group consisting essentially of sorbitan monolaurate, compounds of the Triton series, compounds of the Brij series, polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan tetraoleate, alcohol amines, and combinations thereof.
  • the present invention may further comprise a friction angle reducing additive in combination with the wettable fibers.
  • the wettable fibers may be selected from the group consisting essentially of natural fibers, synthetic fibers, and combinations thereof.
  • an absorbent composite may comprise a water swellable, water insoluble superabsorbent material and a plurality of wettable fibers.
  • the water swellable, water insoluble superabsorbent material in combination with the wettable fibers may have a first gel-bed friction angle at a superabsorbent material swelling level of about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material.
  • the water swellable, water insoluble superabsorbent material also may have gel-bed friction angles, at superabsorbent material swelling levels greater than about 2.0 grams of 0.9 weight percent sodium chloride solution/gram of the superabsorbent material, greater than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less. In the alternative, the first gel-bed friction angle may be about 10 degrees or less.
  • the present invention may further comprise a friction angle increasing additive in combination with the water swellable, water insoluble superabsorbent material.
  • the friction angle increasing additive may be in combination with the wettable fibers.
  • the friction angle increasing additive may be selected from the group consisting essentially of chitosan, sodium silicate, sodium aluminate, alumino silicates, and combinations thereof.
  • the wettable fibers may be selected from the group consisting essentially of natural fibers, synthetic fibers, and combinations thereof.
  • a superabsorbent material may comprise a water swellable, water insoluble superabsorbent material.
  • the superabsorbent material may have a first gel-bed friction angle at a first superabsorbent material swelling level of the superabsorbent material and gel-bed friction angles, at superabsorbent material swelling levels greater than the first superabsorbent material swelling level of the superabsorbent material.
  • the gel-bed friction angles may be greater than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less. In the alternative, the first gel-bed friction angle may be 10 degrees or less.
  • the superabsorbent material may further comprise a friction angle increasing additive within the superabsorbent material in combination with the water swellable, water insoluble superabsorbent material.
  • the friction angle increasing additive may be selected from the group consisting essentially of chitosan, sodium silicate, sodium aluminate, alumino silicates, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of natural materials, modified natural materials, synthetic materials, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of silica gels, agar, pectin, guar gum, alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohols, ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropylcelluloses, polyvinyl morpholinones, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinyl pyridine, acrylonitrile grafted starch, acrylic acid grafted starch, isobutylene maleic anhydride copolymers, polyamines, and combinations thereof.
  • the superabsorbent material may further comprise a structure selected from the group consisting essentially of particles, fibers, flakes, spheres, and combinations thereof.
  • an absorbent composite may comprise a plurality of wettable fibers and a water swellable, water insoluble superabsorbent material in combination with the wettable fibers.
  • the water swellable, water insoluble superabsorbent material may have a first gel-bed friction angle at a first superabsorbent material swelling level of the superabsorbent material and gel- bed friction angles, at superabsorbent material swelling levels greater than the first superabsorbent material swelling level of the superabsorbent material, greater than the first gel-bed friction angle.
  • the first gel-bed friction angle may be about 20 degrees or less. In the alternative, the first gel-bed friction angle may be about 10 degrees or less.
  • the absorbent composite may further comprise a friction angle increasing additive in combination with the water swellable, water insoluble superabsorbent material.
  • the absorbent composite may further comprise a friction angle increasing additive in combination with the wettable fibers.
  • the friction angle increasing additive may be selected from the group consisting essentially of chitosan, sodium silicate, sodium aluminate, alumino silicates, and combinations thereof.
  • the plurality of wettable fibers may be selected from the group consisting essentially of natural fibers, synthetic fibers, and combinations thereof.
  • the water swellable, water insoluble superabsorbent material may be selected from the group consisting essentially of natural materials, modified natural materials, synthetic materials, and combinations thereof.
  • a ring shear testing device such as a Jenike-Schulze Ring Shear Tester apparatus may be used to determine a superabsorbent material gel-bed friction angle. For testing, a sufficient amount (200 - 1000 grams) of swollen superabsorbent material (e.g., swollen 0 - 30g/g or more) is placed within the ring shear cell. For the samples described below, the standard procedure for determining 'yield locus' as described in the manuals 'RST-01.pc, RST-CONTROL' for the Jenike-Shulze Ring shear tester was followed. The specific details for the material preparation and test procedure are given below:
  • the superabsorbent material is swollen to the desired level by 0.9 weight percent aqueous sodium chloride (such as that available from Ricca Chemical Company, Arlington, Texas) in a Kitchen AidTM blender (model #K5SS, 5 Quart); by first pouring a specific amount of the solution (200 - lOOOgrams) in the blender bowl (bowl approximate volume: 5 quart) and then adding a predetermined quantity (20 - 600 grams) of dry superabsorbent material while the stirrer is slowly churning the fluid at the lowest speed setting (setting range 1 - 10, where 1 is the lowest and 10 is the highest). This is done so as to distribute the swelling solution uniformly to all the superabsorbent material.
  • aqueous sodium chloride such as that available from Ricca Chemical Company, Arlington, Texas
  • a Kitchen AidTM blender model #K5SS, 5 Quart
  • the bowl When all solution is absorbed by the superabsorbent material (absorption time: 0 - 30 minutes), the bowl is removed from the blender, covered so as to prevent evaporation and allowed to equilibrate for one hour so that the fluid is distributed evenly throughout each particle. The sample is manually mixed every fifteen minutes to ensure that no clumps are formed.
  • the appropriate coating additive is prepared separately, for example, as described below.
  • the equilibrated (time approximately: 1 hour) and swollen superabsorbent material is coated evenly using a Kitchen AidTM blender by first introducing the swollen superabsorbent material into the bowl, and then slowly adding the coating additive (addition time: 1 - 30 minutes) while turning the superabsorbent material in the bowl at the lowest speed setting (setting range 1 - 10, where 1 is the lowest and 10 is the highest) with the stirrer at all times.
  • the coated superabsorbent material is allowed to rest for 0 - 30 minutes with manual mixing every five minutes to maintain equal distribution of treatment.
  • the gel-bed friction angle and effective cohesion measurements are determined by using the Jenike-Schulze Ring Shear Tester apparatus.
  • the Jenike-Schulze Ring Shear Tester is used to obtain the gel-bed friction angle values of superabsorbent material gel- beds at various swelling levels.
  • the Ring Shear Tester is operated and calibrated according to the manufacturer's instructions provided.
  • a sample is loaded into the ring shear cell (Volume Ring Cell - standard: 942.48 cm 3 ) while ensuring the superabsorbent gel-bed is distributed evenly (see above table). After one hour of assumed equilibration with 0.9 weight percent sodium chloride solution is achieved, the ring shear cell is filled with the bulk superabsorbent material to be tested (see above table).
  • Even filling may be obtained by removing excess material with a spatula, without compressing the superabsorbent material.
  • the superabsorbent material gel-bed is suitably flush with the top of the ring shear cell.
  • the weight of the filled ring shear cell (without the lid) is determined on a mass balance and recorded.
  • the samples described below were tested by the ring shear tester control program (RSTCTRL) for 1 - 2 hours.
  • RSTCTRL On request from RSTCTRL, the filled shear cell is securely placed on the driving axle.
  • the lid is placed on the ring shear cell and positioned a few degrees counterclockwise from the shear position; the ring shear tester pre-sets this start position.
  • the handle of the counterweight should be on the right side of the crossbeam, and the hook on the crossbeam should be facing the handle.
  • the counter weight and the hanger are hooked to the central axis of the crossbeam.
  • the tie rods are attached on each side of the crossbeam, and the ring shear cell is adjusted so that the tie rods are not stressed.
  • RST-Control offers the possibility to adjust the shear cell with arrow keys: ⁇ >, and using: f J, to stop when positioned properly.
  • the pressures at which the sample is pre-sheared are read from a control file.
  • the pre-shearing normal pressure is set at 3000 Pascals and the pre-sheared/pre-consolidated gel-bed is then sheared to failure, to obtain the Mohr-Coulomb envelope, at a range of normal pressures ranging from 500 Pascals to 2500 Pascals.
  • Pre-shearing precedes each shearing measurement.
  • every superabsorbent materialgel-bed is sheared twice at any shearing normal pressure in one experiment.
  • the equipment needs to be run in semiautomatic mode and the data point is obtained manually.
  • superabsorbent material designated as FAVOR® SXM 9543, available from Stockhausen, Inc., a business having offices in Greensboro, North Carolina, was treated to reduce the gel-bed friction angle.
  • FAVOR® SXM 9543 was first swollen to a desired swelling level of 2 grams of 0.9 weight percent of aqueous sodium chloride solution per gram of superabsorbent material, and equilibrated for one hour, as described above.
  • the coating additive was a mixture containing 0.5 grams of glycerol and 0.5 grams of mineral oil for every 1.0 gram of additive mixture plus 0.01 grams lecithin per 2.0 gram of swollen superabsorbent material as an emulsifier.
  • the lecithin was prepared by grinding it to a fine powder for ten minutes and wetting slightly with deionized water (about 2 - 3 milliliters) to aid in mixing with the additive mixture. The lecithin was then added to the additive mixture and mixed for about 30 minutes until a uniform color with no observable lecithin particles was obtained. The additive was then mixed into the superabsorbent material that was previously swollen and had been equilibrating for one hour.
  • the additive mixture and the superabsorbent material were mixed for about two minutes until there was little or no additive mixture adhered to the side of the mixing bowl.
  • the gel-bed friction angle was measured as described above.
  • the gel-bed friction angle of the coated superabsorbent material at the given swelling level was found to be 7 degrees and is summarized in Table 3.
  • FAVOR® SXM 9543 An amount of FAVOR® SXM 9543 was first swollen to a desired swelling level of 2 gram of 0.9 weight percent of aqueous sodium chloride solution per gram of superabsorbent material, and equilibrated for one hour, as described above.
  • the coating additive was a mixture containing 0.2 grams of glycerol and 0.8 grams of mineral oil for every 1.0 gram of additive mixture plus 0.05 grams lecithin per 2.0 gram of swollen superabsorbent material as an emulsifier.
  • the lecithin was prepared by grinding it to a fine powder for ten minutes and wetting slightly with deionized water (about 2 - 3 milliliters) to aid in mixing with the additive mixture. The lecithin was then added to the additive mixture and mixed for about 30 minutes until a uniform color with no observable lecithin particles was obtained. The additive was then mixed into the superabsorbent material that was previously swollen and had been equilibrating for one hour.
  • the additive mixture and the superabsorbent material were mixed for about two minutes and there was little or no additive mixture adhered to the side of the mixing bowl.
  • the gel-bed friction angle was measured as described above.
  • the gel-bed friction angle of the coated superabsorbent material at the given swelling level was found to be 2 degrees and is summarized in Table 3.
  • FAVOR® SXM 9543 was first swollen to a desired swelling level of 2 grams of 0.9 weight percent of aqueous sodium chloride solution per gram of superabsorbent material, and equilibrated for one hour, as described above.
  • the coating material/fluid was a mixture containing 0.5 grams of glycerol and 0.5 grams of mineral oil for every 1.0 gram of additive mixture plus 0.05 grams sorbitan monolaurate per 2.0 gram of swollen superabsorbent material as an emulsifier.
  • the additive was then mixed into the superabsorbent material that was previously swollen and had been equilibrating for one hour.
  • the additive mixture and the superabsorbent material were mixed for about two minutes and there was little or no additive mixture adhered to the side of the mixing bowl.
  • the gel-bed friction angle was measured as described above.
  • the gel-bed friction angle of the coated superabsorbent material at the given swelling level was found to be 2 degrees and is summarized in Table 3.
  • the additive mixture and the superabsorbent material were mixed for about two minutes and there was little or no additive mixture adhered to the side of the mixing bowl.
  • the gel-bed friction angle for each of the swelling levels was measured as described above.
  • the gel-bed friction angle of the coated superabsorbent material at each of the given swelling levels is listed in Table 4. Table 4
  • the coating additive was a mixture containing 0.2 grams of glycerol and 0.8 grams of mineral oil for every 1.0 gram of additive mixture plus 0.02 grams sorbitan monolaurate per 2.0 gram of swollen superabsorbent material as an emulsifier.
  • the additive was then mixed into each of the superabsorbent samples that had been equilibrating for one hour.
  • the additive mixture and the superabsorbent material were mixed for about two minutes and there was little or no additive mixture adhered to the side of the mixing bowl.
  • the gel- bed friction angle was measured as described above.
  • the gel-bed friction angle of the coated superabsorbent material at each of the given swelling levels is listed in Table 5.

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US7297395B2 (en) 2007-11-20
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US20040030312A1 (en) 2004-02-12
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