U.S. patent application number 10/444286 was filed with the patent office on 2003-11-27 for fibrous absorbent material and methods of making the same.
Invention is credited to Chen, Fung-Jou, Li, Yong, Lindsay, Jeffrey Dean, Qin, Jian.
Application Number | 20030220039 10/444286 |
Document ID | / |
Family ID | 22181213 |
Filed Date | 2003-11-27 |
United States Patent
Application |
20030220039 |
Kind Code |
A1 |
Chen, Fung-Jou ; et
al. |
November 27, 2003 |
Fibrous absorbent material and methods of making the same
Abstract
Disclosed is a fibrous absorbent structure that is wet stable
and has large void volume with a density below the critical density
of the fiber employed. In one embodiment, the fibrous absorbent
uses open-celled foam technologies to keep the fibrous structure
expanded and bonded. In other embodiments, the resulting fibrous
structure resembles an open-celled polymeric foam, with fibers
serving as struts stabilized by binder material. In another
embodiment, the resulting fibrous structure is filled with
hydrophilic open-celled foams with the cell size substantially
smaller than the fibrous pores. Such a wet-stable, high void volume
fibrous absorbent can be used in a disposable product intended for
the absorption of fluid such as body fluid, including extensible
absorbent articles.
Inventors: |
Chen, Fung-Jou; (Appleton,
WI) ; Lindsay, Jeffrey Dean; (Appleton, WI) ;
Qin, Jian; (Appleton, WI) ; Li, Yong;
(Appleton, WI) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Family ID: |
22181213 |
Appl. No.: |
10/444286 |
Filed: |
May 21, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10444286 |
May 21, 2003 |
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09842470 |
Apr 26, 2001 |
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6603054 |
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09842470 |
Apr 26, 2001 |
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09083873 |
May 22, 1998 |
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6261679 |
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Current U.S.
Class: |
442/327 |
Current CPC
Class: |
Y10T 428/249984
20150401; Y10T 428/249986 20150401; C08J 2207/12 20130101; D04H
1/68 20130101; D04H 1/64 20130101; Y10S 604/904 20130101; C08J
2300/00 20130101; A61L 15/425 20130101; D04H 1/66 20130101; Y10T
428/249985 20150401; Y10T 442/60 20150401; A61F 13/53 20130101;
Y10T 428/249961 20150401; Y10T 428/249982 20150401; Y10T 428/249965
20150401; C08J 9/0085 20130101 |
Class at
Publication: |
442/327 |
International
Class: |
D04H 013/00; D04H
005/00; D04H 003/00; D04H 001/00 |
Claims
We claim:
1. A method of producing an open low-density absorbent fibrous
structure comprising: a) combining hydrophilic fibers with a
structuring composition to form a mixture, said structuring
composition comprising a binder material and a removable phase; b)
producing a foam within said mixture; c) binding said fibers
together with substantially water-insoluble bonds into a
continuous, porous network, wherein said binder material stabilizes
the porous network.
2. The method of claim 1, wherein said foam causes physical
rearrangement of the fibers in the mixture prior to binding said
fibers together.
3. The method of claim 1, further comprising the step of physically
rearranging said fibers in at least two dimensions after producing
a foam.
4. The method of claim 1, wherein said step of producing a foam
occurs during said step of combining the fibers with the
structuring composition.
5. The method of claim 1, wherein said step of producing a foam
comprises generating a gas by one of a chemical reaction within
said mixture and the action of a blowing agent.
6. The method of claim 1, wherein said step of producing a foam
comprises one of generating a fibrous froth with a high-shear
mixer, injecting gas into said mixture, adding hollow spheres to
said mixture, and depressurizing said mixture.
7. The method of claim 1, further comprising removing a portion of
said removable phase.
8. The method of claim 7, wherein said step of removing the
removable phase comprises releasing gas from gas bubbles within the
mixture.
9. The method of claim 7, wherein said step of removing the
removable phase comprises removal of a liquid.
10. The method of claim 7, wherein said step of removing the
removable phase comprises one of critical point drying, solvent
extraction, supercritical fluid treatment, and sublimation.
11. The method of claim 7, wherein said step of removing the
removable phase comprises evaporation.
12. The method of claim 7, wherein said step of removing the
removable phase comprises one of melting or decomposition of a
solid.
13. A method of producing a low-density absorbent fibrous structure
comprising: a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising a binder material and a removable phase; b) rearranging
said fibers in a three-dimensional structure within said mixture;
c) removing a portion of said removable phase; d) binding said
fibers together into a continuous, porous network, wherein said
binder material forms bonds between said fibers to stabilize said
porous network.
14. The method of claim 13, wherein said bonds formed from said
binder material are substantially water-insoluble.
15. The method of claim 1 or 13, wherein the consistency of the
fibers in said mixture is about 4% or higher.
16. The method of claim 1 or 13, wherein the density of said
absorbent fibrous structure is about 0.1 g/cc or less.
17. The method of claim 1 or 13, wherein the density of said
absorbent fibrous structure is about 0.05 g/cc or less.
18. The method of claim 1 or 13, wherein the removable phase is not
removed by sublimation.
19. The method of claim 1 or 13, wherein the absorbent fibrous
structure has a dry binder material mass fraction of about 0.6 or
lower.
20. The method of claim 1 or 13, wherein the volume of the
absorbent fibrous structure is at least 10% greater than the
initial volume of the mixture of step (b).
21. The method of claim 1 or 13, wherein said binding step
comprises cross-linking said binder material.
22. The method of claim 1 or 13, wherein said binding step
comprises curing said binder material.
23. The method of claim 1 or 13, wherein said binding step
comprises heating said binder material.
24. The method of claim 1 or 13, wherein said structuring
composition further comprises a crosslinking agent.
25. The method of claim 1 or 13, wherein said structuring
composition comprises latex.
26. The method of claim 1 or 13, wherein said structuring
composition comprises a polysaccharide.
27. The method of claim 1 or 13, wherein said structuring
composition comprises a polymer selected from a hydrophilic
cellulose derivative, an alginate, a starch, a hydrophobic starch
derivative, a superabsorbent polymer, and a gum.
28. The method of claim 1 or 13, wherein said structuring
composition contains less than 10% by dry weight of a
polysaccharide.
29. The method of claim 1 or 13, wherein said structuring
composition comprises a protein.
30. The method of claim 1 or 13, wherein said structuring
composition has a bulk viscosity of about 100 centipoise or
greater.
31. The method of claim 1 or 13, wherein less than 50% of the mass
of said structuring composition is removed from said mixture in
non-gaseous form.
32. The method of claim 1 or 13, wherein said structuring
composition further comprises a wet strength agent and said method
further comprises the step of curing said wet strength agent after
the step of adding said fibers to said structuring composition.
33. The method of claim 1 or 13, wherein said structuring
composition comprises an High-Internal-Phase-Ratio Emulsions (HIPE)
emulsion.
34. The method of claim 13, wherein said structuring composition
comprises a blowing agent.
35. The method of claim 13, wherein said removable phase is a
liquid.
36. The method of claim 13, wherein said removable phase is a
solid.
37. The method of claim 1 or 13, wherein said removable phase is a
gas.
38. The method of claim 1 or 13, wherein the density of said porous
network is about 0.05 g/cc or less.
39. The method of claim 1 or 13, wherein said binder material
comprises a polysaccharide or a protein.
40. The method of claim 1 or 13, wherein said structuring
composition comprises a surfactant.
41. The method of claim 1 or 13, wherein said structuring
composition is substantially free of molten thermoplastic
material.
42. The method of claim 1 or 13, wherein said structuring
composition is substantially free of thermoplastic material.
43. The method of claim 1 or 13, wherein said binder material is
preferentially located at or adjacent to fiber-fiber contact
points.
44. The method of claim 1 or 13, wherein said binder material forms
an open-cell foam occupying the spaces surrounded by said
fibers.
45. The method of claim 1 or 13, wherein the mass of said binder
material is less than the mass of said fibers on a dry basis.
46. The method of claim 1 or 13, wherein the mass of said binder
material is less than about 20% of the mass of said absorbent
fibrous structure.
47. The method of claim 1 or 13, wherein said binder material forms
an open-cell foam having a Cell Pore Size of about 500 microns or
less.
48. The method of claim 1 or 13, wherein said binder material is
hydrophilic.
49. The method of claim 1 or 13, wherein said fibers comprise
synthetic fibers.
50. The method of claim 1 or 13, wherein said fibers comprise
papermaking fibers.
51. The method of claim 50, wherein said papermaking fibers are
substantially unbeaten.
52. The method of claim 50, wherein said papermaking fibers have a
Canadian Standard Freeness of about 200 or greater.
53. The method of claim 1 or 13, wherein said fibers comprise about
30% or greater hardwood fibers.
54. The method of claim 1 or 13, wherein said fibers comprise at
least 20% high-yield papermaking fibers.
55. The method of claim 7 or 13, wherein said step of binding the
fibers occurs in part during said step of removing a portion of the
removable phase.
56. The method of claim 7 or 13, wherein said step of binding the
fibers occurs in part prior to said step of removing a portion of
the removable phase.
57. A method of producing a low-density absorbent fibrous structure
comprising: a) coating hydrophobic fibers with a hydrophilic fiber
coating material; b) combining said fibers with a structuring
composition comprising a binder material and a removable phase to
form a mixture; c) producing a foam within said mixture; d) binding
said fibers together into a continuous, porous network, wherein
said binder material stabilizes the porous network, and wherein at
least about 20% of the surface area of said hydrophobic fibers is
coated with hydrophilic material.
58. The method of claim 57, further comprising removing a portion
of said removable phase.
59. The method of claim 57, wherein at least about 50% of the
surface area of said hydrophobic fibers is coated with hydrophilic
material.
60. A method of producing a low-density absorbent fibrous structure
comprising: a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising a non-gaseous phase and a removable phase; b) producing
a foam within said mixture; c) forming water-insoluble bonds with a
binder material to bind said fibers together into a continuous,
porous structure.
61. The method of claim 60, wherein a liquid impervious skin forms
on a portion of the outer surface of said absorbent fibrous
structure.
62. The method of claim 61, further comprising the step of creating
openings in said skin.
63. The absorbent fibrous structure made according to any of claims
1, 13, and 60.
64. The absorbent fibrous structure made according to any of claims
1, 13, and 60 having a Wet Bulk of about 10 cc/g or greater.
65. A disposable absorbent article comprising the low-density
absorbent fibrous structure made according to any of claims 1, 13,
and 60.
66. The method of claim 60, wherein said binder material comprises
a wet strength resin.
67. The method of claim 60, wherein said structuring composition
further comprises a precursor binder material, and wherein said
step of forming water-insoluble bonds comprises converting said
precursor binder material to a binder material.
68. The method of claim 67, wherein converting said precursor
binder material to a binder material comprises one of adding a
chemical agent, elevating the temperature of the precursor binder
material, and applying radiation.
69. A method for producing a continuous absorbent fibrous structure
comprising: a) combining hydrophilic fibers with a structuring
composition comprising a binder material and a removable phase to
form a mixture; b) generating a foam within said mixture; c)
depositing said foam on a moving belt to form a foamed layer
without substantial drainage of said structuring composition from
said layer; d) curing said foamed layer to form an absorbent
fibrous structure.
70. A method for producing a continuous absorbent fibrous structure
comprising: a) forming an air-laid mat of fiberized hydrophilic
fibers on a moving belt to form a fibrous mat; b) impregnating said
mat with a foamable structuring composition comprising a binder
material and a removable phase; c) rearranging said fibers in said
mat through the action of said structuring composition to create a
restructured layer; d) forming water-insoluble bonds in said
restructured layer to form an absorbent fibrous structure.
71. The method of claim 69 or 70 further comprising one of
embossing, calendering, or perforating said absorbent fibrous
structure.
72. An apparatus for continuous production of an absorbent fibrous
structure, comprising: a) a mixing unit wherein fibers and a
foamable structuring composition comprising a binder material and a
removable phase are mixed to form a mixture; b) a foam generating
device capable of producing a fiber-laden foam from said mixture;
c) a moving belt to receive a foamed layer from said foam
generating device; d) a curing unit to create water insoluble bonds
in said foamed layer.
73. An apparatus for continuous production of an expanded fibrous
structure, comprising: a) an air-laying unit for producing a
continuous air-laid mat of fluff pulp on a moving belt; b) an
impregnating unit for impregnating said air-laid mat with a
foamable structuring composition comprising a binder material and a
removable phase; c) a curing unit to create water insoluble bonds
in the impregnated mat, such that an expanded fibrous web is
formed.
74. A foam-structured absorbent fibrous structure comprising a
water-insoluble hydrophilic foamable binder material and over 50%
by weight of hydrophilic fibers, said fibrous structure having a
density of about 0.05 g/cc or less.
75. The absorbent fibrous structure of claim 74, wherein said
binder material has a molecular weight of about 10,000 or
greater.
76. The absorbent fibrous structure of claim 74, wherein said
absorbent fibrous structure is an expanded fibrous structure.
77. The absorbent fibrous structure of claim 74, wherein said
binder material has a molecular weight of about 10,000 or less.
78. The absorbent fibrous structure of claim 74, wherein said
hydrophilic fibers comprise at least 50% by weight of papermaking
fibers with a freeness of about 300 or above.
79. The absorbent fibrous structure of claim 74, wherein said
structure is flexible.
80. The absorbent fibrous structure of claim 74, wherein said
structure is not flexible.
81. The absorbent fibrous structure of claim 74, wherein said
structure is stretchable.
82. The absorbent fibrous structure of claim 74, wherein said
structure has a gradient in one of fiber composition, pore size or
wettability.
83. The absorbent fibrous structure of claim 74, having a Wet Bulk
of about 8 cc/g or greater.
84. An open absorbent fibrous structure comprising a foamable
binder material and about 25% or greater by weight of hydrophilic
fibers, wherein said fibers are arranged as struts between the
cells of an open-cell foam structure, said fibrous structure being
hydrophilic with a density of about 0.1 g/cc or less and comprising
water-insoluble bonds that stabilize the structure.
85. An absorbent article comprising the absorbent fibrous structure
of claim 74 or 84, said article being one of a dental absorbent, a
hemostatic sponge, or a medical sponge.
86. An absorbent article comprising the absorbent fibrous structure
of claim 74 or 84, said article being one of a tampon, a
pantiliner, a sanitary napkin, or a diaper.
87. An absorbent article comprising the absorbent fibrous structure
of claim 74 or 84, wherein said absorbent fibrous structure
comprises an elastomeric binder material.
88. The absorbent fibrous structure of claim 84 wherein said
structure is wet flexible.
89. A filter comprising the absorbent fibrous structure of claim
84.
90. The fibrous structure of claim 84, wherein said fibers are
papermaking fibers.
91. The fibrous structure of claim 84 having a Wet Bulk of about 6
cc/g or greater.
92. The fibrous structure of claim 84, wherein said structure is
biodegradable.
93. The fibrous structure of claim 84, wherein said fibers comprise
substantially unbeaten papermaking fibers.
94. The fibrous structure of claim 84, further comprising bubbles
of dry foamable binder material.
95. The fibrous structure of claim 84, wherein said foamable binder
material comprises a water-soluble polysaccharide or a protein.
96. The fibrous structure of claim 84 having a density of less than
about 0.05 g/cc.
97. The fibrous structure of claim 84 having a Free Swell:AUL Ratio
of about 3 or less.
98. The fibrous structure of claim 84 having a Free Swell Capacity
of about 10 or greater.
99. The fibrous structure of claim 84 having an AUL of about 10 or
greater.
100. The fibrous structure of claim 84 further comprising at least
10% by weight of activated carbon.
101. The fibrous structure of claim 84 further comprising a liquid
impervious skin on a surface of said fibrous structure.
102. A layered foam-fiber composite comprising a first fibrous
layer and a second fibrous layer, said first layer comprising an
absorbent porous fibrous structure comprising a foamable binder
material and about 20% or greater by weight of hydrophilic fibers,
wherein said fibers are arranged as struts between the cells of an
open-cell foam; said second layer comprising a foam-fiber
composite.
103. An absorbent article comprising a liquid pervious topsheet, a
liquid impervious backsheet, and an absorbent fibrous structure
disposed between said backsheet and said topsheet, said absorbent
fibrous structure comprising at least 25% hydrophilic fibers by
weight and a binder residual from a foamable structuring
composition which stabilizes the hydrophilic fibers in a high-bulk
structure, said absorbent fibrous structure having a density of
about 0.1 g/cc or less and a Wet Bulk of about 6 cc/g or
greater.
104. The absorbent article of claim 103 further comprising a fluff
pulp pad disposed between said backsheet and said absorbent fibrous
structure.
105. The absorbent article of claim 103 wherein said absorbent
fibrous structure has a Wet Bulk of about 10 cc/g or greater.
106. The absorbent article of claim 103 wherein said absorbent
fibrous structure has a an AUL of about 10 or greater.
107. The absorbent article of claim 103 wherein said absorbent
fibrous structure has a Free Swell:AUL Ratio of about 3 or
less.
108. The absorbent article of claim 103 wherein said absorbent
fibrous structure is wet flexible.
109. The absorbent article of claim 103 wherein said absorbent
fibrous structure has an open-cell foam structure with bimodal
pores and fibers serving as struts.
110. The absorbent article of claim 103 wherein said absorbent
fibrous structure comprises at least 10% by weight of high-yield
papermaking fibers.
111. The absorbent article of claim 103 wherein said hydrophilic
fibers define the boundaries of an open-celled foam structure
stabilized by said binder residual.
112. The absorbent article of claim 103, wherein said absorbent
fibrous structure comprises elastomeric binder material.
113. The absorbent article of claim 103, wherein said article is
stretchable.
114. The absorbent article of claim 103, wherein said absorbent
fibrous structure is elastically extensible.
Description
BACKGROUND OF THE INVENTION
[0001] In the manufacture of absorbent articles, it is desirable to
employ materials having high void volume, a hydrophilic nature, and
wet resiliency, or the ability to maintain void volume when wet and
when under load. Traditional fluff pulp and creped tissue offer
high void volume and are hydrophilic, but they collapse when
wetted, especially if a load is applied. Wet laid materials in
general suffer from high density due to the largely
two-dimensional, planar arrangement of fibers. Air laid materials
can have high bulk, but are limited in their stability and
resiliency and still have definite limits in porosity and bulk.
[0002] Many nonwoven materials made from long synthetic fibers
offer high void volume and wet resiliency, but lack inherent
hydrophilicity. The fibers can be treated with surfactants or other
additives to increase the hydrophilicity of the structure, but such
processes are expensive and do not provide the same level of
affinity for water offered by cellulose or other hydrophilic
polymers Open cell plastics or plastic foams, also referred to as
expanded or sponge plastics, can offer very high void volume and
wet resiliency, but suffer the same problem of lacking inherent
hydrophilicity and have high cost. Foams made of hydrophilic
materials, such as superabsorbent foams, offer the ability to
absorb and retain liquids, but can suffer from poor wet resiliency
or high cost. Fiber reinforced foams are known wherein fibers are
added to increase the strength of a foam matrix, but such materials
are generally hydrophobic and lack the high-bulk, absorbent
attributes desired of an absorbent article.
[0003] Therefore, there is a need for a fibrous structure that has
many desirable attributes of a foam, particularly an open-celled
foam, but wherein the structure is primarily composed of
hydrophilic fibers with fibers serving at least in part as the
struts between the open cells.
SUMMARY OF THE INVENTION
[0004] It has been discovered that high-bulk fibrous materials
suitable for absorbent articles can be made wherein the fibers are
oriented in three dimensions. The fibers can be distributed in a
substantially uniform distribution or in a substantially nonuniform
distribution wherein the fibers serve as struts which define
boundaries between three-dimensional void spaces, similar to the
solid matrix of an open-cell foam and more particularly similar to
the struts in a reticulated open-cell foam. It has also been
discovered that known methods and materials for producing foams can
be exploited as fiber-structuring tools for the placement,
arrangement and binding of hydrophilic fibers, wherein the
resulting absorbent fibrous structure has good integrity and
resiliency. According to such methods, the fibers are mixed with a
structuring composition having a binder material or precursor
binding material that can be converted into a water-insoluble
binding material, and a removable phase which can be removed from
the fibrous mixture to define void spaces. The resulting structure
is stabilized by the binder material which serves to hold fibers in
place or to establish bonds, particularly water-insoluble bonds,
between fibers. In one sense, a preferred embodiment of the
invention can be described as a foam-reinforced fibrous network, in
contrast to previously known fiber-reinforced foams. In other
words, in many embodiments of the present invention, apart from the
role played by binder materials in holding fibers together, the
components of the structuring composition or foam play a relatively
minor structural role in the final absorbent material, once the
fibers have been properly positioned and bound.
[0005] In another embodiment, the binder material is added to a
foamable structuring composition after the fibers have been
structured by the foam. Thus, the fibers can be mixed with a
structuring composition comprising a removable phase and a
non-gaseous phase, and after production of foam, the binder
material can be added or, alternatively, a precursor binder
material in the structuring composition can be converted to a
binder material to provide water-insoluble bonds between fibers in
an open, absorbent fibrous structure.
[0006] As with traditional open-celled foams, the absorbent fibrous
structures of the present invention are generally "open," meaning
that the void spaces within the absorbent fibrous structure are
substantially interconnected and permit gas transport, analogous to
the open nature of open-cell foams. Specifically, an open structure
can have at least 50% of the void space in the structure occupied
by interconnected voids, and more specifically at least 80% of the
void space occupied by interconnected voids. The materials of the
present invention are also generally substantially gas permeable,
meaning that gas can pass relatively freely through the absorbent
fibrous structure in at least one direction, desirably in two
orthogonal directions, more desirably in three orthogonal
directions, and most specifically in substantially any direction.
In one embodiment, the materials of the present invention have a
Frazier permeability (hereafter defined) of at least about 50 cfm,
more specifically about 100 of more, more specifically still about
200 cfm or more, and most specifically about 400 cfm or more, with
an exemplary range of about 75 cfm to about 1100 cfm. In some
embodiments, however, the absorbent fibrous structure may have a
skin, such as a film of binder material, on one or more surfaces
which is liquid or gas impervious, while the interior of the
absorbent fibrous structure remains substantially open (apart from
any flow restriction caused by the outer skin). For best results in
absorbent articles and filters, if a skin exists, at least one
portion of the outer surface of the absorbent fibrous structure
should be free of either a liquid or gas impervious skin.
[0007] Possible uses of the present invention include absorbent
articles for intake, distribution, and retention of human body
fluids. Examples include feminine care pads, tampons, diapers,
incontinence articles, training pants, bed pads, sweat absorbing
pads, shoe pads, bandages, helmet liners, wipes and wipers, etc.,
or, in a suitably thin and flexible form, as a novel tissue or
towel. A valuable benefit of many embodiments of the present
invention is its ability to maintain a three-dimensional structure
and maintain stability under stress and when wet. Thus, a wide
variety of shaped composites can be envisioned, including tampons,
shock-absorbing shoe pads, articles adapted for particular portions
of garments or the body, gaskets for ostomy bags, hemostatic
sponges and other medical sponges and absorbents for surgical
purposes, dental absorbents such as plugs for extracted teeth or
saliva absorbents to fit in portions of the mouth, and the like.
Besides serving as absorbent articles, materials of the present
invention can serve as components in filters, including filters for
absorbing liquid droplets and other entrained materials in the air,
including face masks. Filters made with the absorbent fibrous
structures of the present invention can be particularly useful when
they comprise activated carbon fibers or granules. Such filtration
materials are capable of absorbing pollutants or odors from gases
and organic pollutants from liquids, particularly water. The
absorbent fibrous structures of the present invention can also be
used in additional products such as shock absorbing pads,
groundcover materials, erosion barriers, pads for absorbing pet
waste, industrial spill and leak absorbents, floating barriers for
oil spills and chemical containment, fireproofing materials,
insulation, packaging materials, padding, and the like. The
absorbent fibrous structures of the present invention can also be
combined with other functional materials internally (as by adding
material into the absorbent fibrous structure) or externally (as by
joining with additional layers) such as odor absorbents, activated
carbon materials, fire retardants, superabsorbent particles,
nonwoven materials, plastic films or apertured films, extruded
webs, closed cell foams, tissue webs, electronic devices such as
alarms indicating wetness or leakage, opacifiers, fillers,
aerogels, sizing agents, antimicrobial agents, adhesive strips and
tapes, and the like.
[0008] Hence, in one aspect, the invention resides in a method of
producing an open low-density absorbent fibrous structure
comprising:
[0009] a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising a binder material and a removable phase;
[0010] b) producing a foam within said mixture;
[0011] c) binding said fibers together with substantially
water-insoluble bonds into a continuous, porous network, wherein
said binder material stabilizes the porous network.
[0012] Said method can further comprise removing a portion of said
removable phase, which can be a gas, a liquid, a solid, or a
combination thereof. The density of the absorbent fibrous structure
suitably can be about 0.2 g/cc (grams per cubic centimeter) or
less, particularly about 0.1 g/cc or less, more particularly still
about 0.05 g/cc or less, and most particularly about 0.03 g/cc or
less, with an exemplary range of from 0.15 g/cc to 0.01 g/cc.
[0013] In another aspect, the invention resides in a method of
producing a low-density absorbent fibrous structure comprising:
[0014] a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising a binder material and a removable phase;
[0015] b) rearranging said fibers in a three-dimensional structure
within said mixture, and desirably into a structure wherein the
fibers are substantially oriented in three dimensions;
[0016] c) removing a portion of said removable phase;
[0017] d) binding said fibers together into a continuous, porous
network, wherein said binder material forms bonds between said
fibers to stabilize said porous network.
[0018] In another aspect, the invention resides in a method of
preparing an absorbent fibrous composite comprising:
[0019] a) preparing a mixture of hydrophilic fibers with a foamable
binder material and an optional carrier liquid, said mixture
comprising about 20% or greater hydrophilic fibers on a dry weight
basis;
[0020] b) generating a fiber-laden foam from said mixture;
[0021] c) curing said fiber-laden foam to yield an open low-density
hydrophilic absorbent fibrous structure.
[0022] In yet another aspect, the invention resides in a method of
producing a low-density absorbent fibrous structure comprising:
[0023] a) coating hydrophobic fibers with a hydrophilic fiber
coating material;
[0024] b) combining said fibers with a structuring composition
comprising a binder material and a removable phase to form a
mixture;
[0025] c) producing a foam within said mixture;
[0026] d) binding said fibers together into a continuous, porous
network, wherein said binder material stabilizes the porous
network, and wherein at least about 20%, more specifically at least
about 50%, and most specifically at least about 70% of the surface
area of said hydrophobic fibers is coated with hydrophilic
material.
[0027] In another aspect, the invention resides in method of
producing a low-density absorbent fibrous structure comprising:
[0028] a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising a non-gaseous phase and a removable phase;
[0029] b) producing a foam within said mixture;
[0030] c) forming water-insoluble bonds with a binder material to
bind said fibers together into a continuous, porous structure.
[0031] In another aspect, the invention resides in a method of
producing a low-density absorbent fibrous structure comprising:
[0032] a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising an optional precursor binder material, a non-gaseous
phase and a removable phase, wherein said structuring composition
is capable of producing a foam;
[0033] b) removing a portion of said removable phase to form a
porous network;
[0034] c) adding binder material to said porous network or
converting said precursor binder material to a binder material;
and
[0035] d) binding said fibers together into a continuous, porous
structure stabilized by said binder material.
[0036] In another aspect, the invention resides in a method of
producing a low-density absorbent fibrous structure comprising:
[0037] a) combining hydrophilic fibers with a structuring
composition to form a mixture, said structuring composition
comprising an optional precursor binder material and a removable
phase;
[0038] b) rearranging said fibers in a three-dimensional structure
within said structuring composition;
[0039] c) removing a portion of said removable phase to form a
porous network;
[0040] d) adding binder material to said porous network or
converting said precursor binder material to a binder material;
and
[0041] e) binding said fibers together into a continuous, porous
structure stabilized by said binder material.
[0042] In another aspect, the invention resides in a method of
producing an open low-density absorbent fibrous structure having at
least 25% hydrophilic fibers by dry weight, comprising:
[0043] a) combining hydrophilic fibers with a hydrophilic
structuring composition to form a mixture;
[0044] b) applying foam generation means for producing a foam
within said mixture;
[0045] c) binding said fibers together with binding means into a
continuous, porous network having water-insoluble bonds;
[0046] d) drying said porous network.
[0047] In another aspect, the invention resides in an absorbent
porous fibrous network made according to any of the above-mentioned
methods, as well as absorbent articles made with such a fibrous
network, said articles desirably being suited for absorption of
human body fluids. For incorporation into absorbent articles known
in the art, the absorbent fibrous structures of the present
invention can have a thickness less than 3 cm, desirably less than
2 cm, and specifically between about 0.3 cm and 1.7 cm.
[0048] In yet another aspect, the invention resides in a
foam-structured absorbent fibrous structure comprising a
hydrophilic water-insoluble foamable binder material and over 50%
by weight of hydrophilic fibers, said fibrous structure having a
density of about 0.05 g/cc or less.
[0049] In still another aspect, the invention resides in an
absorbent fibrous structure comprising a foamable binder material
and about 25% or greater by weight of hydrophilic fibers, wherein
said fibers are arranged as struts between the cells of an
open-cell foam, said fibrous structure being hydrophilic with a
density of about 0.1 g/cc or less.
[0050] In another aspect, the present invention resides in a
layered foam-fiber composite comprising a first fibrous layer and a
second fibrous layer, said first layer comprising an absorbent
porous fibrous structure comprising a foamable binder material and
about 20% or greater by weight of hydrophilic fibers, wherein said
fibers are arranged as struts between the cells of an open-cell
foam; said second layer comprising a foam-fiber composite having a
substantially closed-cell structure or a substantially hydrophobic
foam-fiber composite.
[0051] In another aspect, the invention resides in an absorbent
article comprising a liquid pervious topsheet, a liquid impervious
backsheet, and an absorbent fibrous structure disposed between said
backsheet and said topsheet, said absorbent fibrous structure
comprising at least 25% hydrophilic fibers by weight and more
specifically at least 50% hydrophilic fibers by weight, and most
specifically at least 70% hydrophilic fibers by weight, and a
binder residual from a foamable structuring composition which
stabilizes the hydrophilic fibers in a high-bulk structure, said
absorbent fibrous structure having a density of about 0.1 g/cc or
less and having a Wet Bulk of about 6 cc/g or greater, more
specifically about 8 cc/g or greater, more specifically still about
10 cc/g or greater, more specifically still about 15 cc/g or
greater, and most specifically about 20 cc/g or greater.
[0052] In another aspect, the invention resides in a method for
producing a continuous absorbent fibrous structure comprising:
[0053] a) combining hydrophilic fibers with a structuring
composition comprising a binder material and a removable phase to
form a mixture;
[0054] b) generating a foam within said mixture;
[0055] c) depositing said foam on a moving belt to form a foamed
layer without substantial drainage of said structuring composition
from said layer;
[0056] d) curing said foamed layer to form an absorbent fibrous
structure.
[0057] In still another aspect, the invention resides in a method
for producing a continuous absorbent fibrous structure
comprising:
[0058] a) forming an air-laid mat of fiberized hydrophilic fibers
on a moving belt to form a fibrous mat;
[0059] b) impregnating said mat with a foamable structuring
composition comprising a binder material and a removable phase;
[0060] c) rearranging said fibers in said mat through the action of
said structuring composition to create a restructured layer;
[0061] d) forming water-insoluble bonds in said restructured layer
to form an absorbent fibrous structure.
[0062] Said method can further comprise embossing, calendering,
perforating, brushing, folding, scoring, perf-embossing, and the
like to achieve desired fluid absorbent and mechanical
properties.
[0063] In another aspect, the invention resides in an apparatus for
continuous production of an absorbent fibrous structure,
comprising:
[0064] a) a mixing unit wherein fibers and a foamable structuring
composition comprising a binder material and a removable phase are
mixed to form a mixture;
[0065] b) a foam generating device capable of producing a
fiber-laden foam from said mixture;
[0066] c) a moving belt to receive a foamed layer from said foam
generating device;
[0067] d) a curing unit to create water insoluble bonds in said
foamed layer.
[0068] In another aspect, the invention resides in an apparatus for
continuous production of an expanded fibrous structure,
comprising:
[0069] a) an air-laying unit for producing a continuous air-laid
mat of fluff pulp on a moving belt;
[0070] b) an impregnating unit for impregnating said air-laid mat
with a foamable structuring composition comprising a binder
material and a removable phase;
[0071] c) a curing unit to create water insoluble bonds in the
impregnated mat, such that an expanded fibrous web is formed.
[0072] Based on the theory of foam formation and the role that
fibers can play when interacting with a foam, it has been
discovered that a hydrophilic fibrous structure can be created in
an open cell foam form with the assistance of a structuring
composition. For example, using technologies similar to those that
produce open-celled foams, it is possible to produce a network of
fibers having a three-dimensional fiber orientation and
exceptionally high void volume desirably with density well below
the critical density at which a fibrous mat or pad will neither
collapse nor expand when wetted with water.
[0073] Though the structuring composition in some preferred
embodiments can be initially an aqueous mixture, the resulting
fibrous structure typically lacks the largely two-dimensional,
planar fiber arrangement seen in wet-laid structures, for in the
present invention there is generally no need for drainage of
aqueous components on a foraminous fabric, but the methods of the
present invention yield a three-dimensional network structure
which, in some embodiments, can resemble a reticulated open-celled
foam, wherein the struts between cells consist largely of
hydrophilic fibers. Such a structure is capable of high performance
as an absorbent material. In many embodiments, therefore, the
absorbent fibrous structure is not produced by a wet-laid process
requiring drainage of liquid from a fibrous mat.
[0074] In contrast to typical fiber-reinforced foams, wherein small
quantities of fibers serve to increase the strength of a continuous
foam matrix, the structures of preferred embodiments of the present
invention can be said to be foam-reinforced fibrous structures or
foam-structured fibrous materials, wherein foam technology serves
to provide structure and optionally resiliency to a largely fibrous
structure. Further, in contrast to typical fiber-reinforced foams,
the materials of the present invention can be substantially or
predominately hydrophilic.
[0075] In contrast to air-laid structures, embodiments of the
present invention are structured and given enhanced bulk by the
action of a structuring composition comprising non-gaseous
components, and can also be prepared by interaction with foamable
materials to have properties superior to those of airlaid
materials.
[0076] Hydrophilic fibers comprise a major portion of the absorbent
fibrous structure and can be the predominate structural component
of the structure. On a dry mass basis, the percentage of
hydrophilic fibers in the absorbent fibrous structure can be about
20% or greater, desirably about 30% or greater, more desirably
about 40% or greater, more desirably still about 50% or greater,
and most desirably about 55% or greater. Additionally, the
hydrophilic fibers can comprise about 80% or greater, or about 90%
or greater, or from about 75% to about 98% of the absorbent fibrous
structure on a dry mass basis. In many embodiments, the absorbent
fibrous structure visually appears to be predominately composed of
fibers with relatively little other solid matter visible to the
eye. Suitably, the other solid matter is predominantly located at
fiber-fiber contact points or both on the surface of the fibers and
at fiber-fiber contact points. The fibrous structural elements of
the absorbent fibrous structure, consisting of hydrophilic fibers
and any relatively thin coating of binder material thereon
("relatively thin" in this context means less than 50% of the fiber
diameter), desirably comprise at least about 50% of the solid
volume of the absorbent fibrous structure excluding the volume of
any loose particulates which may have been added into the
structure, and specifically can comprise at least about 60%, more
specifically from about 80% to about 98%, most specifically at
least about 90%, and alternatively substantially 100% of the solid
volume of the absorbent fibrous structure, desirably calculated on
a basis which excludes any loose non-fibrous material which may
have been added or alternatively excluding the volume of any added
superabsorbent material.
[0077] The hydrophilic fibers can be any known cellulosic or
papermaking fibers, as hereafter defined, such as hardwood or
softwood fibers. Hardwood fibers can provide small cells and good
strength, such as when the hydrophilic fibers comprise about 30% or
more hardwood fibers and more particularly about 50% or more
hardwood fibers, while softwood fibers can contribute to higher
bulk and good resiliency and stiffness, when desired, such as when
the hydrophilic fibers comprise about 30% or more softwood fibers
and more particularly about 50% or more softwood fibers. Natural
cellulosic fibers such as cotton, kenaf, milkweed, and others can
be used, as well as chemically modified or synthetically produced
cellulosic fibers. Short hydrophilic textile fibers can also be
used, provided the fiber length is suitably short to permit
suitable distribution of the fibers by the structuring composition,
with average fiber lengths desirably being less than about 15 mm
and more desirably less than about 10 mm, with an exemplary range
of about 0.5 mm to about 7 mm and more specifically from about 1 mm
to about 5 mm. Hydrophilic fibers derived from chitin, chitosan,
starch, or other polysaccharides can also be used, though
cellulosic fibers generally offer significant benefits due to their
abundance, their absorbent nature, and ease of preparation.
[0078] While highly fibrillated and highly refined fibers can be
used, for certain applications they are undesirable due to
excessive flexibility of the fibers, difficulty in drying the
fibers, increased energy requirements to fibrillate the fibers,
high fines contents, and increased yield losses during
fibrillation. Substantially unfibrillated fibers and/or
mechanically undamaged fibers are desirable in a variety of
embodiments.
[0079] In another embodiment, the hydrophilic fibers can be
hydrophobic base fibers whose surfaces have been modified to render
the fibers substantially hydrophilic. For example, polyethylene,
polypropylene, and other synthetic fibers can be rendered
substantially or partially hydrophilic through surface modification
techniques that involve: 1) irradiating the surface of a polymeric
material in the presence of oxygen to create active sites and then
chemically grafting a polymer onto the active sites; 2) providing
an organic surface coating by plasma discharge in the presence of a
plasma polymerizable, halogenated hydrocarbon gas; 3) treating
(e.g., oxidizing) the. surface of the fibers so that it has a
hydrophilic character with a high amount of cation-exchange groups;
4) applying corona discharge treatment, optionally with additional
surfactant treatment; 5) depositing surfactants, proteins,
polysaccharides or other hydrophilic materials by chemical
precipitation, solution coating followed by evaporation of a
solvent, supercritical fluid treatment to deposit solubilized
hydrophilic agents, and other means known in the art; 6)
incorporating water soluble inorganic salts that are hydratable,
hygroscopic or deliquescent, onto fiber surfaces, said salts
including, for example, toxicologically acceptable calcium and
magnesium salts, which can be added to a polymer prior to forming
fibers or preferably added to the surfaces of existing fibers. For
an example of protein application to hydrophobic materials, see
U.S. Pat. No. 5,494,744, issued Feb. 27, 1996 to Everhart et al.
For an example of corona discharge treatment, see U.S. Pat. No.
5,102,738, issued Apr. 7, 1992 to Bell et al. With respect to
surfactant addition in particular, known methods include (1)
passing a formed fibrous web through a bath containing the
surfactant in either neat or solution form and drying the wiper as
needed so that a given amount of the surfactant is deposited on the
wiper, or (2) spraying a surfactant in either neat or solution form
on the fibers as they are being formed or on the fibrous porous web
and drying the web as needed so that a given amount of the
surfactant is deposited on the web, or (3) applying a surfactant in
a supercritical carrier fluid such as supercritical carbon dioxide,
wherein the carrier fluid desirably causes the fiber to swell
during treatment to cause better penetration of the solute into the
surface of the fiber, or, (4) adding surfactant to a thermoplastic
resin prior to extrusion and formation of the resin into a
thermoplastic porous web material. In the later situation, under
known process conditions, the added surfactant exudes or migrates
to the surface of the fibers of the porous web material during or
shortly after fiber formation. This phenomenon has been referred to
as "blooming" the surfactant. It is believed that blooming results
from the insolubility of the surfactant in the thermoplastic
polymer as the polymer cools. See U.S. Pat. No. 4,535,020 to Thomas
et al. for an example of surfactant blooming.
[0080] In one embodiment, hydrophobic fibers are used in the first
step of several methods of the present invention but are coated
with a hydrophilic coating material that can be part of the
structuring composition or a separate agent. As a separate agent,
the hydrophilic coating material can be applied to the fibers
before, during, or after the step of combining the fibers with the
structuring composition. For example, the fibers may first be
treated to render them substantially hydrophilic. In another
example, the hydrophobic fibers may be used with the structuring
composition to create a three-dimensional non-absorbent or
substantially hydrophobic high-bulk fibrous structure, which is
rendered more fully hydrophilic and/or absorbent by the application
of a hydrophilic coating material. The coated fibers have
hydrophilic matter from the hydrophilic coating material covering a
surface area of about 20% or greater, more specifically about 50%
or greater, more specifically still about 70% or greater, and most
specifically about 90% or greater. The ratio of dry hydrophilic
coating material to dry fiber mass can be about 2 or less, more
specifically about 0.5 or less, more specifically still about 0.1
or less, more specifically still about 0.05 or less, and most
specifically about 0.03 or less.
[0081] In another embodiment, the absorbent structure comprises a
portion of activated carbon fibers to yield a porous fibrous
structure having excellent odor absorbing abilities due to the high
permeability of the structure to gas and due to the high fraction
of accessible surface area of the fibers. The surface chemistry of
the activated carbon fibers should be tailored for optimum
absorption or wicking of the target fluids or gases of the fibrous
structure and can be rendered hydrophilic. For example, acidic
groups on the activated carbon fibers can be desirable for
absorbing basic compounds comprising ammonium moieties. Acidic
groups can be added by treating the fibers at elevated temperature
in the presence of steam, carbon dioxide, nitric acid, and the
like. Basic groups, useful for absorbing acidic compounds such as
HCl, can be introduced by treatment with ammonia at elevated
temperatures or by other treatments known in the art. Suitable
fibers and fiber treatment methods include those disclosed in PCT
patent application, "Coated Absorbent Fibers," by James Economy and
Michael Daley of the University of Illinois, published as WO
96/38232, Dec. 5, 1996, and on the Univ. of Illinois Web site at
"http://www.students.uiuc.edu/.about.ahall/activated carbon
fabrics.html" as of January 1998, which discloses a variety of gas
treatments at elevated temperature to activate the fibers and
control the surface chemistry.
[0082] The fibers can additionally contain other additives and
agents commonly known in the papermaking arts. Wet strength agents,
dry strength agents, crosslinking agents, surface chemistry
modifiers, biocides or antimicrobials, softeners, and the like may
be present. When recycled fibers or other papermaking fibers are
used, a quantity of filler materials such as calcium carbonate or
titanium dioxide can be present. For absorbent articles intended to
absorb body fluids, it is desirable that post-consumer recycled
fibers not be used, though opacifiers, fillers, and other agents
can be present or deliberately added. In most cases, virgin
papermaking fibers are desirable for their mechanical properties
and lack of contaminants. For example, odor-removing additives can
be desirably present in the structures of the present invention,
including activated carbon granules or fibers, activated silica
particulates, EDTA, zeolites, polycarboxylic acids, anti-bacterial
agents, talc powder, sodium bicarbonate, encapsulated perfumes,
cyclodextrin, UV absorbers, emollients, chitosan or chitin, and the
like.
[0083] In the production of such high-bulk absorbent fibrous
structures, a structuring composition is used with the fibers. The
structuring composition can include certain materials known in the
art of foam production and generally serves to hold or rearrange
the fibers in a desired three-dimensional orientation. The
structuring or rearrangement of fibers can occur by the flow and
expansion of a foam; by the expansion of a blowing agent; by the
removal of a phase that previously displaced fibers or rearranged
them into a foam-like or open-cell structure; by the action of two
mixed immiscible phases that act to preferentially position fibers
in the liquid meniscus between bubbles; by the hydrodynamic action
of a viscous liquid (including solutions) or liquid-solid slurry or
frozen slurry which holds the fibers in place during removal of a
substantial portion of the liquid or slurry by freeze drying or
solvent exchange; and the like.
[0084] The physical rearrangement of the fibers can take place in
one, two, or three-dimensions. Rearrangement in two or more
directions is desirable, and rearrangement in three dimensions is
most desirable. A one-dimensional rearrangement could occur, for
example, when the action of the structuring composition was
primarily to move fibers in a mat upward in the z-direction, such
that the mat becomes bulkier, but such that the relative x-y
positions of the fibers are not substantially changed.
Two-dimensional rearrangement occurs when fibers in a narrow layer
or plane are moved to new locations in the plane but without
crossing or intermingling into other strata. Most desirable is
three-dimensional rearrangement, where the action of the
structuring composition and more specifically the action of a foam
formed by the structuring composition moves fibers not only
vertically but also to new x-y locations within a web or mat or
other form of the absorbent fibrous structure being made. For
example, bulk motion of a fiber-laden froth or foam due to beating,
stirring, pouring, molding, and the like can result in a
three-dimensional rearrangement of fibers prior to binding of the
fibers. In general, physical rearrangement of the fibers in a
particular direction or dimension can be said to occur if, for
example, a characteristic fiber is typically displaced by about 1
mm or greater, more specifically about 3 mm or greater, more
specifically still about 10 mm or greater, and most specifically
about 5 mm to about 25 mm.
[0085] In one embodiment, the structuring composition is
sufficiently viscous and/or stable that it does not separate
substantially from the fibers by drainage after mixing over a time
space sufficient to dry or cure the structuring composition.
(Curing of the structuring composition occurs when the binder
material forms bonds which stabilize the fibers, and can be caused
by thermal treatment; condensation reactions or other chemical
reactions caused by the effects of electron beams, ultraviolet
radiation, microwave radiation, and the like; chemical
crosslinking; chemical initiation of polymerization; and the like.)
For example, the structuring composition can have a bulk viscosity
of about 100 centipoise or greater, more specifically about 500
centipoise or greater, and more specifically still about 2000
centipoise or greater, using methods suitable for viscosity
measurement of foams. Thus, it is desirable in certain embodiments
that much of the mass of the structuring composition is not removed
in liquid form or in liquid/solid form, as by drainage.
Specifically, it is desirable in certain embodiments, particularly
those involving an aqueous-based foam with gas bubbles, that about
50% or less of the initial mass of the structuring composition be
removed in non-gaseous form or by drainage, more specifically that
about 10% or less of the initial mass of the structuring
composition be removed in non-gaseous form or by drainage, and most
specifically that substantially none of the structuring composition
be removed in liquid form from the mixture of fibers and
structuring composition during formation of the absorbent fibrous
structure.
[0086] The structuring composition comprises a removable phase
which provides void space in the product and a binder material,
optionally with a liquid carrier phase and optionally with other
non-gaseous components such as surfactants, crosslinking agents,
softeners, plasticizers, antimicrobial agents, odor controlling
materials, etc., to achieve the desired functional characteristics
of the absorbent fibrous structure. At least one component of the
structuring composition is non-gaseous. The removable phase can be
liquid water or any other liquid capable of being removed by
evaporation, solvent exchange, critical point drying, supercritical
fluid extraction, wicking, and so forth; ice or other sublimable
solids; solids that can be melted and removed as liquids or further
evaporated; solids that decompose partially or fully to vapors or
fumes upon heating to leave void spaces; and the like. Gas bubbles
in a foam as the removable phase are an especially preferred
embodiment for ease of production and removal. Desirably, the
structuring composition is a foamable composition wherein the
bubbles of the foam serve to displace or rearrange the fibers into
the desired structure. The binder material stabilizes the porous
fibrous structure and can increase the strength of fiber-fiber
bonds. Desirably, the structuring composition is hydrophilic once
dried or cured. In one embodiment, the removable phase is not
liquid water or water vapor and more specifically is not liquid
water. In another embodiment, the gas bubbles are largely composed
of air or other gases besides water vapor and, in a related
embodiment, can be formed without the need to heat aqueous
materials to the boiling point, though water vapor bubbles can be
employed in other embodiments.
[0087] In absorbent fibrous structures derived from a foam
generated through the production, generation, or introduction of
gas bubbles into the fibrous mixture, the liquid or liquid-solid
slurry serves as a non-gaseous phase and the removable phase is the
gas that forms bubbles. Since the gas is not chemically bonded to
the solid matrix, it is removable by diffusion and desirably by
bulk flow, even if some of the original gas in the foam is trapped
in some bubbles. Obviously, the gas is removable if the foam has a
substantially open-cell structure. In the foam-structures useful
for the present invention, at least a portion of the original gas
in a foam produced from gas bubbles will be removed from the
structure. The portion removed should be a substantial fraction of
the removable phase, such as about 20% or more, more specifically
about 50% or more, still more specifically about 80% or more, and
most specifically about 90% on a volumetric basis. Though it may be
ideal to have complete removal of the removable phase, inevitable
some small fraction may be trapped in dead end pores, occasional
closed pores, and the like.
[0088] In a foam produced by liquid phase inversion or by
polymerization of one liquid phase around bubbles of another at
least partly immiscible liquid, the removable phase is generally a
liquid which can be evaporated or otherwise dried to remove it at
least in part from the remaining matrix. The structuring
composition may also be a solid-liquid suspension or slurry or a
three-phase mixture.
[0089] The binder material in the structuring composition can be a
polymeric material such as a soluble polysaccharide (e.g.,
carboxymethyl cellulose, starch and modified starches) or a protein
(e.g., a gelatin), more specifically a polymeric foamable material.
A polymeric binder material may be rendered foamable at least in
part due to the presence of foaming agents such as a surfactant or
tenside, including anionic, nonionic, and cationic surfactants, in
the structuring composition. The polymeric binder material
desirably is hydrophilic. A hydrophilic polymeric foamable binder
material can require addition of a carrier liquid such as water to
create a foam, with water being the preferred carrier fluid, though
in a few cases a polymeric foamable binder material can be foamed
as is, with egg whites being one example. Desirably, the carrier
liquid is a solvent to the polymeric component but not to the
hydrophilic fiber (a liquid comprising a solute that renders the
hydrophilic fibers soluble or partly soluble, such as a
concentrated zinc chloride solution with cellulosic fibers as the
hydrophobic fibers, would not be preferred in many embodiments). A
material is foamable if a partly or substantially stable foam
capable of holding papermaking fibers can be produced by mechanical
agitation in the presence of air or upon application of other
foaming methods mentioned herein and known to those skilled in the
art. Pure water is not foamable, for example, whereas egg whites
and many aqueous surfactant solutions are.
[0090] The binder material may be water swellable or not water
swellable. For best results in absorbent articles, the binder
material desirably is substantially water insoluble, even when the
binder material is water swellable. Preferably, the binder material
provides not only good dry stability but also good wet stability
and wet resiliency to the absorbent fibrous structure when wetted
with liquid water. For applications where wet resiliency is needed
to maintain high void volume even under compressive loads, the
binder material desirably is not water swellable, is desirably
water insoluble, and desirably has a binder wet strength:dry
strength ratio (hereafter defined) of about 10% or greater,
specifically about 20% or greater, more specifically about 40% or
greater, and most specifically about 50% or greater. The same
desirable ranges for binder wet strength:dry strength ratio apply
to swellable binder materials as well.
[0091] Polymers which are suitable for use in certain embodiments
of the present invention include any polymer which is initially
soluble in a solvent such that the soluble polymer may be formed
into a solution by mixing with a liquid solvent, such as water, and
then whereby the polymer is treated to cause the polymer to become
water-insoluble and optionally water-swellable so that an absorbent
foam comprising such water-insoluble polymer exhibits desired
absorbency and physical characteristics.
[0092] For swellable binder materials, carboxymethylcellulose (CMC)
is a useful material capable of binding fibers and absorbing water.
Aside from CMC, polymers which are also suitable for use,
particularly for freeze drying and other embodiments of the present
invention, include a wide variety of anionic, cationic, and
nonionic materials. Suitable polymers include polyacrylamides,
polyvinyl alcohols, ethylene maleic anhydride copolymer,
polyvinylethers, polyacrylic acids, polyvinylpyrrolidones,
polyvinylmorpholines, polyamines, polyethyleneimines,
polyacrylamides, polyquaternary ammoniums, natural based
polysaccharide polymers such as carboxymethyl celluloses,
carboxymethyl starches, hydroxypropyl celluloses, algins,
alginates, carrageenans, acrylic grafted starches, acrylic grafted
celluloses, chitin, and chitosan, and synthetic polypeptides such
as polyaspartic acid, polyglutamic acid, polyasparagins,
polyglutamines, polylysines, and polyarginines, as well as the
salts, copolymers, and mixtures of any of the foregoing polymers.
Polyglucan succinate or glutarate, for example, can also be used,
particularly when cross-linked to form diester-crosslinks.
[0093] Other useful polymeric materials useful as components of the
structuring composition and specifically as binder materials
include anionic and cationic latexes, wet strength agents,
hydrocolloids, pectin, sodium carboxymethylcellulose, thrombin,
collagen, amylose derivatives, algin, synthetic gums, and the like.
However, for some applications, it is desirable that the binder not
be rubbery and thus not be comprised of latex or related rubbery
materials. For products for those who are allergic to latex in
particular, latex is not desirable binder. Where rubber-like
mechanical properties are desired, such as in some portions of
absorbent pads and particularly gasket materials for absorbent
articles, latex an be useful as a binder.
[0094] In one embodiment of the present invention, it is desired
that the polymer used be a polyelectrolyte for high absorbency. In
general, a polyelectrolyte is a glassy polymer. As used herein, the
term "glassy" polymer is meant to refer to a polymer having a glass
transition temperature (Tg) above about 23.degree. C. (about room
temperature) at a relative humidity of about 30 percent or less.
Examples of glassy polymers include, but are not limited to, sodium
polyacrylate, polyacrylic acid, sodium carboxymethyl cellulose, and
chitosan salt polymers. Examples of non-glassy polymers and
non-polyelectrolytes include, but are not limited to, polyethylene
oxide, polyvinyl acetate, and polyvinyl ether polymers.
[0095] Hydrophobic thermoplastics and hot melt adhesives can also
serve as the binder material, though it is preferred that they be
applied primarily are fiber-fiber contact regions rather than
across the entire surface of the fiber to prevent reduction in
hydrophilicity of the absorbent fibrous structure. The absorbent
fibrous structures of the present invention should be substantially
hydrophilic and absorbent.
[0096] One property of a water-insoluble polymer which is relevant
to its effectiveness in providing a desired amount of
liquid-absorbing capacity to an absorbent foam is its molecular
weight. In general, a water-swellable, water-insoluble polymer with
a higher molecular weight will exhibit a higher liquid-absorbing
capacity as compared to a water-swellable, water-insoluble polymer
with a lower molecular weight.
[0097] The water-insoluble polymers useful in the absorbent fibrous
structure of the present invention can generally have a wide range
of molecular weights. Polymers suitable as components of the
structuring composition or as binder materials useful in the
present invention will can have a weight average molecular weight
greater than about 10,000, particularly if they are to be
swellable, and more specifically greater than about 100,000, even
more specifically greater than about 200,000, suitably greater than
about 500,000, more suitably greater than about 1,000,000, and up
to about 20,000,000. Non-swelling polymers useful as components of
a binder material desirably have molecular weights less than about
20,000 and specifically less than about 5,000. Methods for
determining the molecular weight of a polymer are well-known in the
art.
[0098] In some embodiments, the binder material comprises a
crosslinked polymer. Crosslinking can be achieved by any method
known in the art, including those described in more detail
hereafter. Crosslinking can be done before or after removal of the
removable phase.
[0099] The structuring composition will generally have a pH within
the range of from about 2 to about 12, more specifically from about
4 to about 9, more specifically from about 4 to about 7.5, and most
specifically from about 6 to about 7.5.
[0100] The absorbent fibrous structure can be an "expanded fibrous
structure" which, in its dry or cured form, has greater macroscopic
volume and greater void volume than the initial mixture of fibers
and structuring composition. For example, an expanded fibrous
structure can be formed when a fibrous slurry is mixed with a
structuring composition containing blowing agents which
subsequently are activated to expand and add void volume to the
fibrous mixture prior to drying or curing. Likewise, a pressurized
mixture of a structuring composition and fibers can expand to
occupy increased void when the mixture is depressurized as part of
a process for forming an absorbent fibrous structure.
[0101] The absorbent fibrous structure of the present invention can
be substantially biodegradable. The hydrophilic fibers can be
substantially biodegradable. Likewise, the dried structuring
composition or the dried binder material can comprise at least 50%
by weight, and more specifically at least 80% by weight of
biodegradable components, or may be essentially 100%
biodegradable.
[0102] The fibrous structures of the present invention can have
exceptionally low density, such as density significantly below the
critical density of the specific fiber type used, such as a density
of about any of the following or lower, in units of g/cc: 0.2,
0.15, 0.1, 0.07, 0.05, 0.025, 0.02, and 0.01. For example,
structures formed with CMC and eucalyptus fibers by freeze-drying
yield a stiff, highly resilient material having a density of only
0.02 g/cc, a remarkably low density structure for a fibrous
material.
[0103] The absorbent fibrous structure can be flexible according to
ASTM definitions for the flexibility of plastic foams, as described
hereafter.
[0104] Layered structures can be produced with materials of the
present invention. In particular, a layered foam-fiber composite
can be produced comprising a first fibrous layer and a second
fibrous layer, said first layer comprising an absorbent fibrous
structure comprising a foamable binder material and about 20% or
greater by weight of hydrophilic fibers, wherein said fibers are
arranged as struts between the cells of an open-cell foam; said
second layer comprising a foam-fiber composite having a
substantially closed-cell structure or a substantially hydrophobic
foam-fiber composite. In one embodiment of the layered foam-fiber
composite, the thickness of said first layer can be less than about
5 mm and the thickness of said second layer can be less than about
4 mm. Additional layers may be attached, including polyolefin
bonded carded webs, meltblown webs, spunbond webs, or other
materials suitable as surge, intake, or distribution layers for
feminine care articles, diapers, incontinence products, and the
like. Foams comprising activated carbon materials can also be
attached as additional layers.
[0105] Unlike many known fiber-reinforced foams and other fibrous
composites, the materials of the present invention are generally
suitable for use in absorbent articles, and particularly for use in
absorbent articles for absorbing human body fluids. In several
embodiments, the materials of the present invention have suitable
wet resiliency that they are not destroyed or dissolved by
application of liquid water, saline solutions, urine, menses, runny
bowel movement, sweat, blood, saliva, and the like, and can
effectively absorb and retain such fluids, desirably maintaining
integrity and shape when completely wetted with saline solution
over a prolonged period of time such as 1 hour. In several
embodiments, the materials of the present invention have suitable
conformability, softness, or flexibility to serve as elements in
absorbent articles worn next to the body without discomfort or
inadequate body fit. Also, in several embodiments, the materials of
the present invention are made without the use of materials and
methods inappropriate for human health or without undesired
contaminants or waste products such as post-consumer waste, old
newspapers, and the like. More specifically, the absorbent fibrous
structure can consist essentially of materials that are
toxicologically acceptable for prolonged contact with human tissue
or for use in a sanitary napkin for feminine care . Most
specifically, the absorbent fibrous structure can consist
essentially of materials that are toxicologically acceptable for
use in a tampon, hemostatic sponge, wound dressing or bandage.
[0106] In a further embodiment, the absorbent fibrous structure of
the present invention can be provided with a high degree of
flexibility through the use of an elastomeric binder material such
as latex. The absorbent fibrous structure can then be rendered
extensible with such elastomeric bonds, particularly if the
material has been suitably molded for extensibility or has been
foreshortened mechanical compaction, creping, or rush transfer to
create a crepe-like or accordion-like structure permitting
expansion and extension in the plane. Slits normal to the direction
of extension or not aligned with the direction of extension can
also provide extension means to the flexible absorbent fibrous
structure, particularly with elastomeric bonds. Thus, absorbent
articles such as feminine pads or pantiliners can be made
extensible and provided with extensible absorbent cores or other
absorbent components through the use of elastomeric bonds in the
high bulk, flexible absorbent fibrous structure. Other components
in the absorbent article can desirably be extensible as well,
including the topsheet, the backsheet, and other absorbent layers,
using methods known to those skilled in the art. In the case of a
sanitary napkin comprising an absorbent fibrous structure, for
example, making the absorbent fibrous structure and desirably also
the entire sanitary napkin elastically stretchable will reduce the
undesirable tendency of the sanitary napkin to gather
longitudinally inward (i.e., bunch longitudinally) when forces
which tend to stretch the sanitary napkin are removed.
[0107] The absorbent fibrous structure can have gradients in
material properties extending in the thickness direction or in
directions in the plane of the absorbent fibrous structure.
Gradients or variations in basis weight and thickness can readily
be provided, but other material properties such as fiber
composition, pore size, wettability, and the like can have
gradients as well. For example, a planar absorbent fibrous
structure suitable for use in an absorbent article may have large
pores and large open cells near a top surface, with cells that
become progressively smaller near the opposing back surface,
optionally terminating in a skin on the back surface which can be
partially or substantially liquid impervious. Such a structure with
a porosity gradient may be suitable for liquid intake on the top
surface but can prevent liquid leakage from the back surface.
Articles may be provided with gradients in hydrophilicity as well,
with more hydrophilic binder material and fibers in one region
(e.g., a top surface) than elsewhere (e.g., a back surface).
Gradients may extend in the plane, giving, for example, an article
with large cells or pores in a central target region but with more
closed cells or smaller pores near the side edges of the absorbent
fibrous structure to prevent lateral leakage of fluid.
METHODS OF MAKING THE ABSORBENT FIBROUS STRUCTURE
[0108] Many processes known in the art for producing foams and
open-cell foams in particular can be used to produce the absorbent
fibrous structures of the present invention. In general, a
structuring composition is used to help position the fibers and
create void space, resulting in a high-bulk mixture which can be
dried or cured (as by heat or radiation or application of chemical
reagents) into an absorbent fibrous structure.
[0109] Methods for producing the absorbent fibrous structure of the
present invention begin with preparation of fibers and the
structuring composition, which are combined to form a fibrous
mixture. The fibers may in a slurry, such as an aqueous slurry, or
may initially be in dry form, such as fluff or comminuted fibers or
air lad fiber mats. The structuring composition is desirably
capable of producing a foam. The components of the structuring
composition may be added to the fibers or visa versa in one step or
in multiple stages, optionally with at least some ingredient of the
structuring composition being added separately to the mixture at
various stages. A portion of the structuring composition may have
previously been added to the fibers, which can then react or
combine with other reagents in the remainder of the structuring
composition that is subsequently added. For example, fibers loaded
with sodium bicarbonate may react with citric acid in the remainder
of the structuring composition to release carbon dioxide to form a
foam, and remaining citric acid may in turn promote crosslinking of
the fibers upon subsequent heat treatment.
[0110] Following the initial combination of the structuring
composition or at least some of its components with the fibers, the
removable phase in the structuring composition can be generated or
augmented, if necessary, such as by activation of blowing agents to
create gas bubbles in the mixture or by direct introduction of
extraneous gas through injection or mechanical agitation or
high-shear mixing and the like to create a froth or foam. The
interaction of the removable phase with other phases in the mixture
can reposition and displace the fibers to create a high-bulk
fibrous structure, optionally with a distinct bimodal pore size
distribution characteristic of an open cell foam with porous
struts, wherein the pores in the struts correspond to the small
pore spaces between neighboring fibers in a strut, in contrast to
the larger pores of the cells defined by the struts.
[0111] The steps of creating a foam in the mixture and removing at
least a portion of the removable phase typically occur sequentially
but can occur simultaneously as well. In many cases, the act of
removing a portion of the removable phase creates an open structure
in the fibrous structure. In other cases, the structure may become
open before significant removal of the removable phase occurs. In
some open-cell foaming processes, gas bubbles are first produced
and then some of the gas escapes and breaks open windows between
the cells to create an open cell foam. In foams created by freeze
drying, however, the foam structure is created by the removal of
the removable phase (typically water or another suitable volatile
material). Likewise, the steps preferably producing a mixture of
fibers with the structuring composition and creating the foam
therein can also be sequential or simultaneous. The foam may be
produced after the mixture is created, it may be produced during
the mixing operation, or the foam may already have been created in
the structuring composition prior to mixing with the fibers.
[0112] Foams can be prepared by many means. The expansion process
is that of expanding a fluid polymer phase or slurry to a low
density cellular state and then "freezing" the polymer structure by
curing or through cooling of the liquid polymer. The extrusion
process for producing foams uses physical stabilization in a
decompression expansion process. This process uses a blowing agent
blended into the molten polymer that is extruded under pressure.
This solution of polymer and blowing agent is forced out through a
die opening on to a moving belt at normal room temperature and
pressure. This reduction in pressure causes the blowing agent to
vaporize resulting in expansion of the polymer. The polymer is
allowed to cool during expansion such that enough structural
strength is obtained for the required density and dimensional
stability. Freezing of the structure or stabilization of the
polymer structure is a result of the polymer phase cooling to a
point below its glass transition temperature. Cooling comes mainly
from three areas: (1) the vaporization of the blowing agent, (2)
gas expansion, and (3) heat loss to the environment.
[0113] Other methods of producing cellular materials include
leaching out solid or liquid materials that have been dispersed in
a polymer, sintering small particles, dispersing small cellular
particles in a polymer, dispersing gas (or solid) in the fluid
state and stabilizing this cellular state, or by sintering polymer
particles in a structure that contains a gas phase. In any case,
the resulting foam or froth structure comprises a removable
phase.
[0114] Preparation of reticulated open cell foams can include the
application of mechanical force to knock out the windows of closed
cells to render them open. Such forces can be applied by one or
more cycles of compression, by application of a shock wave, or by
thermal shock. Polymeric cell walls can also removed or open by
hydrolysis (e.g., by treatment with caustic solution), oxidation,
and application of elevated temperature or pressure, as will be
recognized by those skilled in the art.
[0115] The removable phase may be liquid, gas, or solid, though gas
is the most commonly used removable phase in commercial foam
production. Nevertheless, many liquids including oils,
hydrocarbons, and aqueous fluids can be used as well as some solids
such as ammonium bicarbonate which decompose to yield gas upon
heating. The interaction of the removable phase with the fibers and
other components of the structuring composition results in moving,
positioning, or structuring the fibers into a high-void volume
form.
[0116] The structuring composition can comprise compounds for
producing a foam generated through the production, generation, or
introduction of gas bubbles into the fibrous mixture. The
structuring composition can also comprise compounds for producing a
foam via liquid phase inversion or by polymerization of one liquid
phase around bubbles of another at least partly immiscible liquid
or by other techniques known in the art to produce foams and
particularly open-cell foams. In general, when the non-gaseous
phase is a liquid distinct from said removable phase, the two
phases are sufficiently immiscible over at least a finite range of
conditions such as temperature, pressure, chemical environment, and
concentration to permit establishment of interfacial regions
between said phases. The fibers generally are preferentially
attracted to one phase or to an interface, where they are largely
held in place during removal of at least a part of the removable
phase to yield a porous fibrous structure. Binder materials,
desirably in a liquid phase of the structuring composition, serve
to increase the integrity of the fibrous structure during or after
removal of at least part of the removable phase.
[0117] A related embodiment, by way of example, can have a solid,
semi-solid or gel phase as the removable phase and a liquid phase
as a separate non-gaseous phase. It is desirable, however, that the
binder material not swell significantly (e.g., the volume increase
is less than 400%, more specifically less than 100%, and more
specifically still less than 10% upon saturation with water). In
another related embodiment, solid particles can be used to confine
the fibers to occupy regions between the particle, whereupon the
particle can be removed as by salvation, melting or sublimation for
ices or frozen hydrates), shrinkage and physical escape from the
fibrous structure, collapse of a hollow particle, and the like.
[0118] In preparing an absorbent fibrous structure comprising
activated carbon fibers, it is desired that the amount of binding
agent be as small as possible to prevent occlusion of pores on the
activated carbon fibers. The binding agent can be non-wetting with
respect to the activated carbon fibers such that it does not extend
over the fiber surface but is primarily located at the menisci
where fibers join and touch, thus serving to bind the fibers
together in the porous state without severely reducing fiber
functionality.
[0119] In the case of freeze drying, some solvent exchange
operations, supercritical fluid extraction, and other variations of
the present invention, a single liquid phase or solution can serve
as both the non-gaseous phase and the removable phase. For example,
a solution of a polysaccharide in water having high viscosity could
be used to hold fibers in a relatively random orientation. The
fiber slurry formed with the solution could be rapidly or slowly
frozen and freeze dried, wherein the structuring composition now as
a frozen solid (both non-gaseous and removable) would serve to hold
the fibers in place, depositing the polysaccharide on the fibers as
the water sublimes, thus increasing the integrity of the fiber
network, which may require further cross linking treatment or
curing or addition of other binder materials for full strength and
resiliency development. Freeze drying technology for foam
production is also disclosed in commonly owned copending
applications, Ser. No. 08/977,918, "Absorbent Foam," and Ser. No.
08/978,263, "Process for Preparing an Absorbent Foam," filed Nov.
25, 1997, both of which are herein incorporated by reference.
[0120] In one embodiment, the process generally comprises forming a
solution of a soluble polymer in a solvent, mixing the solution
with hydrophilic fibers, freezing the solution at a relatively slow
cooling rate to a temperature below the freezing point of the
solvent, removing the solvent from the frozen solution, and
optionally treating the polymer to form a water-swellable,
water-insoluble binder material stabilizing an absorbent fibrous
structure.
[0121] In another embodiment, the process comprises forming a
solution of monomers in a solvent, adding hydrophilic fibers,
polymerizing the monomers to form a solution gel of a crosslinked
polymer in the solvent, freezing the solution gel at a relatively
slow cooling rate to a temperature below the freezing point of the
solvent, and removing the solvent from the frozen solution gel.
Optionally, the solution gel of the crosslinked polymer could be
subjected to additional swelling, by using additional solvent,
before freezing the solution gel.
[0122] In such freeze-drying embodiments, the soluble polymer or
the monomers are typically dissolved in a solvent comprising at
least about 30 weight percent water, beneficially about 50 weight
percent water, suitably about 75 weight percent water, and more
suitably 100 weight percent water. When a co-solvent is employed
with the water, other suitable solvents include methanol, ethanol,
acetone, isopropyl alcohol, ethylene glycol, glycerol, and other
solvents known in the art. However, when a water-soluble polymer is
used, the use or presence of such other, non-aqueous solvents may
impede the formation of a homogeneous mixture such that the polymer
does not effectively dissolve into the solvent to form a
solution.
[0123] The consistency of the fibers in a solution for
freeze-drying can be about 10% or less, more specifically from
about 0.3% to 4%, more specifically still from about 0.4% to about
2.5%.
[0124] It has also been found that the rate at which the solution
is cooled from a temperature above the freezing point of the
solvent to a temperature below the freezing point of the solvent is
helpful in achieving an absorbent foam that exhibits the desired
properties described herein. In a qualitative manner, the cooling
rate used should not be so fast that visible cracks or visible
non-uniformities begin to form in the freezing solution. As such,
there is generally a critical cooling rate that will exist for a
particular solution in order to achieve a desired absorbent foam of
the present invention. Using a cooling rate that is faster than
such a critical cooling rate will generally result in an
undesirable absorbent foam that exhibits a relatively non-uniform
pore structure and cracked polymer matrix. In contrast, using a
cooling rate that is slower than such a critical cooling rate will
generally result in a desirable absorbent foam that has a
relatively uniform pore structure and the absence of any
significant cracks or deformities in the polymer matrix.
[0125] The cooling rate to be used for a particular suspension
plays an important role in the structure of the resulting absorbent
fibrous structure. In one embodiment of the present invention,
wherein water is the solvent and the polymer is used in a
concentration of between about 0.5 to about 2 weight percent,
wherein the weight percent is based on the total weight of the
solvent, good results have been obtained with a decrease in
temperature less than about 0.4.degree. C. per minute, more
specifically less than about 0.3.degree. C. per minute, and most
specifically less than about 0.1.degree. C. per minute.
[0126] Following freezing and sublimation of the ice, the dried
material may need to be further treated to activate the binder
material and fully effect the binding step. For example, with CMC
and many other binder materials, heat treatment is useful to
insolubilize the binder material. With latex as a binder material,
heat treatment is not usually needed. With certain wet strength
resins and crosslinkers, Kymene being one example, some binding can
be achieved without heat treatment, but those skilled in the art
will recognized that improved wet strength can typically be
achieved by curing the resin at an elevated temperature for a brief
period of time. As will be recognized by those skilled in the art,
soluble proteins likewise can be denatured and cured into
water-insoluble or water resistant bonds by thermal treatment, with
or without the addition of other crosslinking agents.
[0127] A related method for producing open-celled foams for the
present invention is that found in U.S. Pat. No. 4,002,173, issued
Jan. 11, 1977 to Manning et al., herein incorporated by reference,
which discloses "reticulated sponges" or reticulated porous
hydrogels comprising a 3-dimensional network of interconnecting
strands of diester-crosslinked polyglucan succinate or glutarate,
especially of amylose. The sponges are made by lyophilizing (freeze
drying) water-soluble salts of the mono- or half-esters, such as
water-soluble salts of amylose succinate or amylose glutarate,
under process conditions of the invention in the presence of a
reticulating agent which causes a controlled melting of the salt
solution as it nears the dry state during the lyophilizing step.
The resulting reticulated, porous, open-celled sponge is then
crosslinked by heating the sponge under dehydrating conditions to
form diester-crosslinks. By properly combining fibers and optional
additional binder agents into the solution prior to freeze drying,
an absorbent fibrous structure can be made.
[0128] The absorbent fibrous structure of the present invention is
also believed to be capable of being formed by a process generally
comprising forming a solution of a soluble polymer in a solvent,
adding hydrophilic fibers and a blowing agent to the solution,
activating the blowing agent, removing the solvent from the
solution, and optionally treating the polymer to form a
water-swellable, water-insoluble polymeric matrix binding fibers
together in an absorbent fibrous structure.
[0129] One embodiment comprises the method of combining hydrophilic
fibers, desirably papermaking fibers such as bleached kraft
eucalyptus fibers or softwood BCTMP, with a moist, fluidlike or
stirrable foam made from a binder material comprising a polymeric
material such as a soluble polysaccharide (e.g., carboxymethyl
cellulose) or a protein (e.g., a gelatin), more specifically a
polymeric foamable material, and optionally an additional foaming
agent. The hydrophilic fibers are combined with the polymeric
foamable binder material and a carrier fluid, if required, to form
a foaming suspension. Desirably, the hydrophilic polymeric binder
material and fiber components are dispersed in a carrier liquid
such as water or an organic liquid such as an alcohol.
[0130] The mixture can then be foamed by the introduction of air by
injection and/or mechanical forces, suitably under high mechanical
shear or agitation to create the foam and disperse the fibers
effectively while preventing significant flocculation.
Alternatively, gas bubbles can be created by chemical reaction or
other means through the action of a blowing agent in the polymeric
foamable binder material. The carrier liquid, if present, or any
other volatile liquid compounds, are then removed by solvent
extraction, freeze drying, evaporation, radiofrequency drying,
microwave drying, and other methods known in the art, yielding a
substantially dry, stable, porous, absorbent fibrous structure.
[0131] A variety of technologies are known for creation of stable
hydrophilic foam structures. Critical point drying can be used to
remove a liquid phase without disrupting the porous structure of
the solid component. Freeze drying of foams has long been used to
create stable foam-like structures from typically aqueous solutions
or suspensions of polymers. The freeze-drying (lyophilization) of
aqueous protein and carbohydrate solutions is known among those
skilled in the art. A loose, foam-, felt- or fleece-like structure
having numerous cavities is obtained, which has the consequence
that such a dry preparation has a high absorptive capacity relative
to body fluids. Either water or a non-aqueous medium such as
t-butyl alcohol can be used. While freeze drying is commonly
performed on a liquid or slurry largely devoid of gas, a foam-like
structure can first be created followed by freeze drying. For
example, the methods described above can be used to create an
aqueouos or alcohol-based foam, followed by freeze-drying to remove
at least part of the removable phase without substantial collapse
of the foam structure.
[0132] For certain high-value products, however, such as medical
sponges, freeze-drying can be an economical and desirable process.
However, for commercial production, it is desirable that the
removal of a removable phase not be conducted by freeze drying or
by any process involving freezing of liquid components. Sublimation
drying is likewise generally not preferred for commercial
production of low-cost, disposable items because of the long times
required, particularly for removal of water. Thus, it can be
desirable in the production of absorbent articles that the process
be carried out without freeze drying, alternatively without
freezing, alternatively without substantial sublimation drying,
alternatively at a temperature substantially above the freezing
point of the structuring composition or, more specifically, above
0.degree. C. and desirably above 5.degree. C.
[0133] In combining papermaking and other fibers with a structuring
composition according to the present invention, the fibers can be
prepared in an aqueous slurry of either low consistency (less than
about 4% consistency), medium consistency (about 4% to about 20%
consistency), or high consistency. Medium consistency foam
preparation requires high input of mechanical energy in most cases
but offers economic and structural advantages when used with
blowing agents or pressure relief methods for void volume
generation, while low consistency slurries can be used to produce
freeze-dried structures without foaming or to produce finer foam
cells than is normally possible with medium-consistency foams. The
use of non-swelling fibers such as cellulosic fibers that have been
chemically crosslinked allows better mixing and dispersion at a
given moisture content because more of the moisture is available
between the fibers rather than taken up by swelling of the fibers.
This also improves the ease of drying.
[0134] With foaming prior to drying, it is desirable that the
fiber-to-carrier liquid mass ratio be high to reduce the amount of
liquid removal required, to save energy costs, and to reduce the
potential disrupting effect of capillary forces on the open-celled
foam structure during removal of carrier fluid. For example, in one
embodiment, the fibers are in a medium consistency aqueous slurry
at a consistency of about 4% or higher (based on dry fiber mass
relative to slurry mass), specifically about 6% or higher, and more
specifically from about 8% to about 20%, as foaming begins.
[0135] For most effective foaming of a medium or high consistency
slurry of paper fibers, high shear is required to put the slurry
into a fluidized Theological state in which the slurry no longer
acts like a nearly solid mass (as do many high consistency mixtures
under static conditions) but behaves rheologically more like a pure
liquid. In this state, addition of air or other gases can result in
a foam if appropriate surfactants and preferably foam stabilizers
are present. In one embodiment, the injected gas is pressurized
such that the dispersed gas bubbles will expand as the pressure is
relieved. For example, pressurized air or carbon dioxide at about 2
psig or higher, preferably about 10 psig or higher, can be
introduced to a pressurized high-shear mixer which permits
continuous extrusion of the fiber slurry out one end or through a
batch vessel that is periodically depressurized. As the pressure
drops, the discrete gas bubbles in the mixture expand until they
approach atmospheric pressure. If the pressurized gas is at twice
the atmospheric pressure, the gas bubbles may expand in size by a
factor of about 2 as the pressure is relieved to increase the
available pore volume. Blowing agents can also be used to create
gas bubbles in situ in the fiber slurry over a wide range of
consistencies.
[0136] For the creation of foams from wood pulp slurries,
surfactants can be useful in improving fiber flowability or
dispersibility under shear.
[0137] High-shear mixers acting on pulp suspensions up to
consistencies of about 30%, for example, can be used to introduce
large amounts of gas into a fiber slurry to provide structure to
the fibrous matter. Soap, detergents, tensides, and the like can be
added to increase the amount of froth or modify the void volume or
bubble size of the mixture. Likewise, proteins or other foam
generating or foam stabilizing additives can be used to enhance the
stability of the foam and to help bind fibers together in an
open-cell array. Crosslinkers, adhesives such as latexes and
starch, and other wet strength additives can be further provided
either before, during, or after the high-shear mixing to help
stabilize the fibrous structure, though addition of such agents
preferably occurs before or during the high-shear mixing phase of
the process. Following creation of the fibrous foam or expanded
fiber mixture, mild agitation can be desirable to prevent settling
of liquid or collapse of the foam. The mixture can be air dried,
heated by radiation such as microwaves or infrared radiation,
inductively heated, heated by conduction or convection, such as by
gentle through drying, or the like to dry the fibrous material and
optionally to crosslink the structure or cure or set the adhesives
or proteins or other binder materials present in the
composition.
[0138] In one embodiment, the foam-fiber mixture can be prepared
from a medium-consistency aqueous fiber slurry with added
surfactants and foam stabilizers in a high-shear fiber mixer known
in the art of high-consistency bleaching and mixing, including the
high shear T-series of fiber mixers from Sunds Defibrator
(Norcross, Georgia) and medium consistency mixers from Ahlstrom and
from Kamyr. In one embodiment, a foaming agent such as a surfactant
and foam stabilizer are mixed with high-consistency fibers, such
that the ratio of fibers to liquid water on a mass basis is about
15% or greater, preferably about 20% or greater, more preferably
about 25% or greater, and most preferably about 30% or greater. Gas
can be introduced at elevated pressure (e.g., above about 5 psi,
preferably above 10 psi, more preferably above about 15 psi, and
most preferably above 30 psi) into the mixer to produced aerated,
slurries of fiber, liquid, and gas. In such an embodiment, the gas
will typically comprising less than about 50% by volume in the high
shear mixer and more specifically less than about 40% and more
specifically still less than about 30%.
[0139] Upon release from the high-shear mixer, the gas bubbles
swell and create foam cells surrounded by fibers, if the surface
tension properties of the liquid are properly adjusted and if the
fibers are sufficiently short and dispersed. The resulting porous,
three-dimensional foam-fiber composite can then be dried to
completion to create a high-bulk fiber structure.
[0140] High-shear mixers are generally not preferred for activated
carbon fibers because of the tendency for fibers to break. Instead,
blowing agents are desired to create the foam from the slurry of
fibers in a carrier fluid, which need not be aqueous. Polyurethane,
for example, can be suitable with known blowing agents. The
polymeric material serving as the foaming agent can also be the
carrier fluid in this case, though an additional solvent as the
carrier liquid will reduce the viscosity of the mixture and
increase the ability to disperse the fibers in a foam at a high
fiber to foaming agent ratio, such that the final porous fibrous
material after drying or other extraction of the carrier liquid
comprises at least 50% fibers by weight.
[0141] The mixture need not be foamed prior to drying but can be
freeze dried (lyophilized) to yield a structure composed of fibers
held in place in part by the polymeric material which is left
behind as the carrier fluid is removed. For freeze-drying
operations without a prior foaming step, the mixture should be
sufficiently dilute with respect to fibers that significant pore
space is left upon removal of the carrier fluid. Desirably, the
ratio of fiber to carrier fluid is about 30% or less, preferably
about 10% or less, and most preferably about 5% or less. Of course,
a stable foam with void spaces and bubbles can be created first and
then freeze dried to create a wide distribution of pore shapes and
sizes.
[0142] When hydrophobic thermoplastics and hot melt adhesives serve
as the binder material, it is preferred that they be applied
primarily are fiber-fiber contact regions rather than across the
entire surface of the fiber. This can be achieved by applying the
binder material in a solvent or as a suspension in carrier fluid
and a allowing menisci to form at fiber-fiber contact points where
the binder material is preferentially deposited as the solvent or
carrier fluid evaporates. For example, latex spheres or polyolefin
microspheres suspended in a carrier liquid can be applied to a
fibrous structure in this manner, and then bonding can occur during
drying or during heat treatment. The same process can also be used
to preferentially apply hydrophilic binder material to fiber-fiber
contact regions. In this process, the binder material can be
applied after the fibers have been mixed with a structuring
composition, in which case at least part of the binder material is
not initially contained in the structuring composition that is
first mixed with the fibers, but the additional binder material is
mixed with the fibers by virtue of applying it to the fibrous
network after the fibers have been structured by a structuring
composition comprising at least one non-gaseous phase. Thus, in
this embodiment, the step of combining fibers with a structuring
composition comprising a binder material takes place in two stages:
first mixing fibers with a precursor structuring composition, and
then adding all or a portion of the binder material to the
structured fibrous network. For example, an viscous foam containing
a first compound may be used to structure fibers, whereupon a
second compound is applied by mist or vapor or gas to the fibrous
structure such that the first and second compounds react to form a
stable binder material. Further, a fibrous-foam may be stabilized
by spraying a cross-linking agent or applying a gas phase which
initiates polymerization of a precursor binder material in the
structuring composition. Thus, it is recognized that the step of
combining hydrophilic fibers with a structuring composition
comprising a binder material may actually occur in two substeps,
the first substep being the mixing of fibers with a portion of the
structuring composition, and the second substep being the addition
of a binder material or components of a binder material or a
reaction that produces binder material. The second substep can
occur after the fibers have been physically rearranged and
structured by said portion of the structuring composition. Thus,
the binder material can be present in the structuring composition
that initially is mixed with the fibers, or a portion of the binder
material can be added later after the fibers have been mixed with a
structuring composition or a portion of a structuring composition,
or a precursor binder material can be present in the structuring
composition which later becomes a binder material upon subsequent
reaction or physical or chemical change (though the precursor
binder material can still be termed a binder material, for example,
if it inherently can serve as a binder upon drying, heat treatment,
radiative treatment, reaction with other components present in the
structuring composition, and the like), or a precursor binder
material can become a binder material upon subsequent reaction with
a reagent that is applied later to the mixture of fibers and
structuring composition. Two-component epoxy adhesives, for
example, with a resin (the binding material precursor) and an
polymerizing agent, represent an example of a binder material that
can be delivered in two steps. Other resins with separate
crosslinking agents or polymerization initiators are also known in
the art.
[0143] In many embodiments, the step of binding the fibers together
comprises curing, polymerizing, or cross-linking the binder
material to establish water-insoluble bonds. Thermal, radiative,
and chemical treatment can be used to promote crosslinking or bond
formation.
[0144] The step of binding the fibers together can occur in any
order. Normally, it will occur after or during removal of the
removable phase, but fiber bonding can begin even during mixing
with the structuring composition and in general may occur prior to
removal of the removable phase.
[0145] The structuring composition and binder material generally
needs to be dried, particularly if an aqueous solution or
suspension is used to form the structuring composition. Drying can
be by any method known in the art, but preferably is
non-compressive drying to maintain the high void volume of the
structure. A degree of compressive drying, such as by contact with
heated drums under tension from a dryer fabric, can be used to
reduce the bulk to a desired level, and calendering, embossing,
perforating, or pressing may also be performed, if needed, to
achieve desired bulk levels, softness, uniformity, or other
objectives.
[0146] Blowing agents for hydrophilic foam systems and other
methods of creating hydrophobic foams are known in the art of
superabsorbent foam materials. Foamed, water-swellable, polymeric
water absorbent material can be prepared by contacting a polymer
capable of having a water-swellable character and containing acid
moieties in acid form with a blowing agent capable of neutralizing
the acid moieties. Carbonate blowing agents can be added to a
monomer solution of the monomers used to form the superabsorbent
polymer. Other blowing agents can be adapted to the present
invention, including those known for polyolefin foam production,
such as organic nitrogen compounds (e.g., azodicarbonamide), sodium
bicarbonate and citric acid mixtures, sodium borohydride, and the
like.
[0147] A foam producing technology for use in the present invention
is the High-Internal-Phase-Ratio Emulsions (HIPE) technology
disclosed in U.S. Pat. No. 5,652,194, "Process for Making Thin-Wet
Absorbent Foam Materials for Aqueous Body Fluids," issued Jul. 29,
1997 to Dyer et al., herein incorporated by reference. As described
therein, collapsed polymeric foam materials can be typically
prepared by polymerizing a particular type of water-in-oil
emulsion. Such an emulsion is formed from a relatively small amount
of a polymerizable monomer-containing oil phase and a relatively
larger amount of a relatively monomer-free water phase. The
relatively monomer-free, discontinuous "internal" water phase thus
forms the dispersed droplets surrounded by the continuous
monomer-containing oil phase. Subsequent polymerization of the
monomers in the continuous oil phase forms the cellular foam
structure. The aqueous liquid remaining in the foam structure after
polymerization can be removed by pressing, thermal drying and/or
vacuum dewatering. Polymeric foams, including foams prepared from
water-in-oil emulsions, can be relatively closed-celled or,
preferably, relatively open-celled in character.
[0148] HIPE-type polymeric foams can be characterized as the
structures which result when a relatively monomer-free liquid is
dispersed as droplets or "bubbles" in a polymerizable
monomer-containing liquid, followed by polymerization of the
monomers in the monomer-containing liquid which surrounds the
droplets. For the purposes of the present invention, the fibers can
be dispersed in the continuous phase with a mixer or other method.
Upon polymerization, the fibers will trapped in the foam structure
forming a portion of the struts between the cells of the foam. The
fibers can help prevent collapse of the foam to maintain high
bulk.
[0149] The resulting polymerized dispersion can be in the form of a
porous solidified structure which is an aggregate of cells, the
boundaries or walls of which cells comprise solid polymerized
material. The cells themselves contain the relatively monomer-free
liquid which, prior to polymerization, had formed the droplets in
the liquid dispersion.
[0150] The oil phase of these HIPE emulsions comprises from about
67 to about 98% by weight of a monomer component having: (a) from
about 5 to about 40% by weight of a substantially water-insoluble,
monofunctional glassy monomer; (b) from about 30 to about 80% by
weight of a substantially water-insoluble. monofunctional rubbery
comonomer; (c) from about 10 to about 40% by weight of a
substantially water-insoluble polyfunctional crosslinking agent
component. The oil phase further comprises from about 2 to about
33% by weight of an emulsifier component that is soluble in the oil
phase and will provide a stable emulsion for polymerization. The
water or "internal" phase of these HIPE emulsions comprises an
aqueous solution containing from about 0.2 to about 20% by weight
of a water-soluble electrolyte. The weight ratio of the water phase
to the oil phase in these HIPE emulsions ranges from about 12:1 to
about 100:1. The polymerized foam is subsequently dewatered (with
or without prior washing/treatment steps) to provide the collapsed
foam material.
[0151] An important aspect of the process of the present invention
is to carry out the emulsion formation and polymerization steps in
a manner such that coalescence of the relatively small water
droplets formed in the HIPE emulsion is reduced. This leads to a
number averaged cell size in the resulting polymeric foam material
of about 50 microns or less. This reduction in coalescence can be
consistently achieved by the use of certain emulsifier systems, by
the use of lower temperatures during polymerization (curing), or
both, as described hereafter. Moreover, these thin, collapsed
absorbent polymeric foam materials can be consistently manufactured
according to the process of the present invention on a potentially
commercial scale, and at a potentially reasonable or low cost.
[0152] According to the present invention, it is not necessary to
collapse the foam-like structure involving paper fibers. Indeed,
the randomly oriented fibers can resist collapse and help the
high-bulk structure maintain its configuration when wetted,
particularly if wet-resilient fibers such as chemically
cross-linked fibers (e.g., cross-linked prior to incorporation into
a foam-like structure) or high-yield fibers are used.
[0153] Another useful foam preparation technique involves thermally
induced phase separation (TIPS) of polymer solutions. In this
technique, a polymer solution is quenched in order to induce phase
separation, either through liquid-liquid phase separation or
polymer crystallization.
[0154] When the TIPS process results in the formation of a
continuous polymer-rich phase, two additional processing steps can
lead to a foam. First, the morphology of the phase-separated
solution is preserved either through vitrification or
crystallization of the polymer. This step preserves the small-scale
morphology of the demixed solution. Next, the solvent is removed
through freeze-drying or supercritical extraction. The TIPS process
is a general method whose primary requirement is polymer
solubility. Low-density microcellular foams have been prepared with
TIPS using many different polymers, including atactic polystyrene,
isotactic polystyrene, poly(4-methyl-1-pentene), polyacrylonitrile,
and water-soluble polymers such as (carboxymethyl)cellulose,
poly(acrylic acid) and dextran. Water soluble polymers are
especially desirable because of their ability to maintain or
enhance the absorbent nature of the absorbent fibrous
structure.
[0155] Another known method for producing foams includes the use of
hollow sphere fillers, such as hollow microspheres or hollow
macrospheres, which occupy void spaces between the components of a
structural matrix. The shell of the hollow sphere is then broken by
mechanical forces such as compression or removed, producing an open
cell encompassing the volume previously occupied by the hollow
sphere prior to breaking or removal of the shell. Microspheres can
be about 10 microns to 1 mm in diameter and typically have a shell
thickness 1 to about 5 microns, while macrospheres have diameters
greater than about 1 mm. Hollow spheres are generally glass or,
desirably, polymeric materials which can be removed at least
partially by solvents or by heat degradation. Hollow spheres for
foam generation are described by F. A. Shutov in the chapter,
"Syntactic Polymer Foams" in Handbook of Polymeric Foams and Foam
Technology, ed. D. Klempner and K. C. Frisch, Hanser Publ., New
York, 1991, pp. 355 to 359.
[0156] It is emphasized that many approaches can be used to form a
fiber network having the structure of the present invention. The
foam-formation techniques could include any known in the art,
including the use of agitation or air injection with surfactants
and polymeric stabilizers followed by freeze-drying or other drying
methods, chemical foaming agents, addition of removable
foam-template cells (solids of prescribed size and/or size
distribution that can be removed from or shrink within a structure
after formation to leave void spaced between the fibrous struts;
removal can be by solvent extraction, sublimation, and other
techniques known in the art), etc.
[0157] The foamed mixture prior to drying and any subsequent curing
or heat setting steps can be formed, while still in a moldable
shape, into any desired form. For example, it can be used to
produce a high-bulk planar material, such as insulation or a slab
that can be subsequently cut to the desired size or shape for an
absorbent article, or it can be directly molded into a
three-dimensional shape suitable for a body-fitting element in an
absorbent articles or a section shaped for bowel movement
containment or adapted to fit into an article of clothing such as a
shoe, a helmet for sporting events, a sweat pad or sweat band, and
the like.
[0158] For production of continuous webs of absorbent fibrous
structure for use, many methods can be used. For example, large
high shear mixers could be used to produce foamed mixtures of
fibers and structuring composition, which could then be extruded,
expanded, coated, scraped, or poured onto a moving mesh or belt to
form an embryonic foamed web or foam layer. The foam layer can then
be molded or shaped into a desired thickness or contoured structure
by contact with a second moving web or moving contour elements
which slightly compresses the web. The web may be picked up by the
moving contour elements or remain on the original belt or wire,
after which it is cured or dried to completion, then cut as needed
or converted into rolls, stacks of sheets, or packaged groups of
absorbent fibrous structures.
[0159] An apparatus for the above-mentioned continuous process may
include any known mixer, such as rotary mixers, extrusion devices,
twin screw mixers, high shear mixers, stirrers, and the like, to
create a mixture of the fibers, either in a slurry or as dry
fibers, with a foamable structuring composition comprising a binder
material (said binder material can include precursor binder
materials which must be polymerized or reacted to be effective as
binders). The mixture is structured by foaming action and
transported to a movable belt or web, including planar webs and
textured webs or moving molding units, where it is deposited on the
belt or molding units. Desirably, there is no substantial drainage
of said structuring composition from said layer through the moving
belt or web. The deposited foamed layer is then dried and given
further treatments, if needed, to create water-insoluble bonds, in
a curing unit, which may be an oven, a radiation chamber (including
infrared, electron beams, ultraviolet light, and the like), a
chemical reaction chamber where gaseous or liquid reactants are
applied to effect curing, and the like.
[0160] In one embodiment, a dry, air-laid web of fiberized or
comminuted fluff pulp is first deposited on a moving belt to form a
mat. The mat is then impregnated with a structuring composition,
either in liquid form, which is subsequently converted to a foam
suitable for rearranging the fibers of the mat, or in the form of
an already created foam which penetrates into the fibrous mat and
further expands or swells or otherwise moves to provide new
structure to the fibrous mat. In any case, the addition of the
structuring composition by impregnation creates a mixture of fibers
and a structuring composition. The structuring composition
comprises a binder material which is cured by drying or other
treatments (e.g., heat treatment, chemical crosslinking, radiation,
etc.) applied to the mixture after the fibers have been physically
rearranged by action of the structuring composition. The removable
phase in this case is a gas, which may be carbon dioxide, air,
water vapor, a nitrogen compound, or other gases known in
foam-producing methods. The resulting absorbent fibrous structure
is preferably an expanded fibrous structure having higher bulk than
the fibrous mat prior to impregnation of the structuring
composition.
[0161] The apparatus for the above-mentioned method can include any
known devices for fiberizing or comminuting fibers, such as a
hammermill. Papermaking fibers or other hydrophilic fibers are
deposited by air into a fibrous mat onto a moving belt, which may
be porous to permit air flow through the belt for improved
deposition of a fibrous mat. An impregnating unit then applies a
foamable structuring composition to the mat. A headbox for foam or
other nozzles, scrapers, etc., may push the structuring composition
into the mat or it may be applied by a mister or spray device in
the air-laying chamber or unit as fibers are being deposited. The
structuring composition desirably expands after contact with the
fibers and before curing to restructure the fibers and desirably
expand the mat. The restructured fibrous mat then passes into a
curing unit, either on the belt onto which the mat was deposited or
after being removed from said belt and placed on another moving
surface. In the curing unit, water-insoluble bonds are formed from
the binder material in the structuring composition to create an
open, stable absorbent fibrous structure.
[0162] In producing a continuous foamed layer on a moving belt,
many operations known in the art of papermaking and nonwovens
processing may be used to create desired properties and structures,
and can be used to restructure the foam and the fibers into desired
forms. For example, there can be a finite velocity difference
between the moving belt and the foam as the foam is poured,
scraped, blown, extruded, brushed, flung, etc., onto the belt, to
cause desired anisotropy in the layer properties, the open cell
structure, the fiber orientation, and the like. Also, there can be
a non-zero impingement angle between a jet or stream of the foam
from a headbox, flow spreader, extruder, overflow weir, and the
like, as it discharges onto the moving belt or moving molding
device. The embryonic, semi-cured, or cured absorbent fibrous
structure can be subjected to differential velocity transfer,
wherein it is transferred from one moving belt to another belt or
fabric with a finite velocity difference. When the transfer is done
with rush, i.e., the second belt or fabric is moving at a lower
velocity than the first moving belt, the material is foreshortened
and is imparted with increased stretch in the machine direction.
Transfer to a faster moving belt can be used to stretch out the
embryonic semi-cured, or cured absorbent fibrous structure. The
absorbent fibrous structure can also be creped to modify texture,
impart stretch, increase flexibility, and the like. The absorbent
fibrous structure can also be embossed, scored, and the like,
either in its dried or cured state, or before drying and curing is
complete.
[0163] An absorbent fibrous structure can be made extensible in one
or more in-plane directions, and desirably elastically extensible
in one or more in-plane directions, by molding the structure to
impart a texture or macroscopic structure capable or stretch, such
as a sine wave or a pleat-like structure. The use of an elastomeric
binder is desirable in creating elastic extensibility in the
article. In addition to molding, mechanical processes can further
impart extensibility, with exemplary processes including rush
transfer, creping, foreshortening or in-plane compaction to create
pleating, crepe folds, or accordion-like structures in the plane,
or aperturing or slitting to create opening that can elongate when
stretched. The absorbent fibrous structure can also be laminated
with elastomeric or stretchable materials.
[0164] In the production of absorbent articles comprising
extensible, stretchable, or elastically extensible absorbent
fibrous structures, other components such as the topsheet or
backsheet can be made extensible or stretchable by suitable molding
(thermal molding or vacuum molding, for example) or by performing a
mechanical operation, such as pleating, corrugating, stamping, or
ring rolling on the topsheet material to provide folds in the
material that are able to open when the topsheet is stretched.
Apertures and slits can also provide extensibility when stretched.
Lamination with elastomer films, elastic bands or threads,
stretchable creped tissue, or other stretchable components. Such
processes can be performed on many of the topsheet materials and
coversheet materials kown in the art for production of absorbent
articles for absorbing body fluids.
[0165] A continuous web of an absorbent fibrous structure can be
molded, shaped or cut into desired shapes for use in absorbent
articles. Cutting of the embryonic, semi-cured, or cured absorbent
fibrous structure can be done with hydraulic jets, air knives, dies
and stamps, metal blades or saws, lasers, and the like. The
absorbent fibrous structure can be laminated, joined to, or coupled
with elastomeric films or threads, plastic films including
apertured films, nonwoven webs such as spunbond or meltblown
layers, airlaid materials, creped or uncreped tissue webs, coform
composite material, superabsorbent materials and fibers,
biodegradable webs, laminated structures, other foam layers,
including open cell and closed cell foams and reticulated open cell
webs, textiles such as cotton webs, fluff pulp mats, activated
carbon materials, and the like, using methods known for high-speed
assembly of absorbent articles.
[0166] In the continuous or batch production of absorbent fibrous
structures, the structure can be imparted with a nonuniform basis
weight or thickness distribution during formation, as by laying
down a foamed structure with varying basis weight onto a moving
belt, or by depositing the embryonic absorbent fibrous structure
onto a molded or textured substrate surface that receives differing
amounts during deposition or after a scraping or leveling process
has removed excess material above a plane over the molded
substrate. Alternatively, a three-dimensional mass or thickness
distribution can be achieved later, including after curing or
drying, by removal of unwanted material as by cutting or pneumatic
removal of selected portions. Thickness can be varied nonuniformly
by pressing or embossing against nonuniform surfaces.
[0167] Gradients in material properties such as cell size or
porosity can be achieved with a variety of methods. In some
embodiments, a foaming material under the influence of gravity or
other body forces will tend to have large bubbles or pores form on
one surface. A skin may also form on a surface when a foamed
structure is dried or cured adjacent to a solid surface such as a
belt, thus creating a gradient in properties. Two or more foamed
layers may be combined into a single stratified layer, as by
deposition from a layered headbox or by use of separate flow
spreaders or extruders, to yield an absorbent fibrous structure
having different porosities and material properties in each layer,
such as one stratum containing softwood and another stratum
containing hardwood fibers, or one stratum having a more wettable
(more hydrophilic) binder material than the other strata, or one
stratum comprising swellable materials unlike the other strata. For
a single, non-stratified layer of an absorbent fibrous structure,
steps taken to dry or cure the structure frequently expose one side
or surface to different conditions than other portions of the
layer, resulting in potential gradients in properties. For example,
activation of blowing agents by heat treatment or exposure to a
gaseous reagent can result in a gradient in bubbles when the
exposure is primarily directed at an exposed surface of the layer
while the other surface of the layer rests on a moving belt or
other surface. Pressing a heated surface against an absorbent
fibrous structure can also preferentially densify or modify one
side of the structure. Piercing, lancing, embossing, brushing, and
other mechanical treatments can be done to establish other
gradients either in the plane or in a thickness direction by
selective application of the extent and depth of treatment.
CROSSLINKED POLYMERS AS THE BINDER MATERIAL
[0168] Crosslinked polymers represent a useful class of binder
materials suitable for the present invention. Crosslinking may be
performed on water-soluble polymers to render them insoluble, for
example, and can be particularly useful in the production of
freeze-dried materials and other embodiments of the present
invention. Crosslinking of the polymer may generally occur either
while the polymer is in solution or after the solvent has been
removed from the solution used to prepare the absorbent foam. Such
crosslinking of the polymer may generally be achieved by either of
two different types of crosslinking agents. Such crosslinking
agents will generally be soluble in the solvent being used, such as
water.
[0169] One type of crosslinking agent is a latent crosslinking
agent. Suitable latent crosslinking agents are generally either
internal latent crosslinking agents or external latent crosslinking
agents. An internal latent crosslinking agent is generally
copolymerizable to the monomer or monomers used to prepare the
polymer and, thus, generally comprise at least one vinyl group and
one functional group or functionality that is capable of reacting
with the side groups on the base polymer, such as a carboxyl group
(--COO.sup.-) on a sodium polyacrylate polymer or a carboxylic acid
group (--COOH) on a polyacrylic acid polymer. Examples of suitable
copolymerizable crosslinking agents include ethylenically
unsaturated monomers, such as ethylene glycol vinyl ether and amino
propyl vinyl ether.
[0170] An external latent crosslinking agent generally crosslinks
the polymer itself after, for example, the polymer has been formed
from the monomer or monomers used to prepare the polymer and/or the
polymer has been mixed with a solvent to form a solution. Latent
crosslinking agents generally do not take part in the overall
polymerization process but, instead, are reactive to the polymer at
a later point in time when a proper crosslinking condition is
provided. Suitable post treatment conditions include using heat
treatment, such as a temperature above about 60.degree. C.,
exposure to ultraviolet light, exposure to microwaves, steam or
high humidity treatment, high pressure treatment, or treatment with
an organic solvent. For heat-treatment in general, best results can
require a temperature between about 50.degree. C. to about
250.degree. C., more specifically from about 80.degree. C. to about
250.degree. C., more specifically still from about 100.degree. C.
to about 200.degree. C., and most specifically from about
100.degree. C. to about 160.degree. C.
[0171] Suitable external latent crosslinking agents are any organic
compound having at least two functional groups or functionalities
capable of reacting with the carboxyl, carboxylic acid, amino, or
hydroxyl groups of a polymer. It is desired that such an organic
crosslinking agent be selected from the group consisting of
diamines, polyamines, diols, and polyols and mixtures thereof;
particularly from the group consisting of primary diols, primary
polyols, primary diamines and primary polyamines and mixtures
thereof. Of the diols and polyols, those possessing longer, such as
4 or greater, carbon chain lengths are generally beneficial.
Specifically, the crosslinking agent may be selected from the group
consisting of chitosan glutamate, type A gelatin,
diethylenetriamine, ethylene glycol, butylene glycol, polyvinyl
alcohol, hyaluronic acid, polyethylene imine and their derivatives
and mixtures thereof. Other suitable organic crosslinking agents
include monochloroacetic acid, sodium chloroacetate, citric acid,
butane tetracarboxylic acid, and amino acids such as aspartic acid,
and mixtures thereof. Citric acid can be especially desirable in
promoting crosslinking and wet resiliency when combined with
cellulose and/or cellulose derivatives such as CMC, and then
treated at elevated temperature. Another suitable latent
crosslinking agent comprises a metal ion with more than two
positive charges, such as Al.sup.3+, Fe.sup.3+, Ce.sup.3+,
Ce.sup.4+, Ti.sup.4+, Zr.sup.4+, and Cr.sup.3+. Suitable metal ion
crosslinking agents include those of the transition elements which
generally have vacant d-orbitals. Suitable metal ion crosslinking
agents include AlCl.sub.3, FeCl.sub.3, Ce.sub.2(SO.sub.4).sub.3,
Zr(NH.sub.4).sub.4(CO.sub.3).sub.4 and
Ce(NH.sub.4).sub.4(SO.sub.4).sub.4.2H.sub.2O, other well known
metal ion compounds and mixtures thereof. Such metal ion
crosslinking agents, when used with a particular polymer, are
believed to form ionic bonds with the carboxyl, carboxylic, amino,
or hydroxyl groups on the polymer. Metal ions with only two
positive charges, such as Zn.sup.2+, Ca.sup.2+, or Mg.sup.2+, are
also suitable as crosslinking agents for certain polymers.
[0172] When the polymer is a cationic polymer, a suitable
crosslinking agent is a polyanionic material such as sodium
polyacrylate, carboxymethyl cellulose, or polyphosphate.
[0173] A second type of crosslinking mechanism that certain
polymers are able to undergo involves a macromolecular
rearrangement of the chains of the polymer during the
solidification process of the polymer such that the polymer forms a
higher ordered structure with a high degree of crystallinity which
is generally water insoluble. Polymers suitable to such a
crosslinking approach include, but are not limited to, polyvinyl
alcohol, chitosan, and carboxymethyl cellulose with a lower degree
of carboxymethylation. Additional strong bonding of the polymer
could be established between the polymer chains during the
solidification process which could result in a generally water
insoluble material. An example of this behavior is the strong
hydrogen bonding in polyvinyl alcohol forming an insoluble
material. A closely related behavior is the formation of hard and
soft segments in water soluble polyurethane materials which makes
them water swellable but water insoluble.
[0174] Suitable crosslinking agents for a polymer solution gel
process are also generally of two different types: either internal
polymerizable or external crosslinking agent. The first type of
crosslinking agent is a polymerizable but instant crosslinking
agent. Suitable polymerizable crosslinking agents are generally
reactive to the monomer or monomers used to prepare the polymer
and, thus, generally comprise at least two functional groups or
functionalities that are capable of reacting with the monomers.
Examples of suitable polymerizable crosslinking agents include
ethylenically unsaturated monomers, such as N,N'-methylene
bis-acrylamide for free radical polymerization, and polyamines or
polyols for condensation polymerization. The second type of
crosslinking agent is a reactive compound having at least two
functional groups or functionalities capable of reacting with the
carboxyl, carboxylic acid, amino, or hydroxyl groups of a polymer
in the solution stage wherein such crosslinking is not latent, in
that no additional conditions are needed to initialize the
crosslinking reaction. Suitable crosslinking agents may be selected
from the group consisting of aldehydes, such as glutaraldehyde, or
glycidyl ethers, such as polyethylene gylcol diglycidyl ether.
[0175] Another approach to form a crosslinked polymer network in
either a polymer solution or on a recovered polymer is the use of a
high energy treatment such as electron beam radiation or microwave
radiation to form free radicals in the polymer which are then used
to generate crosslinking points. This approach is applicable but
not limited to instances where a crosslinking agent is not used to
prepare the absorbent foam.
[0176] If a crosslinking agent is used, it is generally desired
that the crosslinking agent be used in an amount that is
beneficially from about 0.01 weight percent to about 20 weight
percent, more beneficially from about 0.05 weight percent to about
10 weight percent, and suitably from about 0.1 weight percent to
about 5 weight percent, based on the total weight of the polymer
and the crosslinking agent present in an absorbent foam.
[0177] In general, a crosslinking catalyst will not be needed, but
may be beneficial, to assist in the crosslinking of the polymer in
order to prepare the absorbent foam of the present invention. For
example, if citric acid is used as the crosslinking agent, sodium
hypophosphite is beneficially used as a crosslinking catalyst. If a
crosslinking catalyst is used, it is generally desired that the
crosslinking catalyst be used in an amount of from about 0.01 to
about 3 weight percent, suitably from about 0.1 to about 1 weight
percent, based on the total weight of the polymer used.
DEFINITION OF TERMS AND TEST PROCEDURES
[0178] "Foams" are two-phase gas-solid systems that have a
supporting solid lattice of cell walls that are continuous
throughout the structure. The gas (typically air) phase in a foam
is usually distributed in void pockets often called cells.
"Open-cell foams" are polymeric materials having substantial void
space in the form of cells defined by a plurality of mutually
connected, three dimensionally branched webs of polymeric material,
wherein the cells typically have openings to permit fluid
communication from one cell to another. In other words, the
individual cells of the foam are for the most part not completely
isolated from each other by the polymeric material of the cell
walls. Thus the cells in such substantially open-celled foam
structures have intercellular openings or "windows" which are large
enough to permit ready fluid transfer from one cell to the other
within the foam structure. The open-cell foams useful in the
present invention generally have a reticulated character. The
strands of polymeric material which make up the branched webs of
the open-cell foam structure can be referred to as "struts."
Sponge-like materials with interconnected cells are an example of
open-celled foams.
[0179] For purposes of the present invention, a foam material is
"open-celled" if at least 80% of the cells in the foam structure
that are at least 1 micron size are in fluid communication with at
least one adjacent cell. Alternatively, a foam material can be
considered to be substantially open-celled if it has a measured
available pore volume that is at least 80% of the theoretically
available pore volume. In the case of HIPE foams, the theoretically
available pore volume can be determined by the water-to-oil weight
ratio of the HIPE emulsion from which the foam material is
formed.
[0180] "Frazier permeability" is measured as standard cubic feet
per minute of air flow per square foot of material with an air
pressure differential of 0.5 inches of water across the sample. The
sample should be substantially planar for a Frazier permeability
test and should have a basis weight of about 30 gsm. The materials
of the present invention can have Frazier permeabilities of about
50 cfm or above, more specifically about 100 cfm or above, still
more specifically about 200 cfm or above, and most specifically
about 400 cfm or above, with an exemplary range of from about 75
cfm to about 1100 cfm.
[0181] As used herein, an absorbent fibrous structure is "open" if
the structure has continuously connected void spaces that allow gas
to pass through the sample from at least one surface to an opposing
surface.
[0182] As used herein, an open-cell foam structure or absorbent
fibrous structure has "bimodal pores" if there are at least two
distinct classes of pores, a first class comprising cells with
boundaries defined by fibrous struts, and a second class defining
the smaller pores between neighboring fibers. In other words, the
distribution of fibers in the absorbent fibrous structure is not
uniform throughout the space of the material, such that distinct
cells having no or relatively few fibers can be defined in
distinction to the pore spaces between neighboring or touching
fibers. Thus, the fibers are preferentially distributed along what
may be termed the walls or windows of apparent former bubbles. The
absorbent fibrous structures of the present invention can have
bimodal pores and heterogeneous distribution of fibers, though
certain embodiments, such as those produce by freeze drying, can
show relatively high degrees of spatial uniformity in the
distribution of the fibers and thus lack a bimodal pore
distribution as defined herein. This definition of bimodal pores
does not consider the micropores within the fibers themselves.
[0183] As used herein, an absorbent fibrous structure is "flexible"
if it meets a modified flexibility test based on the flexibility
tests for various foams provided by the American Society for
Testing and Materials (ASTM). Specifically, a flexible foam is one
that does not rupture when a 20.times.2.5.times.2.5 cm piece is
wrapped around a 2.5 cm mandrel at a uniform rate of 1 lap/5
seconds at 20 degrees Centigrade. "Rigid" foams are those which
rupture in the above-mentioned test. Absorbent fibrous structures
of the present invention can be either flexible or rigid, with
flexible foams being desirable for some body fit applications in
certain absorbent articles.
[0184] As used herein, "wet flexibility" is determined by a
modified form of the foam flexibility test procedure given in the
ASTM D 3574-86, 3.3 test used to determine flexibility of cellular
organic polymeric foam products. Such a modified test utilizes an
absorbent fibrous structure sample which is 7.times.0.8..times.0.8
cm and which has been saturated to its free absorbent capacity with
commercially available a saline solution such as S/P certified
blood bank saline (Stephens Scientific of Riverdale, N.J.,
distributed by Baxter Healthcare of McGraw Park, Ill., under
catalog #B3158-1) at 37.degree. C. It is important that the cutting
process used to make these samples does not introduce edge defects
in the strip. The saturated absorbent fibrous structure strip is
bent around a 2.5 cm diameter cylindrical mandrel at a uniform rate
of 1 lap in 5 seconds. The absorbent fibrous structure is
considered flexible if it does not tear or break during this test,
i.e., if it passes one bending cycle, then the material is wet
flexible.
[0185] As used herein, an "expanded fibrous structure" is an
absorbent fibrous structure according to the present invention
having greater macroscopic volume than the initial mixture of
fibers and structuring composition. By virtue of having greater
volume, the void volume will also tend to be significantly greater
in the expanded fibrous structure than in the initial mixture of
the fibers and the structuring composition. The volume of the
expanded fibrous structure can be greater than the volume of the
initial mixture by about 10% or greater, more specifically by about
100% or greater, more specifically still about 200% or greater, and
most specifically by about 50% to about 1000%. By way of
illustration, the macroscopic volume can typically be taken as the
volume that would be defined by a film shrink-wrapped around the
article without compacting the article. For further specificity, if
there is any reason for those skilled in the art to be unable to
identify the approximate point in time when an "initial mixture"
exists in determining whether an absorbent fibrous structure is an
expanded fibrous structure, "initial mixture" should then refer to
the mixture created within the first 3 seconds of mixing contact
between the structuring composition and the hydrophobic fibers.
[0186] As used herein, "Polymer foams" are materials made by
generating void spaces inside a bulk polymer, resulting in
substantially reduced density. They can be open-celled or
closed-celled. The nature of these cells and the cell size
determine many properties of the polymer. For example, light weight
and low thermal conductivity are the typical properties of a
conventional foam. The density of conventional polystyrene foam is
in the range of 0.02-0.2 g/cc with closed cells between 50-100
.mu.m in diameter.
[0187] As used herein, "critical density" refers to the density at
which a fibrous mat or pad will neither collapse nor expand when
fully saturated with deionized water at 73.degree. F. For
papermaking fibers, the critical density is generally quoted as 0.2
grams/cc but actually ranges from about 0.17 to 0.25 grams/cc,
which is generally higher than the typical density of foams.
Wet-laid paper sheets tend to have densities near the critical
density. The absorbent fibrous structures of the present invention
generally are produced at an initial density well below the
critical density, such that the critical density is at least 2, 4,
6, 10, 20, or 30 times greater than the dry absorbent fibrous
structure density. However, after calendering or other forms of
mechanical compression, the density of the absorbent fibrous
structure can approach the critical density or be above it, such
that the density of the compressed absorbent fibrous structure can
be greater than the critical density by a factor of about 1.2 or
greater, more specifically 1.5 or greater, and more specifically
still about 2 or greater.
[0188] "Dry binder material mass fraction" is the oven-dry mass of
the structuring composition divided by the combined mass of the
oven-dry structuring composition and the dry fibers used to produce
an absorbent fibrous structure. In this context, "oven dry" means
that the article or material being weighed has been dried at
105.degree. C. for at least 20 minutes such that substantially all
of the removal moisture has been driven off. The absorbent fibrous
structures of the present invention can have a dry binder material
mass fraction of about 0.8 or less, specifically about 0.6 or less,
more specifically about 0.5 or less, more specifically still about
0.3 or less, and most specifically about 0.1 or less.
[0189] As used herein, "biodegradable" refers to the ability of a
compound to ultimately be degraded completely into carbon dioxide
and water or biomass by microorganisms and/or natural environmental
factors.
[0190] As used herein, the term "hydrophobic" refers to a material
having a contact angle of water in air of at least 90 degrees. In
contrast, as used herein, the term "hydrophilic" refers to a
material having a contact angle of water in air of less than 90
degrees. For the purposes of this application, contact angle
measurements are determined as set forth in Robert J. Good and
Robert J. Stromberg, Ed., in "Surface and Colloid Science
Experimental Methods," Vol. II, (Plenum Press, 1979), herein
incorporated by reference. The absorbent fibrous structures of the
present invention are generally hydrophilic as prepared and
therefore generally do not require any subsequent treatment to make
them hydrophilic. This is in contrast to many absorbent foams known
in the art in which the polymeric material of the foam is not
inherently hydrophilic.
[0191] As used herein, the term "surfactant" includes a single
surfactant or a mixture of two or more surfactants. If a mixture of
two or more surfactants is employed, the surfactants may be
selected from the same or different classes, provided only that the
surfactants present in the mixture are compatible with each other.
In general, the surfactant can be any surfactant known to those
having ordinary skill in the art, including anionic, cationic, and
nonionic surfactants. Examples of anionic surfactants include,
among others, linear and branched-chain sodium
alkylbenzenesulfonates, linear and branched-chain alkyl sulfates,
and linear and branched-chain alkyl ethoxy sulfates. Cationic
surfactants include, by way of illustration, tallow
trimethylammonium chloride. Examples of nonionic surfactants,
include, again by way of illustration only, alkyl polyethoxylates;
polyethoxylated alkylphenols; fatty acid ethanol amides; and
complex polymers of ethylene oxide, propylene oxide, and
alcohols.
[0192] As used herein, "binder wet strength:dry strength ratio" of
a binder material is the ratio of wet tensile strength to dry
tensile strength in a fibrous material wherein the fibers are
joined solely by the binder material. The wet tensile strength is
measured after a sample has been fully wetted with water for 2
minutes and is then divided by the tensile strength of the Tappi
conditioned dry sample. A binder that is not attacked, swollen,
chemically altered or solubilized by water presumably has a binder
wet strength:dry strength ratio of essentially 1.0
[0193] As used herein, "noncompressive drying" refers to drying
methods for drying cellulosic webs that do not involve compressive
nips or other steps causing significant densification or
compression of a portion of the web during the drying process. Such
methods include through-air drying; air jet impingement drying;
non-contacting drying such as air flotation drying, through-flow or
impingement of superheated steam; microwave drying and other
radiofrequency or dielectric drying methods; water extraction by
supercritical fluids; water extraction by nonaqueous, low surface
tension fluids; infrared drying; and other methods.
[0194] "Absorbency Under Load" (AUL) is a measure of the liquid
retention capacity of a material under a mechanical load. It is
determined by a test which measures the amount in grams of an
aqueous solution, containing 0.9 weight percent sodium chloride, a
gram of a material can absorb in 1 hour under an applied load or
restraining force of about 0.3 pound per square inch.
[0195] The AUL apparatus comprises a Demand Absorbency Tester (DAT)
as described in U.S. Pat. No. 5,147,343, issued Sep. 15, 1992 to
Kellenberger, herein incorporated by reference, which is similar to
a GATS (Gravimetric Absorbency Test System), available from M/K
Systems, Danners, Mass. A level porous plate is used having ports
confined within a 2.5 cm. diameter area to provide liquid saline
solution, 0.9 (w/w) % NaCl, delivered from a reservoir to the
porous plate such that there is no hydraulic head (neither positive
pressure nor suction) at the top of the porous plate. Thus, fluid
can be absorbed into the absorbent without overcoming a significant
capillary pressure barrier to move liquid out of the porous plate.
Fluid absorbed from the plate is replaced with liquid from the
reservoir, which resides on an electronic balance that measures the
amount of liquid removed from the reservoir and absorbed into the
absorbent. The sample on the porous plate resides within a section
of one-inch (2.54 cm) inside diameter thermoplastic tubing
machined-out slightly to be sure of concentricity. 100 mesh
stainless steel wire cloth is fused on the bottom of the cylinder
to restrain the sample and any particulates therein. Care must be
taken to maintain a flat smooth bottom and not distort the inside
of the cylinder. A 4.4 g piston is made from one inch diameter
solid material (e.g., Plexiglas) and is machined to closely fit
without binding in the cylinder. A standard 100 gm weight placed on
the piston is used to provide a 21,000 dyne/sq.cm. (about 0.3 psi)
restraining load which is commonly experienced in infant diapers.
To carry out the test with a foam-like fibrous material or a foam,
a material sample is cut into circular discs with a diameter
slightly smaller than one inch to freely fit within the sample
tube. The sample mass should be from about 0.05 g to about 0.16
g.
[0196] This test is initiated by placing a 3 cm diameter GF/A glass
filter paper onto the porous plate (the paper is sized to be larger
than the inner diameter and smaller than the outer diameter of the
cylinder), to insure good contact while eliminating evaporation
over the ports of the DAT and then allowing saturation to occur.
The material to be tested is placed on the wire cloth at the bottom
of the AUL apparatus. The sample is then covered with a plastic
spacer disc, weighing 4.4 grams and having a diameter of about
0.995 inch, which serves to protect the sample from being disturbed
during the test and also to uniformly apply a load on the entire
sample. After carefully placing the piston and weight on the sample
in the cylinder, the AUL apparatus is placed on the glass filter
paper. The amount of fluid pick-up is monitored as a function of
time either directly by hand, with a strip chart recorder or
directly into a data acquisition system.
[0197] The amount of fluid pickup measured after one hour is the
AUL value, expressed as grams of liquid per dry gram of the tested
material.
[0198] The AUL of the materials of the present invention can be
above 6 grams/gram, more specifically about 10 grams/gram or
greater, still more specifically about 15 grams/gram or greater,
and most specifically about 25 grams/gram or greater, with an
exemplary range of from about 9 to about 40 grams/gram. While high
AUL values can be achieved without the additional of superabsorbent
material or swellable binder material, especially high values of
AUL are possible through incorporation of superabsorbent material
into the absorbent fibrous structure. Superabsorbent material can
be incorporated as loose particulates, particles bound to the
hydrophilic fibers, superabsorbent fibers, or as a component of the
binder material or structuring composition.
[0199] As used herein, "Free Swell Capacity" (FS) is the result of
a test which measures the amount in grams of an aqueous solution,
containing 0.9 weight percent sodium chloride, that a gram of a
material can absorb in 1 hour under negligible applied load. The
test is done as described above for the AUL test, except that the
100 gm weight is not placed on the sample.
[0200] The Free Swell Capacity of the materials of the present
invention can be above 8, more specifically above 10, more
specifically above 20, and most specifically above 30
grams/gram.
[0201] As used herein, "Free Swell:AUL Ratio" is the ratio of Free
Swell Capacity to AUL. It will generally be greater than one. The
higher the value, the more sensitive the material is to compressive
load, meaning that the sample is less able the sample is to
maintain its potential pore volume and capillary suction potential
under load. Desirably, the materials of the present invention have
"Free Swell:AUL Ratio" of about 4 or less, more specifically about
2 or less, more specifically still about 1.5 or less, and more
specifically about 1.3 or less, with an exemplary range of from
about 1.2 to about 2.5.
[0202] "Cell Pore Size" and "Cell Wall Thickness" are measures of
the characteristic size of a cell in a foam (or absorbent fibrous
structure) and of the thickness of the wall between adjoining
cells, respectively. In making such measurements, a sample is cut
by a sharp razor. The cut foam is attached to metal stubs using
copper tape and imaged in an environmental scanning electron
microscope using 12 kV beam voltage (model E-2020 from Electroscan
Corporation of Wilmington, Mass. or a similar instrument). The
sample chamber pressure is about 1.2 Torr. The environmental
backscatter electron detector is used to collect images, having the
advantage of being able to discern any variations in composition.
Magnification varies depending on the scale of the subject sample,
with a 150 magnification being preferred for a general survey of
the sample and a 2500 magnification to measure cell wall thickness
and cell size. Cell wall thickness and cell size measurements are
taken directly on the environmental scanning electron microscope.
Manual measurement of cell wall thickness measurement is used. The
cell wall thickness and cell size of each sample are averaged from
at least 20 measurements.
[0203] "Papermaking fibers," as used herein, include all known
cellulosic fibers or fiber mixes comprising cellulosic fibers.
Fibers suitable for making the webs of this invention comprise any
natural or synthetic cellulosic fibers including, but not limited
to: nonwoody fibers, such as cotton, abaca, kenaf, sabai grass,
flax, esparto grass, straw, jute hemp, and bagasse, milkweed floss
fibers, and pineapple leaf fibers; and woody fibers such as those
obtained from deciduous. and coniferous trees, including softwood
fibers, such as northern and southern softwood kraft fibers;
hardwood fibers, such as eucalyptus, maple, birch, aspen, or the
like. Woody fibers can be prepared in high-yield or low-yield forms
and can be pulped in any known method, include kraft, sulfite,
groundwood, TMP, RMP, CTMP, BCTMP, and other known pulping methods.
If bleached, any known bleaching method can be used. Synthetic
cellulose fiber types include rayon in all its varieties and other
fibers derived from viscose or chemically modified cellulose.
Chemically treated natural cellulosic fibers can be used such as
mercerized pulps, chemically stiffened or crosslinked fibers,
sulfonated fibers, and the like. For good mechanical properties in
using papermaking fibers, it is often desirable that the fibers be
relatively undamaged and largely unrefined or only lightly refined.
While recycled fibers can be used, virgin fibers are generally
desirable for their mechanical properties and lack of contaminants.
Mercerized fibers, regenerated cellulosic fibers, cellulose
produced by microbes, rayon, and other cellulosic material or
cellulosic derivatives can be used. Suitable papermaking fibers can
also include recycled fibers, virgin fibers, or mixes thereof. In
certain embodiments capable of high bulk and good compressive
properties, the fibers can have a Canadian Standard Freeness of at
least 200, more specifically at least 300, more specifically still
at least 400, and most specifically at least 500.
[0204] As used herein, "high yield pulp fibers" are those
papermaking fibers of pulps produced by pulping processes providing
a yield of about 65 percent or greater, more specifically about 75
percent or greater, and still more specifically from about 75 to
about 95 percent. Yield is the resulting amount of processed fiber
expressed as a percentage of the initial wood mass. High yield
pulps include bleached chemithermomechanical pulp (BCTMP),
chemithermomechanical pulp (CTMP) pressure/pressure
thermomechanical pulp (PTMP), thermomechanical pulp (TMP),
thermomechanical chemical pulp (TMCP), high yield sulfite pulps,
and high yield Kraft pulps, all of which contain fibers having high
levels of lignin. Characteristic high-yield fibers can have lignin
content by mass of about 1% or greater, more specifically about 3%
or greater, and still more specifically from about 2% to about 25%.
Likewise, high yield fibers can have a kappa number greater than
20, for example. The preferred high yield pulp fibers, after being
prepared by pulping and optional bleaching steps and prior to being
formed into dry bales or webs, in one embodiment can also be
characterized by being comprised of comparatively whole, relatively
undamaged fibers, high freeness (200 Canadian Standard Freeness
(CSF) or greater, more specifically 250 CSF or greater, and still
more specifically 400 CSF or greater), and low fines content (less
than 25 percent, more specifically less than 20 percent, still more
specifically less that 15 percent, and still more specifically less
than 10 percent by the Britt jar test). In one embodiment, the
high-yield fibers are preferably predominately softwood, more
preferably northern softwood, and most preferably northern softwood
BCTMP.
[0205] As used herein, the term "cellulosic" is meant to include
any material having cellulose as a major constituent, and
specifically comprising at least 50 percent by weight cellulose or
a cellulose derivative. Thus, the term includes cotton, typical
wood pulps, cellulose acetate, cellulose triacetate, rayon,
thermomechanical wood pulp, chemical wood pulp, debonded chemical
wood pulp, milkweed, bacterial cellulose, and the like.
[0206] "Water retention value" (WRV) is a measure that can be used
to characterize some fibers useful for purposes of this invention.
WRV is measured by dispersing 0.5 gram of fibers in deionized
water, soaking overnight, then centrifuging the fibers in a 1.9
inch diameter tube with a 100 mesh screen at the bottom at 1000 G
for 20 minutes. The samples are weighed, then dried at 105.degree.
C. for two hours and then weighed again. WRV is (wet weight--dry
weight)/dry weight. Fibers useful for purposes of this invention
can have a WRV of about 0.7 or greater, more specifically from
about 1 to about 2. High yield pulp fibers typically have a WRV of
about 1 or greater.
[0207] As used herein, "Absorbent Capacity" refers to the amount of
distilled water that an initially 1-inch cube of absorbent fibrous
material can absorb while in contact with a pool of
room-temperature water and still retain after being removed from
contact with the pool of liquid water and held on a metal screen
and allowed to drip for 30 seconds. Absorbent capacity is expressed
as grams of water held per gram of dry fiber. The structures of the
present invention have absorbent capacity values of about 5 g/g or
greater, preferably about 7 g/g or greater, more preferably from
about 8 g/g to about 15 g/g, and most preferably about 9 g/g or
greater.
[0208] As used herein, "bulk" and "density," unless otherwise
specified, are based on oven-dry mass of a sample and a thickness
measurement made at a load of 0.05 psi with a three-inch diameter
circular platen. Thickness measurements of samples are made in a
Tappi conditioned room (50% RH and 73.degree. F.) after
conditioning for at least four hours. Samples should be essentially
flat and uniform under the area of the contacting platen. Bulk is
expressed as volume per mass of fiber in cc/g and density is the
inverse, g/cc.
[0209] As used herein, "Wet Bulk" is based on a caliper measurement
of a sample according to the definition of "bulk" above (at 0.05
psi), except that the conditioned sample is uniformly misted with
deionized water until the moistened mass of the sample is
approximately 250% of the dry mass of the sample (i.e., the added
mass of the moisture is 150% of the dry sample weight). If the
sample cannot absorb and retain enough moisture from misting to
increase the mass by 150%, then the highest level of achievable
moisture add-on below 150% but still above 100% moisture add on
should be used. The Wet Bulk is calculated as the thickness of the
substantially planar moistened sample under a load of 0.05 psi
divided by the oven-dry sample basis weight in g/cc. Absorbent
fibrous structures of the present invention can have a Wet Bulk of
about 6 cc/g or greater, more specifically about 8 cc/g or greater,
more specifically still about 10 cc/g or greater, more specifically
still about 15 cc/g or greater, and most specifically about 20 cc/g
or greater, with an exemplary range of from about 13 cc/g to about
35 cc/g.
[0210] As used herein, a material will be considered to be "water
soluble" when it substantially dissolves in excess water to form a
solution, thereby losing its initial form and becoming essentially
molecularly dispersed throughout the water solution. As a general
rule, a water-soluble material will be free from a substantial
degree of crosslinking, as crosslinking tends to render a material
water insoluble. A material that is "water insoluble" is one that
is not water soluble according to the above definition.
[0211] As used herein, the term "water-swellable, water-insoluble"
is meant to refer to a material that, when exposed to an excess of
water, swells to its equilibrium volume but does not dissolve into
the water. As such, a water-swellable, water-insoluble material
generally retains its original identity or physical structure, but
in a highly expanded state, during the absorption of the water and,
thus, must have sufficient physical integrity to resist flow and
fusion with neighboring materials.
[0212] As used herein, the term "solvent" is intended to represent
a substance, particularly in a liquid form, that is capable of
dissolving a polymer used herein to form a substantially uniformly
dispersed mixture at the molecular level. For freeze-drying
embodiments, the solvent used in the mixture of fibers and
structuring composition needs to be capable of first freezing and
then be capable of undergoing sublimation, wherein the solvent
passes directly from its frozen state to a vapor state. As such,
the solvent should have a freezing point at which the solvent
changes from a liquid to a solid.
[0213] As used herein, a "Portion" of an element represents any
non-zero fraction of that element including all of the element.
Thus, a portion of the removable phase could be, by way of example,
1%, 5%, 10%, 50%, 90%, or 100% of the removable phase. A portion of
a composition having multiple elements could include differing
fractions for each element. Thus, by way of example, a portion of a
structuring composition comprising surfactant, wet strength resin,
starch, and water could be a mixture containing varying amounts of
all four ingredients or could be a mixture of just a subset of the
ingredients, such as starch, water, and surfactant.
[0214] The term "extensible", as used herein refers to articles
that can increase in at least one of their dimensions in the x-y
plane. The x-y plane is a plane generally parallel to the faces of
the article. The term extensible includes articles that are
stretchable and elastically stretchable (defined below). In the
case of a sanitary napkin comprising an absorbent fibrous structure
as an absorbent core or as an intake layer or surge material, for
example, the article and the absorbent fibrous structure are
desirably extensible both in length and width. The absorbent
article, however, may only be extensible in one of these
directions. Preferably, the article is extensible at least in the
longitudinal direction.
[0215] The absorbent article comprising an absorbent fibrous
structure or the absorbent fibrous structure can, in addition to
being extensible, also be stretchable. The term "stretchable", as
used herein, refers to articles that are extensible when stretching
forces are applied to the article and offer some resistance to
stretching.
[0216] An absorbent article comprising the absorbent fibrous
structure of the present invention or the absorbent fibrous
structure itself also can be elastically stretchable. The terms
"elastically stretchable" or "elastically extensible" are intended
to be synonymous. These terms, used herein, mean that when in-plane
stretching forces are removed, the article or absorbent fibrous
structure will tend to return toward its unextended or unstretched
dimensions (or original dimensions). It need not return all the way
to its unstretched dimensions, however. It may return to relaxed
dimensions between its unstretched dimensions and extended (or
stretched dimensions).
[0217] As used herein, "wet strength agents" are materials used to
immobilize the bonds between the fibers in the wet state. Typically
the means by which fibers are held together in paper and tissue
products involve hydrogen bonds and sometimes combinations of
hydrogen bonds and covalent and/or ionic bonds. In the present
invention, it is desirable to provide a material that will allow
bonding of fibers in such a way as to immobilize the fiber to fiber
bond points and make them resistant to disruption in the wet state.
In this instance the wet state usually will mean when the product
is largely saturated with water or other aqueous solutions, but
could also mean significant saturation with body fluids such as
urine, blood, mucus, menses, runny bowel movement, lymph and other
body exudates.
[0218] There are a number of materials commonly used in the paper
industry to impart wet strength to paper and board that are
applicable to this invention. These materials are known in the art
as "wet strength agents" and are commercially available from a wide
variety of sources. Any material that when added to a paper web or
sheet results in providing the sheet with a wet geometric tensile
strength:dry geometric tensile strength ratio in excess of 0.1
will, for purposes of this invention, be termed a wet strength
agent. Typically these materials are termed either as permanent wet
strength agents or as "temporary" wet strength agents. For the
purposes of differentiating permanent from temporary wet strength,
permanent will be defined as those resins which, when incorporated
into paper or tissue products, will provide a product that retains
more than 50% of its original wet strength after exposure to water
for a period of at least five minutes. Temporary wet strength
agents are those which show less than 50% of their original wet
strength after being saturated with water for five minutes. Both
classes of material find application in the present invention. The
amount of wet strength agent added to the pulp fibers can be at
least about 0.1 dry weight percent, more specifically about 0.2 dry
weight percent or greater, and still more specifically from about
0.1 to about 3 dry weight percent based on the dry weight of the
fibers.
[0219] Permanent wet strength agents will provide a more or less
long-term wet resilience to the structure. In contrast, the
temporary wet strength agents would provide structures that had low
density and high resilience, but would not provide a structure that
had long-term resistance to exposure to water or body fluids. The
mechanism by which the wet strength is generated has little
influence on the products of this invention as long as the
essential property of generating water-resistant bonding at the
fiber/fiber bond points is obtained.
[0220] Suitable permanent wet strength agents are typically water
soluble, cationic oligomeric or polymeric resins that are capable
of either crosslinking with themselves (homocrosslinking) or with
the cellulose or other constituent of the wood fiber. The most
widely-used materials for this purpose are the class of polymer
known as polyamide-polyamine-epichl- orohydrin (PAE) type resins.
These materials have been described in patents issued to Keim (U.S.
Pat. Nos. 3,700,623 and 3,772,076) and are sold by Hercules, Inc.,
Wilmington, Del., as KYMENE 557H. Related materials are marketed by
Henkel Chemical Co., Charlotte, N.C. and Georgia-Pacific Resins,
Inc., Atlanta, Ga.
[0221] Polyamide-epichlorohydrin resins are also useful as bonding
resins in this invention. Materials developed by Monsanto and
marketed under the SANTO RES label are base-activated
polyamide-epichlorohydrin resins that can be used in the present
invention. These materials are described in patents issued to
Petrovich (U.S. Pat. Nos. 3,885,158; 3,899,388; 4,129,528 and
4,147,586) and van Eenam (U.S. Pat. No. 4,222,921). Although they
are not as commonly used in consumer products, polyethylenimine
resins are also suitable for immobilizing the bond points in the
products of this invention. Another class of permanent-type wet
strength agents are exemplified by the aminoplast resins obtained
by reaction of formaldehyde with melamine or urea.
[0222] Suitable temporary wet strength resins include, but are not
limited to, those resins that have been developed by American
Cyanamid and are marketed under the name PAREZ 631 NC (now
available from Cytec Industries, West Paterson, N.J.). This and
similar resins are described in U.S. Pat. No. 3,556,932 to Coscia
et al. and U.S. Pat. No. 3,556,933 to Williams et al. Other
temporary wet strength agents that should find application in this
invention include modified starches such as those available from
National Starch and marketed as CO-BOND 1000. It is believed that
these and related starches are disclosed in U.S. Pat. No. 4,675,394
to Solarek et al. Derivatized dialdehyde starches, such as
described in Japanese Kokai Tokkyo Koho JP 03,185,197, may also
provide temporary wet strength. It is also expected that other
temporary wet strength materials such as those described in U.S.
Pat. Nos. 4,981,557; 5,008,344 and 5,085,736 to Bjorkquist would be
of use in this invention. With respect to the classes and the types
of wet strength resins listed, it should be understood that this
listing is simply to provide examples and that this is neither
meant to exclude other types of wet strength resins, nor is it
meant to limit the scope of this invention.
[0223] Although wet strength agents as described above find
particular advantage for use in connection with this invention,
other types of bonding agents can also be used to provide the
necessary wet resiliency. They can be applied at the wet end of the
basesheet manufacturing process or applied by spraying or printing,
etc. after the basesheet is formed or after it is dried.
BRIEF DESCRIPTION OF THE DRAWINGS
[0224] FIG. 1 depicts an element of an open cell foam.
[0225] FIG. 2 is a representation of a portion of an absorbent
fibrous structure of the present invention having an open-cell foam
characteristic.
[0226] FIG. 3 depicts a adjacent fibers in an absorbent fibrous
structure.
[0227] FIG. 4 shows an absorbent fibrous structure wherein foam
elements from the structuring composition remain intact occupying
the cells defined by the fibers.
[0228] FIG. 5 depicts the cross-section of an absorbent article
comprising an absorbent fibrous structure of the present
invention.
[0229] FIGS. 6 to 8 are photographs of an absorbent fibrous
structure comprising softwood BCTMP fibers and egg white as a
binder material.
[0230] FIGS. 9 to 12 are images taken with scanning electron
microscopy of an absorbent fibrous structure made by freeze-drying
a mixture of papermaking fibers and CMC.
DETAILED DESCRIPTION OF THE INVENTION
[0231] FIG. 1 shows a generic element 1 of an open cell foam having
an interconnected solid matrix 3 which surrounds voids 5. Void
space 5 may have been part of a bubble face that popped, resulting
in an open "window" between the surrounding segments or struts of
the matrix 3. Multiple sections such as those shown in FIG. 1 can
be arranged in three-dimensional form wherein the solid matrix
defines boundaries of interconnected three-dimensional voids.
[0232] A portion of an absorbent fibrous structure having a
structure resembling an open-celled foam with bimodal pores is
shown in FIG. 2. The portion 10 of the absorbent fibrous structure
comprises multiple fibers 12 arranged heterogeneously such that
open windows 14 are defined between the strut-like arrangements of
fibers. The pore space 16 between fibers in a given strut element
is substantially smaller than the pore size of the open windows 14
or the three-dimensional cells (not shown) defined by multiple
interconnected struts surrounding volumes of space. The absorbent
fibrous structures of the present invention can have bimodal pores
as shown in FIG. 2 or more homogeneous fiber distributions.
[0233] FIG. 3 depicts a closer view of adjacent fibers 20 in an
absorbent fibrous structure according to the present invention.
Fibers 20 are bonded and stabilized in part by the presence of
binder material 22, which can be a polymeric material that was
present in a foam prior to drying or curing. The foam may be
largely collapsed, leaving relatively little structural material in
windows and cells between fibers, being primarily concentrated in
the smaller spaces between fibers.
[0234] FIG. 4 depicts another embodiment based on FIG. 2 in which
the foam that served to structure the fibers has not collapsed, but
remains partly in tact as a structural component of the absorbent
fibrous structure 30 occupying a significant portion of the void
space 34 in the cells defined by the fibers 32 in fibrous struts.
Here are depicted hollow spherical shells 38 of a polymeric
foamable material from the structuring composition, the shells
having openings 39 such that they are substantially open celled and
the void spaces contained therein are in fluid communication with
the void spaces defined by the fibrous struts. Single bubbles can
occupy cells or multiple bubbles can fill a cell. The occupied
spaces as depicted have larger dimensions than the interfiber pore
spaces 36, but the foam bubbles can also be smaller. The polymeric
foam material 38 preferably is hydrophilic. It can serve as binder
material in holding the fibers in place and adhering to the fibers,
but additional binder material can also be present between adjacent
fibers, as depicted in FIG. 3.
[0235] Any bubbles defined by a polymeric foamable binder material
or the structuring composition in general during drying or curing
of the foam can be larger or smaller than the characteristic fiber
length of the hydrophilic fibers. Thus, characteristic dimensions
of the residual foam bubbles can be on the order of a fiber length
or substantially smaller or greater. For example, if the average
diameter of the bubbles is roughly as great or greater than the
average length of the fibers, then large open cells are likely to
result which offer high void volume, but relatively little
capillary pressure for effective wicking. If the bubbles are
relatively small, then the resulting structure may be characterized
by a plurality of minute cells, preferably open-cells, inside the
volumetric regions defined by neighboring fibers. In other words,
the fibers, if they could be viewed alone, independently of the
binder material, would appear to define open cells or voids
substantially larger than the characteristic diameter of the open
cells or voids defined by the dry foamable binder material. In this
case, the foamable binder material can contribute to capillary
pressure beyond what is possible with the fibrous structure alone.
In one embodiment, the ratio of foam cell diameter (as measured
with respect to the foamable binder material alone) to
characteristic fiber diameter is about 1 or less, specifically
about 0.3 or less, more specifically about 0.2 or less, still more
specifically about 0.1 or less, and most specifically from about
0.01 to about 0.4. In the embodiment where the foamable binder
material forms cells smaller than the cells defined by the fibers,
the absolute diameter of the cells defined by the foamable binder
material can be about 3 mm or less; specifically about 1 mm or
less, more specifically about 0.3 mm or less, still more
specifically about 0.1 mm or less, and most specifically from about
0.02 mm to about 0.2 mm.
[0236] In a preferred embodiment, the structuring composition
and/or the foamable binder material of the present invention is
substantially hydrophobic when dry or when cured. Preferably, it is
not a thermoplastic resin or a molten thermoplastic resin, such
that the structuring composition or binder material is
substantially free of molten thermoplastic material or, in one
embodiment, is substantially free of thermoplastic materials. In
one embodiment, the binder material or structuring composition
contains less than 10% and preferably less than 2% thermoplastic
material by weight. When dried, the binder material should
preferably be substantially hydrophilic (e.g., has a pure water
contact angle less than 40 degrees and preferably less than 30
degrees).
[0237] FIG. 5 depicts the cross-section of an absorbent article 40
comprising an absorbent fibrous structure 42 disposed between a
liquid impervious backsheet 44 and a liquid pervious cover 46
intended to be adjacent the body of the wearer. The absorbent
fibrous structure can be joined with a layer of fluff pulp (not
shown) or other absorbent materials, including layers of creped or
uncreped tissue, and specifically molded through-air dried tissue
or tissue laminated with superabsorbent material (not shown). The
cover has apertures or openings 48 therein, which may also be slits
or apertures to provide extensibility when stretched. All
components of the article can be stretchable or extensible. The
cover 46 can be replaced with a liquid pervious topsheet such as a
nonwoven web, including one with elastomeric bonds or laminated to
elastomeric materials. The nonwoven web can be combined with
additional elements between the topsheet and the absorbent fibrous
structure 42. Many other elements (not shown) can be incorporated
in such an absorbent article, including a surge layer, an
additional absorbent core adjacent the backsheet 44, wings, tabs,
flaps, cuffs, elastic bands, odor absorbing materials, and other
elements known in the art of absorbent articles and particularly
diapers or feminine pads or pantiliners. To render the absorbent
article extensible or stretchable, the absorbent fibrous structure
is desirably extensible or stretchable. It can comprise elastomeric
bonds, with a binder material comprising latex or other known
elastomers, and can be joined to elastomeric threads or films or
laminated with stretchable material such as a creped tissue.
[0238] FIGS. 6 to 12 are photographs and micrographs of embodiments
of the present invention, hereafter described in the Examples.
[0239] While the principal components of the absorbent fibrous
structure of the present invention have been described in the
foregoing, such a structure is not limited thereto and can include
other components not adversely effecting the desired properties of
the absorbent foam. Exemplary materials which could be used as
additional components would include, without limitation, pigments,
antioxidants, stabilizers, plasticizers, nucleating agents,
surfactants, waxes, flow promoters, solid solvents, particulates,
and materials added to enhance processability of the absorbent
foam. If such additional components are included in an absorbent
foam, it is generally desired that such additional components be
used in an amount that is beneficially less than about 15 weight
percent, more beneficially less than about 5 weight percent, and
suitably less than about 1 weight percent, wherein all weight
percents are based on the total weight amount of the amount of the
polymer, any crosslinking agents, and any other optional components
present in the absorbent fibrous structure.
EXAMPLES
Example 1
[0240] High bulk foam-stabilized fibrous structures were prepared
from dry comminuted papermaking fibers (fluff) with ordinary fresh
egg whites serving as a proteinaceous foamable binder material. In
a first variant, pure whipped egg whites were prepared and fluff
was gradually added. In a second variant, egg whites were mixed
with a small quantity of a commercial liquid dishwashing detergent
to increase the foaming potential of the mixture, and then fibers
were added.
[0241] In the first variant, the whites of three refrigerated eggs
from a Wisconsin source (Grade A large eggs) were whipped for about
4 minutes with a Sunbeam electric egg beater at high speed in a
small cylindrical container about 5 inches in diameter. About half
of the egg white froth was removed during the whipping process to
maintain adequate volume in the container for the addition of
fiber. Small clumps of dry comminuted bleached kraft eucalyptus
fiber were dropped into the contained as the egg beater continued
stirring the mixture at high speed to effectively disperse the
kraft fibers into the foam. Though a balance was not used, an
estimated 4 grams of fiber was mixed into the egg white foam over a
period of about 3 minutes as whipping continued. The mixture became
stiffer with the addition of fibers and increasingly clung to the
beater elements rather than residing in the container. The
foam-fiber mixture was then removed from the container and scooped
onto a metal plate for air drying, with scoops roughly resembling
truncated cones having a base radius of about 1 to 2 inches, a
height of about 0.5 to 2 inches, and an upper radius of about 0.7
to 1.5 inches. One scoop was dried in a microwave oven, resulting
in about 50% or greater loss in height as the mixture dried.
Remaining scoops were dried overnight at room temperature, also
experiencing substantial collapse during drying. Final drying
occurred in a microwave oven for about 1-2 minutes to drive off
remaining moisture. One scoop had an estimated final volume of 15
cc and a room-dry mass of 0.77 g, for a bulk of about 19.5 cc/g.
The structure appeared to be predominately fibers and was evidently
an open-cell structure, as air would readily pass through the dried
scoop under gentle blowing pressure from a human mouth. The dried
material felt relatively stiff, being clearly stiffer than an
unbonded fluff pulp pad. When wetted, dried scoops of the bulky
material retained their shape and displayed obvious
hydrophilicity.
[0242] It was observed that a scoop of the eucalyptus-egg white
mixture which was spread onto a metal plate, with a height of about
0.5 inches, experienced much greater collapse upon drying. Scoops
that were loftier, with heights over 1 inch, experienced less
collapse upon drying. Without wishing to be limited by theory, it
is believed that thicker scoops allowed more fibers to exist in the
vertical direction, whereas the spreading motion to put the foam
into a thin pad oriented somewhat more of the fibers away from the
vertical direction, resulting in less z-direction structural
stability during drying.
[0243] For the second variant, a small quantity of AJAX.RTM. liquid
dishwashing detergent with an antimicrobial additive
(Colgate-Palmolive), an orange-colored fluid, was added to another
batch of 3 fresh, chilled eggs whites as they were whipped to
produce a higher void-volume foam with a faint trace of an orange
color. Again, about half of the egg white mixture was removed
during whipping to leave adequate volume for fiber addition.
Roughly equal parts of dry comminuted bleached kraft eucalyptus and
bleached kraft southern softwood (CR54 from Coosa Pines, Ala.) were
added to the whipped mixture of detergent and about 1.5 egg whites,
with addition taking place by dropping small quantities of the
fluff into the foam as the egg beater continued whipping the
mixture. Approximately 5 grams of fiber were added and dispersed
into the proteinaceous foam. The stiff, high-bulk foam was
deposited in scoops on a solid surface as before. Some were allowed
to dry overnight, another was dried in a microwave after about 2
hours of air drying, and also after about 2 hours of air drying,
another scoop was dried in a conventional kitchen oven at about
200.degree. F. for about 15 minutes, followed by drying to
completion in a microwave oven.
[0244] The hardwood/softwood scoops so prepared exhibited higher
bulk and stability than the previous variant with hardwood alone
and without detergent. Structures experienced less than about 50%
reduction in height during drying, with about 20% height reduction
deemed typical. Analysis of a scoop form this second variant
indicated that the bulk was about 30 cc/g (the dried sample had a
thickness of 1.5 cm, a width of 3 cm, and a length of about 5 cm
for a total volume of roughly 23 cc and a room-dry mass of about
0.78 g). The structures readily absorbed water and retained their
shape when saturated, though compression could result in permanent
void volume loss.
Example 2
[0245] A mixture of egg whites, dishwashing detergent, and fluff
fibers was prepared as in the second variant of Example 1. In Run
A, 16 g of fresh, room-temperature egg white was mixed with 0.46 g
of AJAX liquid dishwashing detergent with an antimicrobial additive
(Colgate-Palmolive). The egg white was whipped for about 1 minute
with an electric egg beater as in Example 2 in a plastic bowl with
an upper diameter of about 8 inches. Eucalyptus fiber was added
gradually until 3 grams had been added, but the foam began to
collapse after the addition of about 2 grams of fiber. An
additional 1.2 g of detergent was added and 10 grams of water
followed by whipping, but the high-bulk foam did not return as
desired. Without wishing to be bound by theory, it is hypothesized
that the egg white foam was not adequately stiff prior to adding
the fiber.
[0246] In Run B, 1.75 g of the liquid detergent was added to an egg
white having a mass of 31 g, which was then beat for several
minutes until stiff. At that point, fiberized eucalyptus was then
added gradually as beating continued until 2 grams had been added.
Then 2 grams of fiberized southern softwood (Coosa Pines CR1654, in
fluff form) was added gradually as beating continued. The result
was a stable, high-bulk foam. A hex-shaped plastic weighing tray
with a volume of about 184 ml was filled with 14.16 g of the wet
foam, which was leveled to be flush with the top of the tray. A
scoop of 8.8 g of wet foam was placed in a second plate, and 4.7 g
of wet foam was placed in a third plate. The air-dry mass of the
three portions is 3.49 g, 2.10 g, and 1.06 g, respectively, which
includes about 5% moisture still retained by the fibers. The
largest portion which filled the hex-shaped tray when wet still
substantially filled the tray after air-drying overnight, though an
estimated 10-15% shrinkage in height had occurred. Excluding some
large voids on the bottom of the hex-shaped foam-fiber portion
having an estimated volume of about 10 cc, the estimated
macroscopic volume of the fibrous structure is about 155 cc, which
gives a macroscopic uncompressed bulk of about 46.7 cc/g (over dry
mass basis). At a load of a 0.05 psi exerted by a 3-inch diameter
plastic platen mounted to a Mitutoyo thickness gauge, the measured
thickness of the sample was 0.754 in and the dry mass of the room
dry sample under the platen was about 2.7 g, giving a dry bulk of
about 32 cc/g. The sample was then misted with deionized water from
a spray bottle to uniformly wet the sample until the wet sample
mass was 9.4 (corresponding to a mass of 7.5 g under the confines
of the 3-inch platen), which is 280% of the dry sample mass. The
bulk of the highly moistened sample was 16.5 cc/g, based on the
thickness measured after 20 seconds of residing under the platen at
a load of 0.05 psi.
[0247] In Run C, a room-temperature egg white having a mass of 30.4
g was beaten with 2 g of the liquid detergent for about 3 minutes
to yield a stiff, stable foam. All of a 5 gram portion of
comminuted spruce BCTMP pulp was gradually added into the foam as
beating continued at medium speed. The high-bulk, stable foam was
distributed onto 3 plastic trays. The three portions of the wet
foam has masses of, respectively, 11.29 g, 7.89 g, and 6.89 g. One
tray was partially dried in a microwave for about 20 seconds, and
then all 3 trays were allowed to air dry overnight. Air dried
weights, respectively, were 3.14 g, 2.16g, and 1.82 g. A portion of
the dried BCTMP foam was removed from a tray and cut to a
substantially rectangular shape having dimensions of about 1.5 cm
by 2.3 cm by 3.2 cm for a total volume of about 11.0 cc. The dry
mass was 0.24 g, for an uncompressed bulk of about 46 cc/g. A
portion of the BCTMP absorbent fibrous structures was later cut
having a room-dry mass of 0.8 g and a rectangular cross section of
1.3 in by 2 in with a thickness of 0.65 in as measured by a 3-in
platen with a load of 162 g. The load corresponds to 0.05 psi for a
3-in diameter sample, but in this case the applied pressure was
about 0.136 psi. The corresponding room-dry bulk was about 32.6
cc/g (accounting for about 5% of the room-dry mass being moisture).
The sample was wetted to a mass of 2.0 g by fine spray from a
deionized water spray bottle over about a 40 second period. The
sample was then placed under the 3-inch platen and the thickness
was recorded as 0.335 in after 15 seconds of residing under the
pressure of 0.136 psi, indicative of a bulk of about 18.7 cc/g. The
bulk would have been even higher at a load of 0.05 psi. Further,
had wet strength additives such as Kymene (Hercules Chemical,
Wilmington, Del.) or crosslinkers been added, even higher wet bulk
values would have been expected, certainly above 20 cc/g.
[0248] FIGS. 6 to 8 show photographs of small portions of the BCTMP
absorbent fibrous structure from Run C. FIG. 6 is a cross section
of a sample having a thickness of about 1.3 cm (the distance from
the top to the bottom surfaces of the sample in the photograph). A
variety of large and small void spaces or cells are evident.
[0249] FIG. 7 shows the outer surface of another portion of a
sample from Run C. Here, the characteristic cell size is somewhat
smaller than the typical fiber length, yet the pore size
distribution appears to be bimodal, with a variety of large cells
and small void spaces between adjacent fibers.
[0250] FIG. 8 shows a cross section from another BCTMP absorbent
fibrous structure from Run C above showing fibers that have been
substantially oriented in a particular direction, apparently by the
flow of the foam, but are substantially heterogeneously
distributed.
[0251] In most of the samples made with egg white, it was evident
that the fibers were not only positioned in space by action of the
foam but were oriented by the flow of the foam created by the
action of the beating elements. Fibers appeared to be substantially
aligned in large regions of the absorbent fibrous structures, with
the angle of alignment changing from one location to another,
indicative of the flow history of the foam when beating was
stopped.
[0252] To examine the solids content of the egg white, an egg white
having a mass of 29.9 g was dried at 105.degree. C. for about 1.5
hours, being divided into small pieces during drying to increase
surface area, and then further dried in a covered container in a
microwave until most of the egg white had become discolored rather
than white and generally appeared to be crusty and hard. The dried
mass was 4.3 g. Thus, in adding about 5 g of fiber to 1 egg white,
the resulting structure will be slightly over 50% fiber by mass.
Addition of about 4 grams of fiber to an egg white will result in
structure having about 50% fiber, and addition of 2 or 3 grams of
fiber to an egg white will result in over about 30% and over about
40% fibers by weight, respectively.
Example 3
[0253] Carboxymethylcellulose (CMC), an anionic polymer, having a
weight average molecular weight greater than 1,000,000 and a degree
of substitution of carboxymethyl groups on the anhydroglucose unit
of the cellulosic material of about 0.7 was obtained from Aqualon
of Wilmington, Del., a subsidiary of Hercules Inc., under the
designation CMC-TH carboxymethylcellulose. 20 grams of
dry-fiberized eucalyptus fibers purchased from Cinibra, Brazil,
with a Canadian Standard Freeness of 625 ml. 1.25 grams of the said
CMC were dissolved in 1000 grams of distilled water at a
temperature of about 23.degree. C. for 2 hours in a Hobart mixer
manufactured by Kitchenaid. The fibers were combined with distilled
water and then added to the CMC solution and stirred for another
hour. The fiber consistency was about 2%. The slurry was then
transferred into a stainless steel pan, wherein the pan had
dimensions of 10 inches (width) by 20 inches (length) by 1 inch
(depth). The pan was then placed in a freeze dryer, available from
The VirTis, Inc., of Gardiner, N.Y., under the designation VirTis
Genesis model 25EL freeze dryer. The slurry in the pan was then
cooled down to about -25.degree. C. at a cooling rate of
0.04.degree. C./minute in order to freeze the water in the slurry.
The slurry in the pan was maintained at about -25.degree. C. for
about an hour to ensure substantially complete freezing of the
water. The frozen slurry was left in the freeze dryer and then
subjected to a vacuum of about 105 millitorrs, provided by a vacuum
pump which had a condenser set to a temperature of about
-60.degree. C. to about -70.degree. C., for at least about 15
hours. The resultant structures were then treated at 130.degree. C.
for 2 hours in order to assist in the crosslinking of the polymers.
The resulting fibrous structure has a density of 0.02 grams/cc,
with a hand feel and rigidity similar to a fine plastic foam. The
CMC superabsorbent foam produced from CMC solution with this
method, as reported in the U.S. patent application Ser. No.
08/977,918, "Absorbent Foam," results in an Absorbency Under Load
(AUL) at 16.2 grams/gram.
[0254] The CMC-eucalyptus absorbent fibrous structure showed good
water absorption. The Free Swell Capacity was 21.9 and the AUL was
13.2. To further stabilize the bonds, one section of the material
was heated to 180.degree. C. for 10 minutes to promote more
extensive crosslinking of the CMC. This sample yielded a Free Swell
Capacity value of 25.3 and an AUL of 17.4, showing an apparent
improvement in wet properties due to the heat treatment. Another
section was sprayed with a Kymene 557-LX solution having 1.1%
solids. A section having a dry mass of 1.1 grams was sprayed on
both sides with a total of about 10.5 g Kymene solution, while
another section with a room dry mass of 6.1 g was sprayed with 30
grams of Kymene solution. The wetted samples did not appear to
collapse or swell when wetted, although some collapse occurred
during handling from slight mechanical compression. Both of the
sprayed samples were then dried in a convective oven at 105.degree.
C. for 25 minutes to cure the Kymene and further stabilize the
structure. The smaller sample that received the most solution had
collapsed significantly during drying and was not tested. The other
sample had some regions that were more collapsed, apparently
because of higher spray loading. An area near the edge where the
spray loading was estimated to be about two-thirds that of the
average was tested. The Free Swell Capacity was 22.2 and the AUL
was 13.2. The dry mass of the circular disks cut for AUL testing
was about 0.08 to 0.1 g per disk. In each case, three disks were
tested for both Free Swell Capacity and AUL, with the above
reported results being the average of three measurements. The
standard deviation for AUL and Free Swell Capacity measurements
ranged from 0.5 to 1.5.
[0255] FIGS. 9 to 12 are SEM micrographs of cross-sections of
freeze dried foams. FIGS. 9 and 10 show freeze-dried CMC foam
without the addition of fibers at magnifications of 100 and 250
times, respectively. FIGS. 11 and 12 show the resulting
freeze-dried absorbent fibrous structure from the present example,
where the solid phase is about 95% hydrophilic fibers, both at
magnifications of 100 times. Cellular void spaces between groups of
fibers are evident, with small visible platelets of solid. CMC
material scattered throughout the assembly. With fibers present,
the void volume is substantially greater than in FIGS. 9 and 10,
where no fibers have been added.
Example 4
[0256] Samples were prepared as in Example 3 above, with the
following deviations. Liquid binder material in the form of Kymene
450 (lot #907M15Ky) from Hercules Inc. was used to replace CMC. 10
grams of Kymene solution, having a solids contents of 12.5 wt.%,
were added into 1000 grams of distilled water at room temperature
in a Hobart mixer. 20 grams of dry fiberized eucalyptus fibers were
added into the Kymene solution. Freeze drying conditions were as in
Example 3. No heat treatment was used. A high bulk, absorbent
fibrous structure was prepared.
Example 5
[0257] The binder material was liquid latex, HYCAR 26683 (lot
#634-062) from B. F. Goodrich, which replaced the CMC of Example 3.
5 grams of latex liquid, having a solids level of 49.1 wt. %, were
added into 100 grams of distilled water at room temperature in a
Hobart mixer. 20 grams of dry-fiberized eucalyptus fibers were
added into the latex solution. Freeze drying conditions were the
same as in Example 3. No heat treatment was used. A soft, highly
flexible absorbent fibrous structure resulted, with a cushiony,
rubbery feel.
Example 6
[0258] As a conceptual example, a high-consistency aqueous slurry
of fibers containing chemical binders such as cross-linking agents
or adhesives (e.g., latex) can be slurried with an ice or a frozen
hydrate representing a removable phase. The fibers so treated
become disposed between the frozen phase, which serves to hold the
fibers apart and define prospective void volumes between the cells.
The removable phase in the slurry can then be removed at least in
substantial part by freeze-drying, evaporation, solvent exchange,
or the like to leave the fibers in place, which can have incipient
bonds formed with the help of the chemical binders, cross-linking
agents or adhesives, holding the fibers into a randomized structure
with three-dimensional fiber orientation and high void volume. The
structure can then be exposed to heat treatment (e.g., 110.degree.
C. for 5 minutes) to cure or fully activate said binders,
cross-linking agents or adhesives. The resulting pad can have a
basis weight of 10-100 gsm or higher and can have a bulk of 25
cc/g. The pad can be embossed to provide channels for flow control,
particularly for flow directed along the surface of the pad, and to
provide densified zones of high capillary pressure for effective
wicking. For example, embossments of elongated sinusoidal lines or
an interconnected repeating diamond patterns can be useful in
enhancing wicking and controlling flow. Such a pad can serve as an
intake material or absorbent core in a feminine pad or diaper, for
example.
[0259] It will be appreciated that the foregoing examples, given
for purposes of illustration, are not to be construed as limiting
the scope of this invention. Although only a few exemplary
embodiments of this invention have been described in detail above,
those skilled in the art will readily appreciate that many
modifications are possible in the exemplary embodiments without
materially departing from the novel teachings and advantages of
this invention. Accordingly, all such modifications are intended to
be included within the scope of this invention, which is defined in
the following claims and all equivalents thereto. Further, it is
recognized that many embodiments may be conceived that do not
achieve all of the advantages of some embodiments, particularly of
the preferred embodiments, yet the absence of a particular
advantage shall not be construed to necessarily mean that such an
embodiment is outside the scope of the present invention.
* * * * *
References