U.S. patent application number 10/675412 was filed with the patent office on 2004-04-01 for absorbent materials having improved fluid intake and lock-up properties.
Invention is credited to Chakravarty, Jayant, Dodge, Richard Norris II, Lange, Nancy Birbiglia, Qin, Jian, Ranganathan, Sridhar, Tsai, Fu-Jya Daniel, Uttecht, Cathleen M., Zhang, Xiaomin.
Application Number | 20040063367 10/675412 |
Document ID | / |
Family ID | 32033058 |
Filed Date | 2004-04-01 |
United States Patent
Application |
20040063367 |
Kind Code |
A1 |
Dodge, Richard Norris II ;
et al. |
April 1, 2004 |
Absorbent materials having improved fluid intake and lock-up
properties
Abstract
Disclosed are absorbent composites, useful in an absorbent
article, having high liquid intake rates. The absorbent composites
may also have a rapid liquid lock-up. Absorbent composites of this
invention have an intake rate of at least about 1.9 cc
liquid/second at an 80% absorbent composite saturation level and a
liquid lock-up fraction of at least about 0.70 at 50%
superabsorbent material saturation. The absorbent composites of
this invention can be a freeze-dried composite, an airformed
absorbent composite, or other fibrous or non-fibrous absorbent
composites.
Inventors: |
Dodge, Richard Norris II;
(Appleton, WI) ; Lange, Nancy Birbiglia; (Oshkosh,
WI) ; Chakravarty, Jayant; (Appleton, WI) ;
Qin, Jian; (Appleton, WI) ; Ranganathan, Sridhar;
(Suwanee, GA) ; Tsai, Fu-Jya Daniel; (Appleton,
WI) ; Uttecht, Cathleen M.; (Menasha, WI) ;
Zhang, Xiaomin; (Appleton, WI) |
Correspondence
Address: |
Pauley Petersen & Erickson
Suite 365
2800 W. Higgins Road
Hoffman Estates
IL
60195
US
|
Family ID: |
32033058 |
Appl. No.: |
10/675412 |
Filed: |
September 30, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10675412 |
Sep 30, 2003 |
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10291239 |
Nov 8, 2002 |
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6689934 |
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10291239 |
Nov 8, 2002 |
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10017683 |
Dec 14, 2001 |
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Current U.S.
Class: |
442/118 ;
442/381; 442/411; 442/414; 442/417 |
Current CPC
Class: |
Y10T 442/659 20150401;
Y10T 442/692 20150401; Y10T 442/696 20150401; Y10T 442/699
20150401; Y10T 442/2484 20150401; A61L 15/60 20130101 |
Class at
Publication: |
442/118 ;
442/381; 442/411; 442/414; 442/417 |
International
Class: |
B32B 005/02; D04H
001/54; D04H 003/14; D04H 013/00 |
Claims
What is claimed is:
1. An absorbent composite, comprising: a water-insoluble fiber; and
a superabsorbent material; wherein the absorbent composite has an
intake rate of at least about 1.9 cubic centimeters of 0.9% by
weight sodium chloride aqueous solution per second at 80% absorbent
composite saturation and a liquid lock-up fraction of at least
about 0.70 at 50% superabsorbent material saturation determined
using 0.9% by weight sodium chloride aqueous solution.
2. The absorbent composite of claim 1, wherein the absorbent
composite has an intake rate of at least about 2.3 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.75 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
3. The absorbent composite of claim 1, wherein the absorbent
composite has an intake rate of at least about 2.7 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.80 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
4. The absorbent composite of claim 1, wherein the absorbent
composite has an intake rate of at least about 3.3 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.80 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
5. The absorbent composite of claim 1, wherein the water-insoluble
fiber comprises a fiber selected from the group consisting of wood
pulp fiber, cotton linter, thermoplastic fibers, elastic fibers,
and combinations thereof.
6. The absorbent composite of claim 1, wherein the water-insoluble
fiber is a hydrophilic fiber.
7. The absorbent composite of claim 6, wherein the water-insoluble
fiber is a hydrophilically treated hydrophobic fiber.
8. The absorbent composite of claim 1, wherein the absorbent
composite is selected from the group comprising an airformed
absorbent composite, a wetformed absorbent composite, and a
freeze-dried composite.
9. The absorbent composite of claim 1, wherein the superabsorbent
material comprises a material selected from the group consisting of
particles, fibers, nonwoven, aggregate, printed, coated, or
combinations thereof.
10. The absorbent composite of claim 9, wherein the superabsorbent
material comprises at least one of a crosslinked anionic and a
crosslinked cationic polymers.
11. The absorbent composite of claim 10, wherein the superabsorbent
material comprises a material selected from the group consisting of
sodium-polyacrylate, carboxymethyl cellulose, carboxymethyl
polysaccharides, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, chitosan salts, polyquarternary
ammonium salts, polyvinyl amines, and combinations thereof.
12. The absorbent composite of claim 1, wherein the absorbent
composite comprises the superabsorbent material in a weight amount
of about 10 to 70 weight percent based on total weight of the
absorbent composite.
13. The absorbent composite of claim 1, further comprising a binder
material.
14. The absorbent composite of claim 13, wherein the binder
material comprises a water-insoluble polymer.
15. The absorbent composite of claim 14, wherein the binder
material is selected from the group consisting of poly(aminoamide)
epichlorohydrin polymer, latex, and combinations thereof.
16. The absorbent composite of claim 14, wherein the binder
material comprises a water-insoluble, water-swellable polymer.
17. The absorbent composite of claim 16, wherein the binder
material comprises a material selected from the group consisting of
sodium-polyacrylate, carboxymethyl cellulose, chitosan salt, and
combinations thereof.
18. The absorbent composite of claim 14, wherein the binder
comprises a thermoplastic fiber.
19. The absorbent composite of claim 18, wherein the binder
material comprises a material selected from the group consisting of
polyethylene fibers, polypropylene fibers, polyester fibers, nylon
fibers, and combinations thereof.
20. The absorbent composite of claim 13, wherein the binder
material is elastic.
21. The absorbent composite of claim 13, wherein the binder
material is water-soluble before a treatment and water-swellable
and water-insoluble after the treatment.
22. The absorbent composite of claim 21, wherein the treatment
comprises a treatment selected from the group consisting of heat,
ultraviolet radiation, microwave radiation, steam, high pressure,
electronic beam radiation, organic solvents, humidity treatment,
and combinations thereof.
23. A freeze-dried composite, comprising: a water-insoluble fiber;
and a superabsorbent material; wherein the freeze-dried composite
has an intake rate of at least about 1.9 cubic centimeters of 0.9%
by weight sodium chloride aqueous solution per second at 80%
freeze-dried composite saturation and a liquid lock-up fraction of
at least about 0.70 at 50% superabsorbent material saturation
determined using 0.9% by weight sodium chloride aqueous
solution.
24. The freeze-dried composite of claim 23, wherein the
freeze-dried composite has an intake rate of at least about 2.3
cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% freeze-dried composite saturation and a
liquid lock-up fraction of at least about 0.75 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
25. The freeze-dried composite of claim 23, wherein the
freeze-dried composite has an intake rate of at least about 2.7
cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% freeze-dried composite saturation and a
liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
26. The freeze-dried composite of claim 23, wherein the
freeze-dried composite has an intake rate of at least about 3.3
cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% freeze-dried composite saturation and a
liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
27. The freeze-dried composite of claim 23, wherein the
water-insoluble fiber comprises a fiber selected from the group
consisting of wood pulp fiber, cotton linter, thermoplastic fibers,
elastic fibers, and combinations thereof.
28. The freeze-dried composite of claim 23, wherein the
superabsorbent material comprises a material selected from the
group consisting of sodium-polyacrylate, carboxymethyl cellulose,
carboxymethyl polysaccharides, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, chitosan salts, polyquarternary
ammonium salts, polyvinyl amines, and combinations thereof.
29. The freeze-dried composite of claim 23, wherein the
freeze-dried composite comprises the superabsorbent material in a
weight amount of about 10 to 70 weight percent based on total
weight of the absorbent composite.
30. The freeze-dried composite of claim 23, further comprising a
binder material.
31. An airformed absorbent composite, comprising: a water-insoluble
fiber; and a superabsorbent material; wherein the airformed
absorbent composite has an intake rate of at least about 1.9 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% airformed absorbent composite saturation and a liquid
lock-up fraction of at least about 0.70 at 50% superabsorbent
material saturation determined using 0.9% by weight sodium chloride
aqueous solution.
32. The airformed absorbent composite of claim 31, wherein the
airformed absorbent composite has an intake rate of at least about
2.3 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% airformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.75 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
33. The airformed absorbent composite of claim 31, wherein the
airformed absorbent composite has an intake rate of at least about
2.7 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% airformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
34. The airformed absorbent composite of claim 31, wherein the
airformed absorbent composite has an intake rate of at least about
3.3 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% airformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
35. The airformed absorbent composite of claim 31, wherein the
water-insoluble fiber comprises a fiber selected from the group
consisting of wood pulp fiber, cotton linter, thermoplastic fibers,
elastic fibers, and combinations thereof.
36. The airformed absorbent composite of claim 31, wherein the
superabsorbent material comprises a material selected from the
group consisting of sodium-polyacrylate, carboxymethyl cellulose,
carboxymethyl polysaccharides, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, chitosan salts, polyquarternary
ammonium salts, polyvinyl amines, and combinations thereof.
37. The airformed absorbent composite of claim 31, wherein the
airformed absorbent composite comprises the superabsorbent material
in a weight amount of about 10 to 70 weight percent based on total
weight of the absorbent composite.
38. The airformed absorbent composite of claim 31, further
comprising a binder material.
39. A wetformed absorbent composite, comprising: a water-insoluble
fiber; and a superabsorbent material; wherein the wetformed
absorbent composite has an intake rate of at least about 1.9 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% wetformed absorbent composite saturation and a liquid
lock-up fraction of at least about 0.70 at 50% superabsorbent
material saturation determined using 0.9% by weight sodium chloride
aqueous solution.
40. The wetformed absorbent composite of claim 39, wherein the
wetformed absorbent composite has an intake rate of at least about
2.3 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% wetformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.75 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
41. The wetformed absorbent composite of claim 39, wherein the
wetformed absorbent composite has an intake rate of at least about
2.7 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% wetformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
42. The wetformed absorbent composite of claim 39, wherein the
wetformed absorbent composite has an intake rate of at least about
3.3 cubic centimeters of 0.9% by weight sodium chloride aqueous
solution per second at 80% wetformed absorbent composite saturation
and a liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation determined using 0.9% by weight
sodium chloride aqueous solution.
43. The wetformed absorbent composite of claim 39, wherein the
water-insoluble fiber comprises a fiber selected from the group
consisting of wood pulp fiber, cotton linter, thermoplastic fibers,
elastic fibers, and combinations thereof.
44. The wetformed absorbent composite of claim 39, wherein the
superabsorbent material comprises a material selected from the
group consisting of sodium-polyacrylate, carboxymethyl cellulose,
carboxymethyl polysaccharides, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, chitosan salts, polyquarternary
ammonium salts, polyvinyl amines, and combinations thereof.
45. The wetformed absorbent composite of claim 39, wherein the
wetformed absorbent composite comprises the superabsorbent material
in a weight amount of about 10 to 70 weight percent based on total
weight of the absorbent composite.
46. The wetformed absorbent composite of claim 39, further
comprising a binder material.
47. An absorbent composite comprising a superabsorbent material and
a non-fibrous structure, wherein the absorbent composite has an
intake rate of at least about 1.9 cubic centimeters of 0.9% by
weight sodium chloride aqueous solution per second at 80% absorbent
composite saturation and a liquid lock-up fraction of at least
about 0.70 at 50% superabsorbent material saturation determined
using 0.9% by weight sodium chloride aqueous solution.
48. The absorbent composite of claim 47, wherein the absorbent
composite has an intake rate of at least about 2.3 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.75 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
49. The absorbent composite of claim 47, wherein the absorbent
composite has an intake rate of at least about 2.7 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.80 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
50. The absorbent composite of claim 47, wherein the absorbent
composite has an intake rate of at least about 3.3 cubic
centimeters of 0.9% by weight sodium chloride aqueous solution per
second at 80% absorbent composite saturation and a liquid lock-up
fraction of at least about 0.80 at 50% superabsorbent material
saturation determined using 0.9% by weight sodium chloride aqueous
solution.
51. The absorbent composite of claim 47, wherein the superabsorbent
material comprises a material selected from the group consisting of
particles, fibers, nonwoven, aggregate, printed, coated, or
combinations thereof.
52. The absorbent composite of claim 47, wherein the superabsorbent
material comprises a material selected from the group consisting of
sodium-polyacrylate, carboxymethyl cellulose, carboxymethyl
polysaccharides, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, chitosan salts, polyquarternary
ammonium salts, polyvinyl amines, and combinations thereof.
53. The absorbent composite of claim 47, wherein the absorbent
composite comprises the superabsorbent material in a weight amount
of about 10 to 70 weight percent based on total weight of the
absorbent composite.
54. The absorbent composite of claim 47, further comprising a
binder material.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of co-pending
U.S. patent application Ser. No. 10/291,239, filed Nov. 8, 2002 and
herein fully incorporated by reference, which is a
continuation-in-part application of U.S. patent application No.
10/017,683, filed Dec. 14, 2001.
FIELD OF THE INVENTION
[0002] This invention relates to absorbent composites having
improved multifunctional absorbent properties useful in absorbent
articles. More specifically this invention relates to absorbent
composites having rapid fluid intake and rapid lock-up of
liquid.
BACKGROUND OF THE INVENTION
[0003] Various absorbent materials and structures are known in the
art. Important characteristics of commercial absorbent materials
and structures include either a high rate of fluid intake or rapid
lock-up of liquid, but not both. Nonwoven surge materials, as
taught in U.S. Pat. No. 5,490,846 to Ellis et al. and in U.S. Pat.
No. 5,364,382 to Latimer, for example, have excellent intake
functionality but typically almost no fluid retention properties.
Current commercial diaper absorbent cores comprising an absorbent
fluff and superabsorbent material combination typically provide
good fluid absorbency but, often depending on the core density,
typically poor fluid intake.
[0004] High liquid intake rate composites can be achieved through a
variety of ways. High stiffness superabsorbent particles, high
stiffness fibers, and/or stabilization of the composite structure
have been shown to be effective at achieving high intake rates and
sometimes maintaining that rate over multiple insults. However,
swelling kinetics of the superabsorbent particles that dictate the
speed of liquid lock-up into the superabsorbent particles are
typically inadequate.
[0005] A typical disposable absorbent product generally has a
composite structure including a topsheet, a backsheet, and an
absorbent structure between the topsheet and backsheet. In current
commercial absorbent structures layers of different materials, such
as a surge layer and an absorbent core layer, are required to
provide desired fluid handling characteristics of high liquid
intake and high liquid lock-up. The result may be an absorbent
article with many production steps and high cost. There is a need
for an absorbent composite having enhanced fluid intake and high
liquid lock-up characteristics that could be used alone or in
combination with other materials in an absorbent article.
SUMMARY OF THE INVENTION
[0006] This invention is directed to absorbent composites having
improved fluid handling properties and methods of making the
absorbent fibrous or non-fibrous structure. The absorbent fibrous
composites of this invention have a high intake rate of liquid and
a high liquid lock-up fraction. Absorbent composites of this
invention can be any foam, foam-like composite, airlaid composite,
airformed composite, wetformed composite, or combinations thereof.
Absorbent composites of this invention can be modified using
treatments such as ultraviolet radiation, ultrasonic, microwave
radiation, and/or in-situ polymerization treatment to enhance
liquid intake and lock-up performance.
[0007] In one embodiment of the invention, the absorbent composite
includes a freeze-dried absorbent composite. The absorbent
composite is made by forming a slurry comprising a water-insoluble
fiber, and a binding agent. An absorbent material is then added to
the slurry. The solution is cooled to a temperature between about
-50.degree. C. and 0.degree. C. at a cooling rate effective to
freeze the water. The frozen water is removed through sublimation
and a fibrous absorbent composite is recovered. The freeze-dried
composites of this invention have an intake rate of at least about
1.9 cubic centimeters (cc) of liquid/second at 80% composite
saturation and a liquid lock-up fraction of at least about 0.70 at
50% superabsorbent saturation, as determined by test procedures
described below.
[0008] In one embodiment of this invention, the absorbent composite
includes an airformed absorbent composite. The airformed composite
is formed by mixing superabsorbent material and a fibrous material
and using an airforming machine to lay down a web of intermingled
fibers and superabsorbent materials onto a porous tissue. The
airformed absorbent composites of this invention have an intake
rate of at least about 1.9 cc liquid/second at 80% absorbent
composite saturation and a liquid lock-up fraction of at least
about 0.70 at 50% superabsorbent saturation, as determined by test
procedures described below.
[0009] In another embodiment of this invention, the absorbent
composite is formed from a non-fibrous matrix. The non-fibrous
absorbent composites of this invention have an intake rate of at
least about 1.9 cc liquid/second at 80% absorbent composite
saturation and a liquid lock-up fraction of at least about 0.70 at
50% superabsorbent saturation, as determined by test procedures
described below.
[0010] Binding agents can be used in absorbent composites of this
invention to provide strength to the absorbent composite structure
both in the dry state and the wet state. Binding agents are
water-insoluble in the absorbent composite and can bind the fibers
of the absorbent composite together. Binding agents can be
water-swellable and can be used to enhance liquid intake and liquid
lock-up. A crosslinking agent may be needed to insolubilize a
water-soluble binding agent after formation of the absorbent
composite.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other objects and features of this invention will
be better understood from the following detailed description taken
in conjunction with the drawings, wherein:
[0012] FIG. 1 is an exploded perspective view of a diaper according
to one embodiment of this invention.
[0013] FIG. 2 shows absorbent fibers in an absorbent structure
according to one embodiment of this invention.
[0014] FIG. 3 is a photograph of an absorbent fibrous structure
according to one embodiment of the invention.
[0015] FIG. 4A is a plan view of an intake rate testing device.
[0016] FIG. 4B is a top view of the intake rate testing device.
[0017] FIG. 5 is a perspective view of a liquid lock-up testing
apparatus.
[0018] FIG. 6 is a plot of intake rate against composite
saturation.
[0019] FIG. 7 is a plot of lock-up fraction against superabsorbent
material saturation.
[0020] FIG. 8 is a plot of intake rate at 80% absorbent composite
saturation against liquid lock-up fraction at 50% superabsorbent
saturation.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Definitions
[0022] Within the context of this specification, each term or
phrase below will include the following meaning or meanings.
[0023] "Foam" refers to 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.
The cells typically have openings to permit fluid communication
from one cell to another. In other words, the individual cells of
the foam are not completely isolated from each other by the
polymeric material of the cell walls. The cells in such
substantially open-celled foam structures have intercellular
openings which are large enough to permit fluid transfer from one
cell to another within the foam structure. For purposes of this
invention, a foam material is "open-celled" if at least 50%, and
desirably at least 80%, of the cells in the foam structure that are
at least about 1 micron size are in fluid communication with at
least one adjacent cell.
[0024] "Superabsorbent saturation level" refers to the amount of
liquid the superabsorbent material has absorbed as compared to, as
a percentage, the total amount of liquid, or the total saturation
level, the superabsorbent material is able to absorb. A 50%
superabsorbent saturation level thus means that the superabsorbent
material has absorbed 50% of the total amount of liquid the
superabsorbent material is able to absorb.
[0025] "Absorbent composite saturation level" refers to the amount
of liquid the absorbent composite (i.e. freeze-dried composite) has
absorbed as compared to, as a percentage, the total amount of
liquid, or the total saturation level, the absorbent composite is
able to absorb. An 80% absorbent composite saturation level thus
means that the absorbent composite has absorbed 80% of the total
amount of liquid the absorbent composite is able to absorb.
"Freeze-dried composite saturation level" is equivalent to
"absorbent composite saturation level" and is used when the
absorbent composite described is a freeze-dried composite.
[0026] "Capillary size" refers to the size of the open cells in the
fibrous composites of this invention. The capillaries, or
interconnected open cells, are the passage ways through which
fluids are taken into the absorbent fibrous composites.
[0027] "Hydrophilic" describes fibers or the surfaces of fibers
which are wetted by the aqueous liquids in contact with the fibers.
The degree of wetting of the materials can, in turn, be described
in terms of the contact angles and the surface tensions of the
liquids and materials involved. Equipment and techniques suitable
for measuring the wettability of particular fiber materials or
blends of fiber materials can be provided by a Cahn SFA-222 Surface
Force Analyzer System, or a substantially equivalent system. When
measured with this system, fibers having contact angles less than
90.degree. are designated "wettable" or hydrophilic, while fibers
having contact angles greater than 90.degree. are designated
"nonwettable" or hydrophobic.
[0028] "Superabsorbent material" refers to a water-swellable,
water-insoluble organic or inorganic material capable, under the
most favorable conditions, of absorbing at least about 10 times its
weight, preferably at least about 30 times its weight in an aqueous
solution containing 0.9% by weight sodium chloride. Superabsorbent
material can comprise particles, fibers, and/or other structural
forms. "Water-swellable, water-insoluble" refers to the ability of
a material to swell to an equilibrium volume in excess water but
not dissolve into the water. The water-swellable, water-insoluble
material generally retains its original identity or physical
structure, even in a highly expanded state during the absorption of
water.
[0029] "Water soluble" refers to materials which substantially
dissolve 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 this definition.
[0030] "Solvent" refers to a substance, particularly in liquid
form, that is capable of dissolving a polymer used herein to form a
substantially uniformly dispersed mixture at the molecular
level.
[0031] The term "absorbent article" includes without limitation
diapers, training pants, swim wear, absorbent underpants, baby
wipes, adult incontinence products, feminine hygiene products,
medical garments, underpads, bandages, absorbent drapes, and
medical wipes, as well as industrial work wear garments.
[0032] The term "non-fibrous" includes, without limitation,
absorbent structures containing no fibrous material, such as an
open-celled polymeric foam.
[0033] These terms may be defined with additional language in the
remaining portions of the specification.
[0034] This invention relates to absorbent composites having a
fibrous or a non-fibrous matrix and superabsorbent material. The
absorbent composites of this invention have both a high liquid
intake into the composite, and a rapid lock-up of liquid. "Intake
rate" refers to the volume of liquid that is transferred into a
composite as a function of time, as determined by a testing
procedure described below. The liquid simply must enter into the
composite and may be present as free liquid in the interstitial
space of the absorbent composite, as liquid absorbed into a
superabsorbent material, and liquid that has passed through the
composite. "Lock-up" refers to the amount of liquid absorbed into
the superabsorbent material of the absorbent composite within a
predetermined amount of time, as determined by a testing procedure
described below. The benefit of a high intake rate, in particular,
results in substantial leakage control. The combined benefits of
high intake rate and high lock-up percentage result in an absorbent
composite which can quickly contain a liquid insult and prevent
that liquid from being expelled from the composite under pressure
or gravity.
[0035] The absorbent composites of this invention may be used alone
or in combination with other absorbent layers, such as a surge
layer. The absorbent composites are useful in absorbent articles
such as diapers, training pants, swim wear, adult incontinence
articles, feminine care products, and medical absorbent
products.
[0036] The absorbent composites of this invention include one or
more superabsorbent materials known in the art, and can be formed
as a freeze-dried composite, an airformed absorbent composite, a
wetformed absorbent composite, or other absorbent fibrous
composite. These composites comprise a water-swellable,
water-insoluble superabsorbent material and an insoluble fiber. The
absorbent composites of this invention can also include one or more
superabsorbent materials known in the art, and can be formed as a
non-fibrous absorbent composite.
[0037] The open porous structure of the absorbent composites of
this invention allow for rapid intake. The open porous structure
results from the forming process and the nature of the fibers and
the superabsorbent stiffness. The superabsorbent materials of this
invention may have a high stiffness. "Stiffness" refers to the
ability of the superabsorbent material to resist deformation
against pressure while in a swollen state. Using a superabsorbent
material with a high stiffness provides a more open porous
structure because the superabsorbent material does not deform as
much during the swelling process as do low stiffness
superabsorbents. The fibers of this invention may have a high
stiffness.
[0038] "Stiffness" of the fibers refers to the ability of the fiber
to resist bending and deformation while in a wetted state. Using a
fiber with a high stiffness provides a more open porous structure
because the fiber does not bend and deform as much in the wetted
state as do low stiffness fibers. Forming processes of this
invention that are used to make absorbent composites also promote a
more open porous structure. Forming processes that cause the
components of the composite to interact in such a way as to cause
the structure to maintain an open porous structure in the wetted
state and after the superabsorbent is swollen are useful. Such
forming processes include but are not limited to freeze-drying, wet
forming, and airforming. The more open structure allows rapid
intake of fluid into the composite.
[0039] The absorbent composites of this invention exhibit enhanced
intake rate and may also exhibit rapid lock-up of liquid. The
intake rate of the absorbent composites of this invention is
defined at the 80% composite saturation level. The rapid liquid
lock-up properties of the absorbent composites of this invention
are defined as a fraction of the amount of liquid absorbed by the
superabsorbent material over the total added liquid to the
absorbent composite at a 50% superabsorbent material saturation
level. To determine the intake rate and lock-up fraction of an
absorbent composite at these saturation levels it may be necessary
to obtain data at various saturation levels and interpolate the
intake rate and lock-up fraction at the 80% composite saturation
and 50% superabsorbent material saturation levels. These particular
saturation levels are important when absorbent composites are used
within absorbent articles. Absorbent composites generally have
difficulty maintaining intake rate at higher saturation levels, and
thus the high saturation levels are where leakage of body fluids
from absorbent articles typically occurs. Likewise, the choice of
50% superabsorbent material saturation level as the point to
characterize liquid lock-up behavior of this invention is due to
the fact that the swelling kinetics of superabsorbent materials
typically become relatively slow at these higher swelling levels,
thus diminishing the ability to rapidly lock-up liquid. This once
again typically results in a tendency for absorbent products to
leak.
[0040] Absorbent composites according to this invention have an
intake rate of at least about 1.9 cubic centimeters liquid/second
at 80% composite saturation level and a liquid lock-up fraction of
at least about 0.70 at 50% superabsorbent material saturation
level. Alternatively, absorbent composites according to this
invention have an intake rate of at least about 2.3 cubic
centimeters liquid/second at 80% composite saturation level and a
liquid lock-up fraction of at least about 0.75 at 50%
superabsorbent material saturation level. As another alternative,
absorbent composites according to this invention have a intake rate
of at least about 2.7 cubic centimeters liquid/second at 80%
composite saturation level and a liquid lock-up fraction of at
least about 0.80 at 50% superabsorbent material saturation level.
As yet another alternative, absorbent composites according to this
invention have a intake rate of at least about 3.3 cubic
centimeters liquid/second at 80% composite saturation level and a
liquid lock-up fraction of at least about 0.80 at 50%
superabsorbent material saturation level.
[0041] Obtaining the intake rate and lock-up fraction of this
invention can be dependent on the specific combination of three
characteristics: 1) the structure of the composite (freeze-dried
composite, airformed, etc.); 2) the superabsorbent material used;
and 3) the fiber type used. As will be seen by the examples below,
making a freeze dried composite and an airformed composite from the
same superabsorbent material and fiber type results in one
composite having intake rate and liquid lock-up of this invention
and one that does not.
[0042] Absorbent composites of this invention are useful in
absorbent articles such as a diaper. FIG. 1 illustrates an exploded
perspective view of a typical disposable diaper. Referring to FIG.
1, disposable diaper 10 includes outer cover 12, body-side liner
14, and absorbent core 40 located between body-side liner 14 and
outer cover 12. Absorbent core 40 can comprise any of the absorbent
composites according to this invention. Outer cover 12 is
constructed of conventional non-absorbent materials. By
"non-absorbent" it is meant that these materials have an absorptive
capacity not exceeding 5 grams of 0.9% by weight aqueous sodium
chloride solution per gram of material.
[0043] Body-side liner 14 is constructed from highly liquid
pervious materials. This layer functions to transfer liquid from
the wearer to the absorbent core 40. Suitable liquid pervious
materials include porous woven materials, porous nonwoven
materials, films with apertures, open-celled foams, and batting.
Examples include, without limitation, any flexible porous sheets of
polyolefin fibers, such as polypropylene, polyethylene, or
polyester fibers; webs of spunbonded polypropylene, polyethylene,
or polyester fibers; webs of rayon fibers; bonded carded webs of
synthetic or natural fibers; or combinations thereof. The various
layers of article 10 have dimensions which vary depending on the
size and shape of the wearer.
[0044] Attached to outer cover 12 may be waist elastics 26,
fastening 28, and leg elastics 30. The leg elastics 30 typically
have a carrier sheet 32 and individual elastic strands 34. The
diaper of FIG. 1 is a general representation of one basic diaper
embodiment. Various modifications can be made to the design and
materials of diaper parts. For example, a surge material can be
placed between the body-side liner 14 and the absorbent core 40, or
placed between the absorbent core 40 and the outer cover 12. Surge
material is typically a non-absorbent nonwoven material which has a
high intake of fluid and is useful in temporarily storing and
distributing fluids to the absorbent material.
[0045] Possible construction methods and materials of an embodiment
of a diaper such as illustrated in FIG. 1, are set forth in greater
detail in commonly assigned U.S. Pat. No. 5,509,915, issued Apr.
23, 1996 in the name of Hanson et al., incorporated herein by
reference. Possible modifications to the diaper illustrated in FIG.
1 are set forth in commonly assigned U.S. Pat. No. 5,509,915 and in
commonly assigned U.S. Pat. No. 5,364,382, issued Nov. 15, 1994 to
Latimer et al.
[0046] An absorbent composite according to one embodiment of this
invention is a freeze-dried absorbent composite comprising
superabsorbent material. The method of making the freeze-dried
absorbent composite according to one embodiment of this invention
includes forming a slurry of water, a binding material, and a water
insoluble fiber material. A water-swellable, water-insoluble
superabsorbent material is then added to the slurry and the slurry
is cooled to a temperature appropriate to freeze the water. The
water is removed from the slurry under a high vacuum while the
slurry is still in the frozen state, and a freeze-dried absorbent
composite is recovered. Co-pending U.S. patent application filed on
Dec. 14, 2001, having Ser. No. 10/017,465, discloses embodiments of
freeze-dried composites and methods for making freeze-dried
composites that can be used to make the freeze-dried composites of
this invention, and is herein incorporated by reference.
[0047] Suitable freezing temperature for making a freeze-dried
fibrous composite is below the freezing point of the slurry solvent
used. When water is used as the slurry solvent the temperature
should be about 0.degree. C. to about -50.degree. C., suitably from
about -5.degree. C. to -50.degree. C., more suitably from about
-10.degree. C. to -40.degree. C., and desirably from about
-10.degree. C. to -30.degree. C. The selection of temperature is
also dependent on the nature and concentration of the slurry. If
the temperature selection is too close to the freezing point of the
polymer slurry solution the frozen slurry may not have enough
strength and may deform under vacuum removal of the solvent. If the
temperature drops too far below the solvent freezing point the
solvent molecules may form crystals which generally causes
substantial cracks in the composite and reduces mechanical
properties of the recovered composites.
[0048] While freezing the slurry it is important to control the
cooling rate of the slurry from room temperature (.about.23.degree.
C.) to freezing temperature. The cooling rate should not exceed a
critical cooling rate. "Critical cooling rate" refers to the
cooling rate at which, or any rate greater, the slurry, as well as
the final absorbent composite, begins to form visible cracks or
visible non-uniformity. Critical cooling rate can vary depending
upon the freezing point of the solvent used, concentration of
slurry, use of a two solvent slurry, crystallizability of the
solvent, ratio of insoluble fibers to superabsorbent material, and
ratio of fibers to binding agent. A cooling rate slower than the
critical cooling rate is preferred and generally results in a much
more uniform pore structure and a softer, more flexible absorbent
composite, due to the elimination of substantial cracks caused by
uneven crystallization of solvent molecules. The cooling rate for
an aqueous slurry having a weight ratio of insoluble fibers to
soluble polymer greater than 9:1 or a weight ratio of
water-swellable superabsorbent material to water-soluble polymer
greater than 9:1, should be between about 0.01.degree. C. and
10.degree. C. per minute, suitably between about 0.05.degree. C. to
3.degree. C. per minute, and desirably between about 0.1.degree. C.
and 1.degree. C. per minute.
[0049] Removal of the frozen solvent is preferably done by vacuum
sublimation. Vacuum suitable for this invention is dependent on the
volatility of solvent used. Higher vacuum can increase the rate of
sublimation and lower vacuum applies a lower pressure on the frozen
slurry that can result in less damage and a higher mechanical
strength of the resulting composite. Vacuum conditions are
desirably less than about 500 millitorrs, or less than about 300
millitorrs, or less than 200 millitorrs, or less than 100
millitorrs. In general, good vacuum can be achieved by either a
good quality vacuum pump or a lower condenser temperature, which
captures more water vapor. Because sublimation is endothermic, the
temperature of the frozen slurry is reduced as water is sublimated
under vacuum. This means that the frozen slurry will be even colder
and therefore it becomes more difficult to release water molecules.
In order to compensate such energy loss, the freeze dryer should be
equipped with a heater which provides just enough heat to
compensate the energy loss to maintain temperature at a
predetermined level.
[0050] The freeze-dried composites of this invention suitably have
an intake rate of at least about 1.9 cc liquid/second at 80%
freeze-dried composite saturation and a liquid lock-up fraction of
at least about 0.70 at 50% superabsorbent material saturation.
Alternatively, the freeze-dried composites of this invention have
an intake rate of at least about 2.3 cc liquid/second at 80%
freeze-dried composite saturation and a liquid lock-up fraction of
at least about 0.75 at 50% superabsorbent material saturation. As
another alternative, the freeze-dried composites of this invention
have an intake rate of at least about 2.7 cc liquid/second at 80%
freeze-dried composite saturation and a liquid lock-up fraction of
at least about 0.80 at 50% superabsorbent material saturation. As
yet another alternative, the freeze-dried composites of this
invention have an intake rate of at least about 3.3 cc
liquid/second at 80% freeze-dried composite saturation and a liquid
lock-up fraction of at least about 0.80 at 50% superabsorbent
material saturation.
[0051] The resulting composite, as shown in FIG. 3, is a soft
freeze-dried absorbent composite including a water-swellable,
water-insoluble superabsorbent polymer and a water insoluble fiber.
The water-swellable, water-insoluble superabsorbent material is
present in the absorbent composite in a weight amount of at least
about 10% by weight, suitably from about 10% to 70% by weight,
alternatively from about 20% to 60% by weight, or from about 30% to
50% by weight. The water-insoluble fiber is present in the
absorbent composite in a weight amount from about 10% to 90% by
weight, suitably from about 20% to 80% by weight, or from about 50%
to 70% by weight. The binding material is present in the absorbent
composite in a weight amount from about 0% to 10% by weight,
suitably from about 1% to 8% by weight, and alternatively from
about 2% to 5% by weight.
[0052] Water-insoluble fibers suitable for the various fibrous
absorbent composites of this invention include both natural fibers
including without limitation, wood pulp, cotton linter, synthetic
fibers including, without limitation, thermoplastic fibers such as
polyethylene fibers, polypropylene fibers, poly(ethylene
terephthalate), polyester fibers, and elastic fibers such as
polyurethane fibers. Hydrophilic fibers are preferred due to their
wettability characteristics. Hydrophobic fibers can be used and are
preferably treated with surfactants or other effective treatment to
alter surface chemistry to increase wettability.
[0053] Fiber size directly affects capillary structure of the final
absorbent composite. Generally, the larger the fiber size, the
larger the capillary size, and when the capillary size gets larger,
the ability to move liquid to high heights against gravity is
diminished. Oppositely, smaller fiber size generally provides
smaller capillary size which can move liquid up to high heights
against gravity, but the rate of liquid movement may be negatively
impacted. Therefore, an appropriate fiber size choice is critical
based on the final function desired. Generally, larger and stiffer
fibers are preferred because they lead to structures with larger
capillaries that would improve the intake rate of the composite.
Fibers useful in this invention have a diameter of about 1 microns
to 100 microns, suitably about 1 microns to 50 microns, and
desirably about 10 microns to 30 microns.
[0054] Water-swellable, water-insoluble superabsorbent materials
suitable for all composite structures of this invention include
crosslinked anionic and cationic polymers. Anionic polymer examples
include without limitation, sodium-polyacrylate, carboxymethyl
cellulose (CMC), carboxymethyl polysaccharides including starch,
chitin, and other gums, polyaspartic acid salt, maleic
anhydride-isobutylene copolymer, and copolymers and admixtures of
these polymers. Cationic examples include without limitation,
chitosan salts, polyquarternary ammonium salts, polyvinyl amines,
and copolymers and admixtures of these polymers. Physical form of
the superabsorbent materials can be particulate, fibrous, nonwoven
aggregate, printed, coated, or other forms.
[0055] Binding materials provide strength to the absorbent fibrous
composite both in the dry state and the wet state. Binding
materials are typically water-soluble or dispersible in the slurry
and water-insoluble in the absorbent fibrous composite after
freeze-drying and/or heat curing. Binding materials bind the
water-insoluble fibers and the superabsorbent materials together.
As shown in FIG. 2, fibers 20 are held together in the fibrous
absorbent composite structure by binding material polymers 22. The
binding material may be water-swellable or not water-swellable. For
use in absorbent articles the binding material is preferably
water-swellable. Preferred binding material polymers are
hydrophilic and substantially water-insoluble in the absorbent
fibrous composite, providing desired wet strength of the fibrous
composite.
[0056] For swellable binding materials, high molecular weight ionic
polymers such as sodium-polyacrylate, carboxymethyl cellulose, and
chitosan salt are useful in that they provide strength and
absorbency to the freeze-dried composite. Other swellable binding
materials include isobutylene-maleic anhydride copolymers,
polyvinyl amines, polyquarternary ammoniums, polyvinyl alcohols,
hydroxypropyl celluloses, polyethylene oxides, polypropylene
oxides, polyethylene glycols, modified polysaccharides, proteins,
and combinations thereof. Non-swellable, low molecular weight
binding materials include poly(aminoamide) epichlorohydrin polymer,
such as KYMENE.RTM. (available from Hercules Inc., Chicopee,
Mass.), latex, and other adhesives. Other non-swellable binding
materials include any wet strength resins used in the paper making
industries and any type of adhesive material. If an adhesive is
used it is preferred that the adhesive is hydrophilic.
[0057] A crosslinking agent may be needed to insolubilize a
water-soluble binding material after formation of the absorbent
composite structure. Crosslinking agents are typically
water-soluble. Suitable crosslinking agents include organic
compounds comprising at least two functional groups capable of
reacting with at least one of carboxyl, carboxylic acid, amino,
and/or hydroxyl groups. Examples of this type of crosslinking
agents include without limitation, diamines, polyamines, diols,
polyols, polycarboxylic acids, and polyoxides. Another suitable
crosslinking agent is a metal ion with more than two positive
charges, including without limitation, Al.sup.3+, Fe.sup.3+,
Ce.sup.3+, Ce.sup.4+, Ti.sup.4+, Zr.sup.4+, and Cr.sup.3+. When
cationic polymer binding agents are used, polyanionic substances
are suitable crosslinking agents. Polyanionic substances include
without limitation, sodium-polyacrylate, carboxymethyl cellulose,
and polymers including the phosphate anion --PO.sub.4.sup.3-.
[0058] In one embodiment of this invention, the method of making a
freeze-dried absorbent composite includes forming a slurry of water
and a water insoluble fiber material with no binding material. A
water-swellable, water-soluble superabsorbent precursor is then
added to the slurry and the slurry is cooled to a temperature
appropriate to freeze the water. The water is removed from the
slurry under high vacuum sublimation, and an absorbent composite is
recovered.
[0059] When the water-soluble superabsorbent precursor is used,
there is no need to add a binding material. The superabsorbent
material will act as the binding material when the water-soluble
superabsorbent precursor is crosslinked to form a water-swellable,
water-insoluble network after composite production. The resulting
composite is also a soft absorbent composite comprising a
water-swellable, water-insoluble superabsorbent polymer and a water
insoluble fiber.
[0060] Examples of water-soluble superabsorbent precursors include,
without limitation, polyacrylic acid, carboxymethyl cellulose, and
chitosan salt. Examples of other superabsorbent precursors include
isobutylene-maleic anhydride copolymers, polyvinyl amines,
polyquarternary ammoniums, polyvinyl alcohols, hydroxypropyl
celluloses, polyethylene oxides, polypropylene oxides, polyethylene
glycols, modified polysaccharides, proteins, and combinations
thereof.
[0061] When a superabsorbent precursor or a water-soluble binding
agent is used in this invention, a crosslinking agent is added.
After the recovery of the freeze-dried fibrous composite the
composite may require treatment to induce the crosslinking to
provide a water-insoluble superabsorbent material or a
water-insoluble binding agent. Suitable post composite treatment
includes without limitation, heat curing at temperature greater
than 60.degree. C., ultraviolet radiation, microwave radiation,
steam or high pressure, electronic beam radiation, organic
solvents, and humidity treatment.
[0062] Absorbent composites of another embodiment of this invention
are airformed absorbent composites. Airformed absorbent composites
are made by combining superabsorbent particles and matrix fibers
into an airforming former unit to mix and lay down a web of
intermingled superabsorbent particles and matrix fibers. The web of
intermingled superabsorbent particles and matrix fibers is formed
directly onto a porous sheet of tissue. One example of a suitable
porous tissue is designated as 9.8 pound White Forming Tissue
available from American Tissue, Inc., Neenah, Wis. The airformed
absorbent composite can then be compressed to a desired density by
a Carver Press. A suitable airformed absorbent composite density is
between about 0.05 gram/cubic centimeter (g/cc) and 0.5 g/cc, a
more suitable density is between about 0.1 g/cc and 0.4 g/cc, and a
preferred density is between about 0.15 g/cc and 0.3 g/cc. The
water-swellable, water-insoluble superabsorbent material is present
in the absorbent composite in a weight amount of at least about 10%
by weight, suitably from about 10% to 70% by weight, desirably from
about 20% to 60% by weight, and preferably from about 30% to 50% by
weight. The water-insoluble fiber is present in the absorbent
composite in a weight amount from about 10% to 90% by weight,
suitably from about 20% to 80% by weight, and desirably about 50%
to 70% by weight.
[0063] Absorbent composites of another embodiment of this invention
are wetformed absorbent composites. Wetformed absorbent composites
are formed by processes well known in the art. One example of a
process for making wetformed absorbent composite is disclosed in
U.S. Pat. No. 5,651,862, issued to Anderson et al. on Jul. 29,
1997, herein incorporated by reference. Wetformed composites are
generally formed by mixing fibers, absorbent materials, and other
possible additives such as binder materials into a liquid medium.
The medium plus the fibers, absorbent materials, and the other
possible additives are conveyed onto a web forming porous
substrate, and the medium is removed by vacuum. The
water-swellable, water-insoluble superabsorbent material is present
in the absorbent composite in a weight amount of at least about 10%
by weight, suitably about 10% to 70% by weight, desirably about 20%
to 60% by weight, and preferably about 30% to 50% by weight. The
water-insoluble fiber is present in the absorbent composite in a
weight amount from about 10% to 90% by weight, suitably about 20%
to 80% by weight, and desirably about 50% to 70% by weight.
[0064] In the various embodiments of this invention, many suitable
types of wettable, hydrophilic fibrous materials can be used to
form the absorbent composites. Suitable matrix fibers include
without limitation, naturally occurring organic fibers composed of
inherently wettable material, such as cellulose fibers; synthetic
fibers composed of cellulose or cellulose derivatives, such as
rayon fibers; inorganic fibers composed of an inherently wettable
material, such as glass fibers; synthetic fibers made from
inherently wettable thermoplastic polymers, such as particular
polyester or polyamide fibers; and synthetic fibers composed of a
nonwettable thermoplastic polymer, such as polypropylene fibers.
The fibers may be hydrophilized, for example, by treatment with
silica, treatment with a material which has a suitable hydrophilic
moiety and is not readily removable from the fiber, or by sheathing
the nonwettable, hydrophobic fiber with a hydrophilic polymer
during or after the formation of the fiber. Combinations of various
fibers can also be used in absorbent composites of this
invention.
[0065] Other embodiments of this invention may include a
non-fibrous matrix. One example of a non-fibrous matrix is an
open-celled foam. Absorbent composites including a non-fibrous
matrix can be formed by mixing superabsorbent and the non-fibrous
matrix in such a way as to distribute the superabsorbent uniformly
or non-uniformly throughout the non-fibrous matrix. The
water-swellable, water-insoluble superabsorbent material may be
present in the absorbent composite in a weight amount of at least
about 10% by weight, suitably about 10% to 70% by weight, desirably
about 20% to 60% by weight, and preferably about 30% to 50% by
weight. The non-fibrous matrix may be present in the absorbent
composite in a weight amount about 10% to 90% by weight, suitably
about 20% to 80% by weight, and desirably about 50% to 70% by
weight.
[0066] Suitable superabsorbent materials include, without
limitation, the alkali metal and ammonium salts of poly(acrylic
acid) and poly(methacrylic acid), poly(acrylamides), poly(vinyl
ethers), (maleic anhydride copolymers with vinyl ethers and
alpha-olefins, polyvinyl pyrrolidone), poly(vinylmorpholinone),
poly(vinyl alcohol), and mixtures and copolymers thereof. Current
commercial superabsorbent materials can be modified to improve the
absorption characteristics for use in the absorbent composites of
this invention. One method of modifying superabsorbent materials is
by using freeze-drying techniques as disclosed in co-pending U.S.
patent application filed by Express Mail No. EV068478187 on Nov. 8,
2002, and having Ser. No. 10/291,237, herein incorporated by
reference, and similar to those described above. Freeze-dried
superabsorbent materials can be used with airforming techniques,
wetlaying techniques, and other composite forming methods to obtain
absorbent composites having the improved absorbent properties of
this invention. One example of such a modified commercial
superabsorbent material is a modified freeze-dried superabsorbent
material FAVOR.RTM. SXM 9543, available in unmodified form from
Stockhausen, Inc., Greensboro, N.C. Freeze-dried superabsorbent
materials can be obtained by absorbing an amount of water or other
solvent, freezing the swollen superabsorbent material, and removing
the water by sublimation using a freeze-drier or similar device.
One method for freeze-drying the FAVOR.RTM. SXM 9543 is described
below.
[0067] Further polymers suitable for use in absorbent composites
include, without limitation, natural and modified natural polymers,
such as hydrolyzed acrylonitrile-grafted starch, acrylic acid
grafted starch, methyl cellulose, chitosan, carboxymethyl
cellulose, hydroxypropyl cellulose, and the natural gums, such as
alginates, xanthan gum, locust bean gum and the like. Mixtures of
natural and wholly or partially synthetic polymers can also be
useful in this invention.
[0068] Other superabsorbent compositions generally suitable only
for dry processes include (1) an acidic water-swellable,
water-insoluble polymer and a basic neutralization agent; (2) a
basic water-swellable, water-insoluble polymer and an acidic
neutralization agent; or (3) an acidic water-swellable,
water-insoluble polymer and a basic water-swellable,
water-insoluble polymer. These mixtures of superabsorbent
compositions are capable of neutralizing each other between the
acidic and basic components in-situ upon urine saturation in the
absorbent products. Such in-situ neutralization process enhances
absorbency of the composition, exhibits a capability of removing
salt from the urine or other body fluid, reduces overall cost of
the absorbent composition due to the use of low-cost non-polymer
based neutralizing agents. Suitable acidic water-swellable,
water-insoluble polymers include functional groups that are capable
of being converted to anions. Such functional groups include, but
are not limited to, carboxylic acid, sulfonic acid, phosphoric
acid. Suitably, the functional groups are carboxylic acid groups.
Examples of suitable acidic polymer include polyacrylic acid,
carboxymethyl cellulose, isobutylene-maleic anhydride copolymer,
polyaspartic acid, polyglutamic acid, polyacrylamido methylpropane
sulfonic acid, polyvinyl acetic acid, polyvinyl phosphonic acid,
polyvinyl sulfonic acid, carrageenan, and alginic acid. Suitable
basic water-swellable, water-insoluble polymers include functional
groups that are capable of being converted to cations. Such
functional groups include, but are not limited to, primary,
secondary, or tertiary amino groups, quaternary ammonium groups,
imino groups, imido groups. Suitably, the basic functional groups
are quaternary ammonium groups and primary amino groups. Examples
of suitable basic polymers include polyvinyl amines,
polyallylamines, polydiallyldimethyl ammonium hydroxide, chitosan,
polyethlene imines, polyasparagins, polyglutamines, polylysines,
and polyarginines. Suitable acidic neutralizing agents include both
acidic water-swellable, water-insoluble polymers listed above and
non-polymer based acidic compounds. These non-polymer based acidic
compounds include organic acidic material such as aliphatic and
aromatic acids, for example, citric acid, glutamic acid or aspartic
acid, and inorganic acids such as metallic oxides, for example,
aluminum oxide, and salts such as iron chloride, calcium chloride,
and combinations of any of these. Suitable basic neutralizing
agents include both basic water-swellable, water-insoluble polymers
listed above and non-polymer based basic compounds. These
non-polymer based basic compounds include organic basic material
such as organic salts, for example, sodium-citrate, and aliphatic
and aromatic amines, imines, and amides, and inorganic bases such
as metallic oxides, for example, sodium oxides, hydroxides, for
example, sodium hydroxide, salts such as sodium carbonate and
sodium bicarbonate, and combinations of any of these. Because two
components can neutralize each other, it is important that these
absorbent compositions avoid any contact with aqueous liquid in the
processes of superabsorbent material preparation and absorbent
product manufacturing. Contact of water triggers neutralization and
therefore eliminates the benefits of the absorbent
compositions.
[0069] The airformed, wetformed, and non-fibrous absorbent
composites of this invention have an intake rate of at least about
1.9 cc liquid/second at 80% absorbent composite saturation and a
liquid lock-up fraction of at least about 0.70 at 50%
superabsorbent material saturation. Alternatively, the airformed,
wetformed, and non-fibrous absorbent composites of this invention
have an intake rate of at least about 2.3 cc liquid/second at 80%
absorbent composite saturation and a liquid lock-up fraction of at
least about 0.75 at 50% superabsorbent material saturation. As
another alternative, the airformed, wetformed, and non-fibrous
absorbent composites of this invention have an intake rate of at
least about 2.7 cc liquid/second at 80% absorbent composite
saturation and a liquid lock-up fraction of at least about 0.80 at
50% superabsorbent material saturation. As yet another alternative,
the airformed, wetformed, and non-fibrous absorbent composites of
this invention have an intake rate of at least about 3.3 cc
liquid/second at 80% absorbent composite saturation and a liquid
lock-up fraction of at least about 0.80 at 50% superabsorbent
material saturation.
EXAMPLES
[0070] To demonstrate this invention, five freeze-dried composite
samples and five airformed composite samples were made. Table 1
summarizes the compositions of each freeze-dried composite sample
made by the following process. For each sample an amount of
distilled water listed in Table 1 was poured into a 4 liter
HOBART.RTM. mixer, Model N50, manufactured by Hobart Canada of
North York, Ontario, Canada. The mixer has 3 mixing settings. The
mixer was initially set at a relatively slow mixing rate (setting
1) and, while stirring, an amount of wood pulp fluff, available
from Bowater Corporation of Coosa Pines, Ala., and designated
CR-1654, listed in Table 1 was added to the appropriate water
amount. Then the appropriate amount of binder material from Table
1, carboxymethyl cellulose, available from Aqualon Company of
Wilmington, Del., designated CMC-7H, was slowly added into the
mixer. The addition of the binder material was slow enough to
prevent agglomeration of the carboxymethyl cellulose powder.
[0071] After mixing for about two minutes, the mixer speed was
increased to mixer setting 2. After mixing for an additional five
minutes at mixer setting 2 the superabsorbent material,
DRYTECH.RTM. 2035, available from Dow Chemical Company of Midland,
Mich., was added into the mixer and mixed for about 10 seconds at
mixer setting 2. The resulting uniform slurries for each sample
were each poured into a separate 25.6 cm wide, 51.2 cm long, and
5.2 cm deep stainless steel pan. Each pan was put into a VirTis
Genesis Freeze Dryer, Model 25 EL, manufactured by VirTis of
Gardiner, N.Y. The samples were freeze dried in the freeze dryer at
a shelf temperature of below -50.degree. C., a condenser
temperature of below -70.degree. C., and a vacuum of less than 100
millitorrs. The samples were freeze dried between 2 to 3 days
depending upon the total loading of frozen water in the dryer. The
freeze dried composite samples were then heat treated at
130.degree. C. for two hours to insolubilize the binder
material.
1TABLE 1 Sample Superabsorbent Wood Pulp Binder Water No. Material
(g) Fluff (g) Material (g) (g) 1 28.3 28.3 6.3 1500 2 28.3 28.3 6.3
2000 3 28.3 28.3 6.3 2500 4 16.8 39.8 6.3 1500 5 39.8 16.8 6.3
1500
[0072] An airformed composite, Sample 6, also made from
DRYTECH.RTM. 2035, and commercially available diaper samples,
Samples 7 and 8, were prepared as a comparison to freeze-dried
composite Samples 1-5 and the airformed composites, Samples 9 and
10, described below. Sample 6 was prepared by combining 1.20 grams
of DRYTECH.RTM. 2035 superabsorbent material with 1.20 grams wood
pulp fibers, designated as CARESSA.RTM. 1300, available from
Buckeye Corporation of Memphis, Tenn., in an airforming handsheet
former unit. The airforming handsheet former unit mixed the
materials and formed a web of intermingled superabsorbent particles
and fibers directly onto a porous sheet of tissue. The tissue was a
9.8 pound White Forming Tissue available from American Tissue Inc.,
Neenah, Wis. A second layer of tissue was placed above the web
following web formation. The airformed composite of Sample 6 was
7.68 cm in diameter and was compressed to a density of 0.2 g/cc
using a Carver Press.
[0073] The commercially available diapers tested were HUGGIES.RTM.
Supreme Step-3 (Bag Code NM034102b0545-1900), designated Sample 7,
and PAMPERS.RTM. Premium Size-2 (Bag Code 1121U017261559),
designated Sample 8. To obtain samples for testing, the diaper was
placed on a die cutting device and a 7.68 cm diameter sample was
taken from the target area of the diaper. The centerpoint of the
7.68 cm die cut sample was 16.64 cm from the front end of the
absorbent pad and spaced in the middle of the absorbent pad in the
cross-direction. Following punching of the sample, all layers were
removed leaving only the superabsorbent-fluff layer of the
products.
[0074] Samples 9 and 10, airformed composites according to this
invention, and Samples 11 and 12, airformed composites not having
the composite properties of this invention included for comparison,
were made using modified FAVOR.RTM. SXM 9543 superabsorbent
material. The FAVOR.RTM. SXM 9543 was modified by freeze-drying
according to the following method. An amount of distilled water was
added into a one gallon HOBART.RTM. mixer (Model N50, manufactured
by Hobart Canada, Ontario, Canada). 100 grams of FAVOR.RTM. SXM
9543 superabsorbent particles were added into the mixer while the
stirrer was on. After stirring for about 2 minutes, the swollen
superabsorbent particles were discharged into a pan (10 inches by
20 inches; 25.4 centimeters by 50.8 centimeters) to form a uniform
thin layer. The pan was placed into a VirTis Genesis freeze dryer
(Model 25 EL) available from The VirTis Inc. of Gardiner, N.Y. The
superabsorbent material was freeze dried in the freeze dryer at a
shelf temperature of less than -50.degree. C., a condenser
temperature of less than -70.degree. C., and a vacuum of less than
100 millitorrs.
[0075] The modified freeze-dried superabsorbent particles of
Samples 9 and 11 were made as described above by absorbing 200
grams of distilled water into 100 grams of FAVOR.RTM. SXM 9543
(swelling level of 2 grams/gram) and freeze-drying. The modified
freeze-dried superabsorbent particles of Samples 10 and 12 were
made as described above by absorbing 500 grams of distilled water
into 100 grams of FAVOR.RTM. SXM 9543 (swelling level of 5
grams/gram) and freeze-drying.
[0076] Sample 9 was prepared by combining 1.20 grams of the
appropriate modified freeze dried FAVOR.RTM. SXM 9543
superabsorbent material with 1.20 grams wood pulp fibers,
designated as CR-1654, available from Bowater Corporation, Coosa
Pines, Ala., in an airforming handsheet former unit. The airforming
handsheet former unit mixed the materials and formed a web of
intermingled superabsorbent particles and fibers directly onto a
porous sheet of tissue. The tissue was a 9.8 pound White Forming
Tissue available from American Tissue Inc. A second layer of tissue
was placed above the web following web formation. The airformed
composite of Sample 9 was 7.68 centimeter in diameter and was
compressed to a density of 0.2 gram/cubic centimeter using a Carver
Press.
[0077] Sample 10 was prepared by combining 1.20 grams of the
appropriate modified freeze dried FAVOR.RTM. SXM 9543 with 1.20
grams wood pulp fibers, designated as CR-1654, available from
Bowater Corporation, Coosa Pines, Ala., in an airforming handsheet
former unit. The airforming handsheet former unit mixed the
materials and formed a web of intermingled superabsorbent particles
and fibers directly onto a porous sheet of tissue. The tissue was a
9.8 pound White Forming Tissue available from American Tissue Inc.
A second layer of tissue was placed above the web following web
formation. The airformed composite of Sample 10 was 7.68 centimeter
in diameter and was compressed to a density of 0.2 grams/cubic
centimeter using a Carver Press.
[0078] Sample 11 was prepared by combining 1.20 grams of the
appropriate modified freeze dried FAVOR.RTM. SXM 9543
superabsorbent material with 1.20 grams wood pulp fibers,
designated as CARESSA.RTM. 1300, in an airforming handsheet former
unit. The airforming handsheet former unit mixed the materials and
formed a web of intermingled superabsorbent particles and fibers
directly onto a porous sheet of tissue. The tissue was a 9.8 pound
White Forming Tissue available from American Tissue Inc. A second
layer of tissue was placed above the web following web formation.
The airformed composite of Sample 11 was 7.68 centimeter in
diameter and was compressed to a density of 0.2 gram/cubic
centimeter using a Carver Press.
[0079] Sample 12 was prepared by combining 1.20 grams of the
appropriate modified freeze dried FAVOR.RTM. SXM 9543 with 1.20
grams wood pulp fibers, designated as CARESSA.RTM. 1300, in an
airforming handsheet former unit. The airforming handsheet former
unit mixed the materials and formed a web of intermingled
superabsorbent particles and fibers directly onto a porous sheet of
tissue. The tissue was a 9.8 pound White Forming Tissue available
from American Tissue Inc. A second layer of tissue was placed above
the web following web formation. The airformed composite of Sample
12 was 7.68 centimeter in diameter and was compressed to a density
of 0.2 grams/cubic centimeter using a Carver Press.
[0080] Intake rate is determined by pre-weighing a 7.68 cm diameter
sample of each of Samples 1-12, and placing the 7.68 cm diameter
sample under a cylindrical port device as shown in FIGS. 4A and 4B.
FIG. 4A shows cylindrical port device 50 having cylinder 52 and
base 54. Cylindrical port device 50 can be made from various
materials, such as plastic, and has a weight that will result in
pressure being placed on sample 60 below the cylindrical port
device 50. As shown in FIG. 4B, additional weights 56 can be placed
on base 54 for testing sample 60 at higher pressures. Sample 60 has
a diameter substantially equal to the diameter of base 54, which is
7.68 cm for each in the present testing, and is placed under base
54 during testing. The cylindrical port device used in testing
Samples 1-12 was made of plastic having a weight of about 39 grams.
Additional weights 56, totaling 250 grams, were added to obtain a
testing pressure on the samples of about 0.09 pounds per square
inch (psi).
[0081] Cylinder 52 is hollow with an inner diameter of 2.54 cm,
allowing for liquid to be poured into cylinder 52 and contact
sample 60 below. For Samples 1-10, 15 cubic centimeters (cc) of
0.9% by weight sodium chloride solution is poured into the
cylindrical port device. The time required for the volume of liquid
to be absorbed into the samples at the base of the device is
recorded. Divide the total charge of 15 cc by the intake time for
each sample to obtain the intake rate for that sample.
[0082] A typical vacuum apparatus useful for lock-up testing is
shown in FIG. 5. Vacuum apparatus 70 has base 72 with mesh screen
74 and vacuum tube 78 attached to a vacuum source. Sample 60 is
placed onto mesh screen 74, typically a size 100 mesh screen, and
sample 60 and base 72 are covered by gas impervious rubber dam 76.
A vacuum is applied through vacuum tube 78 and, because rubber dam
creates a seal around base 72, the vacuum pulls an amount of liquid
from sample 60. The amount of fluid maintained by sample 60 is
determined by subtracting the dry weight of the sample from the wet
weight of the sample after application of the vacuum, and
converting the net weight to milliliters using the density of the
test liquid.
[0083] For Samples 1-12, lock-up testing is done following the
intake rate test by waiting 60 seconds, putting each sample
absorbent composite on a vacuum apparatus and applying a vacuum of
about minus 13.5 pounds per square inch gauge for two minutes.
After applying vacuum for 60 seconds, the mass of sodium chloride
solution left in the sample was determined. Determine liquid
lock-up by dividing the mass of liquid remaining in the sample by
the total initial insult.
[0084] The intake and lock-up tests are repeated for each sample
three times for a total insult of 45 cubic centimeter (cc) 0.9% by
weight sodium chloride solution applied to the sample. After the
lock-up testing of each sample, however, the sample composite has
been drained of some of the liquid from the intake rate testing
insult. Therefore, for the second intake and lock-up tests, a new
(although nominally same in composition) sample is used. The
second, nominally identical sample is given a first 15 cubic
centimeter insult of 0.9% by weight sodium chloride solution insult
(equivalent to the amount from the first intake rate test) and,
after waiting 15 minutes, a second 15 cubic centimeter insult of
0.9% by weight sodium chloride solution, for a total of 30 cubic
centimeter of 0.9% by weight sodium chloride solution. After the
second intake rate test a second lock-up test is performed, so the
third intake rate test also uses a new, nominally identical sample.
The third, nominally identical sample is given a first 15 cubic
centimeter insult of 0.9% by weight sodium chloride solution
(equivalent to the amount from the first intake rate test), a
second of 15 cubic centimeter insult of 0.9% by weight sodium
chloride solution after 15 minutes, and, after waiting an
additional 15 minutes, a third 15 cubic centimeter insult of 0.9%
by weight sodium chloride solution is added to the sample for a
total of 45 cubic centimeter of 0.9% by weight sodium chloride
solution.
[0085] The calculations for intake rate are the same each time. To
calculate lock-up on subsequent insults, divide the cumulative mass
of liquid remaining in the sample after vacuum by the cumulative
amount of liquid that has been added to the sample. When the intake
rate and lock-up tests are complete a saturation test was conducted
on a nominally identical sample to determine total saturation
capacity of the absorbent composite.
[0086] The liquid saturated retention capacity is determined as
follows. The material to be tested is weighed and submerged in an
excess quantity of 0.9% by weight sodium chloride solution at
standard TAPPI conditions. The material to be tested is allowed to
remain submerged for about 20 minutes. After the 20 minute
submerging, the material is removed and, referring to FIG. 5,
placed on a vacuum apparatus with 0.25 inch diameter openings and
covered with size 100 mesh screen 74 which, in turn, is connected
to vacuum source 78 and covered with a flexible rubber dam material
76. A vacuum of about -13.5 pounds per square inch gauge is drawn
on the vacuum apparatus for a period of about 3 minutes with the
use of, for example, house vacuum supply. The material being tested
is then removed from the apparatus and weighed. The amount of
liquid retained by the material being tested is determined by
subtracting the dry weight of the material from the wet weight of
the material (after application of the vacuum), converting the
weight to milliliters by using the density of the test liquid, and
is reported as the liquid saturated retention capacity in
milliliters of liquid retained. For relative comparisons, the
weight of liquid held (wet weight after application of vacuum minus
dry weight) can be divided by the weight of the material 60 to give
specific liquid saturated retention capacity in grams of liquid
retained per gram of tested material.
[0087] The saturation capacity of a superabsorbent material or
insoluble fiber is determined by a centrifuge retention capacity
test. As used herein, the Centrifugal Retention Capacity (CRC) is a
measure of the absorbent capacity of the superabsorbent material or
fiber after being subjected to centrifugation under controlled
conditions. The superabsorbent sample to be tested is taken from
superabsorbent material which is prescreened through U.S. standard
#30 mesh and retained on U.S. standard #50 mesh to obtain a
particle size of between 300 and 600 microns. Testing a fiber
sample is performed "as-is" without fractionation. The CRC can be
measured by placing 0.200 grams of the sample material to be tested
(moisture content of less than 5 weight percent) into a
water-permeable bag which will contain the sample while allowing
the test solution (0.9 percent by weight sodium chloride solution)
to be freely absorbed by the sample. A heat-sealable tea bag
material (grade 542, commercially available from Kimberly-Clark
Corporation, Neenah, Wis.) works well for most applications. The
bag is formed by folding a 12.7 centimeter by 7.62 centimeter
sample of the bag material in half and heat sealing two of the open
edges to form a 6.35 by 7.62 centimeter rectangular pouch. The heat
seals should be about 0.635 centimeters inside the edge of the
material. After the sample is placed in the pouch, the remaining
open edge of the pouch is also heat-sealed. Empty bags are also
made to be tested with the sample bags as controls. Three sample
bags are tested for each superabsorbent material. The sealed bags
are placed between two Teflon coated fiberglass screens having
0.635 centimeter openings (Taconic Plastics, Inc., Petersburg,
N.Y.) and submerged in a pan of 0.9 percent by weight sodium
chloride solution at about 23.degree. C., making sure that the
screens are held down until the bags are completely wetted. After
wetting, the samples remain in the solution for 30 minutes, at
which time they are removed from the solution and temporarily laid
on a nonabsorbent flat surface. The wet bags are then placed into
the basket of a suitable centrifuge capable of subjecting the
samples to a gravitational-force of 300. A suitable centrifuge is a
Heraeus Instruments Labofuge 400, having a water collection basket,
digital rotations per minute (rpm) gauge, and machined drainage
basket adapted to hold and drain the samples. The samples must be
placed in opposing positions within the centrifuge to balance the
basket when spinning. The bags are centrifuged at a target of 1600
rotations per minute, but within the range of 1500-1900 rotations
per minute, for 3 minutes (target gravitational-force of 300). The
bags are removed and weighed, with the empty bags (controls) being
weighed first, followed by the bags containing the superabsorbent
material or fiber. All fluid not locked-up (absorbed) in the
superabsorbent material (or the teabag) is centrifuged out of the
sample.
[0088] The amount of fluid absorbed and retained by the
superabsorbent material (or fiber), taking into account the fluid
retained by the bag material alone, is the Centrifugal Retention
Capacity of the superabsorbent material or fiber, expressed as
grams of fluid per gram of material. This calculation is done by
the following equation: 1 CRC = ( W s - W e - W d ) W d
[0089] Where "CRC" is the Centrifugal Retention Capacity of the
sample (grams/gram), "W.sub.s" is the after centrifuged mass of the
teabag and the sample (grams), "W.sub.e" is the average after
centrifuged mass of the empty teabag (grams), and "W.sub.d" is the
dry mass of the sample (grams). The CRC measurements for each of
three replicate are averaged to provide the CRC value of the
material. The centrifuge retention capacity (in gram of fluid per
gram of superabsorbent material) of superabsorbent materials used
in Samples 1-12 are summarized in Table 2.
2TABLE 2 Superabsorbent Material Centrifuge Retention Sample(s)
(SAM) Capacity (g/g) 1-6 DRYTECH .RTM. 2035 30 7 SAM of HUGGIES
.RTM. 30 8 SAM of PAMPERS .RTM. 26 9 Freeze-dried FAVOR .RTM. 20.3
SXM 9543 (2 g/g) 10 Freeze-dried FAVOR .RTM. 20.2 SXM 9543 (5 g/g)
11 Freeze-dried FAVOR .RTM. 20.3 SXM 9543 (2 g/g) 12 Freeze-dried
FAVOR .RTM. 20.2 SXM 9543 (5 g/g)
[0090] To separate the superabsorbent material from the fluff of a
diaper for CRC testing, the absorbent core of the diaper is first
placed in an airlaid handsheet former. The handsheet former takes
the relatively dense absorbent core of the product and forms a
bulky handsheet on a sheet of tissue. This step in the procedure
opens the superabsorbent material/fluff matrix before being placed
in a "diaper destroyer" for separation.
[0091] The handsheet former has an upper cylinder shaped
compartment which is separated from a rectangular lower compartment
by a diffusion screen which helps ensure uniform handsheet
formation. The absorbent core is separated from the product over
the upper compartment of the airlaid handsheet former so that any
superabsorbent material or fluff that falls out during removal of
the absorbent core goes into the upper compartment. The outer
cover, body-side liner, and any surge materials and/or barrier
tissues are scraped with a spatula to remove any remaining
superabsorbent material or fluff.
[0092] The lid is placed on the upper compartment of the handsheet
former, and pulsating air in the upper compartment and a vacuum at
the bottom of the lower compartment are turned on. The components
of the absorbent core are formed into a bulky superabsorbent
material/fluff airlaid handsheet on a sheet of tissue located at
the bottom of the lower compartment. The tissue provides a barrier
to the superabsorbent material and fluff. The handsheet former is
operated until no superabsorbent material and approximately 0.5
grams or less of fluff is visible in the upper compartment.
[0093] The bulky superabsorbent/fluff pad is then carefully placed
in the diaper destroyer. The mechanics of the diaper destroyer are
the reverse of the handsheet former. Pulsating air circulating at
the bottom of the diaper destroyer breaks apart the bulky pad. The
superabsorbent material from the pad collects at the bottom,
whereas the fluff is drawn off the top with a vacuum. When most of
the fluff has been drawn off, the diaper destroyer is turned off
and the superabsorbent material is collected on a nonstick metal
tray. Shaking the superabsorbent material on the tray tends to
clump the remaining fluff fibers together for easier removal with
tweezers, thus avoiding contamination of the superabsorbent
material with moisture, etc. from the operator.quadrature.s hands.
The collected superabsorbent material is placed in a labeled glass
bottle for further characterization.
[0094] Because intake rate and liquid lock-up fraction change as a
function of saturation, the data should be normalized to a common
set of criteria. Using the saturated capacity of the composite,
determine the percent saturation of the sample following each
insult. For example, a 15 cubic centimeter insult to a sample with
a 45 cubic centimeter saturation capacity yields 33% saturation.
Plot the intake rate of an absorbent composite as a function of the
percent saturation. Interpolate the effective intake rate at the
80% composite saturation level.
[0095] To demonstrate the calculations for determining intake rate
at 80% composite saturation, the following is the calculation for
determining the intake rate of Sample 6 at 80% composite
saturation. The saturation capacity of the 7.68 cm disc of Sample 6
was determined to be 29.13 cubic centimeter liquid. Intake rate is
determined by dividing the insult amount (15 cubic centimeter) by
the intake time. Table 3 summarizes the intake time and intake rate
results for each of the three insults done on Sample 6 during the
intake rate test. A composite saturation percent value is
calculated for Sample 6 at each of 15 cubic centimeter, 30 cubic
centimeter, and 45 cubic centimeter liquid by dividing the
cumulative liquid amount (15, 30, or 45 cubic centimeter) by the
saturation capacity of the composite and multiplying by 100%. The
results are summarized in Table 3. The intake rate data are plotted
against the respective composite saturation percent in a scatter
plot with smoothed lines. FIG. 6 shows the scatter plot for the
values of Table 3 as done using the spreadsheet Microsoft Excel
97.RTM.. To determine the intake rate at 80% composite saturation,
a line is drawn along the scatter plot parallel to the y-axis at
80% composite saturation. The intake rate is then determined from
the scatter plot at the point where the line intersects the
curve.
3TABLE 3 Insult Cumulative Intake Intake Composite Insult Amount
Insult Amount Time Rate Saturation # (cc) (cc) (sec) (cc/sec) (%) 1
15 15 7.28 2.06 52 2 15 30 4.46 3.36 103 3 15 45 4.02 3.73 154
[0096] Liquid lock-up fractions are also normalized. Rather than
normalizing to the composite saturation level, however, the lock-up
fractions are normalized to the saturation capacity of the
superabsorbent material alone. This is done to better reflect the
ability of the superabsorbent material to lock-up liquid relative
to the superabsorbent material total saturation capacity. Again,
example normalization calculations will be done using the Sample 6.
The saturation capacity of the superabsorbent material for Sample 6
is necessary for the calculations and was determined by the
Centrifuge Retention Capacity Test to be 30 gram/gram. As the
matrix fibers of the composite also absorb a small amount of fluid,
this absorption will be taken into account in the calculations. The
typical intrafiber capacities, as determined by the centrifuge
retention capacity test, of the CR-1654 and CARESSA.RTM. 1300
fibers are about 1 gram liquid/gram fiber.
[0097] The lock-up fraction at 50% superabsorbent saturation is
determined by plotting the lock-up fraction test data against the
superabsorbent material saturation and then interpolating the value
from the plot. Lock-up fraction is equal to the amount of liquid in
the sample after vacuuming divided by the cumulative insult amount.
The results for Sample 6 are summarized in Table 4. Superabsorbent
saturation is determined according to the following formula.
[0098] SuperabsorbentSaturation= 2 SuperabsorbentSaturation = ( A )
- ( B ) ( C ) ( D ) ( B ) ( E ) ( F )
[0099] Where "A" is the amount of liquid in the composite after
vacuum, "B" is the composite dry mass, "C" is the fiber fraction,
"D" is the typical intrafiber capacity, "E" is the superabsorbent
fraction, and "F" is the centrifuge retention capacity of the
superabsorbent material. The fiber fraction is the total composite
fiber weight divided by the total composite weight. Likewise the
superabsorbent fraction is the total superabsorbent material weight
divided by the total composite weight. The superabsorbent
saturation values for Sample 6 are summarized in Table 4.
4TABLE 4 Cumu- Amount of lative Liquid in Insult Insult Composite
Composite SAM Insult Amount Amount after Dry Mass Saturation
Lock-up # (cc) (cc) Vacuum (cc) (g) (%) Fraction 1 15 15 8.90 2.51
20 0.59 2 15 30 19.57 2.49 49 0.65 3 15 45 26.58 2.50 68 0.59
[0100] The lock-up fraction data are plotted against the respective
superabsorbent material saturation percent in a scatter plot with
smoothed lines. FIG. 7 shows the scatter plot for the values of
Table 4 as done using the spreadsheet Microsoft Excel 97.RTM.. To
determine the lock-up fraction at 50% superabsorbent saturation, a
line is drawn across the scatter plot parallel to the y-axis at 50%
superabsorbent saturation. The lock-up fraction is then determined
from the scatter plot at the point where the line intersects the
curve.
[0101] Samples 1-12 were tested by the intake rate test and lock-up
test. The results of testing three replicate samples are averaged
and summarized in Table 5. FIG. 8 is a graph of the intake rates
plotted against the lock-up fractions of the samples listed in
Table 5. The freeze-dried composite Samples 1, 2, 3, and 4 and the
airformed composite Samples 9 and 10 all have both the intake rate
and lock-up characteristics of this invention. Freeze-dried
composite sample 5, which had a 60% superabsorbent level, did not
have the intake rate and lock-up characteristics of this invention.
Sample 6 did have an adequate intake rate but a less than desired
lock-up fraction. Samples 5 and 6 demonstrates that the intake rate
and lock-up fraction of this invention are not inherent in the
superabsorbent material alone but can be dependent on the structure
of the composite as well as the specific superabsorbent material
and fiber combination. Samples 11 and 12 also did not have the
desired lock-up fraction and also demonstrate that the lock-up
fraction is not dependent on the superabsorbent material alone, but
on the structure of the composite as well as the specific
superabsorbent material and fiber combination. Sample 7, the
HUGGIES.RTM. diaper sample, exhibited an adequate liquid lock-up
but a less than adequate intake rate for purposes of this
invention. Sample 8, the PAMPERS.RTM. diaper sample, exhibited less
than adequate intake rate and liquid lock-up fraction for the
purposes of this invention. Table 5 shows the superabsorbent
material of the samples as a percentage of the weight of
fiber/superabsorbent material. The liquid lock-up numbers in Table
5 are at a 50% superabsorbent material saturation and the intake
rates are at 80% absorbent composite saturation.
5TABLE 5 Intake Rate Superabsorbent Liquid (cc/s) at 80% Material
Lock-up at 50% composite Sample Structure (wt. %) SAM saturation
saturation 1 Freeze-dried 50 0.83 6.2 composite 2 Freeze-dried 50
0.82 3.3 composite 3 Freeze-dried 50 0.81 3.6 composite 4
Freeze-dried 30 0.78 14.1 composite 5 Freeze-dried 60 0.90 0.40
composite 6 Airformed 50 0.65 2.8 Composite 7 Diaper core 42 0.84
0.80 8 Diaper core 59 0.65 1.7 9 Airformed 50 0.72 2.1 Composite 10
Airformed 50 0.72 2.4 Composite 11 Airformed 50 0.60 3.3 Composite
12 Airformed 50 0.64 3.2 Composite
[0102] Various conventional techniques may be employed to determine
the quantitative amount of superabsorbent material within a test
sample. Suitable analytical techniques include, for example, a
sulfated ash measurement method, such as described in
"Vogel.quadrature.s Textbook of Quantitative Inorganic Analysis,"
Fourth Edition, revised by J. Bassett, R. C. Denney, G. H. Jeffery,
J. Mendham, Longman Inc., 1973, pp. 479-481, herein incorporated by
reference. Another suitable technique would be an ion exchange
method (e.g. sodium ion exchange), such as described in "Treatise
on Analytical Chemistry" Volume 1, edited by I. M. Kolthoff and
Phillip J. Elving, Interscience Publishers, Inc., 1961, pp.
345-350, herein incorporated by reference. Another suitable
technique includes atomic absorption methods, such as described in
"Vogel.quadrature.s Textbook of Quantitative Inorganic Analysis,"
Fourth Edition, revised by J. Bassett, R. C. Denney, G. H. Jeffery,
J. Mendham, Longman Inc., 1978, pp. 310-845, herein incorporated by
reference. "The Encyclopedia of Industrial Chemical Analysis,"
Volume 18, edited by Foster Dee Snell and Leslie S. Ettre,
Interscience Publishers, Inc., 1973, at pp. 207-259, describes well
known, conventional techniques for quantitatively measuring the
amount of sodium within a sample, herein incorporated by
reference.
[0103] The amount of superabsorbent material present in each of
Samples 7 and 8 was determined by sulfated ash testing. The
sulfated ash procedure converts the sodium or other cations
carboxyl salt polymers, such as polyacrylate or carboxymethyl
cellulose superabsorbent material, to the corresponding sulfate
salt. The sulfate salt is determined gravimetrically and is
calculated to the weight of the carboxyl salt polymer by applying a
standard factor determined from a sample of the pure polymer. The
sample is charred over a low flame to remove the bulk of the
volatile matter, cooled, moistened with 1:1 sulfuric acid, the
excess acid volatilized, and the ashing completed as in a regular
ash determination.
[0104] The sulfated ash method can be applied to a wide range of
sample sizes, including a whole diaper. Weigh a sample to the
nearest 0.001 gram, into a previously ignited and tarred (to the
nearest 0.1 milligram) porcelain dish or crucible. When determining
the superabsorbent material content of whole diapers, as much as
possible of extraneous product components (e.g. tapes, elastics)
should be trimmed off first, but not so much as to lose any
superabsorbent material granules. Record both the whole product
weight and the trimmed weight.
[0105] Ignite the sample over a burner flame until most of the
carbonaceous materials are burned off. Cool, and then moisten the
entire residue with 1:1 sulfuric acid. Slowly evaporate the excess
acid over a low flame so as to avoid spattering. Complete the
ignition by placing the sample in a muffle, or alternatively use a
forced air Meker-type burner, at 800.degree. C.-850.degree. C. for
60 minutes or until the ash is free of carbon. Cool in a desiccator
and weigh to the nearest 0.1 milligram.
[0106] A "standard factor" is then determined for the sample. The
standard factor is determined by the following formula. 3
StandardFactor ( F ) = ( gramsofovendrypolymer ) ( gramssulfatedash
) ( 0.95 )
[0107] Dividing the standard factor by 0.95 takes into account the
absorption of moisture that increases the weight of the sample.
Depending on humidity and exposure conditions, the superabsorbent
material can absorb significant levels of water (e.g. 59% at 80%
RH, 100.degree. F.). A standard 5% moisture basis is typically used
in the calculation as an estimate of the additional moisture weight
absorbed by the sample.
[0108] The presence of any other inorganic compound or cation,
besides the superabsorbent material, will generally give a positive
interference. The absence of interferences must be known and/or
blank corrections must be determined if accurate results are to be
obtained by this method. If samples of the material or product
without added superabsorbent material are available, these can be
carried through the procedure determine a correction factor. If the
individual product components are available, they can likewise be
analyzed and a correction factor calculated as a weighted average.
The correction factor is then calculated by dividing the grams of
sulfated ash by the grams of the equivalent superabsorbent free
sample or components. For samples unable to have a correction
factor determined by these methods, an averaged correction factor
can be determined on virgin wood fluff. The typically used
correction factor is 0.00513.
[0109] The calculation for the percent carboxyl salt polymer by
weight of the sample is calculated by the following formula. 4 %
CarboxylSaltPolymer = ( A - BC ) ( F ) ( 100 ) ( C )
[0110] Where "A" is the weight of sulfated ash from the sample, "B"
is the correction factor, "C" is the original weight of sample, and
"F" is the standard factor. The superabsorbent material obtained by
the sulphated ash testing is assumed to be at a 5% moisture
basis.
[0111] While in the foregoing specification this invention has been
described in relation to certain preferred embodiments thereof, and
many details have been set forth for purpose of illustration, it
will be apparent to those skilled in the art that the invention is
susceptible to additional embodiments and that certain of the
details described herein can be varied considerably without
departing from the basic principles of the invention.
* * * * *