US2003219594A1PendingUtilityA1

Meltblown absorbent fibers and composites and method for making the same

46
Priority: May 23, 2002Filed: May 23, 2002Published: Nov 27, 2003
Est. expiryMay 23, 2022(expired)· nominal 20-yr term from priority
Inventors:Jian QinJames H. WangAnthony John WisneskiFu-Jya Tsai
A61L 15/60Y10T428/2913
46
PatentIndex Score
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Claims

Abstract

An absorbent fiber is produced from a melt processable polymer. An absorbent composite includes the absorbent fiber in addition to natural fibers and superabsorbent material. A method of producing the superabsorbent fiber and absorbent composite is also disclosed.

Claims

exact text as granted — not AI-modified
We claim:  
     
         1 . An absorbent fiber, comprising: 
 a melt processable, water soluble polymer; and    a cross-linking agent;    wherein the absorbent fiber has an absorbency under zero load of at least about 5 g/g.    
     
     
         2 . The absorbent fiber of  claim 1 , wherein the polymer comprises a polymer selected from polyethylene oxide, polypropylene oxide, hydroxyl propyl cellulose, methyl cellulose, ethyl cellulose, methylethyl cellulose, polyethylene imine, polyvinyl amine, polyvinyl alcohol, poly(ethylene oxide-co-propylene oxide), polyacrylic acid, polyacrylamide, and combinations thereof.  
     
     
         3 . The absorbent fiber of  claim 1 , wherein the polymer comprises a copolymer.  
     
     
         4 . The absorbent fiber of  claim 3 , wherein at least one monomer of the copolymer is sodium acrylate.  
     
     
         5 . The absorbent fiber of  claim 3 , wherein at least one monomer of the copolymer is methyl methacrylate.  
     
     
         6 . The absorbent fiber of  claim 3 , wherein the copolymer includes a ratio on a dry weight basis of a first monomer to a second monomer of from about 30:70 to about 70:30.  
     
     
         7 . The absorbent fiber of  claim 3 , wherein the copolymer comprises sodium acrylate and methyl methacrylate.  
     
     
         8 . The absorbent fiber of  claim 1 , wherein the polymer has a molecular weight in a range of about 10,000 to about 1,000,000.  
     
     
         9 . The absorbent fiber of  claim 1 , wherein the polymer has a molecular weight in a range of about 50,000 to about 1,000,000.  
     
     
         10 . The absorbent fiber of  claim 1 , wherein the polymer has a molecular weight in a range of about 100,000 to about 500,000.  
     
     
         11 . The absorbent fiber of  claim 1 , wherein the cross-linking agent comprises at least two functional groups capable of reacting with functional groups on the polymer.  
     
     
         12 . The absorbent fiber of  claim 11 , wherein the at least two functional groups of the cross-linking agent comprise a functional group selected from carboxylic acid group, epoxy group, hydroxyl group, amino group, aldehyde group, tri-valent metal ions, and tetra-valent metal ions.  
     
     
         13 . The absorbent fiber of  claim 1 , wherein the cross-linking agent comprises a compound selected from diols, polyols, diamines, polyamines, dicarboxylic acids, polycarboxylic acids, dialdehydes, polyaldehydes, butandiol, diethylene triamine, ethylene glycol diglycidyl ether, citric acid, glutaric dialdehyde, and combinations thereof.  
     
     
         14 . The superabsorbent fiber of  claim 1 , wherein a cross-linking reaction is initiated by a treatment selected from heat treatment, microwave radiation, e-beam radiation, UV radiation, steam treatment, and vapor treatment.  
     
     
         15 . An absorbent composite, comprising: 
 a melt processable, water soluble polymer;    a superabsorbent material;    hydrophilic fibers; and    a cross-linking agent;    wherein the absorbent composite has an absorbency under zero load of at least about 10 g/g.    
     
     
         16 . The absorbent composite of  claim 15 , wherein the superabsorbent material comprises superabsorbent particles.  
     
     
         17 . The absorbent composite of  claim 15 , wherein the superabsorbent material comprises superabsorbent fibers.  
     
     
         18 . The absorbent composite of  claim 15 , wherein the hydrophilic fibers comprise fibers selected from wood pulp fluff, cotton, cotton linter, other cellulose fibers, regenerated cellulose fibers, staple fibers, synthetic hydrophilic fibers, and combinations thereof.  
     
     
         19 . The absorbent composite of  claim 15 , wherein the polymer comprises a polymer selected from polyethylene oxide, polypropylene oxide, hydroxyl propyl cellulose, methyl cellulose, ethyl cellulose, methylethyl cellulose, polyethylene imine, polyvinyl amine, polyvinyl alcohol, poly(ethylene oxide-co-propylene oxide), polyacrylic acid, polyacrylamide, and combinations thereof.  
     
     
         20 . The absorbent composite of  claim 15 , wherein the polymer comprises a copolymer.  
     
     
         21 . The absorbent composite of  claim 20 , wherein at least one monomer of the copolymer is sodium acrylate.  
     
     
         22 . The absorbent composite of  claim 20 , wherein at least one monomer of the copolymer is methyl methacrylate.  
     
     
         23 . The absorbent composite of  claim 20 , wherein the copolymer includes a ratio on a dry weight basis of a first monomer to a second monomer of from about 30:70 to about 70:30.  
     
     
         24 . The absorbent composite of  claim 20 , wherein the copolymer comprises sodium acrylate and methyl methacrylate.  
     
     
         25 . The absorbent composite of  claim 15 , wherein the polymer has a molecular weight in a range of about 10,000 to about 1,000,000.  
     
     
         26 . The absorbent composite of  claim 15 , wherein the polymer has a molecular weight in a range of about 50,000 to about 1,000,000.  
     
     
         27 . The absorbent composite of  claim 15 , wherein the polymer has a molecular weight in a range of about 100,000 to about 500,000.  
     
     
         28 . The absorbent composite of  claim 15 , wherein the cross-linking agent comprises at least two functional groups capable of reacting with functional groups on the polymer.  
     
     
         29 . The absorbent composite of  claim 28 , wherein the at least two functional groups of the cross-linking agent comprise a functional group selected from carboxylic acid group, epoxy group, hydroxyl group, amino group, aldehyde group, tri-valent metal ions, and tetra-valent metal ions.  
     
     
         30 . The absorbent composite of  claim 15 , wherein the cross-linking agent comprises a compound selected from diols, polyols, diamines, polyamines, dicarboxylic acids, polycarboxylic acids, dialdehydes, polyaldehydes, butandiol, diethylene triamine, ethylene glycol diglycidayl ether, citric acid, glutaric dialdehyde, and combinations thereof.  
     
     
         31 . The absorbent composite of  claim 15 , wherein a cross-linking reaction is initiated by a treatment selected from heat treatment, microwave, e-beam radiation, UV radiation, steam treatment, and vapor treatment.  
     
     
         32 . The absorbent composite of  claim 15 , wherein the absorbent composite is a superabsorbent material.  
     
     
         33 . The absorbent composite of  claim 15 , wherein the absorbent composite has an absorbency under zero load of at least 15 g/g.  
     
     
         34 . The absorbent composite of  claim 15 , wherein the absorbent composite has an absorbency under zero load of up to about 50 g/g.  
     
     
         35 . A method of producing an absorbent fiber, comprising the steps of: 
 melting a melt processable, water soluble polymer;    extruding the polymer;    spinning the polymer to form fibers;    adding a cross-linking agent to the fibers; and    curing the fibers.    
     
     
         36 . The method of  claim 35 , wherein the polymer comprises a polymer selected from polyethylene oxide, polypropylene oxide, hydroxyl propyl cellulose, methyl cellulose, ethyl cellulose, methyethyl cellulose, polyethylene imine, polyvinyl amine, polyvinyl alcohol, poly(ethylene oxide-co-propylene oxide), polyacrylic acid, polyacrylamide, and combinations thereof.  
     
     
         37 . The method of  claim 35 , wherein the polymer comprises a copolymer.  
     
     
         38 . The method  claim 37 , wherein at least one monomer of the copolymer is sodium acrylate.  
     
     
         39 . The method of  claim 37 , wherein at least one monomer of the copolymer is methyl methacrylate.  
     
     
         40 . The method of  claim 37 , wherein the copolymer includes a ratio on a dry weight basis of a first monomer to a second monomer of from about 30:70 to about 70:30.  
     
     
         41 . The method of  claim 37 , wherein the copolymer comprises sodium polyacrylate and methyl methacrylate.  
     
     
         42 . The method of  claim 35 , wherein the polymer has a molecular weight in a range of about 10,000 to about 1,000,000.  
     
     
         43 . The method of  claim 35 , wherein the polymer has a molecular weight in a range of about 50,000 to about 1,000,000.  
     
     
         44 . The method of  claim 35 , wherein the polymer has a molecular weight in a range of about 100,000 to about 500,000.  
     
     
         45 . The method of  claim 35 , wherein the cross-linking agent comprises at least two functional groups capable of reacting with functional groups on the polymer.  
     
     
         46 . The method of  claim 45 , wherein the at least two functional groups of the cross-linking agent comprise a functional group selected from carboxylic acid group, epoxy group, hydroxyl group, amino group, aldehyde group, tri-valent metal ions, and tetra-valent metal ions.  
     
     
         47 . The method of  claim 35 , wherein the cross-linking agent comprises a compound selected from diols, polyols, diamines, polyamines, dicarboxylic acids, polycarboxylic acids, dialdehydes, polyaldehydes, butandiol, diethylene triamine, ethylene glycol diglycidyl ether, citric acid, glutaric dialdehyde, and combinations thereof.  
     
     
         48 . The method of  claim 35 , wherein a cross-linking reaction is initiated by a treatment selected from heat treatment, microwave, e-beam radiation, UV radiation, steam treatment, and vapor treatment.  
     
     
         49 . A diaper comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         50 . Training pants comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         51 . Swim wear comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         52 . An adult incontinence garment comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         53 . A feminine hygiene product comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         54 . A medical absorbent product comprising the absorbent fiber produced according to the method of  claim 35 .  
     
     
         55 . A method of producing an absorbent composite, comprising the steps of: 
 melting a melt processable, water soluble polymer;    extruding the polymer;    spinning the polymer to form fibers;    adding hydrophilic fibers to the fibers;    adding a superabsorbent material to the fibers;    adding a cross-linking agent to the fibers; and    curing the fibers.    
     
     
         56 . The method of  claim 55 , wherein the hydrophilic fibers comprise fibers selected from wood pulp fluff, cotton, cotton linter, other cellulose fibers, regenerated cellulose fibers, staple fibers, synthetic hydrophilic fibers, and combinations thereof.  
     
     
         57 . The method of  claim 55 , wherein the polymer comprises a polymer selected from polyethylene oxide, polypropylene oxide, hydroxyl propyl cellulose, methyl cellulose, ethyl cellulose, methylethyl cellulose, polyethylene imine, polyvinyl amine, polyvinyl alcohol, poly(ethylene oxide-co-propylene oxide), polyacrylic acid, polyacrylamide, and combinations thereof.  
     
     
         58 . The method of  claim 55 , wherein the polymer comprises a copolymer.  
     
     
         59 . The method claim of  58 , wherein at least one monomer of the copolymer is sodium acrylate.  
     
     
         60 . The method of  claim 58 , wherein at least one monomer of the copolymer is methyl methacrylate.  
     
     
         61 . The method of  claim 58 , wherein the copolymer includes a ratio on a dry weight basis of a first monomer to a second monomer of from about 30:70 to about 70:30.  
     
     
         62 . The method of  claim 58 , wherein the copolymer comprises sodium acrylate and methyl methacrylate.  
     
     
         63 . The method of  claim 55 , wherein the polymer has a molecular weight in a range of about 10,000 to about 1,000,000.  
     
     
         64 . The method of  claim 55 , wherein the polymer has a molecular weight in a range of about 50,000 to about 1,000,000.  
     
     
         65 . The method of  claim 55 , wherein the polymer has a molecular weight in a range of about 100,000 to 500,000.  
     
     
         66 . The method of  claim 55 , wherein the cross-linking agent comprises at least two functional groups capable of reacting with functional groups on the polymer.  
     
     
         67 . The method of  claim 66 , wherein the at least two functional groups of the cross-linking agent comprise a functional group selected from carboxylic acid group, epoxy group, hydroxyl group, amino group, aldehyde group, tri-valent metal ions, and tetra-valent metal ions.  
     
     
         68 . The method of  claim 55 , wherein the cross-linking agent comprises a compound selected from diols, polyols, diamines, polyamines, dicarboxylic acids, polycarboxylic acids, dialdehydes, polyaldehydes, butandiol, diethylene triamine, ethylene glycol diglycidyl ether, citric acid, glutaric dialdehyde, and combinations thereof.  
     
     
         69 . The method of  claim 55 , wherein a cross-linking reaction is initiated by a treatment selected from heat treatment, microwave, e-beam radiation, UV radiation, steam treatment, and vapor treatment.  
     
     
         70 . A diaper comprising the absorbent composite produced according to the method of  claim 55 .  
     
     
         71 . Training pants comprising the absorbent composite produced according to the method of  claim 55 .  
     
     
         72 . Swim wear comprising the absorbent composite produced according to the method of  claim 55 .  
     
     
         73 . An adult incontinence garment comprising the absorbent composite produced according to the method of  claim 55 .  
     
     
         74 . A feminine hygiene product comprising the absorbent composite produced according to the method of  claim 55 .  
     
     
         75 . A medical absorbent product comprising the absorbent composite produced according to the method of  claim 55.

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