Absorbent materials having improved fluid intake and lock-up properties

• US 20030139712A1
• Filed: 12/14/2001
• Published: 07/24/2003
• Est. Priority Date: 12/14/2001
• Status: Abandoned Application

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Tsai, Fu-Jya Daniel, Ranganathan, Sridhar, Lange, Nancy Birbiglia, Zhang, Xiaomin, Chakravarty, Jayant, Qin, Jian, Uttecht, Cathleen M., Dodge, Richard Norris II
• Application Number:
  US10/017,683
• Publication Number:
  US 20030139712A1
• Time in Patent Office: Days
• US Class Current: 604/368
• CPC Class Codes: A61L 15/60 Liquid-swellable gel-forming materials, e.g. super-absorbents

Abstract

An absorbent composite, useful in an absorbent article, having a high liquid intake rate. The absorbent composite 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.

Claims

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 at least one of a natural fiber and a synthetic fiber.

6. The absorbent composite of claim 5, wherein the water-insoluble fiber comprises a fiber selected from the group consisting of wood pulp fiber, cotton linter, thermoplastic fibers, and elastic fibers.

7. The absorbent composite of claim 1, wherein the water-insoluble fiber is a hydrophilic fiber.

8. The absorbent composite of claim 7, wherein the water-insoluble fiber is a hydrophilically treated hydrophobic fiber.

9. The absorbent composite of claim 1, wherein the absorbent composite is an airformed absorbent composite.

10. The absorbent composite of claim 1, wherein the absorbent composite is a wetformed absorbent composite.

11. The absorbent composite of claim 1, wherein the absorbent composite is a freeze-dried composite.

12. 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.

13. The absorbent composite of claim 12, wherein the superabsorbent material comprises at least one of a crosslinked anionic and a crosslinked cationic polymers.

14. The absorbent composite of claim 13, 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.

15. 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.

16. The absorbent composite of claim 1, further comprising a binder material.

17. The absorbent composite of claim 16, wherein the binder material comprises a water-insoluble polymer.

18. The absorbent composite of claim 17, wherein the binder material comprises a material selected from the group consisting of kymene, latex, and combinations thereof.

19. The absorbent composite of claim 17, wherein the binder material comprises a water-insoluble, water-swellable polymer.

20. The absorbent composite of claim 19, wherein the binder material comprises a material selected from the group consisting of sodium-polyacrylate, carboxymethyl cellulose, chitosan salt, and combinations thereof.

21. The absorbent composite of claim 17, wherein the binder comprises a thermoplastic fiber.

22. The absorbent composite of claim 21, wherein the binder material comprises a material selected from the group consisting of polyethylene fibers, polypropylene fibers, polyester fibers, nylon fibers, and combinations thereof.

23. The absorbent composite of claim 16, wherein the binder material is elastic.

24. The absorbent composite of claim 16, wherein the binder material is water-soluble before a treatment and water-swellable and water-insoluble after the treatment.

25. The absorbent composite of claim 24, 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.

26. An absorbent article comprising

a liquid-permeable body-side liner;

an absorbent composite; and

a substantially liquid-impermeable outer cover adjacent to the absorbent composite 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 saturation determined using 0.9% by weight sodium chloride aqueous solution.

27. The absorbent article of claim 26, 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.

28. The absorbent article of claim 26, 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.

29. The absorbent article of claim 26, 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.

30. The absorbent article of claim 26, wherein the absorbent composite comprises a superabsorbent material in a weight amount of about 10 to 70 weight percent based on total weight of the absorbent composite.

31. The absorbent article of claim 26, wherein the absorbent composite comprises a water-insoluble fiber in a weight amount of about 30 to 90 weight percent, based on total weight of the absorbent composite.

32. The absorbent article of claim 31, wherein the water-insoluble fiber comprises at least one of a natural fiber and a synthetic fiber.

33. The absorbent article of claim 32, 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.

34. The absorbent article of claim 26, wherein the absorbent composite comprises a binder in a weight amount of about 0 to 20 weight percent, based on total weight of the absorbent composite.

35. The absorbent article of claim 26, wherein the absorbent composite comprises a freeze-dried fibrous composite.

36. The absorbent article of claim 26, wherein the absorbent composite comprises an airformed absorbent composite.

37. The absorbent article of claim 26, wherein the absorbent composite comprises a wetformed absorbent composite.

38. The absorbent article of claim 26, wherein the superabsorbent material comprises a material selected from the group consisting of particles, fibers, nonwoven, aggregate, printed, coated, or combinations thereof.

39. The absorbent article of claim 38, 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.

40. The absorbent article of claim 34, wherein the binder material comprises a water-insoluble polymer selected from the group consisting of kymene, latex, and combinations thereof.

41. The absorbent article of claim 34, wherein the binder material comprises a water-insoluble, water-swellable polymer selected from the group consisting of sodium-polyacrylate, carboxymethyl cellulose, chitosan salt, and combinations thereof.

42. The absorbent article of claim 34, wherein the binder material comprises a thermoplastic fiber selected from the group consisting of polyethylene fibers, polypropylene fibers, polyester fibers, nylon fibers, and combinations thereof.

43. The absorbent article of claim 34, wherein the binder material is elastic.

44. The absorbent article of claim 26, wherein the absorbent article is a diaper.

45. The absorbent article of claim 26, wherein the absorbent article is a training pant.

46. The absorbent article of claim 26, wherein the absorbent article is a swim wear garment.

47. The absorbent article of claim 26, wherein the absorbent article is an adult incontinence garment.

48. The absorbent article of claim 26, wherein the absorbent article is a feminine hygiene product.

49. The absorbent article of claim 26, wherein the absorbent article is a medical absorbent product.

50. 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.

51. The freeze-dried composite of claim 50, 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.

52. The freeze-dried composite of claim 50, 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.

53. The freeze-dried composite of claim 50, 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.

54. The freeze-dried composite of claim 50, wherein the water-insoluble fiber comprises at least one of a natural fiber and a synthetic fiber.

55. The freeze-dried composite of claim 54, 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.

56. The freeze-dried composite of claim 50, wherein the superabsorbent material comprises a material selected from the group consisting of particles, fibers, nonwoven, aggregate, printed, coated, or combinations thereof.

57. The freeze-dried composite of claim 56, 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.

58. The freeze-dried composite of claim 50, 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.

59. The freeze-dried composite of claim 50, further comprising a binder material.

60. 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.

61. The airformed absorbent composite of claim 60, 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.

62. The airformed absorbent composite of claim 60, 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.

63. The airformed absorbent composite of claim 60, 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.

64. The airformed absorbent composite of claim 60, wherein the water-insoluble fiber comprises at least one of a natural fiber and a synthetic fiber.

65. The airformed absorbent composite of claim 60, 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.

66. The airformed absorbent composite of claim 60, wherein the superabsorbent material comprises a material selected from the group consisting of particles, fibers, nonwoven, aggregate, printed, coated, or combinations thereof.

67. The airformed absorbent composite of claim 66, 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.

68. The airformed absorbent composite of claim 60, 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.

69. The airformed absorbent composite of claim 60, further comprising a binder material.

70. 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.

71. The wetformed absorbent composite of claim 70, 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.

72. The wetformed absorbent composite of claim 70, 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.

73. The wetformed absorbent composite of claim 70, 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.

74. The wetformed absorbent composite of claim 70, wherein the water-insoluble fiber comprises at least one of a natural fiber and a synthetic fiber.

75. The wetformed absorbent composite of claim 70, 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.

76. The wetformed absorbent composite of claim 70, wherein the superabsorbent material comprises a material selected from the group consisting of particles, fibers, nonwoven, aggregate, printed, coated, or combinations thereof.

77. The wetformed absorbent composite of claim 76, 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.

78. The wetformed absorbent composite of claim 70, 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.

79. The wetformed absorbent composite of claim 70, further comprising a binder material.

80. 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.

81. The absorbent composite of claim 80, 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.

82. The absorbent composite of claim 80, 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.

83. The absorbent composite of claim 80, 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.

84. The absorbent composite of claim 80, wherein the superabsorbent material comprises a material selected from the group consisting of particles, fibers, nonwoven, aggregate, printed, coated, or combinations thereof.

85. The absorbent composite of claim 80, 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.

86. The absorbent composite of claim 80, 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.

87. The absorbent composite of claim 80, further comprising a binder material.