Chemically cross-linked cellulosic fiber and method of making same

• US 7,419,568 B2
• Filed: 06/21/2005
• Issued: 09/02/2008
• Est. Priority Date: 06/11/2002
• Status: Expired due to Fees

• Current Assignee: Rayonier Performance Fibers, LLC (Rayonier Advanced Materials, Inc.)
• Original Assignee: Rayonier TRS Holdings Inc. (Rayonier Incorporated)
• Inventors: Chmielewski, Harry J., Hamed, Othman A., McBee, Dana B.
• Primary Examiner(s): HUG, JOHN ERIC
• Application Number:
  US11/156,717
• Publication Number:
  US 20050256470A1
• Time in Patent Office: 1,169 Days
• Field of Search: 162/135, 162/136, 162/146, 162/157.1, 162/157.6, 162/157.7, 162/158, 162/164.1, 162/168.1, 162/169, 162/173, 162/179, 162183-186, 162/204, 162/182, 162/9, 162/12, 162/76, 811/61, 812/0, 812/5, 812/7, 849/3, 527/103, 427/389.9, 427/391, 427/392, 604374-378
• US Class Current: 162/9
• CPC Class Codes: A61F 13/15203 Properties of the article, e.g. stiffness or absorbency chemical aspects A61L15/00
• CPC Class Codes: A61F 13/53 characterised by the absorbing medium A61F13/20 takes precedence
• CPC Class Codes: C08B 15/10 Crosslinking of cellulose
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: D06M 13/12 Aldehydes; Ketones
• CPC Class Codes: D06M 13/207 Substituted carboxylic acids, e.g. by hydroxy or keto groups; Anhydrides, halides or salts thereof
• CPC Class Codes: D06M 2101/06 cellulosic
• CPC Class Codes: D21C 9/002 by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives

Abstract

The present invention relates to cross-linked cellulosic fiber having improved absorbency characteristics when compared to conventional cross-linked fibers. The cross-linked cellulosic fiber is obtainable by reacting pulp in the sheet or fluff form with one or more reagents selected from organic molecule having acid and aldehyde functional groups “acid aldehydes.” The invention also relates to a method of producing the cross-linked fiber. The method includes heating the treated cellulosic fibers to promote intrafiber cross-linking. The cross-linked fibers are characterized by having an improved centrifuge retention capacity, fluid acquisition rate, resiliency, absorbent capacity, absorbency under load, and other absorbent properties. The inventive cross-linked fibers are useful in forming absorbent composites, and in particular absorbent cores for use in absorbent articles.

Claims

1. A method of making a cross-linked cellulosic fiber, comprising:

treating cellulosic fibers with caustic;

forming a wet laid sheet of the caustic treated fibers;

supplying an acid aldehyde cross-linking agent to the sheet of fibers to form a sheet impregnated with the cross-linking agent; and

drying and curing the cross-linking agent on the impregnated sheet of cellulosic fibers to form intra-fiber cross-links,

wherein the cross-linked fibers produced thereby have a centrifuge retention capacity of not more than 0.6 g saline/g fiber.

2. The method of claim 1, wherein the fibers are treated with caustic which comprises treating cellulosic fibers with an aqueous solution of sodium hydroxide, washing the fibers, and neutralizing the treated fibers.

3. The method of claim 2, wherein treating the cellulosic fibers with caustic is carried out in an aqueous solution containing about 0.5% to about 40% by weight sodium hydroxide, based on the total weight of the solution.

4. The method of claim 2, wherein treating the cellulosic fibers with caustic is carried out in an aqueous solution of sodium hydroxide at 2 to 10% consistency.

5. The method of claim 2, wherein washing and neutralizing is carried out until the residual water has a pH of between 3 and 8.

6. The method of claim 2 wherein the wet laid sheet of caustic-treated cellulosic fibers is in sheet or roll form.

7. The method of claim 2, wherein the wet-laid sheet of caustic treated cellulosic fiber is in the dry or wet state.

8. The method of claim 2, wherein the α

-cellulose content of the caustic treated cellulosic fibers is greater than 65%.

9. The method of claim 8, wherein the α

-cellulose content is at least 90%.

10. The method of claim 1, wherein the cross-linking agent is one or more acid aldehyde organic molecules containing aldehyde and carboxylic acid functional groups, and wherein the cross-linking agent is supplied to the caustic treated fiber in an aqueous solution.

11. The method of claim 1, wherein the cross-linking agent comprises a mixture of cross-linking agents comprising a primary acid aldehyde cross-linking agent and a secondary cross-linking agent, and wherein the mixture is supplied to the fiber in an aqueous solution.

12. The method of claim 11, wherein the secondary cross-linking agent is supplied as an aqueous solution with a surfactant, the secondary cross-linking agent comprising a polyepoxide having a substituent selected from the group consisting of hydrogen;

hydrophobic saturated, unsaturated, cyclic saturated, cyclic unsaturated, branched, unbranched alkyl groups; and

mixtures and combinations thereof.

13. The method of claim 12, wherein the surfactant is selected from the group consisting of nonionic, anionic, cationic surfactant, or combinations and mixtures thereof.

14. The method of claim 1, wherein the cross-linking agent is supplied to the cellulose fiber in an amount from about 0.5 to 10% by weight, based on the total weight of the fiber.

15. The method of claim 1, wherein the cross-linking agent is supplied to the cellulosic fibers in an amount from about 2 to 5% by weight, based on the total weight of the fiber.

16. The method of claim 10, wherein the aqueous solution of acid aldehyde cross-linking has a pH from about 1.5 to about 4.0.

17. The method of claim 12, wherein the surfactant is added in an amount of from about 0.01 to 5% by weight, based on the total weight of the cross-linking agent.

18. The method of claim 1, wherein drying and curing is conducted at a temperature within the range of from about 320°

F. to about 435°

F.

19. The method of claim 1, wherein drying and curing is conducted for about 3 minutes to about 15 minutes at temperatures within the range of from about 320°

F. to about 435°

F.

20. The method of claim 1, wherein drying is conducted at a temperature within the range of from about 150 to about 300°

F., and curing is conducted at a temperature within the range of from about 320 to about 435°

F.

21. The method of claim 1, wherein drying is conducted for about 1 minute to about 10 minutes at temperatures within the range of from about 150 to about 300°

F., and curing is conducted for about 0.5 to about 5 minutes at temperatures within the range of from about 320°

F. to about 435°

F.