Mechanically strong absorbent non-woven fibrous mats

• US 8,367,570 B2
• Filed: 05/16/2006
• Issued: 02/05/2013
• Est. Priority Date: 04/04/2002
• Status: Expired due to Term

• Current Assignee: University of Akron
• Original Assignee: University of Akron
• Inventors: Reneker, Darrell H., Smith, Daniel J.
• Primary Examiner(s): Choi, Peter Y
• Application Number:
  US11/435,066
• Publication Number:
  US 20060246798A1
• Time in Patent Office: 2,457 Days
• Field of Search: 442/327, 442/329, 442/340, 442/375, 442/381, 442/387
• US Class Current: 442/327
• CPC Class Codes: A61F 13/53 characterised by the absorbing medium A61F13/20 takes precedence
• CPC Class Codes: A61F 13/531 having a homogeneous composition through the thickness of the pad A61F13/538, A61F13/539 take precedence
• CPC Class Codes: A61F 2013/530299 being hydrophilic fibres
• CPC Class Codes: A61F 2013/53791 being resilient or elastic
• CPC Class Codes: A61L 15/225 Mixtures of macromolecular compounds
• CPC Class Codes: A61L 26/0052 Mixtures of macromolecular compounds
• CPC Class Codes: B01J 20/261 obtained by reactions only involving carbon to carbon unsaturated bonds macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds per se C08F
• CPC Class Codes: D01D 5/0038 the fibre formed by solvent evaporation, i.e. dry electro-spinning
• CPC Class Codes: D01F 1/10 Other agents for modifying properties
• CPC Class Codes: D01F 6/88 from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
• CPC Class Codes: D01F 6/94 of other polycondensation products
• CPC Class Codes: D04H 1/728 by electro-spinning electro-spinning methods and apparatus D01D5/0007
• CPC Class Codes: D04H 3/02 characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/602 Nonwoven fabric comprises an elastic strand or fiber material
• CPC Class Codes: Y10T 442/609 Cross-sectional configuration of strand or fiber material is specified
• CPC Class Codes: Y10T 442/614 Strand or fiber material specified as having microdimensions [i.e., microfiber]
• CPC Class Codes: Y10T 442/653 Including particulate material other than fiber
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/666 : Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• CPC Class Codes: Y10T 442/696 : Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Abstract

The present invention is generally directed to a liquid entrapping device having the capacity to absorb liquids. More particularly, the present invention is directed to a liquid entrapping device comprising an absorbent component, hydrophilic elastomeric fibrous component in fluid communication therewith, and optionally an adhesive component. The present invention is also directed to a liquid entrapping device having the capacity to absorb liquids while maintaining a suitable degree of mechanical strength. Furthermore, the present invention is generally directed to methods for making and using the foregoing devices and materials.

Claims

1. A liquid entrapping device comprising:

an absorbent component; and

a hydrophilic elastomeric fibrous component,

wherein the absorbent component and the hydrophilic elastomeric fibrous component are in physical proximity thereby resulting in fluid communication,

wherein the absorbent component is more absorbent than the hydrophilic elastomeric fibrous component but wherein the hydrophilic elastomeric fibrous component absorbs more quickly than and has a smaller holding capacity than the absorbent component,

wherein the liquid entrapping device, including the hydrophilic elastomeric fibrous component, is formed from at least one electrospun nanofiber where the at least one electrospun nanofiber comprises both the absorbent component and the hydrophilic elastomeric fibrous component in the nanofiber body, and

wherein the absorbent component is embedded in the electrospun hydrophilic elastomeric fibrous component.

2. The liquid entrapping device of claim 1, wherein the absorbent component is selected from polyesters, polyethers, polyester-polyethers, polymers having pendant carboxylic acids or pendant hydroxyls, polysiloxanes, polyacrylamides, kaolins, serpentines, smectites, glauconite, chlorites, vermiculites, attapulgite, sepiolite, allophane and imogolite, sodium polyacrylates, 2-propenamide-co-2-propenoic acid, and any combination thereof.

3. The liquid entrapping device of claim 1, wherein the hydrophilic elastomeric fibrous component is selected from zein protein, polyester elastomers, polydimethylsiloxane, hydrophilic poly(ether-co-ester) elastomers, silicone-co-polyethyleneglycol elastomers, polyacrylates, thermoplastic polyurethanes, poly(ether-co-urethanes), and any combination thereof.

4. The liquid entrapping device of claim 1, wherein the absorbent component is present in an amount from about 1% (w/w) to about 85% (w/w).

5. The liquid entrapping device of claim 1, wherein the absorbent component is present in an amount from about 5% (w/w) to about 50% (w/w).

6. The liquid entrapping device of claim 1, wherein the absorbent component is present in an amount from about 30% (w/w) to about 50% (w/w).

7. The liquid entrapping device of claim 1, wherein the hydrophilic elastomeric fibrous component is selected from polyurethanes, poly ether-co-urethanes, and any combination thereof.

8. The liquid entrapping device of claim 1, wherein the liquid entrapping device comprises a device selected from a diaper, a tampon, a sanitary napkin, a sanitary wipe, a spill absorbing device, a mop head, and a floor waxing device.

9. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises an absorbency of water from about 400% to about 6000%, wherein absorbency is defined as Q=(W₂−

W₁)/W₁.

10. The liquid entrapping device of claim 9, wherein the liquid entrapping device further comprises an absorbency of water from about 500% to about 5500%.

11. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises an absorbency of urine from about 500% to about 1250%, wherein absorbency is defined as Q=(W₂−

W₁)/W₁.

12. The liquid entrapping device of claim 11, wherein the liquid entrapping device further comprises an absorbency of urine from about 500% to about 1000%.

13. The liquid entrapping device of claim 12, wherein the liquid entrapping device further comprises an absorbency of urine from about 600% to about 1000%, wherein absorbency is defined as Q=(W₂−

W₁)/W₁.

14. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises a capacity to absorb about 100% of its equilibrium capacity in about 5 seconds.

15. The liquid entrapping device of claim 14, wherein the liquid entrapping device further comprises a capacity to absorb greater than about 73% of its equilibrium capacity in about 5 seconds.

16. The liquid entrapping device of claim 15, wherein the liquid entrapping device further comprises a capacity to absorb greater than about 75% of its equilibrium capacity in about two minutes.

17. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises a tensile strength from about 0 to about 3.0 MPa when the device is wetted with water.

18. The liquid entrapping device of claim 17, wherein the liquid entrapping device further comprises a tensile strength from about 0.25 to about 3.0 MPa when the device is wetted with water.

19. The liquid entrapping device of claim 18, wherein the liquid entrapping device further comprises a tensile strength from about 0 to about 2.8 MPa when the device is wetted with water.

20. The liquid entrapping device of claim 19, wherein the liquid entrapping device further comprises a tensile strength from about 0.25 to about 2.8 MPa when the device is wetted with water.

21. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises a breaking point at about 850% to about 900% strain.

22. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises a breaking point at about 600% strain.

23. The liquid entrapping device of claim 1, wherein the liquid entrapping device further comprises from about 1% (w/w) to about 5% (w/w) leachable matter.

24. The liquid entrapping device of claim 23, wherein the liquid entrapping device further comprises from about 1.6% (w/w) to about 4.5% (w/w) leachable matter.

25. The liquid entrapping device of claim 23, wherein the liquid entrapping device further comprises from about 1% (w/w) to about 4% (w/w) leachable matter.

26. The liquid entrapping device of claim 1, wherein the absorbent component is a super absorbent.

27. The liquid entrapping device of claim 1, wherein the absorbent component is capable of holding at least about 50 times its own weight in liquid.

28. The liquid entrapping device of claim 1, wherein the nanofibers are electrospun nanofibers having a fiber diameter of about 1 nanometer to about 3,000 nanometers.

29. A non-woven liquid entrapping device comprising:

a super absorbent component; and

a hydrophilic elastomeric fibrous component,

wherein the super absorbent component and the hydrophilic elastomeric fibrous component are in physical proximity thereby resulting in fluid communication,

wherein the super absorbent component is more absorbent than the hydrophilic elastomeric fibrous component, but wherein the hydrophilic elastomeric fibrous component absorbs more quickly than and has a smaller holding capacity than the super absorbent component,

wherein the non-woven liquid entrapping device, including the hydrophilic elastomeric fibrous component, is formed from at least one electrospun nanofiber where the at least one electrospun nanofiber comprises both the absorbent component and the hydrophilic elastomeric fibrous component in the nanofiber body,

wherein the super absorbent component is embedded in the electrospun hydrophilic elastomeric fibrous component, and

wherein the super absorbent component is present in an amount from about 1% (w/w) to about 85% (w/w).

30. The non-woven liquid entrapping device of claim 29, wherein the hydrophilic elastomeric fibrous component is selected from zein protein, polyester elastomers, polydimethylsiloxane, hydrophilic poly(ether-co-ester) elastomers, silicone-co-polyethyleneglycol elastomers, polyacrylates, thermoplastic polyurethanes, poly(ether-co-urethanes), and any combination thereof.

31. The non-woven liquid entrapping device of claim 29, wherein the absorbent component is present in an amount from about 5% (w/w) to about 50% (w/w).

32. The non-woven liquid entrapping device of claim 29, wherein the absorbent component is present in an amount from about 30% (w/w) to about 50% (w/w).

33. The non-woven liquid entrapping device of claim 29, wherein the hydrophilic elastomeric fibrous component is selected from polyurethanes, poly ether-co-urethanes, and any combination thereof.

34. The non-woven liquid entrapping device of claim 29, wherein the liquid entrapping device comprises a device selected from a diaper, a tampon, a sanitary napkin, a sanitary wipe, a spill absorbing device, a mop head, and a floor waxing device.

35. The non-woven liquid entrapping device of claim 29, wherein the nanofibers are electrospun nanofibers having a fiber diameter of about 1 nanometer to about 3,000 nanometers.

36. The non-woven liquid entrapping device of claim 29, wherein the nanofibers are electrospun nanofibers having a fiber diameter of about 10 nanometers to about 2,000 nanometers.

37. A non-woven liquid entrapping device comprising:

an absorbent component; and

a hydrophilic elastomeric fibrous component,

wherein the absorbent component and the hydrophilic elastomeric fibrous component are in physical proximity thereby resulting in fluid communication,

wherein the absorbent component is more absorbent than the hydrophilic elastomeric fibrous component, but wherein the hydrophilic elastomeric fibrous component absorbs more quickly than and has a smaller holding capacity than the absorbent component,

wherein the non-woven liquid entrapping device, including the hydrophilic elastomeric fibrous component, is formed from at least one electrospun nanofiber where the at least one electrospun nanofiber comprises both the absorbent component and the hydrophilic elastomeric fibrous component in the electrospun nanofiber body,

wherein the absorbent component is embedded in the electrospun hydrophilic elastomeric fibrous component,

wherein the non-woven liquid entrapping device, including the hydrophilic elastomeric fibrous component, is formed from nanofibers having a fiber diameter of about 1 nanometer to about 3,000 nanometers, and

wherein the absorbent component is capable of holding at least about 50 times its own weight in liquid.

38. The non-woven liquid entrapping device of claim 37, wherein the hydrophilic elastomeric fibrous component is selected from zein protein, polyester elastomers, polydimethylsiloxane, hydrophilic poly(ether-co-ester) elastomers, silicone-co-polyethyleneglycol elastomers, polyacrylates, thermoplastic polyurethanes, poly(ether-co-urethanes), and any combination thereof.

39. The non-woven liquid entrapping device of claim 37, wherein the absorbent component is present in an amount from about 5% (w/w) to about 50% (w/w).

40. The non-woven liquid entrapping device of claim 37, wherein the absorbent component is present in an amount from about 30% (w/w) to about 50% (w/w).

41. The non-woven liquid entrapping device of claim 37, wherein the hydrophilic elastomeric fibrous component is selected from polyurethanes, poly ether-co-urethanes, and any combination thereof.

42. The non-woven liquid entrapping device of claim 37, wherein the liquid entrapping device comprises a device selected from a diaper, a tampon, a sanitary napkin, a sanitary wipe, a spill absorbing device, a mop head, and a floor waxing device.

43. The non-woven liquid entrapping device of claim 37, wherein the nanofibers are electrospun nanofibers having a fiber diameter of about 10 nanometers to about 2,000 nanometers.