WO1996015307A1

WO1996015307A1 - Absorbent multiphase composite fiber web

Info

Publication number: WO1996015307A1
Application number: PCT/EP1995/004207
Authority: WO
Inventors: Edward J. PILCICKI; Bi Le-Khac; Robert L. CANNON, Sr.
Original assignee: Camelot Superabsorbents Limited; Camelot Superabsorbents B.V.
Priority date: 1994-11-10
Filing date: 1995-10-26
Publication date: 1996-05-23
Also published as: AU3925395A

Abstract

A two-phase composite fiber comprising a core fiber phase and a water-absorbing surface phase containing the core fiber and a process for producing the composite fiber.

Description

ABSORBENT MULTIPHASE COMPOSITE FIBER WEB

The present invention relates to at least two phase composite fibers having at least a surface phase of a polymer which is capable of absorbing water and a core fiber phase and a process for making such fibers. In particular, the present invention relates to a two phase composite fiber wherein the surface phase is a so-called superabsorbent material.

As used herein, the term "water" when used alone or in the phrases "water- absorbing" , "water-absorbent" and "water-swellable" is understood to mean not only water but also aqueous media such as electrolyte solutions, such as body fluids.

U.S. Patents 4,500,315; 4,540,454; 4,537,590; and 4,573,085 disclose a process for making two phase fibers having a surface or outer phase comprising a water absorbent fiber. These patents disclose coating a base or core fiber with a cross- linkable solution comprising an alkali metal or ammonium salt of an acrylate polymer which is polymerized, and crosslinked in situ to form the water-absorbent phase.

A number of patents disclose water-absorbent polymers which are capable of being crosslinked with crosslinking agents such as di- and polyols; di- and polyamines; agents containing an amine and at least one alcohol group; and naturally occurring materials such as saccharides. One example of such polymers can be found in US

4,731 ,067.

We have now discovered that an alternative two phase fiber may be produced in which the water-absorbent polymer is crosslinked with a crosslinking agent, such as a diol, a polyol, a reactive compound having an amine group and at least one hydroxyl group, glycerol, erythritol, pentaerthritol and mono-, di-, and oligo- saccharides. By these means we obviate the requirement to carry out polymerization in situ by means of, for example, chemical initiators or radiation. According to a first aspect of the present invention there is provided a two phase composite fiber comprising a water absorbent phase on the surface of a core fiber phase wherein the water-absorbent phase forms a coating on the core fiber phase and is formed from: (i) a copolymer containing from about 25 to about 75 mole percent recurring units of at least one α.β-unsaturated monomer bearing at least one pendant unit selected from carboxylic acid units and derivatives of carboxylic acid units, and from about 75 to about 25 mole percent recurring units of at least one copolymerizable co- monomer, wherein from about 20 to about 80 percent of the pendant units introduced through the recurring units of the Q.,/3-unsaturated monomer comprise carboxylic acid units or substitutes convertible into carboxylic acid units, and wherein from about 80 to about 20 percent of the total pendant units comprise carboxylate salt units or substitutes convertible into carboxylic salt units; and

(ii) at least one monomer containing at least two hydroxyl groups or an amine group and at least one hydroxyl group.

Then at least one monomer is preferably selected from alkylene glycols containing 2- 10 carbon atoms and their ethers, cycloalkylene glycols, Bisphenol A, hydroxyl alkylene derivatives of Bisphenol A, hydroquinone, phloroglucinol, hydroxyl alkylene derivatives of diphenols, water soluble reactive compounds bearing one amine group and at least one hydroxyl group, glycerol, erythritol, pentaerythritol and mono-, di- and oligo-saccharides.

Then at least one monomer is preferably present in an amount of from about 0.1 to about 10 parts by weight per 100 parts by weight of the copolymer.

According to second aspect of the present invention there is provided a process for preparing the composite fiber of the above first aspect comprising:

(a) forming a water absorbent phase polymer composition comprising:

(i) a copolymer containing from about 25 to about 75 mole percent recurring units of at least one α,/3-unsaturated monomer bearing at least one pendant unit selected from the group consisting of carboxylic acid units and derivatives of carboxylic acid units, and from about 75 to about 25 mole percent recurring units of at least one copolymerizable co-monomer, wherein from about 20 to about 80 percent of the total pendant units introduced through the recurring units of the ,β- unsaturated monomer comprise carboxylic acid units, and wherein from about 80 to about 20 percent of the total pendant units comprise carboxylate salt units or substituents convertible into carboxylate salt units; and (ii) at least one monomer containing at least two hydroxyl groups, at least one hydroxyl group and an amine group.

(b) preparing an aqueous solution comprising said water-absorbent phase polymer composition;

(c) coating at least one core fiber with said aqueous solution; and

(d) heat treating the coated core fiber.

The aqueous solution of the water-absorbent phase polymer composition preferably comprises at least 10 weight percent of the water-absorbent phase composition.

The coating of the at least one fiber with the aqueous solution preferably provides a pickup on the finished fiber of at least 10 weight percent of the water-absorbent phase polymer composition.

The heat treating step is preferably carried out at from about 120 to about 200°C, preferably 150 to 190°C, for a period of time of from about 5 to about 50 minutes, preferably 5 to 30 minutes.

Without wishing to be bound by any particular theory, it is believed that the heat treatment causes the water to evaporate and the polymer to crosslink. The fiber of the above first aspect or made in accordance with the process ot the above second aspect may be used in a composite web comprising these fibers and non-water absorbent fibers.

The composite web may be used in an article of manufacture such as disposable diapers, sanitary napkins, tampons, pant liners, adult incontinence pads, coverstocks for feminine hygiene products, surgical and dental sponges, bandages, patient underpads, wipes, domestic wipes, industrial wipes, packaging, filters, medical tray pads, fenestration drapes, mortuary pads, cable wrap, food tray pads, food preservation articles, seed germination pads, pet litter, roofing materials, automotive trim, furniture, bedding, clothing and soil modifiers.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Suitable copoly ers to produce water-absorbing polymers for use in the present invention will contain from about 25 to about 75 mole percent recurring units of at least one α,j8-unsaturated monomer and from about 75 to about 25 mole percent recurring units of at least one copolymerizable monomer. The copolymer preferably contains from about 35 to about 65 mole percent of recurring units of at least one ,/3-unsaturated monomer and from about 65 to about 35 mole percent of at least one copolymerizable co-monomer. Most preferably, the copolymerwill be an equimolar copolymer.

Suitable α,/3-unsaturated monomers are those bearing at least one pendant carboxylic acid unit or derivative of a carboxylic acid unit. Derivatives of carboxylic acid units include carboxylic acid salt groups, carboxylic acid amide groups, carboxylic acid imide groups, carboxylic acid anhydride groups and carboxylic acid ester groups.

Examples of suitable c.,_/3-unsaturated monomers include aleic acid, crotonic acid, fumaric acid, mesaconic acid, the sodium salt of maleic acid, the sodium salt of 2- methyl, 2-butene dicarboxylic acid, the sodium salt of itaconic acid, maleamic acid, maleamide, N-phenyl maleimide, maleimide, maleic anhydride, fumaric anhydride; itaconic anhydride, citraconic anhydride; mesaconic anhydride, methyl itaconic anhydride, ethyl maleic anhydride, diethylmaleate, methylmaleate; and the like, and their mixtures.

Any suitable copolymerizable co-monomer can be employed. Examples of suitable copolymerizable co-monomers include ethylene, propylene, isobutylene, C, to C₄ alkyl methacrylates, vinyl acetate, methyl vinyl ether, isobutyl vinyl ether, and styrenic compounds having the formula:

— CH₂

wherein R represents hydrogen or an alkyl group having from 1 to 6 carbon atoms, and wherein the benzene ring may be substituted with low molecular weight alkyl or hydroxyl groups.

Suitable C, to C₄ alkyl acrylates include, for example, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-propyl acrylate, n-butyl acrylate, and the like, and their mixtures.

Suitable C, to C₄ alkyl methacrylates include, for example, methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, n-propyl methacrylate, n-butyl methacrylate, and the like, and their mixtures.

Suitable styrenic compounds include, for example, styrene, c.-methylstyrene, p- methylstyrene, t-butylstyrene, and the like, and their mixtures.

The pendant units on the α,/3-unsaturated monomer, will determine what, if any, additional reactions must be carried out to obtain a copolymer having the requisite pendant units necessary to produce the water-absorbing compositions of this invention. Preferably these water-absorbing compositions will contain from about 20 to about 80 percent pendant carboxylic acid units and from about 80 to about 20 percent pendant carboxylate salt units. Preferably, both units are present in an amount of from about 30 to about 70 percent.

In general, if the α.ø-unsaturated monomer bears only carboxylic acid amide, carboxylic acid imide, carboxylic acid anhydride, carboxylic acid ester groups or mixtures thereof, it will be necessary to convert at least a portion of such carboxylic acid derivative groups to carboxylic acid groups by, for example, a hydrolysis reaction. If the α,/?-unsaturated monomer bears only carboxylic acid salt groups, acidification to form carboxylic acid groups will be necessary using methods and materials well known in the art.

Similarly, the final copolymer must contain from about 80 to 20 percent pendant carboxylate salt units. Accordingly, it may be necessary to carry out a neutralization reaction. Neutralization of carboxylic acid groups with a strong organic or inorganic base such as NaOH, KOH, ammonia, ammonia-in-water solution, or organic amines will result in the formation of carboxylate salt units, preferably carboxylate metal salt units.

Moreover, the sequence and the number of reactions (hydrolysis, acidification, neutralization, etc.) carried out to obtain the desired functionality attached to the copolymer backbone are not critical. Any number and sequence resulting in a final copolymer which possesses from about 20 to about 80 percent pendant carboxylic acid units and from about 80 to about 20 percent pendant carboxylate salt units is suitable.

One copolymer particularly suitable for use is a copolymer of maleic anhydride and isobutylene. Another is maleic anhydride and styrene. Suitable copolymers will have peak average molecular weights of from about 6,000 to about 500,000 or more.

Suitable copolymers of maleic anhydride and isobutylene can be prepared using any suitable conventional method. Such copolymers are also commercially available from Kurary Isoprene Chemical Company, Ltd. , Tokyo, Japan, under the trademark

ISOBAM. ISOBAM copolymers are available in several grades which are differentiated by average viscosity molecular weight: ISOBAM- 10, 160,000 to 170,000; ISOBAM-06, 80,000 to 90,000; ISOBAM-04, 55,000 to 65,000, and ISOBAM-600, 6,000 to 10,000.

To produce a water-absorbing composition of the present invention, at least one copolymer as described above and at least one monomer bearing at least two hydroxyl groups are blended such that the water-absorbing composition contains, in weight percent, from about 70 to about 99.5 total copolymer and from about 0.5 to about 30 total monomer. Preferably, the composition will contain from about 90 to about 99 weight percent total copolymer and from about 1 to about 10 weight percent total monomer.

Suitable monomers include those bearing at least two hydroxyl groups and having a relatively low average molecular weight, less that 1 ,000, can be employed in the practice of this invention.

Suitable monomers include, for example, ethylene glycol, propylene glycol, trimethylene glycol, 1 ,4-butane diol, 2-methyl, 1,3-propane diol, neopentyl glycol, 1,5-pentane diol, diethylene glycol, dipropylene glycol, 1,4-cyclohexane dimethanol, Bisphenol A, l ,4-bis(0 hydroxyethoxy)bisphenol, hydroquinone, phloroglucinol, glycerol, erythritol, pentaerythritol, 1 ,4-dihydroxysedoheptulose, and the like.

Particularly suitable monomers for use in the practice of the present invention are ethylene glycol, propylene glycol, 1-4-butane diol, diethylene glycol, and glycerol. The water-absorbing composition ot the present invention can be prepared using any suitable blending method well known in the art.

While not prescribing to any one theory, the monomer is believed to serve as a high temperature, slow-reacting, cross-linking type agent for the copolymer particles resulting in the formation of covalent cross-link type bounds upon curing. For example, it has been found that if a partially neutralized styrene-malic anhydride copolymer is blended with propylene glycol to form a water-absorbing composition according to the present invention, a temperature of about 150°C or higher is typically required to achieve cure. Similarly, if a partially neutralized ethylene-maleic anhydride copolymer is employed, a temperature of about 140°C or higher is typically needed to achieve cure. If a partially neutralized isobutylene-maleic anhydride copolymer is employed, a temperature of about 200°C or higher is typically needed to achieve cure.

Suitable curing temperatures for the present invention range from about 120°C to about 220°C. Suitable curing times are in the range of from about 5 to 30 minutes.

The curing may be done in any of the well known heat curing methods and apparatus, such as for example, tunnel ovens and counter current hot air dryers.

Notwithstanding the significance of earlier discoveries that cross-linking through ester linkages results in a stable, uncured but heat curable syrup which can be processed using conventional drying techniques, the absorbent properties are extremely difficult to control. There is considerable absorbency variation between fibers and among fiber runs. This difficulty in controlling the absorbent properties of the fibers is due in large part to the fact that in order to achieve cross-linking cure times of about 30 minutes and to obtain a fiber that absorbs 40-50 times its weight of brine, it is necessary to add considerably more diol or glycol than is theoretically needed to achieve cross-linking. The addition of excess amounts or diol or glycol is necessary because during processing of the blend, large amounts of the non-reactive diol or glycol are washed out of the blend or tend to migrate to the fiber surface and do not effect cross-linking. In other words, extra diol or glycol must be added to ensure that sufficient amounts are present to achieve cross-linking of the resultant fibers. Because of the excess amount and uncertain location of this non-reactive compound in the fiber and on the fiber surface, absorbency properties of the fibers are difficult to control and tend to vary considerably. Obtaining optimal curing and consistent absorbency is therefore not easily obtained.

A substantial amount of additional effort has gone into understanding the cross-linking problems exhibited by the fibers of the above-mentioned patents and has led to the discovery of not only the reasons for the problems but also the preferred embodiment of the invention, which provides a solution to those problems. The present invention facilitates the production of the absorbent fibers using conventional equipment, requires considerably less cross-linking agent, shorter cure times, and yields absorbent fibers having uniformly consistent absorbency properties. Quite surprisingly, the absorbent fibers this invention possesses much better absorbent properties as compared to the prior art fibers. According to this aspect of the invention, the uncured but curable, polymer composition preferably comprising the reaction product of; (a) a partially neutralized aqueous polymer composition prepared by the reaction of a strong base with a polymer containing at least about 25 mole percent recurring units of an α. J-unsaturated monomer having in its molecular structure one or two carboxyl groups or one or two other groups convertible to carboxylic groups; the degree of neutralization of said partially neutralized polymer bring within the range of from about 0.2 to about 0.8 equivalent of total carboxyl group of groups convertible to carboxyl groups of the α,jβ-unsaturated monomer with, (b) from about 0.1 to about 10 parts by weight of at least one reactive compound per 100 parts by weight of the partially neutralized aqueous polymer, the reactive compound being a water soluble compound bearing one amine group and at least one hydroxyl group, wherein the reaction product is formed by substituted ammonium carboxylate ionic bonding between the un-neutralized carboxyl groups on the polymer and the amine groups on the reactive compound.

The core fiber may be selected from the group consisting of rayon fiber, cellulose ester fiber, protein fiber, polyamide fiber, polyester fiber, polyvinyl fiber, polyolefin fiber, polyurethane fiber, aramid fiber, glass fiber and mixtures thereof. A particularly useful core fiber is a fiber having a hollow core such as the polyester, typically polyethylene terephthalate fiber, commercially available from E.I. DuPont de Nemours under the trademark HOLLOWFILL. The core fiber may itself be a composite fiber such as the core-sheath fibers having a polyethylene sheath and a polyester core, where polyethylene terephthalate is typically used as the polyester. The core fiber could be a continuous tow or a staple fiber. The coating of the core fiber with the said solution of copolymer and polymer can be effected by any suitable method such as spray coating, or passing said core fiber through a bath containing solution of said copolymer and said polymer.

The following example is illustrative of the present invention but should not be construed as limiting the invention in any way.

Example 1

A suitable amount of a polypropylene mesh fiber was soaked in an excess of 40% solids FIBERSORB (an aqueous solution of the sodium salt of maleic anhydride and isobutylene) syrup for 2 days allowing the syrup to saturate the fiber. The fiber was then removed form the syrup and excess syrup was pressed out. The syrup was then cured in a hot air convection oven at 210°C for 20 minutes.

A second suitable amount of a polypropylene mesh fiber was soaked in an excess of 40% solids FIBERSORB syrup which had been diluted with deionized water to provide a 28% solids syrup. The fiber was soaked in an excess amount of this 28% solids syrup for 2 days to saturate the fiber and then the excess syrup was pressed out. The syrup was then cured in a hot air convection oven at 210°C for 20 minutes.

These prepared samples following the present invention as well as uncoated fiber and a commercially available competitive coated fiber were then tested for fluid retention using the "tea bag" test. The results are given in Table 1 below.

The "tea bag" test is as follows. First 10 pieces of tea bag paper is cut to 5" x 2" and folded to 2.5" x 2" and heat sealed on 2 sides. These bags are then soaked in a 0.9% NaCl saline solution, removed, dabbed lightly with filter paper to remove excess saline solution and weighed. These weights are then averaged and the value is recorded as "W₂". In a triplicate set of tea bags measuring 5" x 2" is placed approximately 0.2 grams of sample staple fiber, the exact weight of which is recorded as W₃, the bags loaded with the sample staple fiber are heat sealed. The triplicate sample containing tea bags are then placed in a 0.9% NaCl saline solution, with stirring, for 10 minutes. Each tea bag is then removed from the saline solution, allowed to drain for 10 seconds and then dabbed lightly with filter paper to remove excess saline solution. Each sample containing tea bag is then weighed and recorded as W,. Each sample containing tea bag is then placed in a Buchner porcelain funnel, a small amount of 0.9% saline solution is poured over the same to re-saturate it, and then the sample containing tea bag is exposed to a vacuum of 10.9 cm of perchloroethylene column for 5 minutes. The sample is removed and weighed and the weight is recorded as W₄.

The Free Swell Liquid Retention is determined using the formula: g/g-KW.-WjVWj] - 1, and the 0.5 psi Liquid Retention is determined using the formula: g/g[(W₄-W₂)/W₃] - 1, where W, = final free swell weight in grams of gel plus wet tea bag,

W₂ = average weight in grams of 10 empty, wet tea bags,

W₃ = original weight in grams dry staple fiber, and

W₄ = final 0.5 psi weight in grams of gel plus wet tea bag.

TABLE 1

Sample Retention (%)

Uncoated polypropylene mesh fiber Free Swell 4.2

0.5 psi 1.1

Commercially available competitivee coated Free Swell 9.6 fiber

0.5 psi 7.2

45 wt. % coating & 55 wt. % fiber, Free Swell 10.5 using 28% solids syrup

0.5 psi 8.4

42 wt. % coating & 58 wt. % fiber, Free Swell 8.6 using 28% solids syrup

0.5 psi 7.5

68 wt. % coating & 32 wt. % fiber, Free Swell 14.8 using 40 % solids syrup

0.5 psi 10.0

78 wt. % syrup & 22 wt. % fiber, Free Swell 9.9 using 40% solids syrup

0.5 psi 7.9

The liquid retention values of the samples of the present invention exceed that of the competitive sample in every case in the 0.5 psi test, and every time except one in the

Free Swell test. This clearly shows the superior results of the present invention in the ability to absorb and retain liquids.

Although the illustrative embodiments of the present invention have been described herein with reference to the accompanying experiments it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.

Claims

1. A two phase composite fiber comprising a water absorbent phase on the surface of a core fiber phase wherein the water-absorbent phase forms a coating on the core fiber phase and is formed from: (i) a copolymer containing from about 25 to about 75 mole percent recurring units of at least one α,/3-unsaturated monomer bearing at least one pendant unit selected from carboxylic acid units and derivatives of carboxylic acid units, and from about 75 to about 25 mole percent recurring units of at least one copolymerizable co-monomer, wherein from about 20 to about

80 percent of the pendant units introduced through the recurring units of the α,/3-unsaturated monomer comprise carboxylic acid units or substitutes convertible into carboxylic acid units, and wherein from about 80 to about 20 percent of the total pendant units comprise carboxylate salt units or substitutes convertible into carboxylic salt units; and (ii) at least one monomer containing at least two hydroxyl groups or an amine group and at least one hydroxyl group.

2. A composite fiber according to Claim 1 wherein the coating on the core fiber provides a pickup on the finished fiber of at least 10 weight percent of the water absorbent phase polymer composition, capable of being water-absorbent.

3. A composite fiber according to Claim 1 or 2 wherein the at least one monomer (ii) is selected from alkylene glycols containing 2-10 carbon atoms and their ethers, cycloalkylene glycols, Bisphenol A, hydroxy alkylene derivatives of Bisphenol A, hydroquinone, phloroglucinol, hydroxy alkaline derivatives of diphenols, water soluble reactive compounds bearing one amine group and at least one hydroxyl group, glycerol, erythritol, pentaerythritol and mono-, di-, and oligo-saccharides.

4. A composite fiber according to any one of Claims 1 to 3 wherein the copolymer contains from about 35 to about 65 mole percent of recurring units of the at least one α,/3-unsaturated monomer and from about 65 to about 35 mole percent of the at least one copolymerisable monomer.

5. A composite fiber according to any one of Claims 1 to 4, wherein the copolymer is equi molar.

6. A composite fiber according to any one of Claims 1 to 5, wherein the fiber comprises at least about 50 weight percent of the water-absorbent composition.

7. A composite fiber according to any one of Claims 1 to 6, wherein the core fiber is rayon fiber, cellulose ester fiber, protein fiber, polyurethane fiber, aramid fiber, glass fiber, hollow fiber or mixtures thereof.

8. A composite fiber according to any one of Claims 1 to 7 wherein the monomer is a water soluble reactive compound bearing one amine group and at least one hydroxyl group and is present in an amount of 0.1 to about 10 parts by weight per 100 parts by weight of the copolymer.

9. A composite fiber according to any one of Claims 1 to 7 wherein the monomer is glycerol, erythritol, pentaerythritol, or mono-, di- and oligo- saccharides, and is present in an amount of from about 0.1 to about 10 parts by weight per 100 parts by weight of said copolymer.

10. A composite fiber according to any one of Claims 1 to 9, wherein the core fiber is a staple fiber.

1 1. A composite fiber according to any one of Claims 1 to 9, wherein the core fiber is a continuous fiber.

12. A process for preparing a composite fiber in accordance with any one of Claims 1 to 11 comprising:

(a) forming a water absorbent phase polymer composition comprising: (i) a copolymer containing from about 25 to about 75 mole percent recurring units of at least one a,j8-unsaturated monomer bearing at least one pendant unit selected from the group consisting of carboxylic acid units and derivatives of carboxylic acid units, and from about 75 to about 25 mole percent recurring units of at least one copolymerizable co-monomer, wherein from about 20 to about 80 percent of the pendant units introduced through the recurring units of the , 3-unsaturated monomer comprise carboxylic acid units, and wherein from about 80 to about 20 percent of the pendant units comprise carboxylate salt units or substituents convertible into carboxylate salt units; and (ii) at least one monomer containing at least two hydroxyl groups or at least one hydroxyl group and an amine group;

(c) coating at least one core fiber with said aqueous solution; and (d) heat treating the coated core fiber.

13. A process according to Claim 12 wherein the aqueous solution of step (b) comprises at least 10 weight percent of the water-absorbent phase polymer composition.

14. A process according to Claim 12 or 13, wherein the heat treating is carried out at a temperature of from about 120 to about 220°C for a period of from about 5 minutes to about 30 minutes.

15. A process according to any one of Claims 12 to 14 wherein the coated fiber is heat treated at a temperature of from about 150 to about 190°C.

16. A process according to any one ot Claims Yi to runner comprising chopping said fiber before or after the heat treatment.

17. A process according to any one of Claims 12 to 16, wherein the heat treatment causes the crosslinking of the copolymer by the monomer.

18. A process according to any one of Claims 12 to 17, wherein said core fiber is coated using a spray or a bath coating means.

19. A process according to any one of Claims 12 to 18, wherein said coated core fiber is heat treated by passing through a tunnel oven means.

20. A process according to any one of Claims 12 to 18, wherein said coated core fiber is heat treated by passing downward through a counter current hot air drier means.

21. A composite web comprising non-water absorbent fibers and two phase composite fibers according to anyone of Claims 1 to 11 or made in accordance with the process of any one of Claims 12 to 21.

22. An article of manufacture comprising the composite web of Claim 21.

23. An article of manufacture according to Claim 22 wherein the article is selected from disposable diapers, sanitary napkins, tampons, pant liners, adult incontinence pads, coverstock for feminine hygiene products, surgical and dental sponges, bandages, patient underpads, wipes, domestic wipes, industrial wipes, packaging, filters, medical tray pads, fenestration drapes, mortuary pads, cable wrap, food tray pads, food preservation articles, seed germination pads, pet litter, roofing materials, automotive trim, furniture, bedding, clothing and soil modifiers.