CN105919733B - 一种具备高效导流性与透气性的吸收芯体及其制造方法 - Google Patents

一种具备高效导流性与透气性的吸收芯体及其制造方法 Download PDF

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Publication number
CN105919733B
CN105919733B CN201610458331.9A CN201610458331A CN105919733B CN 105919733 B CN105919733 B CN 105919733B CN 201610458331 A CN201610458331 A CN 201610458331A CN 105919733 B CN105919733 B CN 105919733B
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China
Prior art keywords
layer
nonwoven layer
super absorbent
absorbent resin
nonwoven
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CN201610458331.9A
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CN105919733A (zh
Inventor
覃叙钧
唐亮
甘益
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Hunan Beijian Sanitary Products Co ltd
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HUNAN KANGCHENG CARE PRODUCTS Co Ltd
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Priority to CN201610458331.9A priority Critical patent/CN105919733B/zh
Publication of CN105919733A publication Critical patent/CN105919733A/zh
Priority to EP17814410.1A priority patent/EP3476377A4/en
Priority to JP2019506771A priority patent/JP2019514643A/ja
Priority to US16/099,950 priority patent/US20190133848A1/en
Priority to PCT/CN2017/072158 priority patent/WO2017219670A1/zh
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Abstract

本发明公开了一种具备高效导流性与透气性的吸收芯体,包括表层、底层以及吸收层，吸收层包括与表层下表面贴合的无纺布层，无纺布层内均匀撒播有高吸水性树脂；表层与无纺布层贴合形成复合层，复合层上设有导流沟槽，导流沟槽将芯体划分成多块吸收区域；复合层与底层上表面连接；无纺布层下表面与底层上表面之间均匀撒播有高吸水性树脂。同时还提供一种加工方法,能够最大限度的降低无纺布塑化程度,增加柔软舒适度，改善触感。该吸收芯体层与层之间搭配不同性能的SAP，芯体在吸液后呈现出明显的凸起，具有柔软舒适、透气性好、吸液扩散快、与皮肤接触面积小的优点。

Description

一种具备高效导流性与透气性的吸收芯体及其制造方法
技术领域
本发明属于卫生用品领域，具体涉及一种具备高效导流性与透气性的吸收芯体及其制造方法。
背景技术
目前已知的处理人体排泄物的吸收芯体大体可分两种。
一种是复合芯体，如图1所示，一般由最外两层无尘纸1，中层无纺布2，以及两层SAP3（高吸水性树脂）组成。
另一种是棉芯体，如图2所示，由无尘纸1或亲水布包裹绒毛浆13与SAP3组成。
除了上述常见结构外，也有部分厂家在吸收体结构上做细微的调整，如在图1的结构上再添加一层木浆，以及在图2的棉芯体上用磨轮压花型。
上述芯体在吸收液体后均为平面状，与皮肤接触面积大，且所能添加的SAP量有限，添加大量SAP容易造成SAP滑动并伴有明显颗粒感，在吸液后将发生芯体分层与滑动成堆。
使用以上结构吸收芯体的产品，在实际使用过程中，有以下几种弊端：
1. 如图1所示，该类型芯体需要添加大量SAP时需要通过加大热熔胶的使用量，否则大量的SAP容易移动，造成分布不均匀，而热熔胶过多将造成吸收速度与透气性明显下降，且手感僵硬。
2. 如图1、图2所示，该两种类型芯体在吸液后成平面状，即使在芯体上压制花纹也会在吸液之后被撑开，使产品面层与皮肤接触面积大，皮肤表面空气无法充分流通并形成对流，液体挥发出来的有害气体，易对皮肤造成伤害，诱发各种易发皮肤病。
3. 如图1所示，该类型芯体吸液扩散效果弱，二次吸收速度慢，芯体利用率不高。
4. 如图2所示，该类型芯体在SAP吸液后，体积膨胀，颗粒具有可移动性。即使在吸收体上压制了网格或条纹，吸液后也会把压纹撑起，导致无法固定SAP颗粒的位置。稍有外力作用的情况下，吸液部分的SAP很容易移位，导致局部堆积成团而其他部位发生断层情况，不仅影响二次吸液效果，还影响穿着的舒适性。
5. 如图2所示，该类型芯体一般大量使用绒毛浆，吸液后大部分液体被绒毛浆瞬时捕捉，难以向两端扩散，容易造成芯体局部膨胀鼓起成包状。除易造成断层外，锁水不牢，容易造成液体反渗，且易挥发出来损害皮肤或影响皮肤触感。
发明内容
针对上述问题，本发明旨在提供一种能够最大限度提升导流性、降低无纺布塑化程度,柔软舒适、透气性好的吸收芯体。
本发明解决问题的技术方案是：一种具备高效导流性与透气性的吸收芯体,包括表层、底层以及在表层和底层之间的吸收层，所述吸收层包括与表层下表面贴合的无纺布层，无纺布层内均匀撒播有高吸水性树脂；
所述表层与无纺布层贴合形成复合层，复合层上设有导流沟槽，该导流沟槽将芯体划分成多块吸收区域；
带有导流沟槽的复合层与底层上表面连接；
无纺布层下表面与底层上表面之间均匀撒播有高吸水性树脂。
上述方案将目前的平面吸收芯体改进为立体吸收芯体，采用导流沟槽将芯体分成多块，第一次吸液后膨胀形成山峰状，第二次吸液时,液体在重力势能作用下自然往下导流，加速了液体传导吸收，有效的提高了二次吸收速度。吸液后形成的更高的凸起减小了面层与皮肤的接触面积，改善了透气性。
将芯体分成多块的另一个好处就是可以让SAP位于一个相对狭小的空间内，防止SAP移位。使得可以在不大量使用热熔胶的情况下添加更多SAP，且无颗粒感。
无纺布层下表面与底层上表面之间添加更多的SAP，有利于芯体的多次吸收。
进一步的，所述无纺布层包括第一无纺布层以及位于第一无纺布层下方的第二无纺布层，第一无纺布层内均匀撒播有第一高吸水性树脂，第二无纺布层内均匀撒播有第二高吸水性树脂，第二无纺布层下表面与底层之间均匀撒播有第三高吸水性树脂；
所述第一无纺布层与第二无纺布层之间形成有空气通道。
在没吸液前空气通道起到空气流通穿戴不闷的作用，吸液后能提供给SAP足够的膨胀空间。
优选的,所述第一、第二、第三高吸水性树脂型号不同,第一、第二、第三高吸水性树脂吸液速度依次逐渐增强，构成由上至下吸液速度由慢到快的梯度差。
所述不同型号的SAP分多层铺设，减少了SAP因移动所产生的成堆颗粒感，可根据SAP的特性来选择SAP所铺放的位置和用量，以根据需要调整芯体的吸收速度、干爽性等，增强了芯体性能的可设计性。从而提高了芯体的整体利用率，并显著提升了芯体的吸收速度与多次吸液效果。
具体的，导流沟槽为S形或直线形。
所述表层与无纺布层贴合的方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种。
所述带有导流沟槽的复合层与底层之间连接方式为胶粘合；
所述导流沟槽采用热粘合制成。
与此同时，本发明还提供一种上述方案所述具备高效导流性与透气性的吸收芯体的制造方法，其特征在于包括如下步骤：
（a）将高吸水性树脂均匀撒播在无纺布层内的空隙中，并将无纺布层与表层贴合形成复合层；贴合方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种；
（b）将步骤（a）中的复合层通过预热装置预热到30～150℃；
（c）通过热粘合的方式，在预热好的复合层上加工出导流沟槽；
（d）将高吸水性树脂均匀撒播在复合后的无纺布层的下表面，并与底层通过胶粘合；
（e）超声波分切或热分切，然后收卷。
上述方法的重点在于，并没有将表层、无纺布层和底层一起热粘合,而是部分层之间先复合，因为所有一起粘合需要高的温度和更多热量才能成型,这样就会使无纺布层塑化严重,导致手感差。
预加热的目的是为了缩小热轧时的温差,能够更好的降低塑化程度,改善手感。
采用超声波分切机或热分切，使分切边的材料相互融合，减少SAP从芯体侧边漏出的可能性，杜绝了成品使用过程的SAP外漏，同时保障了柔软的手感。
一种优选的方案中，所述无纺布层包括第一无纺布层以及位于第一无纺布层下表面的第二无纺布层，第一无纺布层内均匀撒播有第一高吸水性树脂，第二无纺布层内均匀撒播有第二高吸水性树脂，第二无纺布层下表面与底层之间均匀撒播有第三高吸水性树脂；
相应的，步骤（a）中，无纺布层与表层贴合形成复合层的步骤可具体分解为：
（a1）在第一无纺布层的空隙中均匀撒播第一高吸水性树脂，并将第一无纺布层与表层贴合；
（a2）在第二无纺布层的空隙中均匀撒播第二高吸水性树脂，并将第二无纺布层与第一无纺布层叠合；
表层、第一无纺布层、第二无纺布层三者组成步骤（a）中的复合层，第一无纺布层与第二无纺布层之间采用无胶工艺形成有空气通道；
所述第一、第二、第三高吸水性树脂型号不同,第一、第二、第三高吸水性树脂吸液速度依次逐渐增强，构成由上至下吸液速度由慢到快的梯度差。
具体的，步骤（b）中预加热的方式为红外、热风、超声波中的一种或几种，加热温度为80℃。
步骤（c）中的导流沟槽采用热轧加工，且下轧辊表面温度小于上轧辊表面温度，上辊表面温度：80～180℃，下辊表面温度：30～90℃，轧合速度50～150m/min。
之前的加工工艺中，上、下轧辊表面温度相同，本发明的方法中将下轧辊表面温度降低，使得复合层下表面材料被塑化的程度小，能够提升整个芯体的柔软度。
本发明的显著效果是：
1.芯体的制造工艺中并没有将表层、无纺布层和底层一起热粘合,而是部分层之间先复合，后预加热，再热粘合、最后胶粘的方式,能够最大限度的降低无纺布塑化程度,增加柔软舒适度，改善触感。
2.导流型沟槽的设计，在芯体表面能形成稳定的空气通道，加速了液体沿通道快速扩散，同时提高了芯体的整体利用率。
3.SAP分多层下料，使芯体的可容纳性大幅提升，且中间部分材料采用无胶粘合工艺，使芯体整体施胶量明显下降更有利于液体下渗，有效改善吸收速度。
4.芯体中的SAP分层下料使得搭配形式多样化，可以从饱水量、通液性、反渗量等各方面来综合设计各层SAP的型号与施加量，极大的提升了芯体性能的可设计性。
5.芯体不使用绒毛浆，大部分液体在开始阶段被SAP吸收，少部分被纤维无纺布或干法纸暂存，而后由SAP全部吸收并锁定。能够挥发出来的有害气体，大部分会经过透气薄膜和底层无纺布向外挥发，从吸收体表层挥发出来的微乎其微，对皮肤造成的损害减少到最低程度。
附图说明
下面结合附图对本发明作进一步说明。
图1为现有技术中一种吸收芯体结构图。
图2为现有技术中另一种吸收芯体结构图。
图3为本发明实施例1吸收芯体俯视图。
图4为本发明实施例1吸收芯体截面图。
图5为本发明实施例1吸收芯体工艺框图。
图6为本发明实施例2吸收芯体截面图。
图7为本发明实施例2吸收芯体工艺框图。
图8为本发明实施例3吸收芯体俯视图。
图中：1-无尘纸,2-中层无纺布,3-SAP,4-表层，5-底层，6-无纺布层，7-导流沟槽，9-第一高吸水性树脂，10-第二高吸水性树脂，11-第三高吸水性树脂，12-空气通道，13-绒毛浆，61-第一无纺布层，62-第二无纺布层。
具体实施方式
实施例1
如图3～5所示，一种具备高效导流性与透气性的吸收芯体,包括表层4、底层5以及在表层4和底层5之间的吸收层。所述吸收层包括与表层4下表面贴合的无纺布层6，无纺布层6内均匀撒播有高吸水性树脂。
所述表层4与无纺布层6贴合形成复合层，复合层上设有S形导流沟槽7，该导流沟槽7将芯体划分成多块吸收区域。
带有导流沟槽7的复合层与底层5上表面连接。
无纺布层6下表面与底层5上表面之间均匀撒播有高吸水性树脂。
所述表层4与无纺布层6贴合的方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种。
所述带有导流沟槽7的复合层与底层5之间连接方式为胶粘合。所述导流沟槽7采用热粘合制成。
相应的，本实施例还提供一种上述具备高效导流性与透气性的吸收芯体的制造方法，其特征在于包括如下步骤：
（a）将高吸水性树脂均匀撒播在无纺布层6内的空隙中，并将无纺布层6与表层4贴合形成复合层；贴合方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种；
（b）将步骤（a）中的复合层通过预热装置预热到30～150℃；
（c）通过热粘合的方式，在预热好的复合层上加工出导流沟槽7；
（d）将高吸水性树脂均匀撒播在复合后的无纺布层6的下表面，并与底层5通过胶粘合；
（e）超声波分切或热分切，然后收卷。
步骤（b）中预加热的方式为红外、热风、超声波中的一种或几种，加热温度为80℃。
步骤（c）中的导流沟槽7采用热轧加工，且下轧辊表面温度小于上轧辊表面温度，上辊表面温度：80～180℃，下辊表面温度：30～90℃，轧合速度50～150m/min。
上述方法并没有将表层、无纺布层和底层一起热粘合,而是部分层之间先复合，因为所有一起粘合需要高的温度和更多热量才能成型,这样就会使无纺布层塑化严重,导致手感差。
预加热的目的是为了缩小热轧时的温差,能够更好的降低塑化程度,改善手感。
采用导流沟槽7将芯体分成多块，第一次吸液后膨胀形成山峰状，第二次吸液时,液体在重力势能作用下自然往下导流，加速了液体传导吸收。
将芯体分成多块的另一个好处就是可以让SAP位于一个相对狭小的空间内，防止SAP移位。使得可以在不大量使用热熔胶的情况下添加更多SAP，且无颗粒感。
无纺布层6下表面与底层5上表面之间添加更多的SAP，有利于芯体的多次吸收。
采用超声波分切机或热分切，使分切边的材料相互融合，减少SAP从芯体侧边漏出的可能性，杜绝了成品使用过程的SAP外漏，同时保障了柔软的手感。
实施例2
如图6～7所示，重复实施例1，所不同的是：所述无纺布层6包括第一无纺布层61以及位于第一无纺布层61下方的第二无纺布层62。第一无纺布层61内均匀撒播有第一高吸水性树脂9。第二无纺布层62内均匀撒播有第二高吸水性树脂10。第二无纺布层62下表面与底层5之间均匀撒播有第三高吸水性树脂11。
相应的，步骤（a）中，无纺布层6与表层4贴合形成复合层的步骤可具体分解为：
（a1）在第一无纺布层61的空隙中均匀撒播第一高吸水性树脂9，并将第一无纺布层61与表层4贴合；
（a2）在第二无纺布层62的空隙中均匀撒播第二高吸水性树脂10，并将第二无纺布层62与第一无纺布层61叠合；
表层4、第一无纺布层61、第二无纺布层62三者组成步骤a中的复合层，第一无纺布层61与第二无纺布层62之间采用无胶工艺形成有空气通道12。在没吸液前空气通道起到空气流通穿戴不闷的作用，吸液后能提供给SAP足够的膨胀空间。
所述第一、第二、第三高吸水性树脂型号不同,第一、第二、第三高吸水性树脂吸液速度依次逐渐增强，构成由上至下吸液速度由慢到快的梯度差。
不同型号的SAP分多层铺设，减少了SAP因移动所产生的成堆颗粒感，可根据SAP的特性来选择SAP所铺放的位置和用量，以根据需要调整芯体的吸收速度、干爽性等，增强了芯体性能的可设计性。
实施例3
如图8所示，重复实施例1或2，所不同的是，导流沟槽7为直线形。

Claims (9)

1.一种具备高效导流性与透气性的吸收芯体,包括表层（4）、底层（5）以及在表层（4）和底层（5）之间的吸收层，所述吸收层包括与表层（4）下表面贴合的无纺布层（6），无纺布层（6）内均匀撒播有高吸水性树脂；
所述表层（4）与无纺布层（6）贴合形成复合层，复合层上设有导流沟槽（7），该导流沟槽（7）将芯体划分成多块吸收区域；
带有导流沟槽（7）的复合层与底层（5）上表面连接；
无纺布层（6）下表面与底层（5）上表面之间均匀撒播有高吸水性树脂；其特征在于:
所述无纺布层（6）包括第一无纺布层（61）以及位于第一无纺布层（61）下方的第二无纺布层（62），第一无纺布层（61）内均匀撒播有第一高吸水性树脂（9），第二无纺布层（62）内均匀撒播有第二高吸水性树脂（10），第二无纺布层（62）下表面与底层（5）之间均匀撒播有第三高吸水性树脂（11）；
所述第一无纺布层（61）与第二无纺布层（62）之间采用无胶工艺形成有空气通道（12），在没吸液前空气通道（12）起到空气流通穿戴不闷的作用，吸液后能提供给高吸水性树脂足够的膨胀空间。
2.根据权利要求1所述的具备高效导流性与透气性的吸收芯体，其特征在于：第一、第二、第三高吸水性树脂吸液速度依次逐渐增强，构成由上至下吸液速度由慢到快的梯度差。
3.根据权利要求1所述的具备高效导流性与透气性的吸收芯体，其特征在于：导流沟槽（7）为S形或直线形。
4.根据权利要求1所述的具备高效导流性与透气性的吸收芯体，其特征在于：所述表层（4）与无纺布层（6）贴合的方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种。
5.根据权利要求1所述的具备高效导流性与透气性的吸收芯体，其特征在于：所述带有导流沟槽（7）的复合层与底层（5）之间连接方式为胶粘合；
所述导流沟槽（7）采用热粘合制成。
6.一种如权利要求1所述的具备高效导流性与透气性的吸收芯体的制造方法，其特征在于包括如下步骤：
（a）将高吸水性树脂均匀撒播在无纺布层（6）内的空隙中，并将无纺布层（6）与表层（4）贴合形成复合层；贴合方式为热轧、超声波粘合、线缝、胶粘合中的一种或几种；
（b）将步骤（a）中的复合层通过预热装置预热到30～150℃；
（c）通过热粘合的方式，在预热好的复合层上加工出导流沟槽（7）；
（d）将高吸水性树脂均匀撒播在复合后的无纺布层（6）的下表面，并与底层（5）通过胶粘合；
（e）超声波分切或热分切，然后收卷；
步骤（a）中，无纺布层（6）与表层（4）贴合形成复合层的步骤具体分解为：
（a1）在第一无纺布层（61）的空隙中均匀撒播第一高吸水性树脂（9），并将第一无纺布层（61）与表层（4）贴合；
（a2）在第二无纺布层（62）的空隙中均匀撒播第二高吸水性树脂（10），并将第二无纺布层（62）与第一无纺布层（61）叠合；
表层（4）、第一无纺布层（61）、第二无纺布层（62）三者组成步骤（a）中的复合层，第一无纺布层（61）与第二无纺布层（62）之间采用无胶工艺形成有空气通道（12），在没吸液前空气通道（12）起到空气流通穿戴不闷的作用，吸液后能提供给高吸水性树脂足够的膨胀空间。
7.根据权利要求6所述的制造方法，其特征在于：第一、第二、第三高吸水性树脂吸液速度依次逐渐增强，构成由上至下吸液速度由慢到快的梯度差。
8.根据权利要求6所述的制造方法，其特征在于：步骤（b）中预加热的方式为红外、热风、超声波中的一种或几种，加热温度为80℃。
9.根据权利要求6所述的制造方法，其特征在于：步骤（c）中的导流沟槽（7）采用热轧加工，且下轧辊表面温度小于上轧辊表面温度，上辊表面温度：80～180℃，下辊表面温度：30～90℃，轧合速度50～150m/min。
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