CN108743046A - 一种复合芯体及其制造方法 - Google Patents
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Abstract
本发明公开了一种复合芯体,包括表层、底层、以及位于表层和底层之间的吸收层,所述吸收层包括至少一层吸水纤维层、撒播于吸水纤维层上下表面及间隙内的SAP,在表层和最上层的吸水纤维层之间开有至少一个导流孔,所述导流孔将表层贯穿;在底层和最下层的吸水纤维层之间设有至少一条导流通道。同时还提供了复合芯体的制造方法。本发明将复合芯体吸收方式由原来的由表及里的逐层传递吸收转变为跨层扩散快速传导吸收,极大提高液体进入芯体不同层的吸收速度,显著改善芯体的多次吸收、透气性和通液性,大幅提升了芯体的临时储液能力以及芯体的利用率。
Description
技术领域
本发明属于卫生用品领域,具体涉及一种复合芯体及其制造方法。
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。一种是棉芯体,由无尘纸或亲水布包裹绒毛浆与SAP(高吸水性树脂)组成。另一种是复合芯体,一般由最外两层无尘纸,中层无纺布,以及两层 SAP组成。
棉芯体的绒毛浆混合SAP(高吸水性树脂)在瞬时捕液能力表现优异,但其在吸收后吸水材料容易滑动变形堆积、断层。因此,在2006年左右行业中陆续开发出目前市面上常见的复合芯体,复合芯体克服了棉芯体过厚、容易断层、干爽较差的缺点,实现了超薄与柔软。但复合芯体的瞬时捕液能力差,由表及里二次吸收时容易因表层吸液后的高吸水性树脂产生凝胶现象而堵塞下渗通道,发生二次吸收漏液,芯体的整体利用率低,液体难以快速传导至芯体内部及向四周扩散。
部分厂家尝试在复合芯体上压切分割凿穿芯体形成沟槽,此类从上至下贯穿整个芯体的沟槽对导流性并没有显著改善,液体从沟槽流下后并未能有效到达芯体中层进行扩散传导,不能起到提高芯体利用率和跨层传导的效果,而且还致使在生产过程中所开沟槽附近的吸水性树脂大量跌落的情况。
发明内容
针对上述问题,本发明旨在提供一种多次吸收效果好、吸收扩散速度快、利用率高的复合芯体及其制造方法。
本发明解决问题的技术方案是:一种复合芯体,包括表层、底层、以及位于表层和底层之间的吸收层,所述吸收层包括至少一层吸水纤维层、撒播于吸水纤维层上下表面及间隙内的SAP,在表层和最上层的吸水纤维层之间开有至少一个导流孔,所述导流孔将表层贯穿;
在底层和最下层的吸水纤维层之间设有至少一条导流通道。
上述方案的导流孔和导流通道内无SAP,通过控制导流孔的分布数量与位置,形成液体下渗至芯体内部的渠道,又通过导流通道的分布,形成横向扩散及下渗扩散的渠道,使液体快速穿过表层后进入芯体中传导扩散至下层以及横向扩散,经过层层跨层传导和横向扩散,显著改善芯体的多次吸收、透气性和通液性。
优选的,所述吸水纤维层至少设有两层,相邻两层吸水纤维层之间设有至少一条导流通道。多层结构的多次吸收性能更好。
进一步的,所述吸水纤维层与导流孔的交界处设有朝向导流孔的拱起部;和/或
所述吸水纤维层与导流通道的交界处设有朝向导流通道的拱起部;和/或
所述底层与导流通道的交界处设有朝向导流通道的拱起部。
设计拱起部的好处是能够对拱起部两侧的SAP形成一定远离导流孔和导流通道的挤压力,从而阻止SAP进入导流孔和导流通道内,避免吸液后对导流孔和导流通道形成堵塞。
进一步的,在表层设有压槽,所述导流孔分布于压槽内。压槽结构使得表层存在一定的凹陷,凹陷与皮肤之间不接触,利于液体流动扩散。
压槽的分布形式多种多样,一种常见的形式为:所述压槽呈双曲线分布。
优选的,每一条导流通道都是连续的,在同一平面层上的导流通道设有多条,呈网格状分布或双曲线分布。
同时,本发明还提供一种上述复合芯体的制造方法,包括如下步骤:
a)采用定位撒播技术在吸水纤维层的一侧面撒播SAP,需要设置导流通道的位置不撒播SAP,从而形成导流通道;
b)将底层与撒播有SAP的吸水纤维层的那一侧面粘合;
c)在吸水纤维层的另一侧面通过定位撒播技术撒播SAP,需要设置导流孔的位置不撒播SAP,从而形成孔隙;
d)表层开贯通孔;
e)将带有贯通孔的表层与吸水纤维层的另一侧面定位,使表层的贯通孔与孔隙位置对应,然后将表层与吸水纤维层粘合,孔隙与贯通孔结合形成导流孔;
上述步骤中,步骤d)与步骤a)~c)没有先后顺序之分。
进一步的,在步骤a)之前,还包括步骤:
a1)在吸水纤维层成网阶段,通过模具热轧成型,使吸水纤维层的一侧面或两侧面有间断或连续凸起的纤维,形成拱起部;和/或
a2)在底层上提前预制或在线压轧有间断或连续的凸起,形成拱起部;
步骤a1)和a2)没有先后顺序之分;
步骤a)中在吸水纤维层上的拱起部位置不撒播SAP,导流通道的位置与拱起部对应;和/或
步骤b)中底层与吸水纤维层粘合时,底层上的拱起部与不撒播SAP的导流通道位置对应。
更进一步的,离表层最近的吸水纤维层的两侧面均设有间断或连续的拱起部;
步骤e)中表层与吸水纤维层粘合时,吸水纤维层上的拱起部与不撒播SAP的孔隙位置对应。
优选的,步骤e)之后还包括步骤f)在形成有导流孔的位置压轧压槽。
本发明将复合芯体吸收方式由原来的由表及里的逐层传递吸收转变为跨层扩散快速传导吸收,极大提高液体进入芯体不同层的吸收速度,显著改善芯体的多次吸收、透气性和通液性,大幅提升了芯体的临时储液能力以及芯体的利用率。而且,不存在生产过程中SAP跌落的情况。
附图说明
下面结合附图对本发明作进一步说明。
图1为本发明实施例1的芯体俯视图。
图2为本发明实施例1的芯体截面图。
图3为本发明实施例2的芯体俯视图。
图4为本发明实施例2的芯体截面图。
图5为本发明实施例3的芯体俯视图。
图6为本发明实施例3的芯体截面图。
图中:1-表层,2-吸水纤维层,3-底层,4- SAP,5-导流孔,6-吸收层,7-导流通道,8-拱起部,9-压槽。
具体实施方式
为了便于描述,各部件的相对位置关系(如:横、纵等)的描述均是根据说明书附图的布图方向来进行描述的,并不对本专利的结构起限定作用。
实施例1
如图1~2所示,一种复合芯体,包括表层1、底层3、以及位于表层1和底层3之间的吸收层6。
所述吸收层6包括一层吸水纤维层2、撒播于吸水纤维层2上下表面及间隙内的SAP4。所述吸水纤维层2为蓬松无纺布。在表层1和最上层的吸水纤维层2之间开有多个导流孔5。所述导流孔5将表层1贯穿。
在底层3和最下层的吸水纤维层2之间设有多条导流通道7。每一条导流通道7都是连续的,在同一平面层上的导流通道7沿横向和纵向设有多条,呈矩形网格状分布。
所述吸水纤维层2与导流孔5的交界处设有朝向导流孔5的拱起部8;和/或
所述吸水纤维层2与导流通道7的交界处设有朝向导流通道7的拱起部8;和/或
所述底层3与导流通道7的交界处设有朝向导流通道7的拱起部8。
这三种位置怎样设置拱起部8,可任意排列组合,各种情况均可。
在表层1设有压槽9,所述导流孔5分布于压槽9内。所述压槽9呈双曲线分布。
本实施例还提供一种上述复合芯体的制造方法,包括如下步骤:
a)采用定位撒播技术在吸水纤维层2的一侧面撒播SAP4,需要设置导流通道7的位置不撒播SAP4,从而形成导流通道7;
b)将底层3与撒播有SAP4的吸水纤维层2的那一侧面粘合;
c)在吸水纤维层2的另一侧面通过定位撒播技术撒播SAP4,需要设置导流孔5的位置不撒播SAP4,从而形成孔隙;
d)表层1开贯通孔;
e)将带有贯通孔的表层1与吸水纤维层2的另一侧面定位,使表层1的贯通孔与孔隙位置对应,然后将表层1与吸水纤维层2粘合,孔隙与贯通孔结合形成导流孔5;
上述步骤中,步骤d)与步骤a)~c)没有先后顺序之分。
上述步骤中并没有设置拱起部8,如果要设置,那么在步骤a)之前,还包括步骤:
a1)在吸水纤维层2成网阶段,通过模具热轧成型,使吸水纤维层2的一侧面或两侧面有间断或连续凸起的纤维,形成拱起部8;和/或
a2)在底层3上提前预制或在线压轧有间断或连续的凸起,形成拱起部8;
步骤a1)和a2)没有先后顺序之分;
相应的,在步骤a)中在吸水纤维层2上的拱起部8位置不撒播SAP,导流通道7的位置与拱起部8对应;和/或
步骤b)中底层3与吸水纤维层2粘合时,底层3上的拱起部8与不撒播SAP4的导流通道7位置对应。
如果要在吸水纤维层2与导流孔5的交界处设置朝向导流孔5的拱起部8,那么需要在离表层1最近的吸水纤维层2的两侧面均设有间断或连续的拱起部8。
步骤e)中表层1与吸水纤维层2粘合时,吸水纤维层2上的拱起部8与不撒播SAP4的孔隙位置对应。
步骤e)之后还包括步骤f)在形成有导流孔5的位置压轧压槽9。
上述方案导流孔5和导流通道7的引入有利于液体迅速进入芯体内部的不同层快速扩散,明显改善了芯体在吸液前后的透气性和通液性,克服了传统复合芯体受表层SAP吸收后发生胶凝而造成二次吸收下渗的困难,可多次加压吸收。
实施例2
如图3~4所示,重复实施例1,所不同的是:导流孔5的排布方式不同。所述吸水纤维层2设有两层。在同一平面层上的多条导流通道7呈菱形网格状分布。吸水纤维层2与导流通道7的交界处设有朝向导流通道7的拱起部8。加工方法与实施例1类似。
实施例3
如图5~6所示,重复实施例1,所不同的是:不同的导流孔5的深度不同。导流孔5以芯体的纵向中心线对称分布于中间区域。
所述吸水纤维层2设有三层。在同一平面层上的多条导流通道7呈双曲线分布。吸水纤维层2与导流通道7的交界处设有朝向导流通道7的拱起部8。
加工方法与实施例1类似。
Claims (10)
1.一种复合芯体,包括表层(1)、底层(3)、以及位于表层(1)和底层(3)之间的吸收层(6),其特征在于:所述吸收层(6)包括至少一层吸水纤维层(2)、撒播于吸水纤维层(2)上下表面及间隙内的SAP(4),在表层(1)和最上层的吸水纤维层(2)之间开有至少一个导流孔(5),所述导流孔(5)将表层(1)贯穿;
在底层(3)和最下层的吸水纤维层(2)之间设有至少一条导流通道(7)。
2. 根据权利要求1所述的复合芯体,其特征在于:所述吸水纤维层(2)至少设有两层,相邻两层吸水纤维层(2)之间设有至少一条导流通道(7)。
3. 根据权利要求1或2所述的复合芯体,其特征在于:所述吸水纤维层(2)与导流孔(5)的交界处设有朝向导流孔(5)的拱起部(8);和/或
所述吸水纤维层(2)与导流通道(7)的交界处设有朝向导流通道(7)的拱起部(8);和/或
所述底层(3)与导流通道(7)的交界处设有朝向导流通道(7)的拱起部(8)。
4.根据权利要求1所述的复合芯体,其特征在于:在表层(1)设有压槽(9),所述导流孔(5)分布于压槽(9)内。
5.根据权利要求4所述的复合芯体,其特征在于:所述压槽(9)呈双曲线分布。
6.根据权利要求1或2所述的复合芯体,其特征在于:每一条导流通道(7)都是连续的,在同一平面层上的导流通道(7)设有多条,呈网格状分布或双曲线分布。
7.一种如权利要求1所述复合芯体的制造方法,其特征在于包括如下步骤:
a)采用定位撒播技术在吸水纤维层(2)的一侧面撒播SAP(4),需要设置导流通道(7)的位置不撒播SAP(4),从而形成导流通道(7);
b)将底层(3)与撒播有SAP(4)的吸水纤维层(2)的那一侧面粘合;
c)在吸水纤维层(2)的另一侧面通过定位撒播技术撒播SAP(4),需要设置导流孔(5)的位置不撒播SAP(4),从而形成孔隙;
d)表层(1)开贯通孔;
e)将带有贯通孔的表层(1)与吸水纤维层(2)的另一侧面定位,使表层(1)的贯通孔与孔隙位置对应,然后将表层(1)与吸水纤维层(2)粘合,孔隙与贯通孔结合形成导流孔(5);
上述步骤中,步骤d)与步骤a)~c)没有先后顺序之分。
8. 根据权利要求7所述的制造方法,其特征在于:在步骤a)之前,还包括步骤:
a1)在吸水纤维层(2)成网阶段,通过模具热轧成型,使吸水纤维层(2)的一侧面或两侧面有间断或连续凸起的纤维,形成拱起部(8);和/或
a2)在底层(3)上提前预制或在线压轧有间断或连续的凸起,形成拱起部(8);
步骤a1)和a2)没有先后顺序之分;
步骤a)中在吸水纤维层(2)上的拱起部(8)位置不撒播SAP,导流通道(7)的位置与拱起部(8)对应;和/或
步骤b)中底层(3)与吸水纤维层(2)粘合时,底层(3)上的拱起部(8)与不撒播SAP(4)的导流通道(7)位置对应。
9.根据权利要求8所述的制造方法,其特征在于:离表层(1)最近的吸水纤维层(2)的两侧面均设有间断或连续的拱起部(8);
步骤e)中表层(1)与吸水纤维层(2)粘合时,吸水纤维层(2)上的拱起部(8)与不撒播SAP(4)的孔隙位置对应。
10.根据权利要求7所述的制造方法,其特征在于:步骤e)之后还包括步骤f)在形成有导流孔(5)的位置压轧压槽(9)。
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