CN111938918A - 低回渗纸尿裤及其加工工艺 - Google Patents
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Abstract
本发明涉及一种低回渗纸尿裤及其加工工艺，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，所述导流层厚度2‑3mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.2‑0.5mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成。本发明低回渗保护层与芯体吸收层之间存在一个正向扩散和逆向扩散的动态过程，确保将回渗的尿液控制在导流层的底部，避免接触使用部位。
Description
技术领域
本发明涉及一种低回渗纸尿裤及其加工工艺，属于纸尿裤加工技术领域。
背景技术
纸尿裤是一次性用品，使用后即可抛弃的产品。以无纺布、高分子吸水树脂、PE膜等材料制成，所述纸尿裤从结构上大致包括纸尿裤主体、分别纵向设于纸尿裤主体两侧的挡片，所述纸尿裤主体包括由上到下依次设置的面层、吸收芯体层以及底膜。芯体层被称为纸尿裤的心脏，不同芯体的纸尿裤品质差异巨大。芯体吸水性能的核心是高分子吸水树脂SAP的使用量及分布方式，芯体中含大量的SAP来保证纸尿裤的吸水量，吸水后整体膨胀。
现有技术中存在各种型号的高分子吸水树脂，部分已经成功应用于纸尿裤的芯体，具有良好的吸水速率和最大吸水倍数，但其仍存在如下不足：锁水效果和避免出现回渗现象这些对纸尿裤品质至关重要的要素难以均衡兼顾到，回渗后导致使用部位潮湿，皮肤红肿等，影响使用感受。为此本发明提供一种新的低回渗纸尿裤及其加工工艺。
发明内容
本发明的目的之一在于解决现有技术的不足，提供一种新的低回渗纸尿裤及其加工工艺。
本发明解决其技术问题所采用的技术方案是：
低回渗的纸尿裤，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，所述导流层厚度2-3mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.2-0.5mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成，
纸尿裤使用时，尿液经过导流层分散，进入吸收芯体层被吸附，由于吸收芯体层的锁水性能问题，部分未锁住的水会逆向扩散(高浓度至低浓度)，引起回渗，导致使用部位潮湿，皮肤红肿，影响使用感受。本发明中，导流层底部超声喷雾固定一低回渗保护层，低回渗保护层与吸收芯体层之间存在正向和逆向的扩散，尿液进入导流层分散后，低回渗保护层首先迅速吸附饱和，然后迅速向与其贴近的吸收芯体层正向扩散，实现高效的尿液吸收；由于吸收芯体层的强大吸收容量，对低回渗保护层中的吸收的尿液有进一步吸收、夺取的效应，单次尿液吸收完毕后，吸收芯体层即便部分尿液回渗，也会被低回渗保护层优先吸附，低回渗保护层与芯体吸收层之间存在一个正向扩散和逆向扩散的动态过程，确保将回渗的尿液控制在导流层的底部，避免接触使用部位。
另外，本发明导流层采用以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料交错铺网，形成横向、纵向的立体的导流通道，提高了导流效率。
优选的，粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：(2-3)，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开30-60°。
优选的，粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：3，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开45°。
优选的，所述抑菌基质为天然抑菌成分或者无机抑菌成分，抑菌基质的含量占高吸水性材料的5-8％。
优选的，含抑菌基质的高吸水性材料加工方法如下：一定量的水中，加入一定量的抑菌基质，充分搅拌均匀，然后真空和/或超声波辅助脱气处理1-2h，添加一定量的丙烯酸搅拌均匀，形成分散的抑菌基质/丙烯酸反应液体系，体系温度控制在35-45℃；加入一定量的氢氧化钠溶液至体系中，边加边搅拌，控制反应过程温度60-70℃；加入一定量的交联剂和引发剂，控制温度80-90℃反应2-3h形成高吸水性树脂聚合液，经过漂洗，超声波分散至可喷雾状态。
优选的，水和丙烯酸的质量比为(50-60)：(30-40)。
优选的，所述氢氧化钠的添加量以中和度为70-75％为准。
优选的，所述交联剂的添加量为丙烯酸质量的4-6％，引发剂的添加量为丙烯酸质量的0.5-3％。
优选的，所述交联剂为NMBA和/或PEGDA，引发剂为三氯化铁-亚硫氢钠。
一种低回渗的纸尿裤的加工工艺：
S1：制备吸收芯体层；
S2：制备导流层，超声喷雾的雾滴直径0.8-1.5mm；
S3：将吸收芯体层与导流层复合，使导流层的下表面通过固定胶与吸收芯体层的上表面粘接；
S4：表层包覆，表层盖设于吸收芯体层的上表面后，其两侧端分别沿吸收芯体层的两侧向吸收芯体层的下表面延伸，以使所述表层的两侧端均设于吸收芯体层的下表面，表层的下表面与导流层的上表面通过固定胶粘接，表层两侧端通过固定胶与吸收芯体层的下表面粘接；
S5：底膜层粘合，底膜层的上表面与吸收芯体层的下表面粘接；
S6：按常规工艺加工附件、整理后获得低回渗的纸尿裤成品，所述附件包括纵向弹性筋和魔术贴。
本发明的有益效果是：本发明中，导流层底部超声喷雾固定一低回渗保护层，低回渗保护层与吸收芯体层之间存在正向和逆向的扩散，尿液进入导流层分散后，低回渗保护层首先迅速吸附饱和，然后迅速向与其贴近的吸收芯体层正向扩散，实现高效的尿液吸收；由于吸收芯体层的强大吸收容量，对低回渗保护层中的吸收的尿液有进一步吸收、夺取的效应，单次尿液吸收完毕后，吸收芯体层即便部分尿液回渗，也会被低回渗保护层优先吸附，低回渗保护层与芯体吸收层之间存在一个正向扩散和逆向扩散的动态过程，确保将回渗的尿液控制在导流层的底部，避免接触使用部位。
另外，本发明导流层采用以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料交错铺网，形成横向、纵向的立体的导流通道，提高了导流效率。
具体实施方式
下面通过具体实施例，对本发明的技术方案作进一步的具体说明。
实施例1：
低回渗的纸尿裤，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，所述导流层厚度2mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.2mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成，
实施例1中，粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：2，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开30°，所述抑菌基质为天然抑菌成分，抑菌基质的含量占高吸水性材料的5％，含抑菌基质的高吸水性材料加工方法如下：一定量的水中，加入一定量的抑菌基质，充分搅拌均匀，然后真空和/或超声波辅助脱气处理1h，添加一定量的丙烯酸搅拌均匀，形成分散的抑菌基质/丙烯酸反应液体系，体系温度控制在35℃；加入一定量的氢氧化钠溶液至体系中，边加边搅拌，控制反应过程温度60℃；加入一定量的交联剂和引发剂，控制温度80℃反应2h形成高吸水性树脂聚合液，经过漂洗，超声波分散至可喷雾状态，水和丙烯酸的质量比为5:3，所述氢氧化钠的添加量以中和度为70％为准，所述交联剂的添加量为丙烯酸质量的4％，引发剂的添加量为丙烯酸质量的0.5％，所述交联剂为NMBA，引发剂为三氯化铁-亚硫氢钠。
一种低回渗的纸尿裤的加工工艺：
S1：制备吸收芯体层；
S2：制备导流层，超声喷雾的雾滴直径0.8-1.5mm；
S3：将吸收芯体层与导流层复合，使导流层的下表面通过固定胶与吸收芯体层的上表面粘接；
S4：表层包覆，表层盖设于吸收芯体层的上表面后，其两侧端分别沿吸收芯体层的两侧向吸收芯体层的下表面延伸，以使所述表层的两侧端均设于吸收芯体层的下表面，表层的下表面与导流层的上表面通过固定胶粘接，表层两侧端通过固定胶与吸收芯体层的下表面粘接；
S5：底膜层粘合，底膜层的上表面与吸收芯体层的下表面粘接；
S6：按常规工艺加工附件、整理后获得低回渗的纸尿裤成品，所述附件包括纵向弹性筋和魔术贴。
实施例2
低回渗的纸尿裤，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，所述导流层厚度3mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.5mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成，粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：3，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开60°，所述抑菌基质为无机抑菌成分，抑菌基质的含量占高吸水性材料的8％，含抑菌基质的高吸水性材料加工方法如下：一定量的水中，加入一定量的抑菌基质，充分搅拌均匀，然后真空和/或超声波辅助脱气处理2h，添加一定量的丙烯酸搅拌均匀，形成分散的抑菌基质/丙烯酸反应液体系，体系温度控制在45℃；加入一定量的氢氧化钠溶液至体系中，边加边搅拌，控制反应过程温度70℃；加入一定量的交联剂和引发剂，控制温度90℃反应3h形成高吸水性树脂聚合液，经过漂洗，超声波分散至可喷雾状态，水和丙烯酸的质量比为3:2，所述氢氧化钠的添加量以中和度为75％为准，所述交联剂的添加量为丙烯酸质量的6％，引发剂的添加量为丙烯酸质量的3％，所述交联剂为PEGDA，引发剂为三氯化铁-亚硫氢钠。
实施例2低回渗的纸尿裤的加工工艺同实施例1。
实施例3
低回渗的纸尿裤，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，所述导流层厚度3mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.5mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成，粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：3，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开45°，所述抑菌基质为天然抑菌成分，抑菌基质的含量占高吸水性材料的6％，含抑菌基质的高吸水性材料加工方法同实施例1。
实施例3低回渗的纸尿裤的加工工艺同实施例1。
实施例1-3的低回渗的纸尿裤的抑菌和回渗性能测试：
其中回渗量参考GB/T28004-2011纸尿裤(片、垫)的测试方法进行。抑菌性能测试，参照GB15979-1995<一次性使用卫生用品卫生标准>中相关指标测试方法进行。关于回渗量，实施例1-3的低回渗的纸尿裤优于上述国标中的要求，回渗量显著降低。关于抑菌，实施例1-3的低回渗的纸尿裤完全符合上述国标中的微生物学标准，对大肠杆菌和金黄色葡萄球菌的抑菌率达到98％(溶出性)，其抑菌作用在室温下能维持12-14个月。由测试数据可知，本发明的纸尿裤芯体吸液速度也显著提高，最高提高15％以上，另外，待测试的样品均不会起坨。
以上所述的实施例只是本发明的一种较佳的方案，并非对本发明作任何形式上的限制，在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (10)
1.低回渗的纸尿裤，包括纸尿裤主体，所述纸尿裤主体自上到下依次设有表层、导流层、吸收芯体层以及底膜层，所述吸收芯体层自下往上依次包括无尘纸层和高吸水性材料层，其特征在于，所述导流层厚度2-3mm，呈三层复合结构，单层导流层单体以粘胶纤维、直立棉纤维和粗旦纤维的混合物为原料铺网，基于非织造布的加工方法加工而成，三层导流层单体之间的铺网方向交错，导流层的底表面还通过超声喷雾的方式喷覆有一层厚度0.2-0.5mm厚的低回渗保护层，低回渗保护层由含抑菌基质的高吸水性材料构成。
2.根据权利要求1所述的低回渗的纸尿裤，其特征在于：粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：(2-3)，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开30-60°。
3.根据权利要求2所述的低回渗的纸尿裤，其特征在于：
粘胶纤维、直立棉纤维和粗旦纤维的混合物的质量比为1:2：3，三层导流层单体之间的铺网方向沿顺时针或逆时针方向依次错开45°。
4.根据权利要求1所述的低回渗的纸尿裤，其特征在于：所述抑菌基质为天然抑菌成分或者无机抑菌成分，抑菌基质的含量占高吸水性材料的5-8％。
5.根据权利要求1所述的低回渗的纸尿裤，其特征在于：含抑菌基质的高吸水性材料加工方法如下：一定量的水中，加入一定量的抑菌基质，充分搅拌均匀，然后真空和/或超声波辅助脱气处理1-2h，添加一定量的丙烯酸搅拌均匀，形成分散的抑菌基质/丙烯酸反应液体系，体系温度控制在35-45℃；加入一定量的氢氧化钠溶液至体系中，边加边搅拌，控制反应过程温度60-70℃；加入一定量的交联剂和引发剂，控制温度80-90℃反应2-3h形成高吸水性树脂聚合液，经过漂洗，超声波分散至可喷雾状态。
6.根据权利要求5所述的低回渗的纸尿裤，其特征在于：水和丙烯酸的质量比为(50-60)：(30-40)。
7.根据权利要求1所述的低回渗的纸尿裤，其特征在于：所述氢氧化钠的添加量以中和度为70-75％为准。
8.根据权利要求1所述的低回渗的纸尿裤，其特征在于：所述交联剂的添加量为丙烯酸质量的4-6％，引发剂的添加量为丙烯酸质量的0.5-3％。
9.根据权利要求8所述的低回渗的纸尿裤，其特征在于：所述交联剂为NMBA和/或PEGDA，引发剂为三氯化铁-亚硫氢钠。
10.一种权利要求1所述低回渗的纸尿裤的加工工艺，其特征在于：
S1：制备吸收芯体层；
S2：制备导流层，超声喷雾的雾滴直径0.8-1.5mm；
S3：将吸收芯体层与导流层复合，使导流层的下表面通过固定胶与吸收芯体层的上表面粘接；
S4：表层包覆，表层盖设于吸收芯体层的上表面后，其两侧端分别沿吸收芯体层的两侧向吸收芯体层的下表面延伸，以使所述表层的两侧端均设于吸收芯体层的下表面，表层的下表面与导流层的上表面通过固定胶粘接，表层两侧端通过固定胶与吸收芯体层的下表面粘接；
S5：底膜层粘合，底膜层的上表面与吸收芯体层的下表面粘接；
S6：按常规工艺加工附件、整理后获得低回渗的纸尿裤成品，所述附件包括纵向弹性筋和魔术贴。
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