JP6216139B2 - Non-woven fabric for diapers and diapers using the same - Google Patents

Description

  The present invention relates to a nonwoven fabric for diapers and a diaper using the same.

The non-woven fabric is hardly raised because the fibers are bonded in the state of sleeping. For this reason, it is used for infants and nursing diapers. And the nonwoven fabric utilized for a diaper has an uneven surface on the surface which touches skin directly, thereby reducing the contact surface to skin and preventing discomfort or diaper rash.
Furthermore, it is thought that the convex part of this uneven surface exhibits a function of temporarily storing urine. That is, the diaper has an absorbent body made of an absorbent polymer or the like inside the nonwoven fabric, and urine that has permeated through the nonwoven fabric is absorbed by this absorbent body. If it is high, the absorbent body does not absorb urine immediately, so that urine that is not absorbed quickly touches the skin and becomes uncomfortable, and also causes side leakage. In this respect, for example, by forming the convex portion 32 as shown in FIG. 8 of Patent Document 1, the absorber is placed in the space 33 between the top sheet 30 and the intermediate sheet 40 (that is, in the convex portion 32). The amount of urine that cannot be absorbed quickly can be temporarily stored. The urine stored in the convex portion 32 is absorbed by the absorber while spreading in the surface direction by a capillary phenomenon after a short while. In this way, the uneven surface reduces the chance of urine touching the skin and prevents side leakage due to its storage function.

JP 2011-234896 A

By the way, about the diaper, it is desired to make the thickness thin, and if it does so, an absorber will have to become weak in absorption capacity with the thinness. For this reason, about a diaper, it is thought that the structure which temporarily stores much urine by the uneven part of the nonwoven fabric of the surface is required.
An object of this invention is to provide the nonwoven fabric which can temporarily store much urine even if a diaper becomes thin.

The above-mentioned problem is a diaper comprising a first fiber layer having an uneven surface formed of a large number of recesses and protrusions formed on the surface, and a second fiber layer superimposed on the back surface of the first fiber layer. The convex portion bulges on the side opposite to the second fiber layer so that the surface view has a substantially hexagonal shape, and the concave portion is formed on each side of the substantially hexagonal shape. A dot-like part formed by thermocompression bonding to the second fiber layer at a position corresponding to each corner of the substantially hexagonal shape and corresponding to the groove part in contact with the second fiber layer. And the concave and convex surface has the concave portion corresponding to the substantially hexagonal side of the predetermined convex portion and the substantially hexagonal shape of the other convex portion adjacent to the predetermined convex portion. as it said recess corresponding to the edge in common, Contact and exhibits the substantially hexagonal shape of the continuous side-by-side honeycomb It is solved by Tsu for nonwovens.

In the present invention, the convex portion formed on the first fiber layer bulges on the opposite side to the second fiber layer. For this reason, when wearing a diaper using this nonwoven fabric, even if urine may not be absorbed quickly by the absorbent body inside the nonwoven fabric, the urine is temporarily stored in the convex part, You can reduce the chances of touching your skin and side leakage.
Moreover, since the recessed part is a groove shape corresponding to a substantially hexagonal side and the fiber density is higher than that of the protruding part, urine is transferred to the surface through the recessed part by capillary action.
Here, the recessed part has a dot-like part formed by thermocompression bonding to the second fiber layer at a position corresponding to each corner of the substantially hexagonal shape. Accordingly, the pressure for maintaining the substantially hexagonal shape is enhanced by this pressure bonding. If all of the recesses are thermocompression bonded to the second fiber layer, there is a possibility that the capillarity in which urine is diffused in the surface direction of the nonwoven fabric may be hindered due to fiber fusion. However, in the present invention, thermocompression bonding is in the form of dots arranged at each corner of a substantially hexagonal shape, so that urine is easily diffused in the surface direction while increasing the retention force of the substantially hexagonal shape.
And since the uneven surface has a honeycomb shape in which swelled substantially hexagonal shapes are continuously arranged, even if it is pressed from above (that is, pressed by the buttocks or the like at the time of mounting), it is hard to be crushed and is strong against buckling. Part can be formed. Therefore, a large convex portion can be formed as much as it is difficult to be crushed, and a large amount of urine can be temporarily stored in the large convex portion. That is, the present invention does not increase the strength by making a honeycomb structure, but forms a large convex portion so as not to decrease the strength as much as possible, thereby preventing urine skin contact and side leakage. it can.

Preferably, when the surface of the first fiber layer is bent along the flange, the outer peripheral side surfaces of the convex portions adjacent to each other are in contact with each other.
Then, when wearing as a diaper using such a non-woven fabric, the outer peripheral side surfaces of the convex portions adjacent to each other support each other and are more crushed against the force pushed from above (the force pushed by the collar). Difficult convex parts can be obtained.

In addition, the above-described problem is a back sheet that prevents permeation of liquid, a non-woven fabric that is disposed on the surface contacting the body, and urine that is disposed between the back sheet and the non-woven fabric and has permeated the non-woven fabric. A non-woven fabric comprising a first fiber layer having a concavo-convex surface comprising a large number of concave portions and convex portions formed on a surface thereof, and a back surface of the first fiber layer. And the convex portion bulges to the opposite side of the second fibrous layer so that the surface view is substantially hexagonal, and the concave portion is a groove-like in contact with the second fibrous layer with a corresponding along each side of the substantially hexagonal shape and a position corresponding to each corner of the substantially hexagonal shape, and the second fibrous layer has a dot-like portion formed by thermal compression bonding, the uneven surface, the substantially sixth predetermined said protrusion And the recess corresponding to the edge shape as said recess corresponding to the substantially hexagonal sides of the other of the convex portion adjacent to the predetermined said protrusions are common, continuous the substantially hexagonal It is solved by the diapers presenting the honeycomb shape.

That is, in this invention, since the convex part formed in the 1st fiber layer swells on the opposite side to the 2nd fiber layer, as above-mentioned, urine which is not absorbed quickly by an absorber is convex part. Can be temporarily stored in the urine, reducing the chance of urine touching the skin and reducing side leakage.
And a recessed part has the dot-shaped part formed by thermocompression-bonding to a 2nd fiber layer in the position corresponding to each substantially hexagonal corner | angular part. Therefore, as described above, urine can be easily diffused in the surface direction while increasing the retention force of the substantially hexagonal shape.
Furthermore, since the uneven surface has a honeycomb shape in which swelled substantially hexagonal shapes are continuously arranged, even if pressed from above on the buttocks at the time of mounting as described above, it forms a convex portion that is hard to collapse and is strong against buckling it can. Therefore, a large convex part can be formed as much as it is difficult to collapse, and a large amount of urine can be temporarily stored therein.

Preferably, among the six concave portions corresponding to the sides of the substantially hexagonal shape, two parallel concave portions are arranged along the longitudinal direction of the diaper .

  As mentioned above, even if a diaper becomes thin, this invention can provide the nonwoven fabric which can store many urine temporarily.

It is a perspective view which shows the example of preferable embodiment of the diaper formed using the nonwoven fabric for diapers of this invention (The recessed part and convex part of the uneven surface of a nonwoven fabric show only one part), The figure enclosed with the dashed-two dotted line Is an enlarged view of the concavo-convex surface, and a diagram surrounded by an alternate long and short dash line is an enlarged view of fibers on the concavo-convex surface. In the upper diagram of FIG. 1, the left side is notched for convenience of understanding. The perspective view which shows the state which mounted | wore with the diaper shown in FIG. AA schematic sectional drawing of FIG. BB schematic sectional drawing of FIG. FIG. 5A is a perspective view of the convex portion before mounting, and FIG. 5B is a perspective view of the convex portion in the vicinity of the flange portion when mounting. It is a figure which shows the diffusion route of the urine in a nonwoven fabric, Fig.6 (a) is a diffusion route in the case of the uneven surface of FIG. 1, FIG.6 (b) is a diffusion route in the case of other embodiment. The figure showing the manufacturing method of the nonwoven fabric of FIG.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
The embodiment described below is a preferred specific example of the present invention, and thus various technically preferable limitations are given. However, the scope of the present invention is particularly limited in the following description. Unless otherwise stated, the present invention is not limited to these embodiments.
Moreover, in the following drawings, the parts denoted by the same reference numerals have the same configuration.

The diaper 10 shown in FIG. 1 is also referred to as a disposable diaper (diaper), a paper diaper (diaper), or the like. In the present embodiment, the diaper 10 is sold in a folded state at the center portion CL in the longitudinal direction Y. When using this diaper 10, the folded one is expanded as shown in FIG. 1, the central part CL is between the crotch, and one end FR in the longitudinal direction Y is on the ventral side of the user, The other end BA is arranged on the back side of the user. Then, as shown in FIG. 2, the tape 12 provided on both ends in the short side direction X on the other end BA side is attached to both ends 14 and 14 of the surface exposed to the outside of the one end FR. (Hereinafter, the surface exposed to the outside when worn is referred to as the back surface, and the surface in contact with the body is referred to as the front surface).
The illustrated tape 12 is a hook-and-loop fastener. On the other hand, a fibrous member 16 is provided on the back surface of the one end FR so that the hook-and-loop fastener can be easily attached and detached. The member 16 has a strip shape along the short-side direction X, whereby the attachment position of the tape 12 can be adjusted according to the user's physique.
The diaper 10 of the present invention is not limited to such a form. For example, the diaper 10 may be of a pants type or a shorts type from the point of sale, and may be a pad type that is attached to the inside of the underwear. It does not matter. Moreover, the diaper 10 of FIG. 1 can be suitably used for both infants and incontinence of elderly people.

The diaper 10 includes a back sheet 18 that prevents permeation of urine and other filth, a non-woven fabric 20 that is disposed directly on the surface side, as shown in FIG. And an absorbent body 30 that is disposed between the back sheet 18 and the nonwoven fabric 20 and absorbs urine that has passed through the nonwoven fabric 20.
The back sheet 18 is a sheet material that is disposed on the back surface and is exposed to the outside in a mounted state, and is made of a flexible material, for example, a thin plastic film. Specifically, a polyethylene film or polyethylene laminated paper can be used. The backsheet 18 does not allow urine to pass through, but preferably allows water vapor to pass therethrough.

The absorber 30 is a part for absorbing and holding the discharged liquid such as urine, and it is preferable that the absorbing body 30 has a high retention property of the absorbed liquid and is relatively thin and not bulky. As such an absorber 30, for example, a pulp absorber formed by mixing a polymer that is an absorbent material with pulp, or by dispersing a polymer onto the pulp, and the polymer between the sheet materials made of pulp or the like with high density. A polymer sheet or the like arranged in a sheet shape can be used.
The absorbent body 30 is wrapped in a tissue 32 and is prevented from being exposed to the outside. The tissue 23 is formed into a sheet by combining a soft material that absorbs liquid, such as pulp, rayon, cotton, kenaf, bagasse, silk, hydrophilic fiber (polyolefin, polyester, acrylic) or the like. Things can be used.

  The nonwoven fabric 20 is used as a surface material that touches the user's skin because it is a material that is difficult to raise, and has a role of allowing the urine, which is excrement, to permeate through the absorbent body 30. It is also called a sheet. This non-woven fabric 20 is made of a heat-sealable fiber (for example, PET / PE, PP / PE, PET / EP, PP / EP) obtained by fiberizing a synthetic resin without using a binder by a thermal bond method or a spun bond method. It is formed by fusing.

And the nonwoven fabric 20 is comprised from several layers, and consists of the 1st fiber layer 21 and the 2nd fiber layer 22 in FIG.
The first fiber layer 21 is disposed on the surface that directly touches the user's skin, and has an uneven surface 19 composed of a large number of concave portions 33 and convex portions 34, thereby reducing the contact surface of the nonwoven fabric 20 with the skin. To prevent discomfort and diaper rash.
As shown in FIGS. 3 and 4, the second fiber layer 22 is overlapped on the back surface of the first fiber layer 21 (inside the diaper 10), and has a generally flat sheet shape.
And the convex part 34 of the 1st fiber layer 21 bulges on the opposite side to the 2nd fiber layer 22, and the part where the space or the fiber became sparse is formed in the inner side S of the convex part 34. ing. Thereby, even if urine is not quickly absorbed by the absorber 30, the urine can be temporarily stored in the inner side S of the convex portion 34.

  The first fiber layer 21 and the second fiber layer 22 are partially thermocompression bonded as shown in FIG. Specifically, the concave portion 33 of the first fiber layer 21 and the second fiber layer 22 have a dot-like portion 50 formed by partial thermocompression bonding, and the dot-like portion 50 causes a convex portion. The bulge of the part 34 is maintained effectively.

In addition, solid gathers 26 and 26 are provided on both outer sides in the lateral direction X of the uneven surface 19 of the nonwoven fabric 20. The three-dimensional gathered portions 26 and 26 are barriers that prevent the urine from clogging and preventing side leakage even if there is urine that cannot be temporarily stored on the uneven surface 19.
Crotch gathers 31 are further provided on both outer sides in the lateral direction X of the three-dimensional gathers 26, 26. The three-dimensional gathers 26, 26 are in contact with the user's crotch, and excreted urine and the like. Even if it leaks from, it is made not to leak outside.
An elastic body 17 is disposed along the longitudinal direction Y inside each of the three-dimensional gather portion 26 and the crotch gather portion 31. Due to the elastic contraction ability of the elastic body 17, both the gathers 26 and 31 stand up when worn. It is like that.

Here, as shown in the figure surrounded by the two-dot chain line in FIG. 1, the convex portion 34 of the first fiber layer 21 has a substantially hexagonal shape in the surface view, and the concave portion 33 has six sides of the substantially hexagonal shape. It has a groove shape corresponding to.
The concave portion 33 effectively diffuses urine in the surface direction of the nonwoven fabric 20 by the capillary phenomenon while effectively maintaining the shape of the convex portion 34 swelled in a substantially hexagonal shape, and is also possible for the absorber 30. In order to absorb urine as quickly as possible, the dot-like portion 50 formed by thermocompression bonding to the above-described second fiber layer 22 is provided only at the position corresponding to each hexagonal corner of the convex portion 34. Yes.
That is, the urine that has not been quickly absorbed by the absorber 30 is temporarily stored in the inner side S of the convex portion 34 in FIG. 4, and the stored urine then passes through the concave portion 33 in which the fibers are densely capillaryed. Thus, for example, it diffuses in the direction of the arrow DR in the figure surrounded by the two-dot chain line in FIG. 1 and is also transferred to the absorber 30. At this time, if the entire inner bottom portion of the concave portion 33 is thermocompression bonded, the portion is thermally fused, so that there is a possibility that the urine diffusion / transfer function may be hindered. However, in this embodiment, since only a part of the dot-like portion 50 is pressure-bonded, the diffusion / transfer through the urine recess 33 can be effectively exhibited, and the absorption area itself is not reduced.

  In consideration of the liquid transfer function to the absorber 30 in the concave portion 33, the uneven surface 19 is preferably arranged in a region smaller than the absorber 30. As shown in FIGS. 1 and 3, the uneven surface 19 of the present embodiment is formed in a region slightly smaller than the absorber 30 in the short direction X, and about 2 in the short direction X with respect to the long direction Y. Since it has a dimension more than double, urine is difficult to diffuse to the end, and it is longer than the absorbent body 30 and is formed over substantially the entire length with emphasis on the ease of manufacturing.

  The uneven surface 19 of the first fiber layer 21 has a honeycomb shape in which swelled substantially hexagonal shapes are continuously arranged. Specifically, the concave portion 33 corresponding to the hexagonal side of one convex portion 34 and the concave portion 33 corresponding to the hexagonal side of another convex portion 34 adjacent to the concave portion 33 are continuously arranged. Convex portions 34 are arranged. The width W1 of the concave portion 33 is set to a dimension such that the outer peripheral side surfaces 34a of the convex portions 34 come into contact with each other when the convex portions 34 are pressed from above. Although it is necessary to consider the height of the convex portion 34 as the width W1, in the case of the figure, it is set to approximately 0.2 mm to 0.6 mm. For this reason, the convex part 34 which is hard to be crushed and strong against buckling can be formed, and the large convex part 34 can be formed as much as it is hard to be crushed, and a large amount of urine can be temporarily stored in the large convex part 34. The convex portion 34 in the figure has a dimension L1 in the longitudinal direction Y of about 3 to 5 mm, a dimension L2 in the lateral direction X of about 4 to 6 mm, and the dimension L1 is slightly shorter than the dimension L2.

  Furthermore, this convex part 34 is a case where the diaper 10 is attached as shown in FIG. 2 from the state of FIG. 5A where no diaper is attached, and the surface of the first fiber layer is bent along the buttocks. As shown in FIG. 5B, the outer peripheral side surfaces 34a of the convex portions 34 adjacent to each other are in contact with each other. Accordingly, the outer peripheral side surfaces 34a of the convex portions 34 adjacent to each other support each other, and the convex portions 34 that are less likely to be crushed by the force pushed by the collar portion can be obtained.

And about the nonwoven fabric 20 of FIG. 1, compared with the transversal direction X of the diaper 10, urine spread | diffuses more quickly toward the longitudinal direction Y, thereby eliminating the so-called side leakage problem. Yes.
First, as shown in a diagram surrounded by a two-dot chain line in FIG. 1, two groove-like recesses 33, 33 facing each other out of six recesses 33 corresponding to the substantially hexagonal sides of each projection 34 are provided. It is arranged substantially along the longitudinal direction Y. Therefore, as shown in FIG. 6B, when the concave / convex surface is not formed with the concave portion 33 along the longitudinal direction Y, the urine diffuses in a zigzag manner as shown by the arrow RY. The urine can be quickly diffused in the longitudinal direction Y as indicated by an arrow DR in FIG. 6A in which the two concave portions 33 of the portion 34 facing each other are arranged substantially along the longitudinal direction Y.
Moreover, since the dot-shaped part 50 is arrange | positioned corresponding to each hexagonal corner | angular part of the convex part 34, there is little obstruction of the movement of the urine which advances along this longitudinal direction Y, Furthermore, this embodiment Since the dot-shaped part 50 is formed in a circular shape, the urine is easy to go around, and the urine can be diffused more smoothly.
Moreover, as shown in the figure enclosed with the dashed-dotted line of FIG. 1, since the nonwoven fabric 20 has arrange | positioned the fiber 67 along the longitudinal direction Y more than the fiber 66 along the transversal direction X at least. The urine is easily guided along the longitudinal direction Y by the capillary phenomenon.

The nonwoven fabric 20 having such an uneven surface is manufactured as shown in FIG.
That is, the embossing roll device 50 of FIG. 7 has a first roll 40 having a concavo-convex shape 39 on the peripheral surface and a convex portion 42 meshed with the concavo-convex shape 39 of the first roll 40 on the peripheral surface. And a second roll 41 having the same.
And first, the raw fabric 21-1 made of the heat-fusible fiber corresponding to the first fiber layer described above is drawn out and meshed between the first roll 40 and the second roll 41. The first fiber layer 21 having the uneven surface 19 shown in FIG. 3 is formed by the shape 39 and the convex portion 42.
Note that suction holes 38 are formed between the convex portions 42 of the second roll 41, and an uneven surface passes between the first roll 40 and the second roll 41 (meshing portion). The formed first fiber layer 21 moves while adsorbed to the second roll 41.

  Separately, the above-described second fiber layer 22 is fed out between the second roll 41 and the anvil roll 43, and the first fiber layer 21 and the second fiber layer 22 are overlapped. Then, a pressure is applied between the tip of the convex portion 42 and the anvil roll 43. At this time, the anvil roll 43 is heated to a predetermined temperature, and the inner bottom portion of the concave portion 33 of the concave and convex surface of the first fiber layer 21 and the second fiber layer 22 are fused by thermocompression bonding, as shown in FIG. A circular dot-shaped portion 50 is formed.

Next, the first fiber layer 21 and the second fiber layer 22 that are partially thermocompression bonded are cut into an appropriate size by a cutter (not shown) to complete the nonwoven fabric 20 shown in FIG.
The suction through the suction hole 38 of the second roll 41 is performed until the thermocompression bonding of the first fiber layer 21 and the second fiber layer 22, and the subsequent suction is not performed.

By the way, this invention is not limited to the said embodiment, The separate structure of the above-mentioned embodiment may be abbreviate | omitted as needed, or may be combined with the other structure which is not demonstrated.
For example, in this embodiment, the nonwoven fabric 20 has a two-layer structure as shown in FIG. 3, but the present invention is not limited to this, and if the outermost layer has the uneven surface 19, the nonwoven fabric 20 has three or more layers. It does not matter.

  DESCRIPTION OF SYMBOLS 10 ... Diaper, 18 ... Back sheet, 19 ... Uneven surface, 20 ... Nonwoven fabric, 21 ... First fiber layer, 22 ... Second fiber layer, 30 ... Absorber, 33 ... concave, 34 ... convex

Claims (4)

A non-woven fabric for diapers comprising a first fiber layer having a concave and convex surface comprising a large number of concave portions and convex portions formed on the surface, and a second fiber layer superimposed on the back surface of the first fiber layer. And
The convex portion bulges on the side opposite to the second fiber layer so that the surface view has a substantially hexagonal shape,
The recess, said substantially a groove in contact with the second fibrous layer with a corresponding along hexagonal sides, and, at positions corresponding to the corner portions of the substantially hexagonal shape, and the second It has a dot-like part formed by thermocompression bonding to the fiber layer of
The concave / convex surface includes the concave portion corresponding to the substantially hexagonal side of the predetermined convex portion and the concave portion corresponding to the substantially hexagonal side of the other convex portion adjacent to the predetermined convex portion. preparative as common is, non-woven fabric diapers, characterized in that it exhibits the substantially hexagonal shape of the continuous side-by-side honeycomb-shaped.   2. The nonwoven fabric for diapers according to claim 1, wherein when the surface of the first fiber layer is bent along the heel portion, the outer peripheral side surfaces of the convex portions adjacent to each other are in contact with each other. . A backsheet to prevent liquid permeation;
A non-woven fabric disposed on the side of the surface that contacts the body;
An absorber that is disposed between the backsheet and the nonwoven fabric and absorbs urine that has passed through the nonwoven fabric;
A diaper with
The non-woven fabric has a first fiber layer having an uneven surface composed of a large number of recesses and protrusions formed on the surface, and a second fiber layer superimposed on the back surface of the first fiber layer,
The convex portion bulges on the side opposite to the second fiber layer so that the surface view has a substantially hexagonal shape,
The recess, said substantially a groove in contact with the second fibrous layer with a corresponding along hexagonal sides, and, at positions corresponding to the corner portions of the substantially hexagonal shape, and the second It has a dot-like part formed by thermocompression bonding to the fiber layer of
The concave / convex surface includes the concave portion corresponding to the substantially hexagonal side of the predetermined convex portion and the concave portion corresponding to the substantially hexagonal side of the other convex portion adjacent to the predetermined convex portion. diaper, characterized in that in the middle stage as a common, and has a honeycomb shape arranged continuously the substantially hexagonal. The diaper according to claim 3, wherein among the six concave portions corresponding to each side of the substantially hexagonal shape, two concave portions parallel to each other are arranged along a longitudinal direction of the diaper.

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