JPH11113954A - Surface raw material or filtering material for absorbent article, and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an absorbent article which does not generate a twist even when being thin, has a proper rigidity, and is excellent in shape-retaining property and durability by a method wherein on one surface or both surfaces of a water-impermeable film made of a thermoplastic resin on the surface of which, a plurality of small holes are provided, a fiber raw material of a non-woven fabric is jetted and integrally intertwined. SOLUTION: At the time of manufacturing of this surface raw material 5 for an absorbent product, on the surface of a water-impermeable film 1 comprising a resin such as polyethylene, a high speed water stream is jetted, and conical small holes 2 which protrude in the water stream direction are formed. Also, a high speed water stream in which a fiber raw material 3 of a non-woven fabric made of polyethylene is mixed, is jetted to the surface of the water- impermeable film 1, and the fiber raw material 3 of the non-woven fabric is adhered to the water-impermeable film 1 while being intertwined with each other, and at the same time, the fiber raw material 3 enters the small holes 2 as well, and is adhered in a manner to be intertwined. By this method, after a drying, a fiber layer 4 of the non-woven fabric is formed on one surface of the water-impermeable film 1, and the surface raw material 5 wherein the water-impermeable film 1 and the fiber 3 are integrally combined, can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to sanitary napkins, urinary incontinence pads, vaginal discharge sheets, disposable diapers, and other absorbent article surface materials, or masks, cloths, towels, and other filter materials and their production. Pertains to the method.

[0002]

2. Description of the Related Art Conventionally, as a surface material of sanitary napkins, urinary incontinence pads, vaginal discharge sheets, disposable diapers, and other absorbent articles, there are nonwoven fabrics and non-permeable resin films provided with small holes. I do.

[0003] An invention using a water-impermeable film as a surface material is disclosed in Japanese Patent Application Laid-Open No. 1-249052. In this method, a plurality of small holes are provided in the water-impermeable film at appropriate intervals, and the water-impermeable film is arranged on the skin contact surface side to form an absorbent article. And
The body fluid is absorbed and confined inside the absorbent article through the small holes of the water-impermeable film.

[0004]

Most of the body fluid is absorbed into the absorbent article through the plurality of small holes, but the body fluid and moisture attached to the surface of the impermeable film are
Since it does not penetrate into the impermeable film, it gives an unpleasant wet feeling to the user's skin. for that reason,
The impermeable film sticks to the skin or causes poor breathability, resulting in stuffiness of the skin, which may cause discomfort to the user.

Also, in the invention described in Japanese Patent Application Laid-Open No. 51-116080, an absorbent article is formed by using a water-impermeable film provided with a plurality of small holes as a surface material.
The above disadvantages may occur. However, the above document also describes an example in which a nonwoven fabric is arranged on the surface of a water-impermeable film provided with small holes to form a surface material. The small holes in the surface material are formed by piercing a needle into the surface material.

[0006] In an absorbent article using this surface material,
When the bodily fluid is discharged, the bodily fluid is diffused in the direction of the small holes due to the capillary action of the fiber material of the nonwoven fabric, and is absorbed into the absorbent article through the small holes. And since the non-woven fabric is placed on the skin contact side, compared to the case where the water-impermeable film is placed on the skin contact side, it has a softer touch and prevents sticking and stuffiness to the skin, Gave a dry feeling to the elderly.

However, the above-mentioned method requires labor and materials for bonding the water-impermeable film and the non-woven fabric with a heat seal or an adhesive, thereby reducing work efficiency and cost. In addition, if the adhesion between the water-impermeable film and the nonwoven fabric is poor, a gap is generated in the space between them, so that the liquid permeability may be deteriorated and a good effect of absorbing body fluid may not be obtained. Furthermore, since the surface material is formed to be thick, the absorbent article becomes bulky and the wearing feeling is deteriorated.

[0008] In addition, those using a non-woven fabric as a surface material include:
There is an invention described in JP-A-61-176346. In this conventional example, as in the case of the above-mentioned invention, it is intended to improve the absorbability of bodily fluids and obtain a good touch by capillary action of the nonwoven fabric fiber material. And
The surface material is formed by providing small holes corresponding to the protrusions while forming the nonwoven fabric by entanglement of the fiber material of the nonwoven fabric with the mold material having the protrusions by a high-speed water flow.
Thereafter, the fluff present in the small hole is burned off with a flame or the like to shape the small hole. Further, a method is described in which a nonwoven fabric is formed without providing a small hole, and then the nonwoven fabric is pierced with a hot needle to melt the fibrous material, thereby providing a small hole.

[0009] However, when the surface material is formed only of the nonwoven fabric, the non-water-permeable film has a better touch than the case where it comes into contact with the skin, but it is easy to be twisted and deteriorates the feeling of wearing and the function of the absorbent article. was there. For this reason, the fiber density and thickness of the nonwoven fabric are increased, and
When another member having rigidity such as a water-impermeable film is laminated as in No. 0, a bulky absorbent article is formed, and the feeling of wearing is deteriorated. In addition, because the small holes are burned off with a flame or the like and the non-woven fabric is melted and opened with a high-temperature hot needle, the opening edges of the small holes are solidified and come into contact with the skin, resulting in poor usability. was there.

[0010] Further, there is a conventional product using a non-woven fabric for a mask, a cloth, a towel, and other filtering materials. The mask made of this nonwoven fabric is excellent in air permeability, and has less fluff and a good touch as compared with the gauze mask. Also, since it can be formed at low cost,
Suitable for commercialization as a disposable mask.

However, in order to provide a suitable tension to the mask to improve the feeling of wearing and to enhance the filter function against the outside air and dust, it is desirable to form a thick filter material. In addition, it interferes with breathing, giving the user discomfort and increasing costs.
Also, in the case of other filtration products such as cloths and towels, the cost can be reduced by forming the filter thinly, but the operability is deteriorated due to the possibility of skewing and breakage. Increases, but costs increase.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems, and is intended to reduce the thickness of a surface material or a filtering material of an absorbent article formed of a nonwoven fiber material and a water-impermeable film and provided with small holes. Even with this, it is possible to have appropriate rigidity so as not to cause deflection, and to be excellent in shape retention and durability.

[0013] By improving the sense of unity between the nonwoven fabric fiber material and the water-impermeable film, in an absorbent article using the surface material, the liquid permeability of the surface material is improved, and The purpose is to improve the absorbency and to give the user a soft and smooth touch and a good wearing feeling.

[0014] Further, it is intended to improve a feeling of wearing a mask using a filtering material and a filtering function, and to improve operability and durability of other filtering products such as a cloth and a towel. is there. Further, it is intended to form such a surface material or a filter material at low cost without much labor and material.

[0015]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a nonwoven fabric fiber material on one or both surfaces of a thermoplastic resin impermeable film having a plurality of small holes formed on the surface. It is made by spraying and making it tangled together.

Further, the first manufacturing method for forming the surface material or the filtering material as described above includes a method of forming a plurality of small holes by punching a surface of a non-permeable film made of a thermoplastic resin. From the first step and the second step in which the fiber material of the nonwoven fabric is heated and melted on one or both surfaces of the water-impermeable film, and the fibrous fiber material is sprayed from a nozzle to be entangled with the non-water-permeable film. It consists of

The second manufacturing method comprises a first step in which a plurality of small holes are formed in the surface of a thermoplastic resin impermeable film by a boring process, and one or both surfaces of the impermeable film. And a second step of jetting a high-speed water flow mixed with a non-woven fiber material to entangle the non-woven fiber material with the water-impermeable film and bonding them.

[0018]

Since the present invention has the above-mentioned structure,
In a first manufacturing method for forming the surface material or the filter material, first, in a first step, small holes are provided in a water-impermeable film formed of a thermoplastic resin or the like. The opening of the small holes may be made by injecting a high-speed water flow into the water-impermeable film, or by punching out with a punch cutter, and can be made by an appropriate conventional method.

In the second step, a heat-fusible fiber material, which is a base material of the non-woven fabric, is heated and melted on the surface of the water-impermeable film having the small holes formed in the first step, and is heated from the nozzle. Spray fibrous fiber material. Then, the nonwoven fiber material softened by heating adheres to the surface of the water-impermeable film while being entangled with each other. Then, when the nonwoven fabric fiber material is thermally fused to the surface of the water-impermeable film and the heat is cooled, a surface material or a filtering material in which the water-impermeable film and the nonwoven fabric fibers are integrated can be obtained.

The surface material or the filtering material may have a two-layer structure by entangled with a nonwoven fiber material only on one side of the water-impermeable film, or by entangled on both sides of the water-impermeable film. It may have a three-layer structure. Also,
As the fiber material of this nonwoven fabric, conventionally known polyethylene, polypropylene, polyethylene terephthalate, ethyl vinyl acetate, or the like can be used. And
Depending on the purpose of use of the product, various surface materials can be obtained by appropriately changing the length, thickness, fiber density, and spray amount of the nonwoven fiber material, or by appropriately changing the diameter, number, and shape of the small holes. In addition, it becomes possible to form a filtering material.

In a second method for producing a surface material and a filter material, a plurality of small holes are formed on the surface of the water-impermeable film by appropriate perforation processing, as in the first step of the first production method. Open. Then, in the second step, a high-speed water flow in which a nonwoven fabric material is mixed is injected onto one or both surfaces of the water-impermeable film, and the fiber material is entangled with the surface of the water-impermeable film to form a layer of nonwoven fabric fibers. While forming
The fiber material is entangled with the small holes, and the impermeable film and the nonwoven fabric material are integrated. Then, when the moisture is evaporated and the fiber material is dried, a surface material or a filter material in which the fiber material of the nonwoven fabric and the water-impermeable film are integrally bonded can be obtained.

When the absorbent article formed by using the above-mentioned surface material is attached to underwear, the nonwoven fabric material of the surface material comes into contact with the user's skin, so that the skin feels soft. Further, since an air layer is formed by this fiber material, the air permeability is also good. Then, when the body fluid is discharged and comes into contact with the surface material, the body fluid rapidly diffuses while penetrating into the fiber layer of the nonwoven fabric due to the capillary phenomenon of the fiber material, and passes through a plurality of small holes provided in the water-impermeable film. Flows into the interior of the absorbent article. And the bodily fluid is absorbed by the absorber arranged inside the absorbent article,
Since the water-impermeable film is disposed between the absorber and the skin, the wet absorber and the skin do not come into contact with each other and the body fluid does not flow back.

Further, the surface material of the present invention is formed by directly tangling a non-woven fiber material with a water-impermeable film and integrating the non-woven film with the water-permeable film. Is difficult to form. Furthermore, combined with the capillary action of the fiber material entangled in the small holes, the liquid permeability of the small holes is improved, and the body fluid absorption of the absorbent article is improved.

Furthermore, the skin contact surface has good air permeability,
Drying of bodily fluids and sweat is promoted, and a good dry feeling is given to the skin of the user. Conventional products using only a nonwoven fabric as a surface material use a thick nonwoven fabric in order to prevent twisting. However, since the surface material of the present invention uses a water-impermeable film, even if the fiber layer made of the nonwoven fiber material is formed thin, the surface material has appropriate rigidity without causing twisting. For this reason, the bulkiness of the absorbent article and the deformation during the wearing can be well prevented, and the feeling of wearing the absorbent article and the functionality of absorbing the body fluid can be improved.

Also, when the filter medium formed as described above is used for a mask, cloth, towel, etc., the presence of the water-impermeable film provides a thin and moderate rigidity which does not cause twisting, and also has a durability. Excellent products can be formed. In the case of a mask, the mask is light and has a good feeling of wearing, and the small holes provide excellent ventilation. In addition, due to the fiber material of non-woven fabric entangled in the small holes,
A good filter function can be provided without passing dust or the like inside. In the case of a cloth or a towel, the presence of the water-impermeable film does not cause it to be distorted or broken due to friction with the floor or the human body, and is excellent in operability and durability.

[0026]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the manufacturing process in the surface material of the present invention will be described below. (1) is a water-impermeable film formed of a thermoplastic and water-impermeable resin such as polyethylene. I have. Then, in the first step, the water-impermeable film (1)
By spraying a high-speed water flow on the surface of the, a conical small hole (2) projecting in the water flow direction is opened as shown in FIG.

In the second step, the high-speed water flow mixed with the nonwoven fibrous material (3) made of polyethylene is applied to the water-impermeable film (1) with such strength that no opening is formed in the water-impermeable film (1). Spray on the surface of (1). Then, by this high-speed water flow, the nonwoven fabric material (3) adheres to the water-impermeable film (1) while being entangled with each other, and has small holes.
The fiber material (3) also enters (2) and becomes entangled and adheres to the small holes (2).

Then, when the moisture is evaporated and the fiber material (3) dries, as shown in FIG. 4, one side of the water-impermeable film (1) is entangled with the fiber material (3) to form a fiber layer of the nonwoven fabric.
(4) is formed, and as shown in FIG. 1, a water-impermeable film
A surface material (5) in which (1) and the fiber material (3) are integrally bonded is formed. Also, the fiber material (3) is entangled with the inner surface of the small hole (2), but the high-speed water flow passes through the small hole (2), so that the fiber material (3) does not completely block the small hole (2). And
By the fiber material (3) entangled inside the small hole (2),
The water-impermeable film (1) and the nonwoven fabric fiber layer (4) are not easily separated from each other, and the liquid permeability of the small holes (2) can be improved by the capillary action of the fibers.

As described above, by using the water-impermeable film (1), even if the nonwoven fabric fiber layer (4) is formed thin,
The surface material (5) has a moderate rigidity that is less likely to be twisted, has excellent durability, and has a plurality of small holes (2), so that it has a liquid absorbing property. The fiber layer (4) has a good touch and is made of polyethylene fiber material.
Since an air layer is formed due to the entanglement of (3), the air permeability and liquid drainage of the fiber layer (4) are also good.

The surface material (5) formed as described above
In this case, on the back side of the water-impermeable film (1), an absorbent layer (6) made of a material such as cotton, pulp, or an absorbent polymer, and a protective material made of a water-impermeable material such as polyethylene. The sanitary napkin (8) is formed by sequentially arranging the leaky sheets (7). Since the surface material (5) and the leak-proof sheet (7) use a thermoplastic resin as a material, the formation of the sanitary napkin (8) is performed by heat fusion processing.
It can be done easily. Since the surface material (5) is formed to be thin and has an excellent anti-slip effect, a thick padding or the like for maintaining rigidity is inserted when the sanitary napkin (8) is formed. No need. Therefore, the sanitary napkin (8) is thin and does not become bulky, and is less likely to be twisted.

When the sanitary napkin (8) is attached, the fiber layer (4) of the surface material (5) comes into contact with the user's skin, so that the contact with the skin is soft and the skin is sticky. There is no occurrence, and the feel is good. And since the fiber layer (4) is excellent in air permeability and liquid drainage, it prevents the user from sweating, body temperature and stuffiness due to body fluid. In addition, since the occurrence of twisting of the sanitary napkin (8) is prevented, the fit to the skin and the feeling of wearing are improved, and the leakage of body fluid is favorably prevented.

Then, the body fluid discharged from the user comes into contact with the fiber layer (4) of the surface material (5), and the respective fiber materials (3)
Due to the capillary action of the fiber layer (4) as shown by the arrow in FIG.
While rapidly penetrating into the water-impermeable film (1), diffuses in the direction of the small holes (2) provided in the water-impermeable film (1). And the bodily fluid
It passes through the inner surface of (2), flows toward the absorption layer (6), and is absorbed by the absorption layer (6). In the flow of the body fluid, the surface material (5) is composed of the water-impermeable film (1) and the nonwoven fabric fiber layer.
Since (4) is formed integrally, no gap is formed between the fiber layer (4) and the water-impermeable film (1) that would impede the liquid permeability of the small holes (2). Therefore, the body fluid is effectively absorbed by the absorbing layer (6) through the small holes (2) having good liquid permeability.

Since the bodily fluid is securely confined in the absorbing layer (6), the bodily fluid does not flow back to the skin side. Further, since the absorbent layer (6) is covered with the water-impermeable film (1), dirt on the absorbent layer (6) does not adhere to the skin. In this way, the body fluid is reliably absorbed, and the fiber layer (4) disposed on the skin contact surface has a good air permeability and liquid drainage effect, so that the user's skin is always smooth and comfortable. Can be.

Further, by forming a large number of small holes (2) in the surface material (5), it is possible to improve the liquid permeability of the small holes (2) against the surface tension of the body fluid. And since the fiber material (3) of a nonwoven fabric is entangled with the inner surface of the small hole (2), the liquid permeability in the small hole (2) is further improved by the capillary phenomenon of the fiber material (3). It will improve.

The surface material (5) of the present invention can be used for urinary incontinence pads and other body fluid absorbent articles in addition to sanitary napkins. ,
It is possible to obtain a product excellent in body fluid absorbency and touch.

The manufacturing process of the second embodiment for forming a mask utilizing the function of the filter of the present invention will be described. In the first process, as in FIG. 2 of the first embodiment,
An impermeable film (1) is prepared. Then, by punching this water-impermeable film (1) with a punch cutter, a number of small holes (2) are opened as shown in FIG.

In the second step, a polyethylene terephthalate resin, which is a thermoplastic fiber material, is heated and melted, and the melt is jetted out of a nozzle into a fibrous form, whereby the nonwoven fabric material (3) is impermeable to water. Spray on the surface of the film (1). By this spraying, the fiber material (3) softened by heat adheres to the water-impermeable film (1) while entangled with each other. Thereafter, when the heat of the fiber material (3) is cooled, the fiber materials (3) are welded to each other and also to the surface of the water-impermeable film (1). As a result, the fiber layer (4) integrally bonded to the surface of the water-impermeable film (1)
Is formed.

Fiber layer by spraying the fiber material (3)
If (4) is formed on both sides of the water-impermeable film (1),
As shown in FIG. 7, a filtration material (10) having a three-layer structure is completed. As described above, by heating the fiber material (3) and welding it to the water-impermeable film (1), the sense of unity between the water-impermeable film (1) and the fiber layer (4) is increased. This effectively prevents the formation of a gap that hinders the flow, and improves the liquid permeability of the small holes (2). Furthermore, even when the filtration product is used, even if it receives an external stimulus such as friction, the water-impermeable film (1) and the fiber layer (4) do not easily separate from each other, and the operability in use becomes good.

The water impervious film (1) has a small hole formed by air pressure when the fiber material (3) is sprayed from a nozzle.
(2) Since the wind is passing through the inside, as shown in FIG.
As in the embodiment, the fiber material (3) of the nonwoven fabric is entangled with the inner surface of the small hole (2), but does not block the small hole (2).
Since the filtration material (10) formed as described above is a fibrous layer (4) of a nonwoven fabric on both sides, the feel is good. Further, due to the presence of the water-impermeable film (1) having a moderate rigidity, the filter medium (10) is less likely to be twisted or broken even when formed thinly, and has excellent durability.

When a cold disposable mask made of the filtering material (10) is used, the flexible fiber layer (4) comes into contact with the user's skin, and the fiber layer (4) is used as a gauze mask.毛 立 ち 少 な い 少 な い 少 な い, 少 な い 、 良好. In addition, since it is thin, it is light and has a suitable rigidity that is unlikely to cause warping or wrinkling, so that a good mask can be mounted. In addition, the filter medium (10) has a small hole.
Since a large number of (2) are provided to enhance air permeability, the user can easily breathe. Also, on the inner surface of the small hole (2),
Since a plurality of fiber materials (3) are entangled, filter effects such as prevention of dust and virus invasion are not impaired. In addition, since the filtering material (10) is formed of an inexpensive material, the economy as a disposable mask is also improved.

The filtering material (10) may be used for a cloth, a towel, and other filtering products. Then, even if the product is formed thin, the product having appropriate rigidity and durability can be formed due to the presence of the water-impermeable film (1), and the product can be stored and sold compactly. In addition, even if it is stimulated by contact with a contact object such as a human body, a floor, furniture, or the like, it is possible to obtain a filtered product having excellent operability and durability by preventing twisting and breakage.

Since the nonwoven fabric fiber layer (4) is formed while being integrated with the water impermeable film (1), the nonwoven fabric is formed and then adhered to the water impermeable film (1) as in the conventional example. Time and materials can be saved. Therefore, in the present invention, the surface material (5) and the filtering material (10) can be easily formed at low cost. And cost reduction of an absorbent article and a filtration product can be realized. Also fiber material
(3) In addition to the fiber materials used in the first and second embodiments, polypropylene, ethyl vinyl acetate, and the like can be used.

Also, in any case of the surface material (5) and the filter material (10), the number, size, shape, etc. of the small holes (2) can be changed arbitrarily, and the thickness and spraying of the fiber material (3) can be changed. By arbitrarily changing the density and the like, a variety of surface materials (5) and filter media (10) can be formed according to the purpose of use of the product. In addition, these surface materials (5), filtration materials (10)
Can be applied to an appropriate product using a nonwoven fabric as long as it requires the above-mentioned anti-wetting effect, air permeability, and liquid permeability.

[0044]

Since the present invention is constructed as described above, it is possible to provide a small hole and to form a thin and rigid absorbent article surface material and a filter material by a simple method at a low cost. It becomes possible.

In addition, sanitary napkins, urinary incontinence pads, vaginal discharge sheets, disposable diapers and other absorbent articles using this surface material are excellent in the touch and body fluid absorbing ability and also have an effect on the twist during wearing. The user can wear comfortably.

Also, masks, cloths, towels, and other filtration products using this filtering material are thin and have appropriate rigidity that does not easily cause twisting and the like, so that the wearing feeling and the operability are good. It will be excellent in durability.

[Brief description of the drawings]

FIG. 1 is a perspective view of a surface material of an absorbent article according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of a water-impermeable film before providing small holes.

FIG. 3 is a cross-sectional view showing a state in which small holes are provided in a water-impermeable film in a first step.

FIG. 4 is a cross-sectional view of a state in which a nonwoven fabric material is entangled with the surface of the water-impermeable film in the second step.

FIG. 5 is a sectional view of a sanitary napkin using the surface material of the present invention.

FIG. 6 is a cross-sectional view showing a state in which small holes are provided in a water-impermeable film in a first step of the second embodiment of the present invention.

FIG. 7 is a cross-sectional view of a filtering material formed by entanglement of a nonwoven fabric material with a water-impermeable film in a second step of the second embodiment.

[Explanation of symbols]

 1 non-permeable sheet 2 small hole 3 fiber material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B32B 5/18 B32B 5/24 101 5/24 101 A41B 13/02 B

Claims (6)

[Claims] 1. An absorbent article characterized in that a nonwoven fabric material is sprayed onto one or both surfaces of a thermoplastic resin impermeable film having a plurality of small holes formed on its surface to be integrally entangled. Surface material. 2. A filtering material, wherein a nonwoven fabric material is sprayed onto one or both surfaces of a thermoplastic resin impermeable film having a plurality of small holes formed on its surface to be integrally entangled. 3. A first step in which a plurality of small holes are opened by a perforation process on the surface of a thermoplastic resin impermeable film, and a nonwoven fabric material is coated on one or both surfaces of the impermeable film. A step of heating and melting the fiber material, spraying a fibrous fiber material from a nozzle to entangle the fiber material, and bonding the fibrous material to the water-impermeable film. 4. A first step of opening a plurality of small holes on a surface of a thermoplastic resin non-water permeable film by punching, and a nonwoven fabric material is coated on one or both sides of the non-water permeable film. A heating and melting process, and a fibrous fibrous material is sprayed from a nozzle and entangled with the non-water-permeable film so as to be bonded to the water-impermeable film. 5. A first step in which a plurality of small holes are opened on a surface of a thermoplastic resin non-water permeable film by punching, and a nonwoven fabric material is coated on one or both sides of the non-water permeable film. Injecting the mixed high-speed water flow, the fiber material of the non-woven fabric is entangled with the water-impermeable film and then bonded.
A method for producing a surface material of an absorbent article, comprising: 6. A first step in which a plurality of small holes are opened by a perforation process on the surface of a thermoplastic resin impermeable film, and a nonwoven fabric material is coated on one or both sides of the impermeable film. Injecting the mixed high-speed water flow, the fiber material of the non-woven fabric is entangled with the water-impermeable film and then bonded.
And a process for producing a filter medium.