RU2509182C2 - Method of production of nonwoven fabric perforated without physical or thermal deformation and absorbing article having such nonwoven fabric - Google Patents

Abstract

FIELD: textiles, paper.

SUBSTANCE: absorbing article according to the present invention comprises the following elements: a liquid-permeable upper sheet; a liquid-tight lower sheet; an absorbing element located between the upper sheet and the lower sheet for absorbing liquid, permeating through the upper sheet, and a receiving layer located between the upper sheet and the absorbing element for supplying liquid penetrating through the upper sheet to the absorbing element. The receiving layer comprises a nonwoven fabric perforated without physical or thermal deformation.

EFFECT: invention provides a method of production of nonwoven fabric, perforated without physical or thermal deformation, and an absorbing article comprising such nonwoven fabric.

24 cl, 8 dwg

Description

FIELD OF TECHNOLOGY

The invention relates to a method for producing a non-woven fabric, perforated without physical or thermal deformation, and an absorbent product having such a non-woven fabric. More specifically, the present invention relates to an absorbent article, such as a diaper, a sanitary towel for women, a panty liner, etc., which has a non-woven fabric, perforated without physical or thermal deformation, while allowing the rapid capture of a large amount of fluid released by the user's body and easy delivery to the absorbent element.

BACKGROUND

One example of a traditional absorbent article is shown in FIG. Referring to FIG. 1, a conventional absorbent article 10 includes: a liquid permeable topsheet 2 from the body side; liquid impervious bottom sheet 4 from the outside; an absorbent element 6 located between the upper sheet 2 and the lower sheet 4; and a receiving layer 8 located between the top sheet 2 and the absorbent element 6.

The top sheet 2 may be in contact with the skin of the user. The top sheet 2 serves to provide softness, so that the user feels comfortable when wearing the product. The absorbent element 6 serves to quickly absorb the liquid released from the body of the user through the top sheet 2 to contain the liquid. The absorbent element 6 may be made of pulp fibers or pulp fibers mixed with ultra-absorbent particles. The bottom sheet 4 is located under the absorbent member 6. The bottom sheet 4 may be made of a liquid-impervious film material, so that the liquid held inside the absorbent member 6 is not discharged outward.

The receiving layer 8 serves to quickly absorb liquid and deliver absorbed liquid to the absorbent element to prevent, therefore, moisturizing the skin of the user. For this purpose, the receiving layer 8 may consist of a non-woven fabric having a low fiber density and a large bulk. However, the production of such a receiving layer requires materials with a high base weight, which leads to an increase in production costs. The receiving layer 8 may consist of a perforated non-woven fabric to maintain or improve its functionality, while reducing its production costs.

In accordance with the prior art, the receiving layer consists of a perforated non-woven fabric. Such a nonwoven fabric can be produced by physically cutting a portion of a sheet of connected fibers by means of a cutting device (e.g., a punch) or by punching a sheet of connected fibers by means of a heated rod. As another example, such a nonwoven web may have perforations when passing between one roll with protrusions on it and another roll configured to fit it. Thus, the perforated non-woven fabric can be deformed due to physical or thermal pressure applied during the perforation. Accordingly, there is a problem in that the density of the nonwoven web, as well as the density of the fibers around the perforation increases (however, the bulk decreases). There is also another problem in that physical or thermal pressure during the perforation process causes fiber damage and stiffness of the receiving layer.

SUMMARY OF THE INVENTION

Technical problem

The present invention addresses the following problems. The present invention provides a method for producing a nonwoven fabric, in which a nonwoven fabric is perforated without applying physical or thermal pressure to the nonwoven fabric, while preventing an increase in the density of the fibers of the nonwoven fabric and reducing damage to the fibers, while increasing the softness of the receiving layer. The present invention also provides an absorbent article having such a nonwoven web.

TECHNICAL SOLUTION

A nonwoven web perforated without physical or thermal deformation in accordance with one embodiment of the present invention can be produced by the following steps: mixing fibers; opening mixed fibers; carding of open fibers; perforation of cardan fibers without physical or thermal deformation; perforated fiber compounds; and final processing of the connected fibers.

Preferably, the perforation may include periodic ejection of air in the direction of the carded fibers with a given pressure, with the formation of perforations and to push the carded fibers around the perforation.

Preferably, the perforation can be carried out simultaneously with carding. In this case, the open fibers can be carded on the conveyor with protrusions on it with the formation of a perforated web. The connection may also include the application of air with a given pressure or pressure caused by alternating contact with the upper side and / or lower side of the canvas.

In another aspect of the present invention, an absorbent article in accordance with one embodiment may comprise the following elements: a liquid permeable top sheet; liquid impervious bottom sheet; an absorbent element located between the upper sheet and the lower sheet for absorbing liquid passing through the upper sheet; and a receiving layer located between the upper sheet and the absorbent element for supplying fluid passing through the upper sheet to the absorbent element. The receiving layer may include a non-woven fabric perforated without physical or thermal deformation.

An absorbent article in accordance with another embodiment of the present invention may comprise the following elements: a liquid permeable top sheet; liquid impervious bottom sheet; an absorbent element located between the upper sheet and the lower sheet for absorbing liquid passing through the upper sheet; and a receiving layer located between the top sheet and the absorbent element for supplying fluid passing through the top sheet to the absorbent element. The top sheet may include a non-woven fabric perforated without physical or thermal deformation.

An absorbent article according to another embodiment of the present invention may comprise the following elements: a liquid permeable top sheet, a liquid impermeable lower sheet, an absorbent element located between the upper sheet and the lower sheet to absorb liquid passing through the upper sheet; and a receiving layer located between the upper sheet and the absorbent element for supplying fluid passing through the upper sheet to the absorbent element. The receiving layer may include a laminate that includes a non-woven fabric perforated without physical or thermal deformation and a non-perforated non-woven fabric laminated to its upper and / or lower side.

In one embodiment, preferably, the total perforation area may be in the range of 5 ~ 80% of the total area of the non-woven fabric. Preferably, the diameter of the perforation may be in the range of 2 ~ 30 mm. More preferably, the diameter of the perforation may be in the range of 5 ~ 10 mm. Preferably, the weight of the base of the perforated non-woven fabric may be in the range of 20 ~ 400 g / m ² .

According to the nonwoven fabric production method of the present invention, perforations can be formed in the nonwoven fabric without physical or thermal deformation, while preventing an increase in fiber density around the perforation and reducing the stiffness caused by this increase. Accordingly, the user may feel soft when such a non-woven fabric is applied to the skin of the user.

In addition, since the non-woven fabric can be produced with a low density and increased volume of voids, the non-woven fabric can quickly transfer the liquid released from the user's body to the absorbent element.

Also, the non-woven fabric can be made to have the same thickness as the non-perforated non-woven fabric, even when using a small amount of fibers. That is, the non-woven fabric can be made to have the same thickness as the non-perforated non-woven fabric, despite the use of a material with a low basis weight, which leads to a reduction in production cost.

When the perforation is large enough, the top sheet can be partially pressed into the perforations, thereby reducing the contact area between the top sheet and the skin of the user. Also, the distance between the top sheet and the absorbent element is reduced by perforation. Essentially, the absorbent element can absorb moisture contained in the top sheet by capillary phenomena. Thus, reducing the contact area between the top sheet and the skin of the user, as well as reducing the moisture contained within the top sheet, allows the top sheet of the absorbent article to be kept in a moisture-free state.

If the ratio of perforations to nonwoven webs is high, the perforated nonwoven webs may be weakened and prone to deformation during perforation. In this regard, the perforated non-woven fabric, which can be provided with the non-perforated non-woven fabric, can be laminated on the upper or lower side of the perforated non-woven fabric, while maintaining a high ratio of perforations to the non-woven fabric, without reducing the intensity of the non-woven fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

1 is a sectional view showing one example of a traditional absorbent article.

FIG. 2 is a perspective view showing one example of an absorbent article in accordance with one embodiment of the present invention.

Figure 3 is a view in section along III-III of Figure 2.

4 is a perspective view showing a nonwoven fabric for use in an absorbent article in accordance with one embodiment of the present invention.

5 is a schematic view showing a perforation process after a carding process.

Fig.6 is an enlarged view of the area indicated by the letter "A" in Fig.5.

Fig. 7 is a schematic view showing how open fibers are carded when perforated.

Fig.8 is a view in section along the line D-D in Fig.7.

MODE FOR CARRYING OUT THE INVENTION

Below will be presented a more detailed description regarding a method of manufacturing a non-woven fabric, perforated without physical or thermal deformation and an absorbent product having such a non-woven fabric in accordance with embodiments of the present invention.

2 is a perspective view showing one example of an absorbent article in accordance with one embodiment of the present invention. Figure 3 is a sectional view taken along line III-III of Figure 2. FIG. 4 is a perspective view of a nonwoven fabric for using an ox absorbent article in accordance with one embodiment of the present invention.

Referring to FIGS. 2 and 3, an absorbent article 100, which is made in accordance with one embodiment of the present invention, includes the following elements: a top sheet of software for passage of fluid or excrement secreted by the user's body through it; an absorbent element 130 containing liquid from the top sheet 110; a bottom sheet 120 located below the absorbent member 130 to prevent outward leakage of fluid contained within the absorbent member 130; and a receiving layer 115 located between the top sheet 110 and the absorbent member 130 for quickly delivering fluid passing through the top sheet 110 to the absorbent member 130. As shown in FIG. 2, when the absorbent article 100 is used as a diaper, the absorbent article 100 may further include an elastic element 150 for wrapping around the legs of the child and a waistband 160 for covering the waist of the child.

The top sheet 110 (which may be referred to as “lining” in the prior art) is in direct contact with the skin of the user. The top sheet 110 allows fluid released from the user's body to pass through it and then quickly move to the absorbent element 130. Thus, for the top sheet of software, it is preferable to have wettability, hydrophilicity and porosity. Preferably, the topsheet 110 may be made of a nonwoven web of material that has a relatively low density and is bulky in size. Non-woven fabric materials may contain one type of fiber, such as polyester or polypropylene, bicomponent or composite fibers having a low melting point component and a high melting point component. For example, fibers may include nylon, polyester, cotton, acrylic, etc. or combinations thereof. The bicomponent fiber may consist of a polyester core and a polyethylene sheath.

An absorbent element 130 is disposed between the upper sheet 110 and the lower sheet 140 to quickly absorb and retain liquid therein. In general, the absorbent element 130 should be compressive, supple and non-irritating to the wearer's skin. For example, the absorbent element 130 may be made of pulp fibers or pulp fibers mixed with ultra absorbent particles.

The bottom sheet 140 is located below the absorbent member 130. The bottom sheet 140 may be made of a liquid impermeable plastic film, such that the liquid entrained by the absorbent member 130 is not released, staining or contaminating the user's underwear.

A receiving layer 115 is located between the upper sheet 110 and the absorbent member 130. The receiving layer 115 is used to quickly absorb liquid passing through the upper sheet of software and deliver the absorbed liquid to the absorbent element 130 to prevent penetration of the absorbed liquid to the skin of the user. The receiving layer 115 may be a connected carded web or web laid with air made from natural and / or artificial fibers. The coupled cardan web can be, for example, a powder-bonded cardan web connected using infrared technology, a cardan web or cardan web connected in a through air flow (TABCW).

To increase the absorption rate of the receive layer 115 and increase its softness, a nonwoven web 120 perforated without physical or thermal deformation in accordance with one embodiment of the present invention can be used as the receive layer 115.

In another embodiment, a nonwoven web 120 perforated without physical or thermal deformation, in accordance with one embodiment of the present invention, can be used as the top sheet 110.

In another embodiment, the non-woven fabric 120, perforated without physical or thermal deformation in accordance with one embodiment of the present invention, can be used as the receiving layer 115 in the form of a laminate, in which the non-perforated non-woven fabric is laminated to the non-woven fabric 120. In this case, the non-perforated non-woven the web may be located between the topsheet 110 and the perforated nonwoven web 120 or between the perforated nonwoven web 120 and the absorbent member 130. Not erforirovannoe nonwoven web may include a spunbond fabric coupled carded web, airlaid web is connected in the through-air stream carded web, etc., but not limited thereto. Preferably, the basis weight of the non-perforated nonwoven web can be in the range of 10 ~ 30 m ² .

The top sheet 110, the nonwoven fabric 120, the absorbent member 130, and the bottom sheet 140 can be assembled into various well-known forms of absorbent products using conventional techniques known in the art. For example, the above components may be bonded to each other using thermal or ultrasonic bonding, hot melt adhesives and combinations thereof, or any other suitable means of attachment.

4 is a perspective view showing a non-woven fabric perforated without physical or thermal deformation in accordance with one embodiment of the present invention. As shown in FIG. 4, a plurality of perforations are formed or formed in the sheet 121 of the nonwoven fabric 120. In one embodiment, the nonwoven fabric 120 can be produced by the following steps: mixing the fibers, opening the mixed fibers; carding of open fibers; perforation of cardan fibers without physical or thermal deformation; connection of perforated fibers; and final processing of the joined fibers.

Steps such as mixing, opening, carding, bonding and finishing may be carried out in accordance with conventional techniques known in the art.

Preferably, the total area of perforations may be in the range of 5 ~ 80% of the total area of the non-woven fabric. Preferably, the diameter of the perforations may be in the range of 2 ~ 30 mm. More preferably, especially in terms of absorption time, the diameter of the perforations may be in the range of 5 ~ 10 mm. Preferably, the weight of the base of the perforated non-woven fabric may be in the range of 20 ~ 400 g / m ² .

Figure 5 schematically shows the perforation process after the carding process. Figure 6 shows an enlarged view of the area indicated by the letter "A" in Figure 5.

Referring to FIGS. 5 and 6, in one embodiment, the nonwoven web 120 can be perforated by blowing or ejecting air in the direction of the carded fibers at a predetermined air pressure after the carding process. Blowing or ejection of air can be carried out intermittently or continuously for a predetermined period of time. In one embodiment, for perforating the cardan fibers 121a, air tubes 170 may be placed or mounted perpendicular to the plane of the sheet 121 of cardan fibers 121a. If air is ejected or blown out of the air tube in the direction of the carded fiber sheet 121, its portion into which the ejected air strikes is pushed out or blown out to form or form a perforation or aperture 122a. In this case, before the bonding process, a perforation or hole 122a is formed in the sheet 121 from carded fibers 121a. Then, if the bonding process is completed, perforation 122 is formed or formed in the nonwoven fabric, as shown in FIG. 4.

In another embodiment, the punching process and the carding process can be carried out simultaneously, so as to form a perforated nonwoven fabric, as shown in Figs. 7 and 8. Fig. 7 schematically shows that open fibers are carded when perforations or holes are formed therein. On Fig presents a view in section taken along the line D-D of Fig.7. As shown in Figs. 7 and 8, a perforated nonwoven web can be produced in such a way that the open fibers are cardan on the carriage conveyor 180 with protrusions or pins 181 on it. These protrusions or pins may have a circular or polygonal cross section or a conical shape. As can be seen more clearly in FIG. 8, when open fibers are poked on the carding conveyor 180, perforations such as perforations 122a shown in FIG. 6 are formed in the sheet of carded fibers 121b by protrusions 181 perforating it. After completion of such a carding process, the joining process can be carried out in such a way that a predetermined air pressure or alternating contact pressure is applied to the upper side and / or lower side of the carded fiber sheet 12lb. In such a process, the joints of the perforations 122, which correspond to the protrusions 181 of the carding conveyor 180 in shape and size, can be formed in the non-woven fabric 120, as shown in FIG. 4.

In accordance with the above-described perforation process, there is no loss of fibers during the production of the nonwoven fabric 120. Also, there is no deformation caused by physical or thermal pressure.

The above-described embodiments of the perforation process are provided for illustrative purposes only and are not intended to limit the present invention to a particular process, as described herein. The nonwoven fabric can be perforated in various other ways that do not cause deformation due to physical or thermal pressure.

Table 1 below shows that thickness and density values in non-perforated nonwoven webs and nonwoven webs, perforated by air ejection in accordance with one embodiment of the present invention.

Table 1 Code C Q code Code F Thickness (mm) 1.87 1,69 1.86 Density (g / m ² ) 0,043 0,041 0,037

Code C: Nonwoven web of TABCW material (80 g / m ^2, no perforations)

Code G: Nonwoven web of TABCW material (70 g / m ^2, no perforations)

Code F: A nonwoven web of TABCW material (70 g / m ^2, perforated air ejection)

As shown in Table 1, if the basis weight of the nonwoven fabric is reduced under the same conditions (for example, a comparison between Code C and Code G), then the density decreases and the thickness becomes less. However, the perforated non-woven fabric (Code F) in accordance with the present invention has a thickness almost equal to the thickness of Code C and a density even lower than that of Code C, despite the use of materials with a basis weight less than that of code C. In addition, perforated the non-woven fabric (Code F) in accordance with the present invention has a thickness greater than that of the G code and a density even lower than that of the G code, despite using materials with the same base weight as that of G. Therefore, the perforated non-woven fabric (Code F) as applicable According to the present invention, it may thicken, and its density may decrease, despite the use of materials with a base weight less than that of code C and code G, while reducing the amount of use of raw materials.

Table 2 below shows the experimental results of the absorption rate of the liquid and the amount of evaporating moisture (g / s / m ² ) of absorbent products using a receiving layer of non-woven fabric, in which only the receiving layer is excellent, and any other components besides the receiving layer are the same.

table 2 Code C Code F The first time of absorption (sec) 19.08 17.08 The second time of absorption (sec) 24.92 20.60 Third absorption time (sec) 26.72 23.42 The amount of evaporating moisture (g / s / m ² ) 21.87 18.59

Code C: Absorbent product including a receiving layer of TABCW material (80 g / m ² , no perforations)

Code F: Absorbent product including a receiving layer of TABCW material (70 g / c ² , perforated by air ejection)

As shown in Table 2, the absorption time of an absorbent article including a perforated non-woven fabric (Code F) is reduced by about 10 to about 17% compared to an absorbent article of Code C. In addition, the amount of evaporated moisture of an absorbent article including a perforated non-woven fabric ( Code F) is increased by about 15% compared to the absorbent article of Code C. Thus, the absorbent article according to the present invention can quickly absorb liquid released from the user's body and, in addition, by it be a significant amount of evaporating moisture per second, while remaining free from moisture for a long time.

Although the present invention has been particularly described and shown with reference to exemplary embodiments, one skilled in the art will recognize that various changes or modifications can be made without departing from the scope of the present invention.

Claims (24)

1. A method of manufacturing a non-woven fabric perforated without physical or thermal deformation, comprising:
fiber blending;
opening mixed fibers;
carding of open fibers;
perforation of carded fibers without physical or thermal deformation;
connection of perforated fibers; and
final processing of connected fibers. 2. The method according to claim 1, in which the perforation involves intermittent ejection of air in the direction of the carded fibers with a given pressure with the formation of perforations and pushing carded fibers around the perforation. 3. The method according to claim 1, in which carding and punching are carried out simultaneously so that open fibers are carded on the conveyor for carding with protrusions on it with the formation of a perforated web, and the connection involves the application of a given air pressure or variable pressure to the top side and / or underside of the web. 4. Non-woven fabric perforated without physical or thermal deformation, which is produced by the method according to any one of claims 1 to 3. 5. The nonwoven fabric according to claim 4, in which the total perforation area is in the range of 5 ~ 80% of the total area of the nonwoven fabric. 6. Non-woven fabric according to claim 4, in which the diameter of the perforation is in the range of 2 ~ 30 mm 7. The nonwoven fabric according to claim 6, in which the diameter of the perforation is in the range of 5 ~ 10 mm 8. Non-woven fabric according to claim 4, in which the weight of the basis of the perforated non-woven fabric is in the range of 20 ~ 400 g / m ² . 9. An absorbent article comprising:
liquid permeable top sheet;
liquid impervious bottom sheet;
an absorbent element located between the upper sheet and the lower sheet to absorb liquid penetrating through the upper sheet; and
a receiving layer located between the top sheet and the absorbent member for supplying liquid penetrating through the top sheet to the absorbent member, the receiving layer comprising a nonwoven web perforated without physical or thermal deformation according to claim 4. 10. Absorbent product according to claim 9, in which the total area of perforations is in the range of 5 ~ 80% of the total area of the non-woven fabric. 11. Absorbent product according to claim 9, in which the diameter of the perforation is in the range of 2 ~ 30 mm 12. Absorbent product according to claim 11, in which the diameter of the perforation is in the range of 5 ~ 10 mm 13. Absorbent product according to claim 9, in which the weight of the basis of the perforated non-woven fabric is in the range of 20 ~ 400 g / m ² . 14. Absorbent product containing:
liquid permeable top sheet;
liquid impervious bottom sheet;
an absorbent element located between the upper sheet and the lower sheet to absorb liquid penetrating through the upper sheet; and
a receiving layer located between the top sheet and the absorbent member for supplying liquid penetrating through the top sheet to the absorbent member, the receiving layer comprising a laminate that includes a non-woven fabric perforated without physical or thermal deformation according to claim 4 and a non-perforated non-woven fabric laminated on him. 15. Absorbent product according to 14, in which the total area of perforations is in the range of 5 ~ 80% of the total area of the non-woven fabric. 16. The absorbent product of claim 14, wherein the diameter of the perforation is in the range of 2 ~ 30 mm. 17. Absorbent product according to clause 16, in which the diameter of the perforation is in the range of 5 ~ 10 mm 18. Absorbent product according to 14, in which the weight of the basis of the perforated non-woven fabric is in the range of 20 ~ 400 g / m ² . 19. The absorbent product according to 14, in which the weight of the base non-perforated non-woven fabric is in the range of 10 ~ 30 g / m ² . 20. Absorbent product containing:
liquid permeable top sheet;
liquid impervious bottom sheet;
an absorbent element located between the upper sheet and the lower sheet to absorb liquid penetrating through the upper sheet; and
a receiving layer located between the top sheet and the absorbent member for supplying liquid penetrating through the top sheet to the absorbent member, the top sheet comprising a non-woven web perforated without physical or thermal deformation according to claim 4. 21. The absorbent product according to claim 20, in which the total area of perforations is in the range of 5 ~ 80% of the total area of the non-woven fabric. 22. Absorbent product according to claim 20, in which the diameter of the perforation is in the range of 2 ~ 30 mm 23. Absorbent product according to item 22, in which the diameter of the perforation is in the range of 5 ~ 10 mm 24. The absorbent product according to claim 20, in which the basis weight of the perforated nonwoven fabric is in the range of 20 ~ 400 g / m ² .

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