WO2021133269A1

WO2021133269A1 - A diaper preventing skin disorders caused by urine and feces and a production method thereof

Info

Publication number: WO2021133269A1
Application number: PCT/TR2019/051203
Authority: WO
Inventors: Özlem ESEN; Dilsah YAMAN; Çağla BEKTAŞ; Asli Merve ÇAKIR
Original assignee: Evyap Sabun Yag Gliserin Sanayi Ve Ticaret Anonim Sirketi
Priority date: 2019-12-24
Filing date: 2019-12-24
Publication date: 2021-07-01

Abstract

The present invention relates to a diaper; which, in order to prevent skin disorders such as rash, irritation, redness, rash caused by urine and feces, comprises at least one substance selected from the group comprising antibacterial agents, antimicrobial agents, probiotics and natural oils in its absorbent core layer and the topsheet, barrier and side tape portions which are in contact with the skin; and a method for producing the said diaper.

Description

A DIAPER PREVENTING SKIN DISORDERS CAUSED BY URINE AND FECES AND A PRODUCTION METHOD THEREOF

Field of the Invention

The present invention relates to a diaper which is developed to prevent skin disorders such as rash, irritation and eruption caused by urine and feces, and to a method of producing the said diaper.

Background of the Invention

The diapers are produced by combining a plurality of components in a certain order in accordance with the anatomy and requirements of the user. The uppermost layer of the diaper which is in contact with the baby’s skin is called a topsheet. The said topsheet is generally produced from non-woven fabrics. Beneath the topsheet, there is provided an acquisition and distribution layer for transferring the urine and feces towards the front, back and the absorbent core layer. Below this layer, there is an absorbent core layer comprised of superabsorbent polymers (SAP) and shredded and fluffed cellulose (pulp). The absorbent core layer performs the absorption function of the diaper and swells when it comes into contact with the liquid. In addition, barriers are utilized to prevent urine and feces from leaking out of the diaper. The barriers provided on both sides of the diaper also contain lycra or rubber pieces that provide the C form of the diaper.

At the outermost layer of the diaper there is provided a backsheet. The said backsheet is obtained by applying nonwoven fabric lamination on the polymer film obtained by extrusion of the polymer matrix comprising polyolefin materials such as LDPE, HDPE, LLDPE, PP, Metallocene PE-PP and copolymers thereof. Inorganic fillers are added to these polyolefins in the film extrusion process to provide a breathable porous structure.

The front tape, elastic side panels and side tapes are used to ensure that the diaper completely fits the baby's body.

The diapers that are currently used are insufficient in providing an effective solution to the skin disorders such as diaper rash, irritation and eruption occurring on baby’s skin due to urine and feces. In order to protect sensitive baby skin against skin irritation caused by urine and feces, the diaper manufacturers generally prefer to use breathable materials in the backsheet, which is the outermost layer of the diaper. This way, it is aimed to enable fresh air to reach the skin. However, due to the decrease in the efficiency of the microporous structure as a result of the combination of too many layers that form the diaper, and the fact that the hotmelt adhesive holding the said layers together clog the air channels on the backsheet, the desired level of efficiency cannot be obtained from the breathable backsheet structures.

The International patent application document no. WO 2005/039470 Al, one of the state of the art applications, discloses a diaper which is breathable by means of its microporous polymeric structure. The microporous structure is generally provided by the calcite added into the polymer melt solution prior to the extrusion of the polymer film used in the production of backsheet.

In the current state of the art, there are also studies for the production of lotion- applied diapers to soothe the baby’s skin by forming a protective layer on the skin, and reduce the urinary/fecal exposure. In the said studies, lotion is applied to the topsheet of the diaper which is the uppermost layer of the diaper which touches the skin of the baby. For this purpose, lotion is applied to the topsheet material after the final cut and before it is connected with the other diaper components. The United States patent document no. US6118041 A relates to application of intermittent or continuous lotion on the topsheet layer for forming a barrier between the skin and feces by altering the surface energy of the skin. The said lotion includes raw materials such as petrolatum and mineral oils, cream stabilizers and hydrophilic surfactants, all of which form the cream. The lotion having the said content is applied to the surface by immersing or spraying. In the said document, it is stated that said lotion applied to the topsheet reaches the skin through direct contact, the movements of the baby or the body temperature of the baby, and prevents the skin problems by forming a protective barrier layer on the skin surface.

In the United States patent application no. US6120488 A, lotion is applied to the topsheet and leg cuffs to prevent skin problems. It is stated in the document that increased skin coverage is achieved by means of the lotion applied to the leg cuffs.

The United States patent application no. US9492337 B2 suggests use of human milk oligosaccharides on the topsheet of the diaper. This way, it is aimed to protect the skin and treat the irritations that occur.

On the other hand, application of lotion to the topsheet and/or the barrier brings along several disadvantages. Perfume or similar ingredients contained in the lotion may cause irritation to the baby’s skin. At the same time, this lotion clogs the liquid passageways on the nonwoven fabric surface which forms the diaper, causing a decrease in the capillary gradient and adversely affecting the hydrophilic property of the surface. This reduces the absorption time and the rewet (amount of wetness returned to the skin) performances which are the main performance criteria of the diaper. Thus, due to the fact that the diaper absorbs the urine over a more delayed period of time and the skin remains wet for a long time, the possibility of encountering problems of leakage and diaper rash increases. This constitutes one of the main problems in the diaper sector and has a negative impact on the consumer.

Besides the lotions applied to the diaper components, various powder and cream products which are applied externally to solve skin irritation problems are often preferred by the users. However, applying these products to the irritated areas at each diaper change is a laborious process. At the same time, the said products may affect the performance of the nonwoven fabric of the diaper or the elasticity and elongation properties of the side ears and leg cuff bands.

Summary of the Invention

The objective of the present invention is to provide a diaper to prevent skin disorders such as diaper rash, irritation, redness and eruption, which are among the main problems experienced by parents associated with diaper use. It is possible to prevent skin disorders and to provide full protection for sensitive baby skin with the additives applied to the core layer and the parts of the diaper which are in contact with the baby’s skin.

Another objective of the present invention is to provide a diaper comprising antibacterial and antimicrobial agents preventing growth of bacteria and fungi, and beneficial microorganisms such as probiotics in the topsheet, barrier, elastic side tapes and absorbent core layer. Within the scope of the invention, a direct application method and/or microencapsulation technology can be used for the application of said agents and microorganisms to the desired regions.

Detailed Description of the Invention

The present invention relates to a diaper to prevent skin problems such as rash, irritation, redness and eruption. The diaper of the present invention; which enables to prevent skin disorders such as rash, irritation, redness, rash caused by urine and feces; comprises at least one beneficial material or microorganism selected from the group comprising antibacterial agents, antimicrobial agents, probiotics, natural oils and microcapsules containing them in its absorbent core layer and/or the topsheet, barrier and side tapes which are in contact with the skin. While the said antibacterial agents, antimicrobial agents, probiotics and natural oils can be applied directly to the absorbent core layer, topsheet, barrier and side tapes, they can also be incorporated by microencapsulation method.

In one embodiment of the invention, at least one antibacterial and antimicrobial agent is used, which can be used for both antibacterial and antimicrobial purposes, and which is selected from a group comprising halogenated salicylic acid, anilides, organic-based compounds such as quaternary ammonium compounds and quaternary ammonium sulfonamide derivatives, bamboo, chitin, chitosan nano-fibers and combinations thereof. Within the scope of the invention, natural polymers such as bamboo, chitosan and chitin are utilized to obtain antimicrobial and antibacterial properties. Chitin is the second most common polymer in nature after cellulose. Chitin is insoluble in water and has very low chemical reactivity. By means of this feature, it is suitable to be used in non-woven fabric layers of the diaper that contact the baby’s skin. While chitosan, which is obtained by deacetylation of chitin, can be used as an antibacterial finishing agent, it can also provide antibacterial activity directly as chitosan fibers. In addition to cellulose, hemicellulose and lignin which are the main components of its chemical structure, bamboo fiber contains protein, fat, fruit extract and bamboo-kun, which is a natural antimicrobial substance, and therefore has antimicrobial properties. The air permeability of the bamboo fiber is high and can be mixed with the natural and synthetic fibers at any ratio in the scope of the present invention.

In one embodiment of the invention, the natural oil used is at least one natural oil selected from the group comprising avocado oil, coconut oil, chamomile oil, rose oil and combinations thereof. In one embodiment of the invention, vitamins are used as beneficial materials or microorganisms, and this vitamin is preferably vitamin E, which is one of the vitamins beneficial to skin.

The microcapsules used in the said diaper are ruptured due to the pH sensitivity of the shell in the presence of urine and feces, the presence of liquid and moisture in the environment due to urine and feces, the pressure resulting from the weight of the baby and/or the body temperature of the baby; and release the composition comprising antibacterial agent, antimicrobial agent, probiotics and natural oil out of the capsule, allowing the said composition to spread throughout the diaper.

There are two types of microcapsules that can be used in the diaper of the present invention. There are matrix-type water soluble capsules and shell-type water insoluble capsules. Matrix-type water-soluble capsules consist of starch capsules in dry powder form and are biodegradable. The matrix-type water soluble capsule, which starts to diffuse slowly when it is exposed to moisture, releases its content of antibacterial agent, antimicrobial agent, probiotic and natural oil out of the capsule when it encounters urine. Shell-type water insoluble capsules, on the other hand, contain at least one of the substances selected from a group comprising polymers such as melamine, cyclodextrin and chitosan and combinations thereof, and are water-dispersible. When the shell-type water insoluble capsule is exposed to moisture, a slow diffusion takes place throughout the shell. By diffusion is meant the diffusion of the active substance within the shell to the outside without rupturing of the shell. When the shell is ruptured under mechanical stress, the composition comprising the antibacterial agent, antimicrobial agent, probiotics and natural oil contained in the said capsule is released out of the capsule.

In one embodiment of the invention, the average particle size of the microcapsules for matrix-type water-soluble capsules is smaller than 150 pm (preferably smaller than 100 pm, or more preferably smaller than 75 pm). The average particle size of the shell-type water-insoluble microcapsules, which is smaller than that of the matrix-type microcapsules, is in the range of 2-50 pm (preferably 5-40 pm or more preferably 10-20 pm).

In one embodiment of the invention, when the beneficial materials or microorganisms which are antibacterial agents, antimicrobial agents, probiotics, natural oils or microcapsules containing them are used in the absorbent core layer of the diaper, the amount of the beneficial materials or microorganisms is about 5- 80% by weight of the mixture comprising superabsorbent polymers and cellulose. This ratio is important for the diffusion of the said microcapsules to the surface. Within the scope of the invention, it is preferred that the microcapsules are distributed homogeneously in the absorbent core layers which have a homogeneous distribution. However, in the case that there are different proportions of superabsorbent polymer-cellulose mixture in different regions of the absorbent core layer, the distribution of the microcapsules used also differs.

In diapers containing more superabsorbent polymer - cellulose mixture in the front and middle regions; the amount of the beneficial materials or microorganisms used in the front and middle regions constitutes 55-90% (preferably 60-85%, or more preferably 65-70%) of the amount of the microcapsules present in the entire absorbent core layer. In the said case where the front and middle regions of the diaper contain more superabsorbent polymer - cellulose mixture, the amount of the beneficial materials or microorganisms used in the rear region of the diaper may be in the range of 10-45% (preferably 15- 40%, or more preferably 20-30%) in the entire absorbent core layer.

In one embodiment of the invention, in addition to or as an alternative to the beneficial materials or microorganisms added to the absorbent core layer; fibers and/or fabrics directly containing beneficial materials or microorganisms are used in the production of topsheets, barriers and/or side tapes. The beneficial materials or microorganisms, including antibacterial agents, antimicrobial agents, probiotics, natural oils, and microcapsules containing them, are added to the polymer or fiber spinning solution during fiber production in the nonwoven fabric production process before passing through the spinneret. Thus, it is possible to produce woven or nonwoven fabrics from the said fibers having beneficial materials or microorganisms. The topsheet, barrier and side tape are produced from the woven or non-woven fabrics that are obtained. This way, parts such as topsheets, barriers, side tapes, which are components of diapers and are made of woven or non-woven fibers/fabrics, directly contain beneficial materials or microorganisms therein to prevent skin problems without requiring or in addition to addition thereof afterwards.

When producing topsheet, barrier and side tape portions from microcapsule- containing fibers, firstly, the beneficial materials or microorganisms containing antibacterial agents, antimicrobial agents, probiotics, natural oils or microcapsules containing them are added to the polymer or fiber spinning solution during fiber production before passing through the spinneret. In the next processing step, the fibers having a beneficial material or microorganism content are formed into a non-woven fabric, and the topsheet, barrier and side tape portions of the diaper that contact the skin are produced.

In one embodiment of the invention, the ratio of the beneficial materials or microorganisms to the polymer matrix is at least 5% by weight (preferably greater than 30%) for providing effective protection.

Within the scope of the invention, in order to obtain a diaper which enables prevention of skin disorders such as rash, irritation, redness and eruption caused by urine and feces; a solution containing beneficial materials and microorganisms is applied to the fabrics or fibers contained in the diaper or directly to the whole diaper by methods of impregnation, immersion and/or printing. Within the scope of the invention, direct integration of the beneficial materials or microorganisms into the nonwoven fabric or fibers makes it possible to modify the chemical structure of the fibers to allow covalent bond formation. In a different embodiment of the invention, in order to prevent skin disorders such as rash, irritation, redness and eruption; fibers containing beneficial materials or microorganisms such as antibacterial agents, antimicrobial agents, probiotics, natural oils and microcapsules containing thereof are blended in between the standard fibers during the nonwoven fabric production process.

Throughout the specification, the term “diaper” has been used to facilitate understanding in the technical field, and it includes absorbent diapers that may be used for all age groups.

Claims

1. A diaper which enables to prevent skin disorders caused by urine and feces; characterized in that it comprises at least one beneficial material or microorganism selected from the group comprising antibacterial agents, antimicrobial agents, probiotics, natural oils and microcapsules containing them in its absorbent core layer and/or the topsheet, barrier and side tapes which are in contact with the skin.

2. Diaper according to Claim 1, characterized in that it comprises at least one antibacterial and antimicrobial agent selected from a group comprising halogenated salicylic acid, anilides, organic -based compounds such as quaternary ammonium compounds and quaternary ammonium sulfonamide derivatives, bamboo, chitin, chitosan nano-fibers and combinations thereof.

3. Diaper according to Claim 1, characterized in that it comprises at least one natural oil selected from the group comprising avocado oil, coconut oil, chamomile oil, rose oil and combinations thereof.

4. Diaper according to Claim 1, characterized in that the beneficial material or microorganism is vitamins.

5. Diaper according to Claim 4, characterized in that the beneficial material or microorganism is vitamin E.

6. Diaper according to Claim 1, characterized by the microcapsules whose shell portions are ruptured due to the pH sensitivity of the shell in the presence of urine and feces, the presence of liquid and moisture in the environment due to urine and feces, the pressure resulting from the weight of the baby and/or the body temperature of the baby; and which release the composition comprising antibacterial agents, antimicrobial agents, probiotics and natural oils out of the capsule, allowing the said composition to spread.

7. Diaper according to Claim 6, characterized by microcapsules which starts to diffuse slowly when exposed to moisture and has a matrix-type water soluble capsule shell comprising starch in dry powder form.

8. Diaper according to Claim 7, characterized by microcapsules whose average particle size is smaller than 150 pm for matrix-type water soluble capsules.

9. Diaper according to Claim 6, characterized in that it comprises water dispersible microcapsules having water insoluble capsule shell containing at least one of the substances selected from a group comprising polymers such as melamine, cyclodextrin and chitosan and combinations thereof.

10. Diaper according to Claim 9, characterized by microcapsules whose average particle size is in the range of 2-50 pm for shell-type water insoluble capsules.

11. Diaper according to Claim 1, characterized by the beneficial materials or microorganisms, which, when used in the absorbent core layer of the diaper, constitute 5-80% by weight of the mixture comprising superabsorbent polymers and cellulose.

12. Diaper according to Claim 1, characterized in that it comprises fibers and/or fabrics which are used in the topsheet, barrier and side tape parts of the diaper and which contain beneficial materials and microorganisms.

13. Diaper according to Claim 12, characterized in that it comprises fibers and/or fabrics which are used in the topsheet, barrier and side tape parts of the diaper and which contain at least 5% by weight of beneficial materials and microorganisms in proportion to the polymer matrix in order to provide an effective protection.

14. A method of producing the diaper according to any of the preceding claims, characterized by application of the beneficial materials and microorganisms to the fibers or fabrics contained in the diaper or directly to the whole diaper by methods of impregnation, immersion and/or printing in order to obtain a diaper which enables prevention of skin disorders such as rash, irritation, redness and eruption caused by urine and feces.