A manufacturing process for disposable hygiene products

Abstract

This invention relates to the field of disposable hygiene products and provides a manufacturing process for disposable hygiene products, comprising the following steps: (1) A first nonwoven fabric has a pocket area, and the first nonwoven fabric is passed through a dotted cutting mechanism, which cuts a dotted line in the pocket area; an application mechanism places a wet wipe or cotton wipe on the pocket area for conveying; a glue spraying mechanism sprays glue on the first nonwoven fabric, but not on the pocket area; a first composite mechanism composites an impermeable membrane with the first nonwoven fabric to form a water-repellent layer, and a pocket is formed in the pocket area; (2) a second composite mechanism composites an absorbent core layer, a water-repellent layer, and a liquid-permeable top layer; (3) a cutting mechanism cuts the fabric to form a sheet-like body. The pocket of this invention is positioned between the impermeable membrane and the first nonwoven fabric, saving costs, simplifying the process, resulting in a thinner and more aesthetically pleasing body, and solving the technical problems of high production costs and low production efficiency associated with setting pockets in disposable hygiene products.

Description

Technical Field

[0001] This invention relates to the field of disposable hygiene products, and more particularly to a manufacturing process for disposable hygiene products. Background Technology

[0002] Some existing disposable hygiene products have a pocket for holding wet wipes or cotton wipes. The process usually involves applying the wet wipes or cotton wipes to an impermeable base layer, then applying a piece of non-woven fabric, which is then fixed in place by spraying adhesive or hot pressing. This method is not only complex and requires multiple steps, resulting in high production equipment costs, but it also increases the thickness of the product by adding non-woven fabric to the pocket.

[0003] Chinese Patent Application No. 202121295760.1 discloses a pull-up diaper that is easy to wear, including a diaper body and a connecting strap. The upper part of the diaper body has an elastic waistband with adhesive surfaces on both sides. The connecting strap is sewn to one side of the elastic waistband, and its inner side has an adhesive surface. An extension strap is sewn to the other side of the connecting strap. Extended cotton pads are provided on both sides of the lower part of the diaper body, and a storage pocket is sewn to the outer side of the diaper body. An abdominal pad is provided in the middle of the inner wall of the diaper body, and a skin-friendly cotton layer is provided inside the diaper body. A diversion layer is provided at the lower end of the skin-friendly cotton layer, and a super absorbent polymer layer is provided at the lower end of the diversion layer. The storage pocket of this pull-up diaper requires the lamination and bonding of individual pocket pieces, which requires high precision, has a complex manufacturing process, and high production costs. Furthermore, the storage pocket is separate from the pull-up diaper, causing it to protrude, taking up space and being unsightly. Summary of the Invention

[0004] Therefore, to address the aforementioned problems, this invention proposes a manufacturing process for disposable hygiene products. This process solves the technical problems of high production costs and low production efficiency associated with adding pockets to disposable hygiene products.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A manufacturing process for disposable hygiene products includes the following steps:

[0007] (1) Manufacturing a water-repellent layer:

[0008] a1. The first nonwoven fabric has a pocket area, and the first nonwoven fabric passes through a virtual cutting mechanism, which cuts a virtual line in the pocket area to form a virtual line cut.

[0009] a2. The applicator places a wet wipe or cotton towel on the pocket area for delivery;

[0010] a3. The glue spraying mechanism sprays glue onto the first non-woven fabric, but no glue is sprayed on the pocket area. The first composite mechanism combines the liquid-impermeable membrane with the first non-woven fabric to form a water-repellent layer, and a pocket is formed in the pocket area.

[0011] (2) The second composite structure combines the absorbent core layer, the water-repellent layer, and the liquid-permeable top layer;

[0012] The cutting mechanism cuts the material to form a sheet-like structure.

[0013] Further:

[0014] After step (1), the water-repellent layer passes through a hot press roller and is hot-pressed around the periphery of the pocket area.

[0015] The body has two pockets, one for holding wet wipes and the other for holding cotton towels.

[0016] The body has a pocket for holding wet wipes.

[0017] It also includes the production steps of the absorbent core layer: the first feeding bin of the polymer feeding mechanism feeds the polymer into the mold cavity to form the absorbent core layer. The mold wheel is provided with three adsorption chambers. The adsorption force of the middle adsorption chamber is the smallest. The mold cavity is provided with multiple adsorption holes. At least one boss is provided in the middle of the mold cavity. The boss is located in the middle adsorption chamber. At least one first protrusion is provided in the middle of the boss. The first protrusion is not provided with adsorption holes. At least one first guide groove is formed at the top of the middle of the absorbent core layer along the length direction. A second guide groove corresponding to the boss is formed at the bottom of the middle of the absorbent core layer. There is a reverse osmosis section between the first guide groove and the second guide groove. The reverse osmosis section is provided with a through-hole corresponding to the first protrusion in the middle. The first guide groove and the second guide groove are connected through the through-hole.

[0018] The top of the protrusion is a first inclined surface, and the two first inclined surfaces slope downward along the direction of the first protrusion. The reverse osmosis section has a V-shaped structure.

[0019] The reverse osmosis section includes two opposing inclined sections, the sum of the widths of the two inclined sections being greater than the width of the first guide channel.

[0020] The mold cavity is provided with multiple horizontally arranged second protrusions, which are connected to the boss, so that the bottom of the absorbent core layer forms a third guide groove corresponding to the second protrusion. The third guide groove is arranged horizontally.

[0021] The mold wheel is provided with a blowing cavity, and the absorbent core layer is demolded through the blowing cavity.

[0022] The depth of the second guide channel is greater than the depth of the first guide channel.

[0023] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0024] This invention incorporates a pocket within the existing water-repellent layer, positioned between the liquid-impermeable membrane and the first non-woven fabric. The pocket only tears when forcefully pulled along the dotted-line cut, providing excellent sealing. It is secured using adhesive spraying, creating a pocket area in the un-adhesive-sprayed area. Therefore, existing production equipment only requires the addition of an application mechanism and a dotted-cutting mechanism, resulting in low production costs and a simple process. The absence of an additional non-woven fabric pocket on the main body saves material costs, simplifies the process, and makes the main body appear more natural, thinner, and more aesthetically pleasing through a one-piece molding. Furthermore, the water-repellent layer is laminated using hot-press rollers to prevent adhesive detachment during wear, which could cause the pocket to enlarge. Moreover, the mold cavity structure incorporates a first guide channel, a second guide channel, and a reverse permeation section on the absorbent core layer. Liquid flowing into the first guide channel within the absorbent core layer can flow into the second guide channel through the opening, providing excellent longitudinal flow guidance and improving the absorbent core layer's flow performance. Simultaneously, the reverse permeation section acts as a barrier, increasing the liquid pressure within the second guide channel, which is beneficial for the second flow. The first and second guide channels form a deep, buffered channel that facilitates the longitudinal flow of a large volume of liquid, effectively preventing side leakage. Furthermore, the top of the boss has a first inclined surface, creating a V-shaped structure for the backflow section, which facilitates the flow of liquid from the second through-hole into the second guide channel. Additionally, the combined width of the two inclined sections is greater than the width of the first guide channel. When there is a large amount of liquid in the second guide channel, the upward pressure exerted on the inclined sections causes them to abut against each other, increasing the space within the second guide channel. When some or all of the two inclined sections move to abut against each other, the opening is partially or completely sealed, effectively preventing backflow and overflow. Simultaneously, the inclined sections exert downward pressure on the liquid, enhancing the diffusion of liquid within the second guide channel. Furthermore, the third guide channel facilitates the lateral flow of liquid, preventing leakage from both ends of the first and second guide channels. Finally, the blowing chamber facilitates the demolding of the absorbent core layer, preventing it from becoming stuck in the mold cavity. Attached Figure Description

[0025] Figure 1 This is a simplified structural diagram of the production apparatus of the present invention;

[0026] Figure 2 This is a simplified structural diagram of the polymer feeding mechanism;

[0027] Figure 3 This is a partial simplified diagram of the mold cavity in its unfolded state;

[0028] Figure 4 yes Figure 3 A simplified structural diagram of the adsorption pores in the mold cavity is not shown.

[0029] Figure 5 This is a simplified side view of the mold cavity;

[0030] Figure 6 This is a simplified front view diagram of the mold cavity;

[0031] Figure 7 This is a partial simplified diagram of the unfolded state of the mold wheel;

[0032] Figure 8 This is a structural diagram of disposable hygiene products;

[0033] Figure 9 This is a partial cross-sectional view of a disposable hygiene product;

[0034] Figure 10 This is a top view of the absorber core.

[0035] Figure 11 This is a cross-sectional view of the absorber core.

[0036] Figure 12 This is a cross-sectional view of the absorbing core layer from another angle;

[0037] Figure 13 This is a bottom view of the absorber core.

[0038] Figure 14 This is a schematic diagram of another structure of disposable hygiene products. Detailed Implementation

[0039] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0040] refer to Figures 1 to 13 This embodiment provides a manufacturing process for disposable hygiene products, including the following steps:

[0041] (1) Manufacturing a water-repellent layer 1:

[0042] a1. The first nonwoven fabric 11 has a pocket area. The first nonwoven fabric 11 passes through the virtual cutting mechanism 51, and the virtual cutting mechanism 51 cuts a virtual line slit 111 in the pocket area.

[0043] a2. The applicator 52 places the wet wipe 13 on the pocket area for delivery;

[0044] a3. The adhesive spraying mechanism 53 sprays adhesive on the first non-woven fabric 11, but no adhesive is sprayed in the pocket area. The first composite mechanism 54 composites the liquid-impermeable membrane 12 with the first non-woven fabric 11 to form a water-repellent layer 1, and a pocket 10 is formed in the pocket area.

[0045] (2) Manufacturing the absorbent core layer 2:

[0046] The polymer feeding mechanism 4 feeds polymer into the mold cavity 42 through the first feeding bin 41 to form the absorbent core layer 2. The mold wheel 43 has three adsorption chambers 430, with the middle adsorption chamber 430 having the least adsorption force. The mold cavity 42 has multiple adsorption holes 420, and the middle part of the mold cavity 42 has multiple bosses 421. The bosses 421 are located in the middle adsorption chamber 430, and the middle part of the bosses 421 has a first protrusion 422. The first protrusion 422 does not have adsorption holes 420. The top of the middle part of the absorbent core layer 2 forms a first guide groove 21 that runs along the length direction, and the bottom of the middle part of the absorbent core layer 2 forms a groove that runs along the length direction. The second guide channel 22 corresponding to 421 has a reverse osmosis section 23 between the first guide channel 21 and the second guide channel 22. The reverse osmosis section 23 has a through-hole 231 in the middle corresponding to the first protrusion 422. The first guide channel 21 and the second guide channel 22 are connected through the through-hole 231. The top of the protrusion 421 is a first inclined surface 4211. The two first inclined surfaces 4211 are inclined downward along the direction of the first protrusion 422. The reverse osmosis section 23 has a V-shaped structure. The reverse osmosis section 23 includes two opposing inclined parts 432. The sum of the widths of the two inclined parts 432 is greater than the width of the first guide channel 21. The mold cavity 42 is provided with a plurality of horizontally arranged second protrusions 423, which are connected to the boss 421, so that the bottom of the absorbent core layer 2 forms a third guide groove 24 corresponding to the second protrusions 423, and the third guide groove 24 is arranged horizontally; the mold wheel 43 is provided with a blowing cavity 431, and the absorbent core layer 2 is demolded through the blowing cavity 431.

[0047] (3) The second composite mechanism 55 combines the absorbent core layer 2, the water-repellent layer 1, and the liquid-permeable top layer 3;

[0048] (4) The cutting mechanism 56 cuts to form a sheet-like body.

[0049] The aforementioned reverse osmosis section 23 can also be horizontally arranged, arc-shaped, or have other structural arrangements, depending on the specific circumstances.

[0050] The sum of the widths of the inclined portions 432 may not exceed the width of the first guide channel 21. The reverse osmosis effect of this structure is relatively poor, and the specific configuration should be determined according to the circumstances.

[0051] The second protrusion 423 and the third guide groove 24 mentioned above may also be omitted, depending on the specific circumstances.

[0052] After step (1), the above-mentioned water-repellent layer 1 can be hot-pressed around the pocket area by hot-pressing rollers or ultrasonic hot pressing, which is a well-known technology and will not be described in detail here.

[0053] The pocket 10 on the main body can be one, two, three or even more. The pocket 10 can hold wet wipes 13 or cotton wipes, depending on the situation.

[0054] The aforementioned absorbent core layer 2 can also be other structures, depending on the specific circumstances.

[0055] The blowing cavity 431 may not be provided on the mold wheel 43 mentioned above, depending on the specific situation.

[0056] The third guide channel 24 mentioned above may not be provided; the specific setting depends on the circumstances.

[0057] The aforementioned virtual cutting mechanism 51, application mechanism 52, second composite mechanism 55, first composite mechanism 54, and cutting mechanism 56 are known devices and will not be described in detail here.

[0058] The aforementioned glue spraying mechanism 53 is a known device that can be equipped with multiple glue spraying nozzles. It does not spray glue in the pocket area, which is a known structure and will not be described in detail here.

[0059] The side of the boss 421 is a second inclined surface 4212, which slopes upward along the direction of the first inclined surface 4211. The second guide channel 22 formed has third inclined surfaces 220 on both sides, which slope upward along the direction of the reverse osmosis section 23. In this structure, the width of the second guide channel 22 gradually increases from top to bottom. The third inclined surface 220 not only has the function of blocking and reverse osmosis, but also increases the effective contact area between the liquid and the third inclined surface 220, thereby increasing the absorption rate of the liquid in the second guide channel 22 by the absorption core layer 2.

[0060] The opening 231 of the absorbent core layer 2 does not penetrate the front and rear ends of the reverse osmosis section 23. The front and rear ends of the protrusion 421 have fourth inclined surfaces 4213, with adsorption holes 420 on the fourth inclined surfaces 4213. The reverse osmosis section 23 includes an inclined portion 233 formed on the fourth inclined surface 4213 and a horizontal portion 234 connected to the inclined portion 233. The inclined portion 233 slopes downwards along the front and rear ends, and the horizontal portion 234 is flush with the bottom surface of the absorbent core layer 2. The depth of the first guide groove 21 located on the inclined portion 233 gradually increases along the two ends, and the depth of the second guide groove 22 located on the inclined portion 233 gradually decreases along the two ends. In this structure, the horizontal portion 234 has a flow-blocking effect, effectively preventing the liquid in the second guide groove 22 from flowing out along both ends.

[0061] Due to the provision of the second protrusion 423, a ridge 25 corresponding to the second protrusion 423 is formed on the top of the absorbent core layer 2, and the ridges 25 have a good effect of flow obstruction and flow guidance.

[0062] The third guide channel 24 is located at the front and rear ends of the bottom of the absorbent core layer 2, so that the middle part of the bottom of the absorbent core layer 2 does not have a good lateral guiding effect, preventing the side leakage of a large amount of liquid in the middle. The front and rear ends of the absorbent core layer 2 have a good lateral guiding effect, improving the absorption rate of the front and rear ends of the absorbent core layer 2 and increasing the effective absorption area of ​​the absorbent core layer 2 for liquid.

[0063] refer to Figure 14 Alternatively, the present invention may laminate a second nonwoven fabric 14 onto the first nonwoven fabric 11, forming a pocket 10 between the second nonwoven fabric 14 and the first nonwoven fabric 13, depending on the specific circumstances.

[0064] This invention is applicable to pull-up diapers, disposable diapers, or other disposable hygiene products.

[0065] This invention can employ a PLC or other automatic control system, which are well-known technologies and will not be described in detail here.

[0066] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A process for the production of a disposable hygiene article, characterized in that: Includes the following steps: (1) Manufacturing a water-repellent layer: a1. The first nonwoven fabric has a pocket area, and the first nonwoven fabric passes through a dotted cutting mechanism, which cuts a dotted line in the pocket area; a2. The applicator places a wet wipe or cotton towel on the pocket area for delivery; a3. The glue spraying mechanism sprays glue onto the first non-woven fabric, but no glue is sprayed on the pocket area. The first composite mechanism combines the liquid-impermeable membrane with the first non-woven fabric to form a water-repellent layer, and a pocket is formed in the pocket area. The process also includes the production steps of the absorbent core layer: the first feeding bin of the polymer feeding mechanism feeds the polymer into the mold cavity to form the absorbent core layer. The mold wheel has three adsorption chambers, with the middle chamber having the lowest adsorption force. The mold cavity has multiple adsorption holes. At least one boss is located in the middle of the mold cavity, within the middle adsorption chamber. At least one first protrusion is located in the middle of the boss, without any adsorption holes. At least one first guide channel is formed at the top of the middle section of the absorbent core layer, extending along its length. A second guide channel, corresponding to the boss, is formed at the bottom of the middle section of the absorbent core layer. A reverse osmosis section exists between the first and second guide channels, with an opening in the middle of the reverse osmosis section corresponding to the first protrusion. The first guide channel... The second guide channel is connected to the second guide channel through a through-hole; the top of the boss is a first inclined surface, and the two first inclined surfaces slope downward along the direction of the first protrusion; the reverse osmosis section has a V-shaped structure; the reverse osmosis section includes two opposing inclined parts, and the sum of the widths of the two inclined parts is greater than the width of the first guide channel; the mold cavity is provided with a plurality of horizontally arranged second protrusions, and the second protrusions are connected to the boss, so that the bottom of the absorbent core layer forms a third guide channel corresponding to the second protrusion, and the third guide channel is arranged horizontally; the side of the boss is a second inclined surface, and the second inclined surface slopes upward along the direction of the first inclined surface, and the two sides of the formed second guide channel are third inclined surfaces, and the third inclined surfaces slope upward along the direction of the reverse osmosis section; (2) The second composite structure combines the absorbent core layer, the water-repellent layer, and the liquid-permeable top layer; (3) The cutting mechanism cuts the material to form a sheet-like body.

2. The manufacturing process of a disposable hygiene product according to claim 1, characterized in that: After step (1), the water-repellent layer passes through a hot press roller and is hot-pressed around the pocket area.

3. The manufacturing process of a disposable hygiene product according to claim 1, characterized in that: The body has two pockets, one for holding wet wipes and the other for holding cotton towels.

4. The manufacturing process of a disposable hygiene product according to claim 1, characterized in that: The body has a pocket for holding wet wipes.

5. The manufacturing process of a disposable hygiene product according to claim 1, characterized in that: The mold wheel is provided with a blowing cavity, and the absorbent core layer is demolded through the blowing cavity.

6. The manufacturing process of a disposable hygiene product according to claim 1, characterized in that: The depth of the second guide channel is greater than the depth of the first guide channel.

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