A method for manufacturing an air-cushion sanitary napkin

Abstract

The present application relates to the field of disposable sanitary products, and particularly relates to a preparation method of a light, thin, soft and comfortable air cushion sanitary napkin, comprising the following steps: 1) preparing a liquid permeable surface layer: a, feeding an upper layer in a roll structure; b, feeding a lower layer in a roll structure, and pressing a pattern on the lower layer by an ultrasonic welding assembly, the pattern having grooves; c, applying glue to the lower surface of the upper layer and combining the upper layer with the upper surface of the lower layer; 2) preparing a flow guide layer; 3) preparing an absorbent core layer; 4) preparing a liquid impermeable bottom layer; 5) sequentially combining the liquid permeable surface layer, the flow guide layer, the absorbent core layer and the liquid impermeable bottom layer; 6) applying glue to the back of the product of step 5 at intervals to form a glue application layer; 7) feeding release paper in a roll structure, cutting the release paper and attaching the release paper to the glue application layer; 8) cutting the product of step 7 to form a single sanitary napkin body.

Description

Technical Field

[0001] This invention relates to the field of disposable hygiene products, and more particularly to a method for preparing an air-cushioned sanitary napkin. Background Technology

[0002] Sanitary napkins are commonly used hygiene products for women. Generally, sanitary napkins consist of three layers: a liquid-permeable top layer, an absorbent core layer, and a bottom layer. The liquid-permeable top layer comes into contact with the skin and is used to quickly absorb excrement. The absorbent core layer is responsible for absorbing and locking in excrement. The bottom layer acts as a waterproof barrier to prevent excrement from seeping into underwear, and there is adhesive on the back of the bottom layer for attaching it to underwear.

[0003] Traditional sanitary napkins use a mixture of fluff pulp and superabsorbent resin for their absorbent core, which provides good absorption and diffusion, but is often quite thick. Newer generation sanitary napkins use ultra-thin absorbent paper as the absorbent core, which solves the problem of thickness, but often has a slower absorption speed, is harder overall, and is not soft enough, often feeling like there is a foreign object when using them, resulting in poor comfort. Summary of the Invention

[0004] Therefore, in view of the above problems, the present invention provides a method for preparing a thin, soft and comfortable air cushion sanitary napkin.

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

[0006] A method for preparing an air-cushioned sanitary napkin includes the following steps:

[0007] 1) Preparation of a liquid-permeable surface layer:

[0008] a. Unwind and convey the top layer, which has a roll-like structure, defining the conveying direction along the top layer as the longitudinal direction and the width direction as the transverse direction.

[0009] b. The lower layer, which is in a roll structure, is unwound and conveyed, and an embossed pattern is pressed onto the lower layer by an ultrasonic welding assembly. The embossed pattern has grooves.

[0010] c. Apply adhesive to the lower surface of the upper layer and bond it to the upper surface of the lower layer;

[0011] 2) Prepare the flow guide layer;

[0012] 3) Preparation of the absorber core layer:

[0013] d. The pre-formed absorbent core body is unwound and conveyed, and the absorbent core body is perforated by the absorbent core forming assembly, so that the absorbent core body has perforated areas. Each perforated area is distributed at intervals along the longitudinal direction of the absorbent core body, and each perforated area has at least one cavity.

[0014] e. Unwind and convey the lower layer of hydrophilic fabric, which is in a roll shape, and apply adhesive to its upper surface;

[0015] f. Composite the lower layer of hydrophilic fabric onto the lower surface of the absorbent core body;

[0016] g. Apply superabsorbent polymer particles to each cavity of the product in step f;

[0017] h. Unwind and convey the upper hydrophilic fabric, which is in a roll shape, and apply adhesive to its lower surface;

[0018] i. Lay the upper layer of hydrophilic fabric onto the upper surface of the product from step g;

[0019] 4) Prepare an impermeable liquid-absorbing bottom layer;

[0020] 5) The liquid-permeable surface layer, the flow-guiding layer, the absorbent core layer, and the liquid-impermeable bottom layer are sequentially composited and connected;

[0021] 6) Apply adhesive to the back of the product from step 5 at intervals to form an adhesive layer;

[0022] 7) Unwind and convey the roll-shaped release paper, then cut it and attach it to the sizing layer;

[0023] 8) Cut the product from step 7 into individual sanitary napkin bodies.

[0024] Furthermore, in step h above, after the upper hydrophilic fabric is unwound and conveyed, the upper hydrophilic fabric is pressed to make the upper hydrophilic fabric have concave blind holes, and each of the blind holes is embedded in the cavity.

[0025] Furthermore, in step 2 above, the fabrication process of the flow guide layer is as follows:

[0026] j. Unwind and transport the roll-shaped guide layer body;

[0027] k. The guide layer body is lifted up by the spaced top plates to form a protrusion, and the guide layer body between two adjacent top plates is adsorbed and transported by the adsorption component.

[0028] l. Apply adhesive to one side of the protrusion, and then fold the protrusion toward the side with adhesive by using a folding plate. At the same time as folding, the top plate descends, so that one side of the protrusion adheres to the upper surface of the guide layer body to form a folded part.

[0029] m. Drill holes in the guide layer body in step I between two adjacent folds to form through holes.

[0030] Furthermore, the basis weight of the superabsorbent polymer particles in the cavity located in the same open area gradually decreases from the longitudinal center of the absorbent core layer to both longitudinal sides.

[0031] Furthermore, the basis weight of the superabsorbent polymer particles in the cavity located in the same open area gradually decreases from the transverse center of the absorbent core layer to the transverse sides.

[0032] Furthermore, the absorbent core is a polyurethane sponge.

[0033] Furthermore, the weight of the absorbent core on the absorbent core body is 30g to 50g.

[0034] Furthermore, the thickness of the absorbent core on the absorbent core body is 1mm to 3mm.

[0035] Furthermore, the thickness of both the upper and lower hydrophilic fabrics is 0.05mm to 0.1mm.

[0036] By adopting the aforementioned technical solution, the beneficial effects of the present invention are: the preparation method of this air cushion sanitary napkin is applicable to the production of the above-mentioned air cushion sanitary napkin structure, and has high production efficiency and good product quality. At the same time, it can make minor modifications to the traditional main production line to form a completely new production line and reduce production costs. Attached Figure Description

[0037] Figure 1 This is a top view of the sanitary napkin body in an embodiment of the present invention;

[0038] Figure 2 yes Figure 1 Schematic diagram of the cross-sectional structure at point AA;

[0039] Figure 3 yes Figure 2 A magnified view of a section at point C;

[0040] Figure 4 yes Figure 1 Schematic diagram of the cross-sectional structure at point BB;

[0041] Figure 5 This is a flowchart illustrating the preparation process of the sanitary napkin body in an embodiment of the present invention;

[0042] Figure 6 This is a flowchart illustrating the fabrication process of the flow guiding layer in this embodiment of the invention;

[0043] Figure 7 This is a cross-sectional structural diagram of another state of the sanitary napkin body in an embodiment of the present invention;

[0044] Figure 8 This is a schematic diagram of the structure of the absorber core forming assembly in an embodiment of the present invention. Detailed Implementation

[0045] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0046] The embodiments of the present invention are as follows:

[0047] refer to Figures 1 to 4 As shown, a type of air-cushioned sanitary napkin includes a sanitary napkin body, defined as extending longitudinally along its length and laterally along its width. The sanitary napkin body includes a liquid-permeable top layer 1, a diversion layer 2, an absorbent core layer 3, and a liquid-impermeable bottom layer 4, stacked sequentially from top to bottom. An adhesive layer 5 is provided on the back of the liquid-impermeable bottom layer 4, and a release paper 6 is covered on the adhesive layer 5. The liquid-permeable top layer 1 includes a top layer 11 and a bottom layer 12. The top layer 11 includes ultra-fine denier fibers of 0.6D to 1.0D, and the bottom layer 12 includes fibers of 2.0D to 3.0D. An embossed pattern 13 is pressed onto the bottom layer 12 using an ultrasonic welding process; the embossed pattern has grooves. The top layer 11 is adhered to the upper surface of the bottom layer 12. The absorbent core layer 3 includes an upper hydrophilic fabric 31, a lower hydrophilic fabric 32, and an absorbent core. 33. The absorbent core 33 is a polyurethane sponge. The weight of the absorbent core 33 is 30g to 50g, preferably 35g. The thickness of the absorbent core 33 is 1mm to 3mm, preferably 3mm. The thickness of the upper hydrophilic fabric 31 and the lower hydrophilic fabric 32 is 0.05mm to 0.1mm, preferably 0.08mm. The upper hydrophilic fabric 31 is adhered to the upper surface of the absorbent core 33, and the lower hydrophilic fabric 32 is adhered to the lower surface of the absorbent core 33. The absorbent core 33 has a plurality of cavities 7 in the longitudinal middle. In this embodiment, there are 112 cavities 7. The number of cavities 7 is determined according to the specifications of the sanitary napkin body. The cavities 7 are arranged in an array. The diameter of the opening on the upper surface of each cavity 7 is 0.1mm to 0.5mm. Each cavity 7 is filled with superabsorbent polymer particles 8.

[0048] The upper hydrophilic fabric 31 and the lower hydrophilic fabric 32 mentioned above are hydrophilic nonwoven fabrics.

[0049] This air-cushion sanitary napkin features a double-layer structure design with an upper layer 11 and a lower layer 12 on its liquid-permeable surface layer 1. The lower layer 12 is embossed with a pattern 13 using ultrasonic welding, creating a three-dimensional hollow structure that effectively improves liquid absorption and breathability. The upper layer 11 comprises 0.6D to 1.0D ultra-fine denier fibers, and the lower layer 12 comprises 2.0D to 3.0D fibers, ensuring both softness and durability of the liquid-permeable surface layer 1. Furthermore, the cavity 7 in the longitudinal center of the absorbent core 33 is filled with superabsorbent polymer (SAP) particles 8. This allows the cavity 7 to preferentially collect absorbed urine, which is then locked in by the SAP particles 8. After absorbing water and expanding, the SAP particles 8 fill the cavity 7, thus... The upper surface of the absorbent core 33 forms a flat structure, and the liquid that continues to seep down is guided along the longitudinal direction of the absorbent core layer 3, improving the absorption efficiency of the absorbent core layer 3. Furthermore, the absorbent core 33, made of polyurethane sponge, has a certain degree of elasticity and is thin and light, while also possessing good conductivity, water absorption, and a low reverse osmosis rate, improving the comfort of use. In practical use, due to its elasticity, the volume of the cavity 7 changes during use, facilitating air circulation within the cavity 7 and improving the ventilation effect of the absorbent core 33. It also has a certain water absorption capacity. Under the state of compression and expansion, the superabsorbent polymer particles 8 in the cavity 7 are squeezed into the gaps of the absorbent core 33 and fixed, facilitating the collection of liquid in the cavity 7 in the early stage. At the same time, during subsequent water absorption and expansion, they are squeezed towards the center, ensuring a good liquid seepage effect and improving the utilization rate of the cavity.

[0050] The embossed pattern 13 described above includes several pattern units arranged in an array. In order to improve the aesthetic effect of the product, the pattern units can be designed as regular or irregular shapes in terms of the functional characteristics of the embossed pattern. The regular shape can be a circle, triangle or rectangle, and the irregular shape can be a pearl shape or a leaf shape.

[0051] Furthermore, the volume ratio of the superabsorbent polymer particles 8 located in the same cavity 7 to the volume of the cavity 7 is 1:3 to 6. The weight of the superabsorbent polymer particles 8 gradually decreases from the longitudinal center of the absorbent core layer 3 towards both sides, and also gradually decreases from the transverse center of the absorbent core layer 3 towards both sides. This ensures the absorption efficiency in the center of the absorbent core 33 while reducing the amount of superabsorbent polymer particles 8 used, thus lowering costs. Simultaneously, it improves the liquid's flowability. After rapid water absorption in the central region, because the weight of the superabsorbent polymer particles 8 on the periphery is less than that in the center, they cannot completely fill the cavity 7 after absorbing water and expanding, thus creating a water-retaining effect, maintaining a dry effect in the area in contact with the skin, and increasing the liquid absorption speed.

[0052] In this embodiment, the flow guiding layer 2 has a plurality of longitudinally distributed flow guiding grooves 21. A through hole 22 is provided at the bottom of each flow guiding groove 21 corresponding to the cavity 7. Specifically, the flow guiding layer 2 includes a flow guiding layer body 23. A plurality of folded portions 24 are spaced apart on the flow guiding layer body 23 in the transverse direction. Each folded portion 24 is distributed in the longitudinal direction, such that each folded portion 24 has a first plane 241 and a second plane 242. The first plane 241 is adhered to the upper surface of the flow guiding layer body 23, and the second plane 242 is adhered to the lower surface of the liquid-permeable surface layer 1, forming a gap between two folded portions 24. The guide channel 21 and the through holes 22 are distributed between the two folded portions 24. This facilitates the formation of the guide channel 21. The bottom of the guide channel 21 is separated from the liquid-permeable surface layer 1, and the first plane 241 and the second plane 242 on the folded portion 24 are separated. This creates a hollow structure between the liquid-permeable surface layer 1, the guide layer 2, and the absorbent core layer 3, giving the sanitary napkin a "breathing" breathability and improving comfort. Furthermore, when the superabsorbent polymer particles 8 in the cavity 7 absorb water and expand, blocking the through holes of the guide layer, the longitudinal guiding effect on the guide channel 21 is reduced, ensuring better liquid absorption efficiency.

[0053] The polyurethane foam mentioned above is the product disclosed in Chinese Patent Application No. 202011053611.4, which describes a modified superabsorbent polyurethane foam, its preparation method, and its uses. This is prior art and will not be elaborated further here.

[0054] refer to Figure 5 , Figure 6 and Figure 7 As shown, the preparation method of the above-mentioned air cushion sanitary napkin includes the following steps:

[0055] 1) Preparation of liquid-permeable surface layer 1:

[0056] a. Unwind and transport the upper layer 11, which has a roll-like structure, defining the direction of transport along the upper layer 11 as the longitudinal direction and the direction of its width as the transverse direction.

[0057] b. The lower layer 12, which is in a roll structure, is unwound and conveyed, and an embossed pattern 13 is pressed onto the lower layer by an ultrasonic welding assembly. The embossed pattern 13 has grooves.

[0058] c. Apply adhesive to the lower surface of the upper layer 11 and laminate it onto the upper surface of the lower layer 12;

[0059] 2) Preparation of the flow guide layer 2:

[0060] j. Unwind and transport the roll-shaped guide layer body 23;

[0061] k. The guide layer body 23 is lifted up by the spaced top plates 91 to form a protrusion 92, and the guide layer body 23 between two adjacent top plates 91 is adsorbed and transported by the adsorption component 93.

[0062] 1. Apply adhesive to one side of the protrusion 92, and then fold the protrusion 92 toward the side with adhesive by the folding plate 94. At the same time as folding, the top plate 91 descends, so that one side of the protrusion 92 adheres to the upper surface of the guide layer body 23, forming the folded part 24.

[0063] m. Drill holes in the guide layer body 23 between two adjacent folds 24 in step I to form through holes 22.

[0064] 3) Preparation of absorber core layer 3:

[0065] d. The pre-formed absorbent core body 33 is unwound and conveyed, and the absorbent core body 33 is perforated by the absorbent core forming assembly 100, so that the absorbent core body 33 has perforated areas a, each perforated area a is distributed at intervals along the longitudinal direction of the absorbent core body 33, and each perforated area a has at least one cavity 7.

[0066] e. Unwind and convey the lower layer hydrophilic fabric 32, which has a roll structure, and apply adhesive to its upper surface;

[0067] f. Composite the lower layer of hydrophilic fabric 32 onto the lower surface of the absorbent core body 33;

[0068] g. Apply superabsorbent polymer particles 8 into each cavity 7 of the product in step f;

[0069] h. Unwind and convey the upper hydrophilic fabric 31, which is in a roll shape, and apply adhesive to its lower surface;

[0070] i. Lay the upper hydrophilic fabric 31 onto the upper surface of the product in step g;

[0071] 4) Prepare an impermeable liquid-absorbing bottom layer 4;

[0072] 5) The liquid-permeable surface layer 1, the flow guiding layer 2, the absorbent core layer 3, and the liquid-impermeable bottom layer 4 are sequentially bonded together;

[0073] 6) Apply adhesive to the back of the product from step 5 at intervals to form adhesive layer 5;

[0074] 7) Unwind and convey the roll-shaped release paper 6, and then cut and attach it to the sizing layer 5;

[0075] 8) Cut the product from step 7 into individual sanitary napkin bodies.

[0076] The preparation method of this air cushion sanitary napkin is applicable to the production of the above-mentioned air cushion sanitary napkin structure, and has high production efficiency and good product quality. At the same time, it can be slightly modified within the traditional main production line to form a completely new production line, thereby reducing production costs.

[0077] Furthermore, in step e above, after the lower hydrophilic fabric 32 is unwound and conveyed, the lower hydrophilic fabric 32 is pressed to give it concave blind holes 320. Each of the blind holes 320 is embedded in the cavity 7, so that the superabsorbent polymer particles 8 added to the cavity 7 are located in the middle of the cavity 7. The seeping liquid can be absorbed by the superabsorbent polymer particles 8 more quickly, improving the absorption efficiency. In addition, the superabsorbent polymer particles 8 located in the middle can extend to the upper and lower sides during water absorption and expansion, giving them a buffer space, which can improve the absorption amount and absorption efficiency of the superabsorbent polymer particles 8.

[0078] In this embodiment, reference Figure 8 As shown, the absorbent core forming assembly 100 includes a frame, a feeding bin 101 and a cleaning device 102 fixed on the frame, and feeding rollers 103, first guide rollers 104, second guide rollers 105, third guide rollers 106, cutter rollers 107, concave rollers 108, convex rollers 109, pressure rollers 110, and bottom rollers 111 rotatably mounted on the frame. The feeding roller 103 is located below the discharge port of the feeding bin 101 and has a storage trough 112 for storing superabsorbent polymer granules 8. The convex roller 109 is located below the feeding roller 103 and has at least one protrusion 113. The number of protrusions corresponds to the number of cavities 7 on the absorbent core 33. The concave roller 108 is located below the convex roller 107. On the periphery of 9, the concave roller 108 has a concave hole 114 that mates with the protrusion 113. The cutting roller 107 is located on the periphery of the concave roller 108 and has a cutting blade 115 that mates with the concave hole 114 for cutting the cavity 7. The first guide roller 104 is located at the input end of the cutting roller 107 and the concave roller 108. The second guide roller 105 is located at the input end of the concave roller 108 and the protruding roller 109. The third guide roller 106 is located at the output end of the feeding roller 103 and the protruding roller 107. The pressure roller 110 and the bottom roller 111 are located at the output end of the third guide roller 106 and the protruding roller 109. The pressure roller 110 is located on the upper side of the bottom roller 111. The cleaning device 102 is located on the periphery of the cutting roller 107 for removing waste material from the cutting roller 107.

[0079] The aforementioned cleaning device 102 has a negative pressure adsorption function and is capable of removing waste material adhering to the cutter roller 107. It is existing technology and will not be described in detail here.

[0080] In use, the absorbent core 33 is guided by the first guide roller 104 into the space between the cutter roller 107 and the concave roller 108. The cutter 115 on the cutter roller 107 engages with the concave hole 114 on the concave roller 108 to cut and shape the cavity 7 on the absorbent core 33. The absorbent core 33 is then conveyed by the concave roller 108. The lower hydrophilic fabric 32 is guided by the second guide roller 105 into the space between the concave roller 108 and the convex roller 109. The convex roller 109 uses the protrusions 113 to squeeze the corresponding area of ​​the lower hydrophilic fabric 32 into the cavity 7 of the absorbent core 33. The convex roller 109 then drives the lower hydrophilic fabric 32 and the absorbent core... The absorbent core 33 is conveyed synchronously. Then, the superabsorbent polymer granules 8 in the feeding bin 101 are fed into the storage tank 112 on the feeding roller 103. The feeding roller 103 rotates to transfer the superabsorbent polymer granules 8 in the storage tank 112 to the cavity 7 of the absorbent core 33. The upper hydrophilic fabric 31 is guided to the pressure roller 110 and the bottom roller 111 through the third guide roller 106. The pressure roller 110 and the bottom roller 111 fix the upper hydrophilic fabric 31, the absorbent core 33 and the lower hydrophilic fabric 32 together. This absorbent core molding assembly has a simple structure and high production precision, ensuring good product quality.

[0081] 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 method for preparing an air-cushioned sanitary napkin, characterized in that: Includes the following steps: 1) Preparation of a liquid-permeable surface layer: a. Unwind and convey the top layer, which has a roll-like structure, defining the conveying direction along the top layer as the longitudinal direction and the width direction as the transverse direction. b. The lower layer, which is in a roll structure, is unwound and conveyed, and an embossed pattern is pressed onto the lower layer by an ultrasonic welding assembly. The embossed pattern has grooves. c. Apply adhesive to the lower surface of the upper layer and bond it to the upper surface of the lower layer; 2) Preparation of the flow guide layer: j. Unwind and transport the roll-shaped guide layer body; k. The guide layer body is lifted up by the spaced top plates to form a protrusion, and the guide layer body between two adjacent top plates is adsorbed and transported by the adsorption component. l. Apply adhesive to one side of the protrusion, and then fold the protrusion toward the side with adhesive by using a folding plate. At the same time as folding, the top plate descends, so that one side of the protrusion adheres to the upper surface of the guide layer body to form a folded part. m. Drill holes in the guide layer body in step I between two adjacent folds to form through holes; 3) Preparation of the absorber core layer: d. The pre-formed absorbent core body is unwound and conveyed, and the absorbent core body is perforated by the absorbent core forming assembly, so that the absorbent core body has perforated areas. Each perforated area is distributed at intervals along the longitudinal direction of the absorbent core body, and each perforated area has at least one cavity. e. Unwind and convey the lower layer of hydrophilic fabric, which is in a roll shape, and apply adhesive to its upper surface; f. Composite the lower layer of hydrophilic fabric onto the lower surface of the absorbent core body; g. Apply superabsorbent polymer particles to each cavity of the product in step f; h. Unwind and convey the upper hydrophilic fabric, which is in a roll shape, and apply adhesive to its lower surface; i. Lay the upper layer of hydrophilic fabric onto the upper surface of the product from step g; 4) Prepare an impermeable liquid-absorbing bottom layer; 5) The liquid-permeable surface layer, the flow-guiding layer, the absorbent core layer, and the liquid-impermeable bottom layer are sequentially composited and connected; 6) Apply adhesive to the back of the product from step 5 at intervals to form an adhesive layer; 7) Unwind and convey the roll-shaped release paper, then cut it and attach it to the sizing layer; 8) Cut the product from step 7 into individual sanitary napkin bodies.

2. The method for preparing the air-cushion sanitary napkin according to claim 1, characterized in that: In step e above, after the lower hydrophilic fabric is unwound and conveyed, the lower hydrophilic fabric is pressed to make it have concave blind holes, and each of the blind holes is embedded in the cavity.

3. The method for preparing the air-cushion sanitary napkin according to claim 2, characterized in that: The basis weight of the superabsorbent polymer particles in the cavity located in the same open area gradually decreases from the longitudinal center of the absorbent core layer to both longitudinal sides.

4. The method for preparing the air-cushion sanitary napkin according to claim 3, characterized in that: The basis weight of the superabsorbent polymer particles in the cavity located in the same open area gradually decreases from the transverse center of the absorbent core layer to the transverse sides.

5. The method for preparing an air-cushioned sanitary napkin according to claim 1, characterized in that: The absorbent core is a polyurethane sponge.

6. The method for preparing an air-cushioned sanitary napkin according to claim 5, characterized in that: The weight of the absorbent core on the absorbent core body is 30g to 50g.

7. The method for preparing an air-cushion sanitary napkin according to claim 6, characterized in that: The thickness of the absorbent core on the absorbent core body is 1mm to 3mm.

8. The method for preparing an air-cushion sanitary napkin according to claim 1, characterized in that: The thickness of both the upper and lower hydrophilic fabrics is 0.05mm to 0.1mm.

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