Sanitary article containing nanofibers

Abstract

A disposable hygiene article comprising a topsheet and a nanofiber layer, the topsheet comprising a perforated hydrophilic nonwoven fabric layer, wherein the perforated hydrophilic nonwoven fabric layer has a plurality of apertures and a skin-facing surface and a garment-facing surface opposite the skin-facing surface; the nanofiber layer is disposed on the garment-facing surface of the perforated hydrophilic nonwoven fabric layer, wherein the nanofiber layer has densely packed nanofibers disposed between at least a portion of the plurality of apertures and loosely packed nanofibers disposed on at least a portion of the plurality of apertures.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application 63 / 369,264, filed July 25, 2022, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to disposable hygiene products. More specifically, this disclosure relates to disposable hygiene products comprising a nanofiber layer capable of controlled release of active ingredients onto the wearer's skin and improving fluid retention and redistribution. Background Technology

[0004] Disposable hygiene products such as diapers, training pants, incontinence clothing, adult incontinence pads, and feminine hygiene products are typically in close contact with the wearer's skin to absorb bodily fluids. These fluids can expose the wearer's skin to biological and physical irritants. Prolonged exposure to these irritants can lead to dermatitis, inflammation, and discomfort for the wearer.

[0005] Disposable hygiene products containing highly efficient absorbent cores have been developed, which are configured to rapidly transfer fluid from the wearer's body to the core, partially addressing issues of skin irritation and wearer comfort. However, prolonged use of such disposable hygiene products may still lead to skin irritation due to friction between the skin and the nonwoven materials typically used in disposable hygiene products.

[0006] Single-use hygiene products have been developed that are formulated to release active ingredients that can treat and / or prevent skin irritation and related complications. However, such single-use hygiene products may experience a sudden release of the active ingredients upon exposure to bodily fluids.

[0007] Therefore, there is a need for improved disposable hygiene products that overcome at least some of the aforementioned drawbacks. Summary of the Invention

[0008] This invention generally relates to disposable hygiene products that improve the redistribution and retention of bodily fluids and enable the controlled release of an active ingredient that can be used to soothe the skin, protect the skin from irritation or infection, and / or promote the healing of rashes / broken skin.

[0009] In a first aspect, this document provides a disposable hygiene product comprising: a topsheet including a perforated hydrophilic nonwoven fabric layer, wherein the perforated hydrophilic nonwoven fabric layer includes a plurality of pores and a skin-facing surface and a clothing-facing surface opposite to the skin-facing surface; and a nanofiber layer disposed on the clothing-facing surface of the perforated hydrophilic nonwoven fabric layer, wherein the nanofiber layer includes densely packed nanofibers disposed between at least a portion of the plurality of pores; and loosely packed nanofibers disposed on at least a portion of the plurality of pores, wherein the densely packed nanofibers are spaced at 100 μm / s. 3 The nanofibers exist at a density of 20-30 per 100 μm, and the loosely packed nanofibers are distributed at a density of 100 μm. 3 The density of 5-10 nanofibers exists in the middle.

[0010] In some embodiments, the densely packed nanofibers and the loosely packed nanofibers have an average diameter of 100 to 1,000 nm.

[0011] In some embodiments, each of the plurality of holes has a diameter of 100-1,000 μm.

[0012] In some embodiments, the plurality of holes have an inter-hole distance of 100-1,000 μm.

[0013] In some embodiments, the densely packed nanofibers and the loosely packed nanofibers comprise polymers selected from the group consisting of: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymer of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), polylactic-co-glycolic acid (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and combinations thereof.

[0014] In some embodiments, the perforated hydrophilic nonwoven fabric layer comprises microfibers having an average diameter of 10 to 30 μm.

[0015] In some embodiments, the perforated hydrophilic nonwoven fabric layer comprises polyethylene, polypropylene, or a combination thereof.

[0016] In some embodiments, the nanofiber layer further includes an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

[0017] In some embodiments, the active ingredient is selected from the group consisting of: calamine, dimethylsiloxane, kaolin, lanolin, petrolatum, talc, corn starch, white petrolatum, zinc oxide, silver, copper, copper oxide, titanium oxide, iodine, triclosan, polyethylene glycol (PEG), sodium alginate, and mixtures thereof.

[0018] In some embodiments, the microfibers have an average diameter of 10 to 30 μm; the densely packed nanofibers and the loosely packed nanofibers have an average diameter of 100 to 1,000 nm; the plurality of pores have an inter-pore distance of 100-1,000 μm; the densely packed nanofibers and the loosely packed nanofibers comprise polymers selected from the group consisting of polymers including: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymers of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), polylactic acid-co-glycolic acid (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and combinations thereof; and the top sheet comprises a nonwoven material comprising fibers containing polyethylene, polypropylene, or combinations thereof.

[0019] In some embodiments, the nanofiber layer further includes an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

[0020] In some embodiments, the disposable hygiene product of the first aspect further includes: a backsheet; and an absorbent core disposed between the backsheet and the nanofiber layer, wherein the absorbent core comprises a superabsorbent polymer (SAP).

[0021] In some embodiments, the backsheet comprises polypropylene, polyethylene, nylon, polyester, or a combination thereof.

[0022] In some embodiments, the SAP comprises sodium polyacrylate.

[0023] In some embodiments, the microfibers have an average diameter of 10 to 30 μm; the densely packed nanofibers and the loosely packed nanofibers have an average diameter of 100 to 1,000 nm; the plurality of pores have an inter-pore distance of 100-1,000 μm; the densely packed nanofibers and the loosely packed nanofibers comprise polymers selected from the group consisting of polymers including: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymers of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), polylactic acid-co-glycolic acid (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and combinations thereof; and the top sheet comprises a nonwoven material comprising fibers containing polyethylene, polypropylene, or combinations thereof.

[0024] In some embodiments, the nanofiber layer further includes an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

[0025] In some embodiments, the active ingredient is selected from the group consisting of: calamine, dimethylsiloxane, kaolin, lanolin, petrolatum, talc, corn starch, white petrolatum, zinc oxide, silver, copper, copper oxide, titanium oxide, iodine, triclosan, polyethylene glycol (PEG), sodium alginate, and mixtures thereof.

[0026] In a second aspect, this article provides a diaper that includes the disposable hygiene product of the first aspect.

[0027] In a third aspect, this document provides a diaper comprising any of the disposable hygiene products described herein. Attached Figure Description

[0028] The above and other objects and features of this disclosure will become apparent when taken in conjunction with the accompanying drawings and the following description of this disclosure.

[0029] Figure 1 This is a schematic diagram of a disposable sanitary product according to certain embodiments described herein.

[0030] Figure 2 It is a scanning electron microscope (SEM) image showing the top sheet of a disposable hygiene product.

[0031] Figure 3 These are SEM images showing densely packed and loosely packed nanofibers on a perforated hydrophilic nonwoven fabric set on a top sheet.

[0032] Figure 4 These are SEM images showing densely packed and loosely packed nanofibers on pores in a perforated hydrophilic nonwoven fabric set on a top sheet.

[0033] Figure 5 This is a schematic diagram of a disposable sanitary product according to certain embodiments described herein.

[0034] Figure 6 This is a cross-sectional view of a disposable sanitary product according to certain embodiments described herein.

[0035] Figure 7 This is a view illustrating the advantages of disposable hygiene products according to certain embodiments described herein compared to conventional hygiene products.

[0036] Figure 8 This is a schematic diagram of a nanofiber layer and a perforated hydrophilic nonwoven fabric layer according to certain embodiments described herein.

[0037] Figure 9 This is a schematic diagram of an exemplary apparatus for manufacturing a top sheet by electrospinning, according to certain embodiments described herein.

[0038] Figure 10 This is a graph showing the experimental results of controlled release of the active ingredient from the nanofiber layer according to certain embodiments described herein. Detailed Implementation

[0039] definition

[0040] Throughout the application, when a composition is described as having, containing, or including specific components, or when a process is described as having, containing, or including specific process steps, it is contemplated that the compositions of this teaching may also consist of or be substantially composed of the described components, and the processes of this teaching may also consist of or be substantially composed of the described process steps.

[0041] In this application, when an element or component is referred to as being included in and / or selected from the list of described elements or components, it should be understood that the element or component can be any one of the described elements or components, or the element or component can be selected from a group consisting of two or more of the described elements or components. Furthermore, it should be understood that the elements and / or features of the compositions or methods described herein can be combined in various ways, whether express or implied herein, without departing from the spirit and scope of this teaching.

[0042] It should be understood that the order of steps or the sequence of certain actions is not important as long as this instruction remains operational. Furthermore, two or more steps or actions can be performed simultaneously.

[0043] Unless otherwise specified, the use of the singular in this document includes the plural (and vice versa). Furthermore, unless otherwise specified, when the term “about” is used before a quantity, this teaching also includes the specific quantity itself. As used herein, the term “about” means a change of ±10%, ±7%, ±5%, ±3%, ±1%, or ±0% relative to a nominal value, unless otherwise indicated or implied.

[0044] The terms "skin-facing surface" and "skin-facing side" refer to the surface of a hygiene product and / or its components that faces the wearer's skin when worn, while the terms "clothing-facing surface" and "clothing-facing side" refer to the surface of an absorbent product and / or its components that faces away from the wearer's skin when worn. Hygiene products and their components (including any individual material comprising a topsheet, nanofiber layer, backsheet, absorbent core, and its components) have a skin-facing surface and / or side as well as a clothing-facing surface and / or side.

[0045] refer to Figure 1 This disclosure provides a disposable hygiene product 100, comprising: a top sheet 110 including a perforated hydrophilic nonwoven fabric layer, wherein the perforated hydrophilic nonwoven fabric layer includes a plurality of pores and a skin-facing surface 111 and a clothing-facing surface 112 opposite to the skin-facing surface; and a nanofiber layer 120 disposed on the clothing-facing surface of the perforated hydrophilic nonwoven fabric layer, wherein the nanofiber layer 120 includes densely packed nanofibers disposed between at least a portion of the plurality of pores; and loosely packed nanofibers disposed on at least a portion of the plurality of pores, wherein the densely packed nanofibers are spaced at 100 μm per pore. 3 The nanofibers exist at a density of 20-30 per 100 μm, and the loosely packed nanofibers are distributed at a density of 100 μm. 3 The density of 5-10 nanofibers exists in the middle.

[0046] Perforated hydrophilic nonwoven fabric layers can be made from any suitable, relatively liquid-permeable material known in the art that allows liquids to pass through. Examples of suitable perforated hydrophilic nonwoven fabric layer materials include nonwoven spunbond or carded webs of polypropylene, polyethylene, nylon, polyester, and blends of these materials.

[0047] In examples where the perforated hydrophilic nonwoven fabric layer is prepared from a hydrophobic polymer such as polypropylene, or from a perforated hydrophobic nonwoven fabric layer comprising a hydrophobic polymer, the hydrophobic polymer or surface of the perforated hydrophobic nonwoven fabric layer can be treated, for example, by plasma treatment to increase the hydrophilicity of the polymer or surface of the perforated hydrophobic nonwoven fabric layer. Besides plasma treatment, hydrophilic modification of the nonwoven fabric layer can also be achieved by altering the fabric preparation process or by modifying the surface of the hydrophobic polymer fabric through thin-layer deposition, graft polymerization, physical modification, or combinations thereof.

[0048] In some embodiments, the perforated hydrophilic nonwoven fabric layer comprises plasma-treated polypropylene to increase surface hydrophilicity.

[0049] The perforated hydrophilic nonwoven fabric layer comprises microfibers with average diameters of 10 to 30 μm, 12 to 28 μm, 14 to 26 μm, 16 to 24 μm, 18 to 24 μm, 18 to 22 μm, 20 to 22 μm, 10 to 25 μm, 10 to 20 μm, 10 to 15 μm, 15 to 30 μm, 20 to 30 μm, or 25 to 30 μm. In some embodiments, the perforated hydrophilic nonwoven fabric layer comprises microfibers with an average diameter of about 20 μm.

[0050] Each of the multiple pores present in the perforated hydrophilic nonwoven fabric layer may have a diameter of 100-1,000 μm, 200-900 μm, 300-800 μm, 400-700 μm, 500-600 μm, 100-900 μm, 100-800 μm, 100-700 μm, 100-600 μm, 100-500 μm, 200-1,000 μm, 300-1,000 μm, 400-1,000 μm, 500-1,000 μm, 200-900 μm, 300-800 μm, 400-700 μm, 400-600 μm, or 450-550 μm. In some embodiments, each of the plurality of pores present in the perforated hydrophilic nonwoven fabric layer is about 500 μm.

[0051] The interpore distance of the perforated hydrophilic nonwoven fabric layer can be 100-1,000 μm, 200-900 μm, 300-800 μm, 400-700 μm, 500-600 μm, 100-900 μm, 100-800 μm, 100-700 μm, 100-600 μm, 100-500 μm, 200-1,000 μm, 300-1,000 μm, 400-1,000 μm, 500-1,000 μm, 200-900 μm, 300-800 μm, 400-700 μm, 400-600 μm, or 450-550 μm. In some embodiments, the interpore distance of the perforated hydrophilic nonwoven fabric layer is approximately 500 μm.

[0052] The densely packed and loosely packed nanofibers in the nanofiber layer may include one or more polymers selected from the group consisting of: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymers of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), poly(lactic-co-glycolic acid) (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and blends and copolymers thereof. In some embodiments, the nanofiber layer may include one or more polymers selected from the group consisting of: PA6, PAN, n-PAN, and blends and copolymers thereof.

[0053] The densely packed and loosely packed nanofibers in the nanofiber layer can have diameters ranging from 100 to 1,000 nm. In some embodiments, the densely packed and loosely packed nanofibers in the nanofiber layer have diameters of 200-900 nm, 300-900 nm, 400-900 nm, 500-900 nm, 600-900 nm, 700-900 nm, 800-900 nm, 200-800 nm, 300-800 nm, 400-700 nm, 500-600 nm, 100-300 nm, or 700-900 nm. In some embodiments, the densely packed and loosely packed nanofibers in the nanofiber layer have diameters of about 200 nm or about 800 nm.

[0054] Densely packed nanofibers can be stacked at 100 μm 3The nanofibers are present at densities of 20-30, 21-29, 22-28, 23-27, 24-26, 20-25, or 25-30 nanofibers. In some embodiments, the densely packed nanofibers can be at densities of 100 μm. 3 There are approximately 20 or 30 nanofibers in the middle.

[0055] Loosely packed nanofibers can be stacked at 100 μm 3 The nanofibers are present at densities of 5-10, 6-9, 7-8, 5-7, or 7-10. In some embodiments, the loosely packed nanofibers can be at densities of 100 μm. 3 The density is approximately 5 to 10 nanofibers.

[0056] In some embodiments, the nanofiber layer disposed on the clothing-facing surface of the perforated hydrophilic nonwoven fabric layer has a thickness between 0.7 and 0.8 mm.

[0057] The nanofiber layer deposited on the surface of the perforated hydrophilic nonwoven fabric facing the garment can have a density of 20-100 g / m². 2 30-90g / m 2 40-80g / m 2 50-70g / m 2 20-50g / m 2 Or 50-100g / m 2 The base weight.

[0058] In some embodiments, when tested at a surface velocity of 5.3 cm / s, the nanofiber layer disposed on the clothing-facing surface of the perforated hydrophilic nonwoven fabric layer exhibits a pressure drop of 0.5-10, 0.5-9, 0.5-8, 0.5-7, 0.5-6, 0.5-5, 0.5-4, 0.5-3, 0.5-2, or 0.5-1 mm H2O.

[0059] Advantageously, the nanofiber layer may further comprise an active ingredient that can soothe the skin, protect it from irritation or infection, and / or promote the healing of rashes / broken skin. In some embodiments, the nanofiber layer further comprises an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

[0060] In some embodiments, the ingredients are selected from the group consisting of: calamine, dimethylsiloxane, kaolin, lanolin, petrolatum, talc, corn starch, white petrolatum, zinc oxide, silver, copper, copper oxide, titanium oxide, iodine, triclosan, polyethylene glycol (PEG), sodium alginate, and mixtures thereof.

[0061] The active ingredient can be pre-embedded in the nanofiber layer at a concentration of 0.1-50 wt / wt% relative to the weight of the densely packed nanofiber polymer, the loosely packed nanofiber polymer, and the active ingredient. In some embodiments, the active ingredient is pre-embedded in the nanofiber layer at concentrations of 5-50 wt / wt%, 10-50 wt / wt%, 15-50 wt / wt%, 20-50 wt / wt%, 25-50 wt / wt%, 30-50 wt / wt%, 35-50 wt / wt%, 40-50 wt / wt%, or 45-50 wt / wt% relative to the weight of the densely packed nanofiber polymer, the loosely packed nanofiber polymer, and the active ingredient. In some embodiments, the active ingredient is preset in the nanofiber layer at concentrations of 14.2-33 wt / wt%, 14.2-29.4 wt / wt%, 16.67-29.4 wt / wt%, 14.2-16.67 wt / wt%, 16.67-33 wt / wt%, or 29.4-33 wt / wt%, relative to the weight of the densely packed nanofiber polymer, the loosely packed nanofiber polymer, and the active ingredient.

[0062] The nanofiber layer can stabilize and maintain the properties of active ingredients in the absence of moisture, and release active ingredients in a controlled manner without sudden release in the presence of moisture, while redistributing fluids over a larger area of ​​the absorbent core, thereby improving absorption.

[0063] The nanofiber layer also increases the rate of fluid absorption and helps redistribute the fluid within the absorbent core, which reduces backflow.

[0064] Figure 2 A scanning electron microscope (SEM) image of the top sheet 110 is shown. The top sheet 110 includes a perforated hydrophilic nonwoven fabric 150. The perforated hydrophilic nonwoven fabric 150 includes microfibers and nanofibers disposed on the surface of the hydrophilic nonwoven fabric. The microfibers are observed in the SEM image at a scale bar of 50 μm. The nanofibers are observed in the SEM image at a scale bar of 10 μm.

[0065] Figure 3 SEM images with a scale bar of 10 μm are shown, in which microfibers and nanofibers can be observed. Nanofibers 300 include densely packed nanofibers 310 located on microfibers 200 and loosely packed nanofibers 320 located on perforations of a hydrophilic nonwoven fabric.

[0066] Figure 4SEM images with a scale bar of 100 μm are shown, in which pores in the hydrophilic nonwoven fabric layer can be observed. Densely packed nanofibers 310 are located on the surface of the perforated hydrophilic nonwoven fabric layer between at least a portion of the pores 160. Loosely packed nanofibers 320 are located on at least a portion of the plurality of pores 160.

[0067] refer to Figure 5 In some embodiments, the disposable hygiene product further includes a backing sheet 140 and an absorbent core 130 disposed between the backing sheet 140 and the nanofiber layer 120.

[0068] An absorbent core 130, disposed between the nanofiber layer 120 and the backing sheet 140, absorbs and retains bodily fluids that have permeated the top sheet. The absorbent core can employ any absorbent means capable of absorbing or retaining bodily fluids. The absorbent core can be manufactured in various sizes and shapes (e.g., rectangular, elliptical, asymmetrical, etc.) and made from a variety of liquid absorbent materials commonly used in the manufacture of absorbent articles, such as pulverized wood pulp. Examples of other suitable absorbent materials include, but are not limited to, wrinkled cellulose fillers; meltblown polymers; chemically hardened, modified, or cross-linked cellulose fibers; synthetic fibers, such as crimped polyester fibers; peat moss; paper towels containing tissue wraps and tissue laminates; absorbent foams; and absorbent sponges. In some embodiments, the absorbent core comprises a nonwoven fiber material selected from the group consisting of: polyester, polyethylene terephthalate, polyethylene, polypropylene, polyethylene terephthalate / polyethylene, polyethylene terephthalate / polypropylene, polypropylene / polyethylene, PLA, PLA / polypropylene, PVA, viscose, cotton, wool, ester acetate, polyvinyl chloride, bamboo, polyacrylic acid / polyvinyl chloride and copolymers and blends thereof.

[0069] The absorber core 130 may further include SAP 131 ( Figure 6 (As shown in the figure). There are no particular limitations on the type of SAP. In some embodiments, SAP is polyacrylate, polymethacrylate, or mixtures and / or copolymers thereof. Exemplary SAPs include, but are not limited to, sodium polyacrylate, sodium polymethacrylate, potassium polyacrylate, potassium polymethacrylate, starch-grafted polyacrylate, starch-grafted polymethacrylate, polyvinyl alcohol-grafted polyacrylate, polyvinyl alcohol-grafted polymethacrylate, cellulose-grafted polyacrylate, cellulose-grafted polymethacrylate, etc.

[0070] Various backsheet constructions and materials are available and known in the art, and this disclosure is not intended to limit it to any particular material or construction of these components. Backsheet 140 can be made of any suitable flexible, liquid-impermeable material known in the art. Exemplary backsheet materials include, but are not limited to, films of polyethylene, polypropylene, polyester, nylon, and polyvinyl chloride, as well as blends of these materials.

[0071] Figure 6 This is a cross-sectional view of a disposable sanitary product according to certain embodiments. Figure 5 In contrast, the disposable hygiene product further includes a collection distribution layer (ADL) 132 disposed between the nanofiber layer 120 and the absorbent core 130. The ADL 132 may include a hydrophilic mesh to ensure faster liquid entry into the absorbent core 130. The ADL 132 may include fibers selected from the group consisting of polyesters, copolyesters, polypropylene, polyethylene, polylactic acid, polyamides, copolymers and mixtures thereof.

[0072] The various components of the disposable hygiene product described herein can be adhered using adhesive means 190, such as glue. For example, glue can be used to adhere one or more of the nanofiber layer 120, ADL 132, absorbent core 130, and backing sheet 140 together. Optionally, a separate breathable sheet layer 133 can be provided between the absorbent core 130 and the backing sheet 140.

[0073] The disposable hygiene products described herein can be manufactured in a configuration capable of absorbing large amounts of water and bodily fluids such as urine, feces, menstrual blood, blood, and other excretions. Such products include, but are not limited to, diapers, training pants, incontinence clothing, adult incontinence pads, feminine hygiene pads, feminine hygiene underwear, panty liners, maternity pads, disposable sheets, wound dressings, etc.

[0074] Figure 7 This illustrates the advantages achieved by the disposable hygiene product described herein (right) compared to conventional hygiene products (left). Conventional hygiene products, such as diapers, are prone to backflow when the central portion 135 of the absorbent core 130 becomes saturated. This can slow absorption when fluid is repeatedly added. The nanofiber layer 120 disposed on the top sheet 110 increases the rate of fluid absorption and helps redistribute the fluid within the absorbent core 130, which can reduce backflow. The nanofiber layer 120 may include active ingredients for soothing and protecting the skin from irritation or infection.

[0075] The disposable hygiene products described herein can be manufactured using conventional methods well known to those skilled in the art.

[0076] Perforated hydrophilic nonwoven fabric layers can be readily manufactured using well-known methods. In some embodiments, the perforated hydrophilic nonwoven fabric layers are prepared by hot air bonding. In such instances, the hot air nonwoven fabric is formed from carded short fibers, and hot air from a drying apparatus is used to penetrate the web, which is then heated and bonded.

[0077] In addition to hot air bonding, perforated hydrophilic nonwoven fabric layers can also be manufactured by spunbonding. During spunbonding, after the polymer is extruded and stretched to form continuous filaments, the filaments are laid into a web, and then the web is subjected to self-bonding, thermal bonding, chemical bonding, or mechanical reinforcement to form a nonwoven fabric.

[0078] Then, the perforated hydrophilic nonwoven fabric layer can be loaded onto the electrospinning device, so that loosely packed nanofibers and densely packed nanofibers can be deposited onto the perforated hydrophilic nonwoven fabric layer during the electrospinning process.

[0079] Figure 8 The nanofiber layer 120 and the perforated hydrophilic nonwoven fabric layer 150 are schematically shown. The nanofiber layer 120 can be deposited on the hydrophilic nonwoven fabric layer 150 by a free-surface electrospinning process, which includes: providing a solution comprising a polymer solution; applying an electric field to the polymer solution to form nanofibers; and depositing the nanofibers on the clothing-facing surface of the hydrophilic nonwoven fabric layer to form a nanofiber layer disposed on the clothing-facing surface of the perforated hydrophilic nonwoven fabric layer.

[0080] Figure 9 A horizontal schematic diagram of an apparatus for manufacturing the topsheet 110 described herein by electrospinning, according to certain embodiments, is shown. Nanofibers can be obtained by electrospinning a polymer solution 410, which optionally includes one or more active ingredients. Unlike conventional electrospinning processes that produce a substrate layer for nanofiber deposition, the method described herein can be used to prepare the topsheet 110, which includes a perforated hydrophilic nonwoven fabric layer 150 and a nanofiber layer 120 disposed on the garment-facing surface of the perforated hydrophilic nonwoven fabric layer 150. Figure 9 As shown, the top sheet 110 includes a top layer 170 and a bottom layer 180. The top layer 170 is located near the negatively charged collection electrode 420. The top layer 170 is a nonwoven fabric, which may have 10 12 The resistance of the thin film is ohms per square meter. The bottom layer 180 is located away from the negatively charged collecting electrode 420. The bottom layer 180 can be a perforated hydrophilic nonwoven fabric 150, which can have 10 ohms per square meter. 9 The resistance of the thin film is ohms per square meter. The bottom layer 180 can become negatively charged through a triboelectric process. During the electrospinning process, nanofibers can be deposited on the surface of the bottom layer.

[0081] During the electrospinning process, a positive charge can be induced at the top layer 170 due to the presence of the negatively charged collecting electrode 420. During electrospinning, the polymer solution 410 becomes charged due to the strong positive voltage provided by the positively charged spinning electrode 430. A Taylor cone is formed on the positively charged spinning electrode 430, and positive charge accumulates on the surface. When the electric field force applied to the Taylor cone overcomes the surface tension, the polymer jet is pulled out from the Taylor cone. After solvent evaporation and polymer jet solidification, nanofibers are deposited onto the bottom layer 180. As the nanofibers approach the bottom layer 180, the nanofiber density is affected by the charge distribution on the bottom layer 180. The top layer 170 with induced positive charge can repel most of the nanofibers through the pores in the bottom layer 180, resulting in a loosely packed nanofiber on the pores. On the other hand, the negative charge between the pores in the bottom layer partially cancels out the positive charge in the top layer, resulting in minimal charge repulsion and thus a densely packed nanofiber between the pores.

[0082] Performance Evaluation: Four Characteristics Used for Evaluation of Diapers with and without Nanofibers

[0083] Diapers containing nanofibers (specifically, loosely packed nanofibers on pores) and corresponding diapers without nanofibers were evaluated based on the following four characteristics: (1) absorption time upon first liquid addition, (2) absorption time upon second liquid addition, (3) rewetting, and (4) leakage. Absorption time was defined as the time required for the diaper to absorb a specific amount of test solution. Rewetting was defined as the amount of test solution that returns to the top layer of the diaper (closer to the wearer's skin) under a specific pressure after the diaper has absorbed a specific amount of test solution. Leakage was defined as the amount of test solution that permeates through the backing layer of the diaper (away from the wearer's skin) under a specific pressure after the diaper has absorbed a specific amount of test solution.

[0084] Example

[0085] Example 1: Used to evaluate the absorption time of the first liquid addition and the absorption time of the second liquid addition. Assessment procedures for reinfiltration and leakage

[0086] The following procedure should be used to evaluate diapers:

[0087] 1. Place the diaper on a sheet lined with absorbent paper (basic weight 140-150g / m²). 2 On the sample rack (with a water absorption rate of not less than 480%).

[0088] 2. Place the dosing module onto the absorbent area of ​​the diaper surface.

[0089] 3. Under a certain pressure (1.8-2.2 kPa), inject a certain volume (40 mL) of physiological saline (0.9% w / v sodium chloride solution) into the dosing module.

[0090] 4. Use an automatic timing device to record the time from the start of adding the liquid until the diaper is completely absorbed by the saline solution.

[0091] 5. Add liquid to the same diaper twice, and express the diaper's absorption time as the absorption time during the first liquid addition and the absorption time during the second liquid addition.

[0092] 6. After completing the second liquid addition, remove the dosing module.

[0093] 7. Place a certain number of absorbent sheets on the diaper.

[0094] 8. Place the diaper into the pressure module and maintain it under a certain pressure (3.8-4.2 kPa) for a specific time (1 minute).

[0095] 9. The amount of rewetting in a diaper is indicated by the increase in the mass of the absorbent paper on the diaper.

[0096] 10. The amount of diaper leakage is indicated by the increase in the mass of the absorbent paper at the bottom of the diaper.

[0097] The table below summarizes the absorption time at the first liquid addition, the absorption time at the second liquid addition, the rewetting rate, and the leakage rate for diapers including nanofibers (specifically, using loosely packed nanofibers on pores) and corresponding diapers without nanofibers. For all entries, the perforated hydrophilic nonwoven fabric layer is made of plasma-treated polypropylene.

[0098]

[0099] The results show that the use of nanofibers generally shortens absorption time, reduces rewetting, and decreases leakage. The degree of improvement is highly dependent on the nanofiber material. Of the three materials selected, as shown in the table, n-PAN is the best polymer in terms of improving diaper absorption time, rewetting, and leakage, followed by PAN and PA6.

[0100] Example 2: Controlled release test results of active ingredients

[0101] Example 2A: Nanofibers obtained by electrospinning a solution containing 10% n-PAN and 2% sodium alginate

[0102] Solution preparation: Dissolve 1 g of n-PAN in 9 ml of N,N-dimethylformamide. Mix the solution at room temperature using a roller mixer for at least 8 hours until n-PAN is completely dissolved in N,N-dimethylformamide. Add 0.2 g of sodium alginate to 1 ml of deionized water and stir at room temperature using a roller mixer for at least 8 hours. Combine the two homogenized solutions and stir using a vortex mixer for 1 minute until a stable emulsion is formed.

[0103] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0104] Controlled release studies: Release profiles were studied using high-performance liquid chromatography (HPLC). Cumulative active ingredient levels were studied hourly. Figure 10 The dashed curve passing through the triangular point illustrates the release of sodium alginate from n-PAN nanofibers. Sodium alginate was gradually released from the n-PAN nanofibers over 8 hours. No sudden release was observed initially, and the release rate decreased after 2 hours. After 8 hours, almost 100% of the sodium alginate had been released from the nanofibers.

[0105] Example 2B: Nanofibers obtained by electrospinning a solution containing 10% n-PAN and 5% PEG

[0106] Solution preparation: Dissolve 1 g of n-PAN in 9 ml of N,N-dimethylformamide. Mix the solution at room temperature using a roller mixer for at least 8 hours until n-PAN is completely dissolved in N,N-dimethylformamide. Add 0.5 g of PEG to 1 ml of deionized water and stir at room temperature using a roller mixer for at least 8 hours. Combine the two homogenized solutions and vortex mix for 1 minute until a stable emulsion is formed.

[0107] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0108] Controlled release research: Figure 10The solid line curve passing through the triangle point illustrates the release of PEG from the n-PAN nanofibers. Sudden release of PEG was observed within the first 2 hours. After 2 hours, PEG was gradually released from the n-PAN nanofibers. PEG was completely released from the nanofibers within 8 hours.

[0109] Example 2C: Nanofibers obtained by electrospinning a solution containing 10% PAN and 2% sodium alginate

[0110] Solution preparation: Dissolve 1 g of PAN in 9 ml of N,N-dimethylformamide. Mix the solution at room temperature using a roller mixer for at least 8 hours until the PAN is completely dissolved in the N,N-dimethylformamide. Add 0.2 g of sodium alginate to 1 ml of deionized water and stir at room temperature using a roller mixer for at least 8 hours. Combine the two homogenized solutions and stir using a vortex mixer for 1 minute until a stable emulsion is formed.

[0111] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0112] Controlled release research: Figure 10 The dashed curve passing through the circular dots illustrates the release of sodium alginate from PAN nanofibers. Compared to n-PAN, PAN exhibits a faster sodium alginate release rate. Most of the sodium alginate is released from PAN nanofibers within 4 hours, while the remainder is released gradually over the last 4 hours.

[0113] Example 2D: Nanofibers obtained by solution electrospinning containing 10% PAN and 5% PEG

[0114] Solution preparation: Dissolve 1 g of PAN in 9 ml of N,N-dimethylformamide. Mix the solution at room temperature using a roller mixer for at least 8 hours until the PAN is completely dissolved in the N,N-dimethylformamide. Add 0.5 g of PEG to 1 ml of deionized water and stir at room temperature using a roller mixer for at least 8 hours. Combine the two homogenized solutions and stir using a vortex mixer for 1 minute until a stable emulsion is formed.

[0115] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0116] Controlled release research: Figure 10 The solid line curve passing through the circular dots illustrates the release of PEG from PAN nanofibers. Compared to n-PAN nanofibers, PAN nanofibers still exhibit a faster PEG release rate, indicating that the release curve for the same composition is highly dependent on the choice of nanofiber material. A sudden release of PEG was observed in the first 2 hours, followed by a gradual release over the last 6 hours.

[0117] Example 2E: Nanofibers obtained by solution electrospinning containing 12% PA6 and 2% sodium alginate

[0118] Solution preparation: Dissolve 1.2 g of PA6 in 9 ml of a mixture of acetic acid (AA) and formic acid (FA). The AA:FA ratio is 2:1. Mix the solution at 60°C using a roller mixer for at least 8 hours until PA6 is completely dissolved in the AA and FA mixture. Add 0.2 g of sodium alginate to 1 ml of deionized water and stir using a roller mixer for at least 8 hours at room temperature. Combine the two homogeneous solutions and stir using a vortex mixer for 1 minute until a stable emulsion is formed.

[0119] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0120] Controlled release research: Figure 10The dashed curve passing through the square dots illustrates the release of sodium alginate from PA6 nanofibers. Compared to n-PAN or PAN nanofibers, the release rate of PA6 nanofibers is stable. Sodium alginate is gradually released from PA6 nanofibers over 8 hours, and no sudden release was observed.

[0121] Example 2F: Nanofibers obtained by electrospinning a solution containing 12% PA6 and 5% PEG

[0122] Solution preparation: Dissolve 1.2 g of PA6 in 9 ml of a mixture of acetic acid (AA) and formic acid (FA). The AA:FA ratio is 2:1. Mix the solution at 60°C using a roller mixer for at least 8 hours until PA6 is completely dissolved in the AA and FA mixture. Add 0.5 g of PEG to 1 ml of deionized water and stir using a roller mixer for at least 8 hours at room temperature. Combine the two homogeneous solutions and vortex mix for 1 minute until a stable emulsion is formed.

[0123] Electrospinning: The emulsion (i.e., the spinning solution) is filled into the carrier of the electrospinning equipment (NanoSpider, model NS1S500U, from Elmarco, Czech Republic). Before starting the electrospinning process, the carrier is operated to ensure that the electrode wires can be coated with the spinning solution. After starting the electrospinning process, the voltage on the spinning electrode is set to +60kV, while the voltage on the collecting electrode is set to -40kV. The spinning solution is drawn into nanofibers deposited on the surface of the bottom layer of the composite substrate (i.e., the perforated hydrophilic nonwoven fabric layer). After the spinning solution is exhausted, the voltage of both electrodes (i.e., the spinning electrode and the collecting electrode) is set to 0.

[0124] Controlled release research: Figure 10 The solid line curve passing through the square dots illustrates the release of PEG from PA6 nanofibers. Most PEG was released from the PA6 nanofibers within 6 hours, followed by gradual release over the final 2 hours. No sudden release was observed, and all PEG was released within 8 hours.

[0125] Benefiting from the teachings given in the foregoing description and accompanying drawings, those skilled in the art will conceive of various modifications and other embodiments of this disclosure. Therefore, it should be understood that this disclosure is not limited to the specific embodiments described herein, but includes modifications and other embodiments within the scope of the appended claims.

Claims

1. A disposable hygiene product, comprising: The top sheet includes a perforated hydrophilic nonwoven fabric layer, wherein the perforated hydrophilic nonwoven fabric layer includes a plurality of pores and a skin-facing surface and a clothing-facing surface opposite the skin-facing surface; A nanofiber layer is disposed on the garment-facing surface of the perforated hydrophilic nonwoven fabric layer, wherein the nanofiber layer comprises densely packed nanofibers disposed between at least a portion of the plurality of pores, and loosely packed nanofibers disposed on at least a portion of the plurality of pores, wherein the densely packed nanofibers are spaced at 100 µm / s². 3 The nanofibers exist at a density of 20-30 per 100 µm. 3 The density of 5-10 nanofibers exists within the structure; Backing; and An absorbent core is disposed between the backsheet and the nanofiber layer, wherein the absorbent core comprises a superabsorbent polymer (SAP).

2. The disposable sanitary product according to claim 1, wherein, The densely packed nanofibers and the loosely packed nanofibers have an average diameter of 100 to 1,000 nm.

3. The disposable sanitary product according to claim 1, wherein, Each of the plurality of holes has a diameter of 100-1,000 µm.

4. The disposable sanitary product according to claim 1, wherein, The plurality of holes have a spacing of 100-1,000 µm between them.

5. The disposable sanitary product according to claim 1, wherein, The densely packed nanofibers and the loosely packed nanofibers comprise polymers selected from the group consisting of: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymers of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), polylactic-co-glycolic acid (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and combinations thereof.

6. The disposable sanitary product according to claim 1, wherein, The perforated hydrophilic nonwoven fabric layer comprises microfibers having an average diameter of 10 to 30 μm.

7. The disposable sanitary product according to claim 1, wherein, The perforated hydrophilic nonwoven fabric layer includes polyethylene, polypropylene, or a combination thereof.

8. The disposable sanitary product according to claim 1, wherein, The nanofiber layer further includes an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

9. The disposable sanitary product according to claim 8, wherein, The active ingredients are selected from the group consisting of: calamine, dimethylsiloxane, kaolin, lanolin, petrolatum, talc, corn starch, white petrolatum, zinc oxide, silver, copper, copper oxide, titanium oxide, iodine, triclosan, polyethylene glycol (PEG), sodium alginate and mixtures thereof.

10. The disposable sanitary product according to claim 6, wherein, The densely packed nanofibers and the loosely packed nanofibers have an average diameter of 100 to 1,000 nm; the plurality of pores have an inter-pore distance of 100-1,000 µm; the densely packed nanofibers and the loosely packed nanofibers comprise polymers selected from the group consisting of polymers including: cellulose acetate (CA), polyamide 6 (PA6), polystyrene (PS), polyacrylonitrile (PAN), copolymer of polyacrylonitrile and methyl acrylate (n-PAN), polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), polylactic acid (PLA), polylactic acid-co-glycolic acid (PLGA), polybutylene terephthalate (PBT), polyurethane (PU), gelatin, chitosan, polyhydroxybutyrate-co-hydroxyvalerate (PHBV), and combinations thereof; and the top sheet comprises a nonwoven material comprising fibers containing polyethylene, polypropylene, or combinations thereof.

11. The disposable sanitary product according to claim 10, wherein, The nanofiber layer further includes an active ingredient selected from the group consisting of antioxidants, anti-inflammatory agents, antimicrobial agents, emollients, and mixtures thereof.

12. The disposable sanitary product according to claim 1, wherein, The backsheet comprises polypropylene, polyethylene, nylon, polyester, or a combination thereof.

13. The disposable sanitary product according to claim 1, wherein, The SAP includes sodium polyacrylate.

14. A diaper comprising a disposable sanitary product according to any one of claims 1 to 13.

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