High-fluffiness glue-free absorption core body and manufacturing method thereof

Abstract

The invention discloses a high-fluffiness glue-free absorption core and a manufacturing method thereof.The high-fluffiness glue-free absorption core comprises hot air non-woven fabric, first melt-blown fabric and second melt-blown fabric, the hot air non-woven fabric is made of three-dimensional hollow PET fibers and ES fibers, SAP is scattered into gaps of the hot air non-woven fabric, the melt-blown fibers and the ES fibers of the first melt-blown fabric and the second melt-blown fabric form three-dimensional entanglement in the process, and the high-fluffiness glue-free absorption core is formed. The hot-air non-woven fabric and the SAP are combined into a whole after being pressed and shaped, the materials are subjected to hydrophilic finishing, rolling, slitting, inspection and warehousing through after-finishing equipment, the high-fluffiness non-adhesive absorption core is formed, the fluffiness of the absorption core and the storage space and flexibility of the SAP are greatly improved by means of the high-fluffiness structure of the hot-air non-woven fabric, and the high capillary effect of the melt-blown fibers is combined, so that the high-fluffiness non-woven fabric is obtained. A good diffusion effect is achieved, the actual utilization rate of the SAP is improved, material waste is reduced, the problem of back seepage is solved, in addition, no hot melt adhesive is adopted for bonding of all the layers, absorption barrier caused by a hot melt adhesive barrier is eliminated, and positive help is brought to improvement of the absorption speed of the absorption core body.

Description

Technical Field

[0001] This invention relates to a disposable hygiene product, and more particularly to a high-fluff, glue-free absorbent core and its manufacturing method. Background Technology

[0002] In the field of disposable hygiene products (such as diapers, sanitary napkins, and nursing pads), the absorbent core, as a core functional component, directly determines the user experience and practical value of the product. As consumers increasingly demand comfort, absorbency, and safety in hygiene products, traditional absorbent cores have gradually revealed a series of technical shortcomings that make them difficult to meet market demands.

[0003] Traditional absorbent cores often employ a structure combining fluff pulp and superabsorbent polymer (SAP), or a composite of ordinary nonwoven fabric (such as cleanroom paper) and SAP to form the absorbent carrier. However, these traditional structures have several technical limitations in practical applications: Firstly, traditional absorbent cores have low bulk and narrow internal fiber gaps, limiting the space for SAP. Secondly, the nonwoven fabrics (such as cleanroom paper) used in traditional cores have coarser fibers and weaker capillary effects, resulting in slow liquid diffusion within the core, often concentrating in localized areas. This prevents a large amount of SAP from participating in the absorption process, leading to material waste and potential problems such as localized saturation and backflow. Furthermore, the use of hot melt adhesives between the layers of traditional composite cores increases absorption barriers and affects the absorption rate. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, the present invention provides a high-fluff, glue-free absorbent core and its manufacturing method.

[0005] The technical solution adopted by this invention to solve its technical problem is: A high-loft, non-adhesive absorbent core includes a middle layer of hot-air nonwoven fabric and a first meltblown fabric and a second meltblown fabric respectively laminated on the upper and lower sides of the hot-air nonwoven fabric. The first meltblown fabric, the second meltblown fabric and the hot-air nonwoven fabric are fixedly connected by fiber entanglement. The hot-air nonwoven fabric is made of three-dimensional hollow PET fiber and ES fiber, and SAP is dispersed inside the hot-air nonwoven fabric.

[0006] The basis weight of the first and second meltblown fabrics is 20-50 gsm.

[0007] The weight of the SAP is 30-100 gsm.

[0008] The fineness of the three-dimensional hollow PET fiber is 3D-7D; the fineness of the ES fiber is two types, namely 4D-6D and 1.5D-2D.

[0009] The three-dimensional hollow PET fiber and ES fiber are both hydrophilic fibers treated with hydrophilic oil agents.

[0010] The proportion of the three-dimensional hollow PET fiber is 20%-35%; the proportion of the ES fiber in 4D-6D is 35%-50%, and the proportion of the ES fiber in 1.5D-2D is 30%-45%.

[0011] A method for manufacturing a high-loft, glue-free absorbent core includes the following steps: Three-dimensional hollow PET fibers and ES fibers are added to a blending box in a certain proportion through a metering feeder. After thorough mixing, the fibers are conveyed to a carding machine to form a cotton web. The cotton web is then conveyed to a hot air box via a conveyor belt. After being solidified by hot air at 125-130℃, the cotton web is further shaped by a cooling roller to form a hot-air nonwoven fabric. The hot-air nonwoven fabric is conveyed by a conveyor belt onto the uncooled, bonded, and pressed first meltblown fabric produced by a first meltblown fabric preparation device. Then, SAP is sprinkled into the gaps of the hot-air nonwoven fabric through a SAP feeding device. A second meltblown fabric is then formed on top of the hot-air nonwoven fabric by a second meltblown fabric preparation device. The meltblown fibers and ES fibers of the first and second meltblown fabrics form a three-dimensional entanglement during the process. After pressing and shaping, they are integrated into one piece. The material is then subjected to hydrophilic finishing by a finishing device. Finally, the material is wound, slit, inspected, and stored to form a high-loft, glue-free absorbent core.

[0012] The beneficial effects of this invention are as follows: This invention includes a hot-air nonwoven fabric, a first meltblown fabric, and a second meltblown fabric. The hot-air nonwoven fabric is made of three-dimensional hollow PET fibers and ES fibers. SAP is sprinkled into the gaps of the hot-air nonwoven fabric. The meltblown fibers and ES fibers of the first and second meltblown fabrics form a three-dimensional entanglement during the process. After pressing and shaping, they are combined into one piece. After finishing equipment performs hydrophilic finishing on the material, it is wound, slit, inspected, and stored to form a high-loft, glue-free absorbent core. The high-loft structure of the hot-air nonwoven fabric greatly improves the loft of the absorbent core and the storage space and softness of SAP. Combined with the strong capillary effect of meltblown fibers, it achieves a good diffusion effect, improves the actual utilization rate of SAP, reduces material waste, and reduces the problem of backflow. In addition, no hot melt adhesive is used between the layers, eliminating the absorption barrier caused by the hot melt adhesive barrier, which positively contributes to the improvement of the absorption speed of the absorbent core. Attached Figure Description

[0013] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0014] Figure 1 This is a schematic diagram of the structure of the present invention. Detailed Implementation

[0015] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0016] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0017] The following describes some embodiments of the present invention with reference to the accompanying drawings.

[0018] Reference Figure 1 A high-loft, adhesive-free absorbent core includes a middle layer of hot-air nonwoven fabric 1 and a first meltblown fabric 2 and a second meltblown fabric 3 respectively laminated to the upper and lower sides of the hot-air nonwoven fabric 1. The first meltblown fabric 2 and the second meltblown fabric 3 have a basis weight of 20-50 gsm. The first meltblown fabric 2, the second meltblown fabric 3 and the hot-air nonwoven fabric 1 are fixedly connected by fiber entanglement. The hot-air nonwoven fabric 1 is made of three-dimensional hollow PET fiber and ES fiber. SAP is dispersed inside the hot-air nonwoven fabric 1. The basis weight of the SAP is 30-100 gsm. The high-loft structure of the hot-air nonwoven fabric greatly improves the loft of the absorbent core and the storage space and softness of SAP. Combined with the strong capillary effect of meltblown fiber, it achieves a good diffusion effect, improves the actual utilization rate of SAP, reduces material waste, and reduces the problem of backflow. In addition, since no hot melt adhesive is used to bond the core components, the absorption barrier caused by the hot melt adhesive barrier is eliminated, which positively contributes to the improvement of the absorption speed of the absorbent core.

[0019] The fineness of the three-dimensional hollow PET fiber is 3D-7D; the fineness of the ES fiber is two types, namely 4D-6D and 1.5D-2D. The hollow structure of the three-dimensional hollow PET fiber can form sufficient internal gaps, which, combined with the gradient filling of ES fibers of different fineness, gives the hot air nonwoven fabric excellent fluffy properties.

[0020] The three-dimensional hollow PET fiber and ES fiber are both hydrophilic fibers treated with hydrophilic oil agents.

[0021] Furthermore, the proportion of the three-dimensional hollow PET fiber is 20%-35%; the proportion of the 4D-6D ES fiber is 35%-50%; and the proportion of the 1.5D-2D ES fiber is 30%-45%. Through precise optimization, the three-dimensional hollow PET fiber ensures fluffiness and support, the high-fineness ES fiber improves fiber entanglement and softness, and the low-fineness ES fiber fills the gaps and optimizes liquid conduction. The synergistic effect of the three ensures the high performance of the core while avoiding the excessive use of a single high-priced fiber, achieving a balance between performance and material cost, and further enhancing the market competitiveness of the product.

[0022] A method for manufacturing a high-loft, glue-free absorbent core includes the following steps: Three-dimensional hollow PET fibers and ES fibers are added to a blending box in a certain proportion through a metering feeder. After thorough mixing, the fibers are conveyed to a carding machine to form a cotton web. The cotton web is then conveyed to a hot air box via a conveyor belt. After being solidified by hot air at 125-130℃, the cotton web is further shaped by a cooling roller to form a hot-air nonwoven fabric. The hot-air nonwoven fabric is conveyed by a conveyor belt onto the uncooled, bonded, and pressed first meltblown fabric produced by a first meltblown fabric preparation device. Then, SAP is sprinkled into the gaps of the hot-air nonwoven fabric through a SAP feeding device. A second meltblown fabric is then formed on top of the hot-air nonwoven fabric by a second meltblown fabric preparation device. The meltblown fibers and ES fibers of the first and second meltblown fabrics form a three-dimensional entanglement during the process. After pressing and shaping, they are integrated into one piece. The material is then subjected to hydrophilic finishing by a finishing device. Finally, the material is wound, slit, inspected, and stored to form a high-loft, glue-free absorbent core.

[0023] When the first meltblown fabric 2 and the second meltblown fabric 3 are prepared, meltblown masterbatch and hydrophilic masterbatch can be used as raw materials. After the meltblown masterbatch and hydrophilic masterbatch are mixed, they are spun into fibers by meltblown process to make them hydrophilic. The meltblown masterbatch accounts for 80%-95% of the total masterbatch and the hydrophilic masterbatch accounts for 5%-20% of the total masterbatch. The fiber fineness of the meltblown extrusion process is 1-25µm.

[0024] Furthermore, the meltblown masterbatch used in the first meltblown fabric 2 and the second meltblown fabric 3 is required to not overheat and deform in the hot air drying oven, that is, a masterbatch with a relatively higher melting point is required.

[0025] If the hot air nonwoven fabric 1, the first meltblown fabric 2, and the second meltblown fabric 3 are purchased raw materials, structural adhesive must be sprayed between the hot air nonwoven fabric 1 and the first meltblown fabric 2 and the second meltblown fabric 3 during the manufacturing of the absorbent core to ensure their bonding strength.

[0026] After the first meltblown fabric 2, the second meltblown fabric 3 and the hot air nonwoven fabric 1 are combined, they need to be pressed to a thickness of 2-5mm by a transmission roller. During the roller pressing process, the fiber hooking and entanglement between the first meltblown fabric 2, the second meltblown fabric 3 and the hot air nonwoven fabric 1 can further improve the bonding strength.

[0027] In this invention, the term "a plurality of" refers to two or more unless otherwise expressly defined. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. The terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection via an intermediate medium. Those skilled in the art will understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0028] It should be noted that when a component is referred to as being "assembled on," "mounted on," "fixed to," or "set on" another component, it can be directly on the other component or there may be an intermediate component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intermediate component present. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0029] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0030] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A highly fluffy, glue-free absorbent core, characterized in that, The hot air nonwoven fabric (1) includes a middle layer and a first meltblown fabric (2) and a second meltblown fabric (3) respectively laminated on the upper and lower sides of the hot air nonwoven fabric (1). The first meltblown fabric (2), the second meltblown fabric (3) and the hot air nonwoven fabric (1) are fixedly connected by fiber entanglement. The hot air nonwoven fabric (1) is made of three-dimensional hollow PET fiber and ES fiber. SAP is dispersed inside the hot air nonwoven fabric (1).

2. The high-fluff, glue-free absorbent core according to claim 1, characterized in that... The basis weight of the first meltblown fabric (2) and the second meltblown fabric (3) is 20-50 gsm.

3. The high-fluff, glue-free absorbent core according to claim 1, characterized in that... The weight of the SAP is 30-100 gsm.

4. The high-fluff, glue-free absorbent core according to claim 1, characterized in that... The fineness of the three-dimensional hollow PET fiber is 3D-7D; the fineness of the ES fiber is two types, namely 4D-6D and 1.5D-2D.

5. The high-fluff, glue-free absorbent core according to claim 4, characterized in that... The three-dimensional hollow PET fiber and ES fiber are both hydrophilic fibers treated with hydrophilic oil agents.

6. The high-fluff, glue-free absorbent core according to claim 4, characterized in that... The proportion of the three-dimensional hollow PET fiber is 20%-35%; the proportion of the ES fiber in 4D-6D is 35%-50%, and the proportion of the ES fiber in 1.5D-2D is 30%-45%.

7. A method for manufacturing a high-fluff, glue-free absorbent core, characterized in that, Includes the following steps: Three-dimensional hollow PET fibers and ES fibers are added to a blending box in a certain proportion through a metering feed box. After the fibers are fully mixed, they are conveyed to a carding machine and formed into a cotton web after carding. The cotton web is then conveyed to a hot air box via a conveyor belt. After the cotton web is solidified by hot air at 125-130℃, it is then shaped by a cooling roller to form a hot air nonwoven fabric. The hot air nonwoven fabric is conveyed by a conveyor belt to the top of the first meltblown fabric produced by the first meltblown preparation equipment, which is not cooled, bonded, or pressed. Then, through a SAP feeding device, SAP is sprinkled into the gaps of the hot air nonwoven fabric. Then, a second meltblown fabric is formed by meltblowing on the hot air nonwoven fabric by a second meltblown fabric preparation equipment. The meltblown fibers and ES fibers of the first and second meltblown fabrics form a three-dimensional entanglement in the process. After pressing and shaping, they are combined into one piece. Then, the material is hydrophilically treated by a finishing equipment. Finally, after winding, slitting, inspection, and warehousing, a high-loft, glue-free absorbent core is formed.

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