Flow control member for an absorbent core, method for making same, and absorbent sanitary article

Abstract

This invention discloses a flow control component for an absorbent core, as well as an absorbent core and / or absorbent sanitary product incorporating the flow control component. The flow control component includes an upper surface layer, a middle spacer layer, and a lower surface layer. The upper and lower surface layers are woven from yarns, and the middle spacer layer is formed by the middle layer yarns passing through the upper and lower surface layers multiple times, creating connection points. The yarns of the upper and lower surface layers and the middle layer are each formed from a single fiber or spun from several fibers. The ratio of the number of yarns in the upper surface layer to the lower surface layer per unit area is 1:1, while the ratio of the number of yarns in the middle spacer layer to the number of yarns in the upper surface layer is from 0.1:1 to 20:1. By controlling the weaving composition and ratio of the yarns in the upper and lower surface layers and the middle spacer layer, a specific liquid seepage and diffusion guiding effect can be achieved.

Description

Technical Field

[0001] This invention relates to a disposable absorbent sanitary product and the fluid flow control element used therein, as well as a method for preparing the same. More specifically, this invention relates to a flow control element for an absorbent core, a method for preparing the same, and an absorbent sanitary product using the same flow control element. Background Technology

[0002] Disposable absorbent hygiene products such as sanitary napkins, diapers, and incontinence protection devices generally include a top layer that is permeable to liquid and faces the wearer when in use, a bottom layer that is impermeable to liquid, an absorbent core sealed between the top and bottom layers, and a fluid flow control component located between the top and bottom layers. This fluid flow control component has the function of liquid collection and storage and is also called a flow control component.

[0003] Chinese invention patent CN 201280078034.1 discloses an absorbent article having a spacer fabric as a fluid flow control component. This absorbent article is a personal hygiene item, comprising a liquid-permeable top sheet, a liquid-impermeable back sheet, an absorbent core surrounded between the top and back sheets, and a fluid flow control component disposed between the top and back sheets. The fluid flow control component is a spacer fabric with a basis weight of 150-300 gsm, and includes a top layer, a bottom layer, and an interconnecting layer of pile fibers between the top and bottom layers. The pile fibers have a fineness of 80-130 dtex, and the density of pile fiber connection points is 50-150 points / cm². However, in this patent, to ensure the softness of the material and the flow efficiency of the fluid in the interconnecting layer, the density of pile fiber connection points is limited to only 50-150 points / cm². 2 One fatal flaw of this approach is that it leads to increased backflow, severely affecting the wearing experience.

[0004] Chinese invention patent CN 201410176570.6 discloses an absorbent core, an absorbent core forming device, and a method for manufacturing an absorbent core. The absorbent core includes an absorbent core surface layer, an absorbent core middle layer, and an absorbent core bottom layer. The density of the absorbent core middle layer and the absorbent core bottom layer is greater than that of the absorbent core surface layer. That is, the aggregation degree of the fluff pulp fibers in the surface layer, middle layer, and bottom layer of the absorbent core is from relatively loose to dense, with a density gradient design, so as to quickly absorb body fluids, promote liquid penetration, and reduce the possibility of body fluid leakage from absorbent sanitary products.

[0005] Chinese utility model patent CN202020071102.3 discloses a high-absorption and high-diffusion composite core structure and an absorbent product using the same. The composite absorbent core includes an outer composite absorbent core and an inner composite absorbent core circumferentially surrounded by the outer composite absorbent core. An annular liquid diffusion guide area is provided between the outer composite absorbent core and the inner composite absorbent core. One side of the annular liquid diffusion guide area surrounds the inner absorbent core circumferentially along the outer side of the inner absorbent core, while the other side surrounds the outer absorbent core circumferentially along the inner side of the outer absorbent core, and is laterally connected to the outer absorbent core and the inner absorbent core respectively.

[0006] The aforementioned existing technologies mainly address the absorption rate, cavity construction, and the combination of hydrophilicity and hydrophobicity of each layer separately. Specifically, CN 201410176570.6 and CN 202020071102.3 primarily use short fibers and nonwovens, failing to form a complete laminate design with superior functionality. They mainly achieve localized functionality by increasing absorption capacity, designing drainage channels, designing multi-layered nonwoven layers for flow guidance and reverse osmosis, and compressing the core, without forming an overall laminate solution. CN201280078034.1 describes an absorbent article with a spacer fabric serving as a fluid flow control component, but it has a liquid-impermeable backing sheet, hindering liquid penetration from the upper layer to the lower layer, and it lacks the ability to control the directional differences in liquid diffusion in the horizontal direction.

[0007] Since the cross-section of many absorbent articles is not square but elongated, it is necessary to provide a flow control element for composite absorbent cores that can control the directional difference in liquid diffusion capacity in the horizontal direction, a method for its preparation, and absorbent sanitary articles using such a flow control element. Summary of the Invention

[0008] One of the objectives of this invention is to provide a flow control component for composite absorbent cores and disposable absorbent sanitary products, which can control the directional difference of liquid diffusion in the horizontal direction and is used for the preparation of the same, and a method thereof.

[0009] To achieve the aforementioned objectives, the present invention provides a flow control component for an absorbent core, comprising, from top to bottom, an upper surface layer, an intermediate spacer layer, and a lower surface layer. The upper surface layer is woven from upper surface layer yarns, the lower surface layer is woven from lower surface layer yarns, and the intermediate spacer layer is formed by the intermediate layer yarns repeatedly passing through the upper and lower surface layers. The intermediate layer yarns form connection points when passing through the upper and lower surface layers. The upper surface layer yarns, lower surface layer yarns, and intermediate layer yarns are each formed from a single fiber or spun from several fibers. The weaving composition and proportion of the yarns in the upper surface layer, lower surface layer, and intermediate spacer layer are controlled such that the ratio of the number of yarns in the upper surface layer to the lower surface layer per unit area is 1:1, while the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper surface layer is 0.1:1 to 20:1, thereby achieving a specific liquid infiltration and diffusion guiding effect.

[0010] The present invention relates to a flow control element for composite absorbent cores and / or absorbent sanitary products. By controlling the weaving composition and proportion of the yarns in the upper surface layer, lower surface layer, and intermediate spacer layer of the flow control element, a specific liquid seepage diffusion guiding effect is achieved. This control has very practical technical effects: for elongated flow control elements, composite absorbent cores, and absorbent sanitary products, if the liquid diffusion capacity can be controlled to exhibit directional differences—that is, the liquid diffusion capacity differs in different directions—then making the liquid diffusion capacity in the narrower width direction less than that in the longer length direction will be highly advantageous in preventing side leakage in the width direction.

[0011] Preferably, in the flow control component of the present invention, the ratio of the number of yarns in the upper surface layer to the number of yarns in the lower surface layer per unit area is 1:1, while the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper surface layer is 0.2:1 to 10:1.

[0012] More preferably, in the flow control member of the present invention, the ratio of the number of yarns in the upper surface layer to the number of yarns in the lower surface layer per unit area is 1:1, while the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper surface layer is 0.5:1 to 5:1.

[0013] As a specific embodiment of the present invention, the ratio of the number of yarns in the upper surface layer, the middle spacer layer and the lower surface layer of the flow guide control component is approximately 1:1:1. This design allows the liquid falling vertically to the flow guide control component to tend to diffuse evenly in all horizontal directions of the flow guide control component.

[0014] As another specific embodiment of the present invention, the ratio of the number of yarns in the upper surface layer, the middle spacer layer and the lower surface layer of the flow control component is approximately 1:2:1. This scheme allows the liquid falling vertically to the flow control component to tend to diffuse along the warp direction woven by the flow control component.

[0015] In another specific embodiment of the present invention, the ratio of the number of yarns in the upper surface layer, the middle spacer layer and the lower surface layer of the flow guide control component is approximately 1:0.67:1. This scheme allows the liquid falling vertically to the flow guide control component to tend to diffuse along the weft direction woven by the flow guide control component.

[0016] In the flow control component of this invention, the number of yarns in each layer can be controlled by adjusting the number of independent yarn lines during the weaving of the upper, middle, and lower layers. Each independent yarn line originates from an independent yarn ball and can be separated from yarns originating from other yarn balls. Practice has shown that the ratio of independent yarn lines used in weaving the upper, middle, and lower layers is consistent with the ratio of yarns per unit area in the upper, middle, and lower layers; furthermore, the ratio of yarn balls used in weaving the upper, middle, and lower layers is consistent with the ratio of yarns per unit area in the upper, middle, and lower layers.

[0017] As can be seen, in this invention, the proportion of yarn balls in the upper layer, middle spacer layer, and lower layer can be used to control the proportion of yarn strands in the upper layer, middle spacer layer, and lower layer per unit area, thereby achieving different abilities of liquid falling to the flow control component to diffuse in different horizontal directions of the flow control component, thus realizing directional differences.

[0018] It is worth noting that in the flow control component of the present invention, the number of yarns in each layer refers to the number of individual yarns, not just the number of fibers contained in each layer of yarns. A single yarn can be spun from a number of fibers, for example, the number of fibers (filaments) in each single yarn layer can be 144, 72, 48, 36, or 24.

[0019] Preferably, in the flow control component of the present invention, the fineness of the upper surface yarn and the fineness of the lower surface yarn can be controlled between 30D and 150D respectively.

[0020] As a specific embodiment of the present invention, the upper and / or lower surface of the flow control component can be fluffy, for example, by pulling out yarn or by friction to obtain a fluffy surface.

[0021] In this invention, the flow control element is highly resistant to compression and possesses a free volume that allows it to contain and temporarily retain a relatively large volume of liquid. When the absorbent sanitary product is subjected to pressure applied by the wearer, the expelled bodily fluids can be effectively received into the free volume and can flow within it to different parts of the absorbent core for absorption, thereby minimizing the risk of leakage.

[0022] In this invention, the term "disposable" means something that is discarded after limited use without being cleaned or repaired for reuse.

[0023] In this invention, the basis weight of the entire flow control component is 30-500 gsm, and the thickness is 0.1-15 mm; preferably, the basis weight of the entire flow control component is 50-300 gsm, more preferably 60-290 gsm; when measured without applying pressure, its thickness is preferably 0.5-6 mm, more preferably 1-5 mm.

[0024] In this invention, the fibers used in each yarn include thermoplastic polymer fibers, preferably selected from, but not limited to, polyester, polyamide, and polyolefins, such as polyethylene and polypropylene, or mixtures thereof. The layers of the yarn or flow control element may also include (e.g., coated) surfactants to promote liquid penetration so that it can be rapidly drained without retaining any liquid, thereby maintaining free volume for the next outflow. Preferably, the yarns of the upper layer, the lower layer, and the middle layer are polyester.

[0025] On the other hand, in order to achieve the objective of this invention, this invention also provides a method for preparing the above-mentioned flow control component, which comprises, from top to bottom, an upper surface layer, an intermediate spacer layer, and a lower surface layer; wherein:

[0026] (1) The upper layer is woven from the upper layer yarn, the lower layer is woven from the lower layer yarn, and the middle interlayer is formed by the middle layer yarn passing through the upper and lower layers multiple times.

[0027] (2) The intermediate layer yarn forms a connection point when it passes through the upper and lower layers;

[0028] (3) The yarn for weaving the upper layer, the yarn for weaving the lower layer, and the yarn for weaving the middle interlayer are each formed by a single fiber or spun from several fibers.

[0029] (4) When weaving the upper layer, the lower layer and the middle layer, the weaving composition and proportion of the yarns of the upper layer, the lower layer and the middle spacer layer are controlled as follows, so that the ratio of the number of independent yarns in the upper layer and the lower layer is 1:1, and the ratio of the number of independent yarns in the middle spacer layer to the number of independent yarns used in the upper layer is 0.1:1 to 20:1. Each independent yarn comes from an independent yarn ball and can be separated from the yarns from other yarn balls.

[0030] Furthermore, to achieve the objective of this invention, the present invention also provides an absorbent core for absorbent sanitary products, the absorbent core including the aforementioned flow control element. This absorbent core may be a composite absorbent core.

[0031] In another aspect, in order to achieve the objective of this invention, this invention also provides an absorbent sanitary product, particularly a disposable absorbent sanitary product, which includes the aforementioned flow control element.

[0032] In this invention, absorbent hygiene products can be sanitary napkins, diapers, nursing pads, or other forms of products.

[0033] As a specific embodiment of the absorbent sanitary product of the present invention, the absorbent sanitary product may include a liquid-permeable top sheet, a liquid-impermeable bottom sheet, an absorbent core surrounding the top sheet and the bottom sheet, and the aforementioned flow control member disposed between the top sheet and the bottom sheet.

[0034] The flow control component of this invention achieves a specific liquid seepage and diffusion guiding effect by controlling the weaving composition and proportion of the yarns in the upper surface layer, lower surface layer, and intermediate spacer layer, thereby preventing side leakage. The flow control component of this invention exhibits excellent control capabilities in terms of compression set, elasticity, backflow control rate, and the directionality of liquid diffusion.

[0035] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. However, these specific embodiments are merely descriptions of certain specific implementations of the present invention and are not intended to limit the present invention. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the flow control component of the present invention;

[0037] Figure 2 This diagram illustrates the uniform diffusion of liquid along the upper surface of the flow control component in various directions according to a specific embodiment of the present invention.

[0038] Figure 3 A schematic diagram showing that, in another specific embodiment of the invention, the liquid tends to diffuse more along the warp direction woven into the flow control element;

[0039] Figure 4 This diagram illustrates that, in another specific embodiment of the invention, the liquid tends to diffuse more along the weft direction of the flow control element.

[0040] The meanings of the various reference numerals in the figure are as follows:

[0041] 1. The upper surface layer of the flow control component;

[0042] 2. Lower surface layer of the flow control component

[0043] 3. Intermediate spacer layer of the flow control component

[0044] 4. The upper surface of the flow control component;

[0045] 5. Liquid that diffuses uniformly in all directions along the flow control component;

[0046] 6. Liquids tend to diffuse radially along the flow control components;

[0047] 7. Liquids tend to diffuse in the latitudinal direction along the flow control components. Detailed Implementation

[0048] The implementation and use of various embodiments of the present invention are discussed in detail below. However, it should be understood that the specific embodiments discussed are merely illustrative of particular ways of implementing and using the present invention, and are not intended to limit the scope of the invention. In the description, the structural positions of various components, such as upper, lower, top, bottom, etc., are not absolute but relative. These directional descriptions are appropriate when the various components are arranged as shown in the figures, but these directional descriptions also change accordingly when the positions of the various components in the figures change.

[0049] like Figure 1 As shown, the flow control component of the present invention is woven by textile machinery. The flow control component includes, from top to bottom, an upper surface layer 1, an intermediate spacer layer 3, and a lower surface layer 2. Each layer is woven from yarn. The upper surface layer 1 is woven from yarn used for the upper surface layer, the lower surface layer 2 is woven from yarn used for the lower surface layer, and the intermediate spacer layer 3 is formed by the yarn used for the intermediate spacer layer passing through the upper and lower surface layers multiple times. The yarn in each layer can be a single fiber yarn or a yarn spun from multiple fibers.

[0050] Example 1

[0051] In this embodiment of the invention, the flow control component comprises, from top to bottom, an upper surface layer 4, an intermediate spacer layer 3, and a lower surface layer 2. The ratio of the number of independent yarns when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:1:1, that is, the ratio of the number of independent yarn balls when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:1:1. When liquid falls vertically onto the flow control component woven in this manner, the liquid tends to diffuse evenly in all horizontal directions of the flow control component, such as... Figure 2 As shown, reference numeral 4 represents the upper surface layer of the flow control component, and reference numeral 5 represents the liquid falling onto the upper surface layer 4 of the flow control component, which diffuses in a basically uniform manner in all horizontal directions of the flow control component.

[0052] Example 2

[0053] In this embodiment of the invention, the flow control element comprises, from top to bottom, an upper surface layer 4, an intermediate spacer layer 3, and a lower surface layer 2. The ratio of the number of independent yarns when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:2:1, that is, the ratio of the number of independent yarn balls when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:2:1. When liquid falls vertically onto the flow control element woven in this manner, the liquid tends to diffuse along the warp direction of the flow control element's weave, such as... Figure 3 As shown in the figure, reference numeral 4 represents the upper surface layer of the flow control component, and reference numeral 6 represents the liquid falling onto the upper surface layer 4 of the flow control component. The liquid tends to diffuse along the warp direction of the flow control component, that is, the diffusion ability of the liquid along the warp direction of the flow control component is greater than its diffusion ability along the weft direction of the flow control component.

[0054] Example 3

[0055] In this embodiment of the invention, the flow control element comprises, from top to bottom, an upper surface layer 4, an intermediate spacer layer 3, and a lower surface layer 2. The ratio of the number of independent yarns when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:0.67:1, that is, the ratio of the number of independent yarn balls when weaving the upper surface layer, intermediate spacer layer, and lower surface layer is 1:0.67:1. When liquid falls vertically onto the flow control element woven in this manner, the liquid tends to diffuse along the weft direction of the flow control element's weave, such as... Figure 4 As shown in the figure, reference numeral 4 represents the upper surface layer of the flow control component, and reference numeral 7 represents the liquid falling onto the upper surface layer 4 of the flow control component. The liquid tends to diffuse along the weft direction of the flow control component, that is, the diffusion ability of the liquid along the weft direction of the flow control component is greater than its diffusion ability along the warp direction of the flow control component.

[0056] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A flow control member for an absorbent core, the flow control member comprising, in order from top to bottom, an upper stratum, an intermediate spacer layer, and a lower stratum; the upper stratum being woven from upper stratum yarns, the lower stratum being woven from lower stratum yarns, the intermediate spacer layer being formed by the multiple traversals of intermediate layer yarns through the upper stratum and the lower stratum; the intermediate layer yarns forming junction points as they traverse the upper stratum and the lower stratum; the upper stratum yarns, the lower stratum yarns, and the intermediate layer yarns each being formed from one fiber or spun from a plurality of fibers; characterized in that, The weaving composition and ratio of the yarns in the upper surface layer, lower surface layer and intermediate spacer layer of the flow guide control component are controlled so that the ratio of the number of yarns in the upper surface layer to the number of yarns in the lower surface layer per unit area is 1:1, and the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper surface layer is 0.1:1 to 20:1, so as to achieve a specific liquid seepage diffusion guiding effect.

2. The flow control component as described in claim 1, characterized in that, The ratio of the number of yarns in the upper layer to the number of yarns in the lower layer is 1:1, while the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper layer is 0.2:1 to 10:

1.

3. The flow control component as described in claim 2, characterized in that, The ratio of the number of yarns in the upper layer to the number of yarns in the lower layer is 1:1, while the ratio of the number of yarns in the intermediate spacer layer to the number of yarns in the upper layer is 0.5:1 to 5:

1.

4. The flow control component as described in claim 3, characterized in that, The ratio of yarn count in the upper layer, middle spacer layer, and lower layer is 1:1:1, which causes the liquid falling vertically onto the flow control component to tend to diffuse evenly in all horizontal directions of the flow control component.

5. The flow control component as described in claim 3, characterized in that, The ratio of yarn counts in the upper layer, middle spacer layer, and lower layer is 1:2:1, which causes liquid falling vertically onto the flow control element to tend to diffuse along the warp direction woven into the flow control element.

6. The flow control component as described in claim 3, characterized in that, The ratio of yarn count in the upper layer, middle spacer layer, and lower layer is 1:0.67:1, which causes liquid falling vertically onto the flow control element to tend to diffuse along the weft direction woven into the flow control element.

7. The flow control component as described in any one of claims 1-6, characterized in that, The basis weight of the flow control component is 30-500 gsm, and the thickness is 0.1-15 mm.

8. A method for preparing a flow control element as described in any one of claims 1-7, wherein the flow control element comprises, from top to bottom, an upper surface layer, an intermediate spacer layer, and a lower surface layer; wherein: (1) The upper layer is woven from the upper layer yarn, the lower layer is woven from the lower layer yarn, and the intermediate spacer layer is formed by the intermediate layer yarn passing through the upper layer and the lower layer multiple times; (2) The intermediate layer yarn forms a connection point when it passes through the upper surface layer and the lower surface layer; (3) The yarn for weaving the upper surface layer, the yarn for weaving the lower surface layer, and the yarn for weaving the intermediate spacer layer are each formed from a single fiber or spun from several fibers; (4) When weaving the upper layer, the lower layer, and the middle layer, the weaving composition and proportion of the yarns of the upper layer, the lower layer, and the middle spacer layer are controlled as follows, so that the ratio of the number of independent yarns in the upper layer and the lower layer is 1:1, and the ratio of the number of independent yarns in the middle spacer layer to the number of independent yarns used in the upper layer is 0.1:1 to 20:

1. Each independent yarn comes from an independent yarn ball and can be separated from the yarns from other yarn balls.

9. An absorbent core for absorbent sanitary products, characterized in that, The absorber core includes a flow control element as described in any one of claims 1-7.

10. An absorbent sanitary product, characterized in that, The absorbent hygiene product includes the flow control element as described in any one of claims 1-7.

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