Composite foaming core body

Abstract

The utility model discloses a composite foaming core body, the composite foaming core body comprises a first surface layer, a middle foaming layer and a second surface layer, the first surface layer and the second surface layer are made of non-woven fabrics, the middle foaming layer is an open pore foaming body which is provided with a plurality of foam pores, the foam pores are communicated with one another, the thickness of the open pore foaming body is 1mm-5mm, and the thickness of the open pore foaming body is 1mm-5mm. The pore diameter of the pores is 50-400 [mu] m, fibers in the non-woven fabrics of the first surface layer and the second surface layer are tiled and arranged along the surface of the open-pore foaming body, and part of the fibers are inserted into the pores of the open-pore foaming body. In the using process, the non-woven fabric of the first surface layer plays a role in guiding flow, the utilization area of the absorption core body is increased, and the absorption speed of body fluid is increased; the foam holes of the open-cell foaming body in the middle foaming layer are communicated with one another, body fluid can rapidly permeate into the open-cell foaming body along part of fibers penetrating through the foam holes, and the communicated foam holes provide a body fluid storage space.

Description

Technical Field

[0001] The utility model relates to the technical field of foaming materials, in particular to a composite foaming core body used for sanitary absorbent products. Background Art

[0002] Usually, the core of sanitary absorbent products is made of fluff pulp or dust-free paper. Both fluff pulp and dust-free paper are made of fibers and are hydrophilic. When body fluid reaches the absorbent layer, they can quickly absorb body fluid. However, after absorbing body fluid, part of the body fluid will return to the absorbent surface along the fibers, causing a large back-infiltration of body fluid. Users will feel unfresh and damp, especially fluff pulp, which will agglomerate and break after absorbing liquid. At the same time, fluff pulp and dust-free paper are only fiber supports in the thickness direction. When squeezed by external force, the fiber density of fluff pulp and dust-free paper increases, and the thickness will drop sharply, thus affecting the air permeability and absorbency of the entire absorbent product. Utility Model Content

[0003] The utility model aims to provide a composite foam core which is soft, comfortable, breathable and absorbent, so as to overcome the defects of existing products.

[0004] To achieve the above purpose, the solution of the utility model is:

[0005] A composite foam core, comprising a first surface layer, an intermediate foam layer and a second surface layer, wherein the first surface layer and the second surface layer are non-woven fabrics, the intermediate foam layer is an open-cell foam having a plurality of pores which are interconnected, the open-cell foam has a thickness of 1 mm to 5 mm, and a pore diameter of 50 μm to 400 μm, the fibers of the non-woven fabrics in the first surface layer and the second surface layer are arranged flat along the surface of the open-cell foam, and some of the fibers penetrate into the pores of the open-cell foam.

[0006] The open-cell foam is a polyurethane open-cell foam.

[0007] The nonwoven fabric is hot air nonwoven fabric, spunbond nonwoven fabric, spunlace nonwoven fabric or composite nonwoven fabric.

[0008] The nonwoven fabric has openings, embossing or printing patterns.

[0009] The composite foam core has openings that penetrate the first surface layer, the middle foam layer and the second surface layer.

[0010] With the above structure, since the composite foam core comprises a first surface layer, an intermediate foam layer and a second surface layer, during use, when body fluid penetrates through the surface layer of the absorbent product and contacts the first surface layer of the composite foam core, the non-woven fabric of the first surface layer plays a guiding role, and the body fluid will flow along the fiber arrangement direction of the non-woven fabric, while the fibers in the non-woven fabric are arranged flat along the surface of the open-cell foam, and some of the fibers will penetrate into the pores of the intermediate foam layer. Therefore, the body fluid diffuses on the non-woven fabric of the first surface layer along the plane XY direction and the thickness Z direction, thereby increasing the utilization area of ​​the absorbent core and accelerating the absorption speed of the body fluid; while the intermediate foam layer The pores of the open-cell foam in the foam layer are interconnected, and body fluids will quickly penetrate into the open-cell foam along some fibers interspersed with the pores. The interconnected pores provide a storage space for body fluids, especially the increased body fluid flow rate can also make the absorbent product absorb body fluids quickly, without causing side leakage or back leakage due to untimely absorption, providing a buffer time for body fluid absorption, so that the body fluid has ample time to penetrate into the second surface layer non-woven fabric, thereby being absorbed by the second surface layer non-woven fabric, and the pores are interconnected but randomly distributed, so the body fluid back-infiltration route is long and tortuous, thereby greatly improving the dryness of the composite foam core. In addition, the open-cell foam of the middle foam layer has air permeability and resilience. During use, under the action of external pressure, the middle foam layer is compressed and the air in the pores is discharged. After the external pressure is released, the foam layer begins to rebound, and the pores are filled with air again, so that the gas has fluidity, forming a breathable composite foam core, which greatly increases the air permeability and comfort of the absorbent product. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a partial cross-sectional view of the composite foam core in Example 1 of the utility model;

[0012] Figure 2 This is a schematic diagram of manufacturing the middle foaming layer of the composite foaming core in Example 1 of the utility model;

[0013] Figure 3 This is a schematic diagram of composite manufacturing of the composite foam core in Example 1 of the utility model;

[0014] Figure 4 This is a schematic diagram of manufacturing the composite foam core in Example 2 of the utility model;

[0015] Figure 5 It is a partial cross-sectional view of the composite foam core in Example 3 of the utility model;

[0016] Figure 6 This is a schematic diagram of punching holes in the composite foam core in Embodiment 3 of the utility model;

[0017] Figure 7 It is a partial cross-sectional view of the composite foam core in Example 4 of the utility model;

[0018] Figure 8 This is a schematic diagram of the composite manufacturing of the composite foam core in Example 4 of the utility model. DETAILED DESCRIPTION

[0019] In order to further explain the technical solution of the present utility model, the present utility model is described in detail below through specific embodiments.

[0020] Example 1

[0021] like Figure 1 , Figure 2 and Figure 3 As shown, the embodiment discloses a composite foam core 1, comprising a first surface layer a1, an intermediate foam layer b1 and a second surface layer c1, wherein the first surface layer a1 and the second surface layer c1 are non-woven fabrics, the intermediate foam layer b1 is an open-cell foam having a plurality of pores d1, and the pores d1 are interconnected, the thickness of the open-cell foam is 1 mm to 5 mm, and the pore diameter is 50 μm to 400 μm, wherein: in this embodiment, the thickness of the open-cell foam is 2 mm, and the pore diameter is 100 μm to 300 μm, the fibers of the non-woven fabrics in the first surface layer a1 and the second surface layer c1 are arranged flat along the surface of the open-cell foam, and some of the fibers penetrate into the pores d1 of the open-cell foam.

[0022] The composite foam core of the utility model adopts the following manufacturing method:

[0023] (1) The bottom release paper 11 is unwound by an unwinding device; the open-cell foam raw material, which is uniformly stirred at a high speed, including polyether polyol or polyester polyol, polyisocyanate and catalyst, is uniformly poured onto the bottom release paper 11 by a dispensing mechanism A1; the surface release paper 11' is unwound by an unwinding device and covers the open-cell foam raw material layer;

[0024] (2) transporting the open-cell foam raw material to the aging oven B1, and reacting in the aging oven B1 to form an open-cell foam with interconnected cells, thereby forming the intermediate foam layer b1;

[0025] (3) The surface release paper 11' and the bottom release paper 11 are peeled off from the middle foaming layer b1 by a winding device, respectively. The middle foaming layer b1 is dried by a drying oven C1 and wound up by a winding device;

[0026] (4) The rolled-up middle foam layer b1 is unrolled, and the first surface layer a1 is unrolled and coated with glue through a roller coating device D1, preferably a PUR adhesive, and then the first surface layer a1 and the middle foam layer b1 are composited together through a composite device E1 composed of a pair of composite rollers; the second surface layer c1 is unrolled and coated with glue through a roller coating device F1, and then composited with the semi-finished product after composited with the first surface layer a1 and the middle foam layer b1 through a composite device G1, to form the composite foam core comprising the first surface layer a1, the middle foam layer b1 and the second surface layer c1.

[0027] With the above structure and manufacturing method, since the composite foam core 1 includes the first surface layer a1, the middle foam layer b1 and the second surface layer c1, during use, when the body fluid penetrates through the surface layer of the absorbent product and contacts the first surface layer a1 of the composite foam core 1, the non-woven fabric of the first surface layer a1 plays a role of diversion, and the body fluid diffuses along the plane XY direction and the thickness Z direction on the non-woven fabric of the first surface layer a1, increasing the utilization area of ​​the absorbent core and accelerating the absorption speed of the body fluid; and the pores d1 of the open-cell foam in the middle foam layer b1 are interconnected, and the body fluid will quickly penetrate into the open-cell foam along some fibers interspersed with the pores d1. At the same time, the open-cell foam of the middle foam layer b1 is also breathable and resilient, which greatly increases the breathability and comfort of the absorbent product. In addition, in step (4), the intermediate foam layer b1 can be composited with the first surface layer a1 and the second surface layer c1 simultaneously, or can be composited with the first surface layer a1 and the second surface layer c1 in sequence, or composited with the first surface layer a1 and the second surface layer c1 in steps, that is, the intermediate foam layer b1 is first rolled up after being composited with the first surface layer a1, and then unrolled and composited with the second surface layer c1, which can be flexibly selected according to the manufacturing equipment.

[0028] Example 2

[0029] like Figure 4 As shown, the embodiment discloses a method for manufacturing a composite foam core 2:

[0030] (1) The bottom release paper 21 is unwound by an unwinding device; the open-cell foam raw material, which is uniformly stirred at a high speed, including polyether polyol or polyester polyol, polyisocyanate and catalyst, is uniformly poured onto the bottom release paper 21 by a dispensing mechanism A2; the surface release paper 21' is unwound by an unwinding device and covers the open-cell foam raw material layer;

[0031] (2) transporting the open-cell foam raw material to the aging oven B2, and reacting in the aging oven B2 to form an open-cell foam with interconnected cells, thereby forming the intermediate foam layer b2;

[0032] (3) The surface release paper 21' and the bottom release paper 21 are peeled off from the middle foaming layer b2 by a winding device, and the middle foaming layer b2 is dried by a drying oven C2;

[0033] (4) After the first surface layer a2 is unrolled, it is coated with glue by a roller coating device D2, and then the first surface layer a2 and the intermediate foam layer b2 are composited together by a composite device E2 at the same time. After the second surface layer c2 is unrolled, it is coated with glue by a roller coating device F2, and then the composited semi-finished product after the composited first surface layer a2 and the intermediate foam layer b2 is composited by a composite device G2 at the same time, to form the composite foam core comprising the first surface layer a2, the intermediate foam layer b2 and the second surface layer c2.

[0034] In this embodiment, after the middle foaming layer b2 is dried by the drying oven C2, it does not need to be rolled up, but is directly compounded with the first surface layer a1 and the second surface layer a2, which not only simplifies the process route, but also prevents the middle foaming layer b2 from generating secondary pollution during the rolling and transportation process. The first surface layer a2 and the second surface layer c2 in the composite foaming core 2 can be hot air non-woven fabrics, spunbond non-woven fabrics, spunlace non-woven fabrics or composite non-woven fabrics, which can play a role in rapid penetration and diversion, increase the mechanical tensile strength of the overall foaming core, improve the machine performance of the foaming core, meet the machine requirements of high-speed machines when manufacturing absorbent products, and effectively solve the problem of deformation and breakage of the foaming core due to absorption of a large amount of liquid by consumers when wearing it.

[0035] Example 3

[0036] like Figure 5 and Figure 6 As shown, the embodiment discloses a composite foam core 3, comprising a first surface layer a3, an intermediate foam layer b3 and a second surface layer c3, wherein the first surface layer a3 and the second surface layer c3 are non-woven fabrics, the intermediate foam layer b3 is an open-cell foam having a plurality of pores d3, and the pores d3 are interconnected, the thickness of the open-cell foam is 1 mm to 5 mm, and the pore diameter is 50 μm to 400 μm, wherein: in this embodiment, the thickness of the open-cell foam is 3 mm, and the pore diameter is 50 μm to 250 μm, the fibers of the non-woven fabrics in the first surface layer a3 and the second surface layer c3 are arranged flat along the surface of the open-cell foam, and some of the fibers are inserted into the pores d3 of the open-cell foam, and the composite foam core 3 also has an open hole e3 that runs through the composite foam core 3.

[0037] The composite foam core of the utility model adopts the following manufacturing method:

[0038] The manufacturing steps of the composite foam core 3' without openings e3 can be carried out with reference to Examples 1 and 2. After the composite foam core 3' without openings e3 is formed, it is unwound and punched by a punching device H3 to form openings e3 that penetrate the composite foam core 3. The punching device H3 is composed of a pair of mutually meshing needle rollers and concave rollers, and the composite foam core 3' is pierced by the needle rollers and concave rollers. Punching can also be performed by a punching device, that is, directly forming openings by pressure stamping, or laser punching, etc. The punching device can also be directly placed after the composite device, and then rolled up after punching.

[0039] In this embodiment, since there is an opening e3 running through the composite foam core 3, when in use, body fluid can quickly reach the second surface layer c3 from the first surface layer a3 through the opening e3, thereby adding a fast absorption and penetration channel to the composite foam core 3, effectively preventing side leakage and back leakage caused by untimely absorption when the amount of body fluid suddenly increases.

[0040] Example 4

[0041] like Figure 7 and Figure 8 As shown, the embodiment discloses a composite foam core 4, comprising a first surface layer a4, an intermediate foam layer b4 and a second surface layer c4, wherein the first surface layer a4 and the second surface layer c4 are non-woven fabrics, the intermediate foam layer b4 is an open-cell foam having a plurality of pores d4, and the pores d4 are interconnected, the thickness of the open-cell foam is 1 mm to 5 mm, and the pore diameter is 50 μm to 400 μm, wherein: in this embodiment, the thickness of the open-cell foam is 4 mm, and the pore diameter is 150 μm to 400 μm, the fibers in the non-woven fabrics of the first surface layer a4 and the second surface layer c4 are arranged flat along the surface of the open-cell foam, some of the fibers penetrate into the pores d3 of the open-cell foam, and the first surface layer a4 also has an open cell f4.

[0042] The composite foam core of the utility model adopts the following manufacturing method:

[0043] The manufacturing steps of the intermediate foam layer b4 can be carried out with reference to Examples 1 and 2. After the first surface layer a4 is unrolled, it is firstly punched by a punching device I4 to form a first surface layer a4 having openings f4, and then glued by a roller coating device D4, and then the first surface layer a4 and the intermediate foam layer b4 are composited together by a composite device E4 at the same time; after the second surface layer c4 is unrolled, it is glued by a roller coating device F4, and then composited with the semi-finished product after the composite of the first surface layer a4 and the intermediate foam layer b4 by a composite device G4 at the same time, forming the composite foam core comprising the first surface layer a4, the intermediate foam layer b4 and the second surface layer c4, wherein the first surface layer a4 has openings f4.

[0044] In this embodiment, since the first surface layer a4 has openings f4, body fluid can quickly penetrate into the middle foaming layer b4 through the openings f4, which speeds up the absorption of body fluid and prevents leakage of body fluid. In addition, the first surface layer a4 can be embossed to increase the comfort of the composite foaming core, or printed to form a printed pattern, so that the first surface layer a4 can be identified by the pattern and the aesthetics of the absorbent product can be increased. The punching, embossing or printing pattern can be directly performed online, that is, the first surface layer a4 is punched, embossed or printed and then immediately enters the composite process, or it can be performed offline, that is, before the composite process, the first surface layer a4 has been punched, embossed or printed on other equipment.

[0045] In this embodiment, the first surface layer a4 is punched, embossed or printed. Of course, the second surface layer b4 may also be punched, embossed or printed accordingly.

Claims

1. A composite foam core, characterized in that: The composite foam core comprises a first surface layer, an intermediate foam layer and a second surface layer; the first surface layer and the second surface layer are non-woven fabrics; the intermediate foam layer is an open-cell foam having a plurality of pores which are interconnected; the thickness of the open-cell foam is 1 mm to 5 mm, and the pore diameter is 50 μm to 400 μm; the fibers of the non-woven fabric in the first surface layer and the second surface layer are arranged flat along the surface of the open-cell foam, and some of the fibers penetrate into the pores of the open-cell foam.

2. A composite foam core as claimed in claim 1, characterized in that: The open-cell foam is a polyurethane open-cell foam.

3. A composite foam core as claimed in claim 1, characterized in that: The nonwoven fabric is hot air nonwoven fabric, spunbond nonwoven fabric, spunlace nonwoven fabric or composite nonwoven fabric.

4. A composite foam core as claimed in claim 1, characterized in that: The nonwoven fabric has openings, embossing or printing patterns.

5. A composite foam core as claimed in claim 1, characterized in that: The composite foam core has openings that sequentially penetrate the first surface layer, the middle foam layer and the second surface layer.

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