Partitioned absorption core manufacturing equipment and partitioned absorption core

Abstract

The utility model discloses a partition type absorption core body which comprises a first wrapping non-woven layer and a second wrapping non-woven layer. A second wrapping non-woven layer; the core body layer is arranged between the first wrapping non-woven layer and the second wrapping non-woven layer; the second polymer layer is arranged between the first wrapping non-woven layer and the core body layer; the total length of the core body layer in the longitudinal direction is not smaller than 40% of the total length of the absorption core body in the longitudinal direction, and the absorption core body is only provided with the second macromolecule layer in the front side area and the rear side area of the core body layer in the longitudinal direction. The utility model further relates to manufacturing equipment of the partition type absorption core body, and the partition type absorption core body can be manufactured on line through the manufacturing equipment.

Description

Technical Field

[0001] This utility model relates to the field of hygiene products technology, specifically to a device for manufacturing a partitioned absorbent core and the absorbent core obtained therefrom. Background Technology

[0002] Consumers rely on disposable absorbent products in their daily lives, including items such as adult incontinence products, bedwetting pants, training pants, and diapers. Many manufacturers strive to better meet users' needs for these products. For example, there is a need to further improve the fit, comfort, and leak protection of many products.

[0003] A key component of many absorbent articles is the absorbent core, such as the absorbent wick, contained within the article. These absorbent cores are typically responsible for capturing and retaining bodily fluids, preventing leakage from the absorbent article, and further keeping the fluid away from the wearer's skin, which helps promote skin health. Improving the structure and performance of absorbent cores to produce thinner products that absorb fluids faster and leak less is a consistently important area of ​​market demand.

[0004] The absorbent cores of commonly available disposable absorbent products can be broadly categorized into two types: traditional cores and absorbent cores. Traditional cores typically consist of fluff pulp, absorbent powder, hot melt adhesive, and a non-woven fabric covering. Their shape can be designed as a long rectangle or a dumbbell shape. Traditional cores offer good softness and excellent absorbency, but they are relatively thick and heavy, have poor breathability, and tend to harden when compressed, compressing them and compromising their softness, resulting in an uncomfortable feel.

[0005] The absorbent core typically consists of two layers of nonwoven material, a middle loose layer, and two layers of superabsorbent resin material. For example, refer to the absorbent core disclosed in Chinese Patent Application No. CN202222200844.3, which includes: a diffusion-absorbing layer, an intermediate layer, and a seepage-proof absorbent layer stacked sequentially; the seepage-proof absorbent layer is a segmented hollow viscose fiber nonwoven fabric, in which hollow and solid fiber segments are alternately or spaced apart. This absorbent core overcomes the shortcomings of excessively thick wood pulp cores, which are prone to breakage and clumping, and improves upon the poor temporary liquid-trapping capacity and weak diffusion performance of existing absorbent cores. It effectively enhances the product's repeated liquid absorption capacity, significantly improves the diffusion properties of the absorbent core, and also possesses good absorption performance and anti-backflow performance.

[0006] To ensure a good fit and prevent leakage, the absorbent core is typically designed as a long rectangle or a dog bone shape, with its two ends extending to the wearer's abdomen and upper buttocks respectively. During actual use, bodily fluids are constrained by gravity and the limited fluid diffusion of the absorbent core, meaning that the areas near the ends are often not used for absorbing or retaining bodily fluids. Because the absorbent core is composed of multiple layers of superabsorbent particles and multiple layers of nonwoven fabric, this design results in high material costs and waste. Furthermore, since the absorbent core is disposable, it also puts significant pressure on the environment. Additionally, because the ends of the absorbent core are closer to the wearer's skin than the groin area, it can cause discomfort such as stuffiness or lack of breathability.

[0007] Therefore, there remains a need to improve the absorbent core of absorbent products, which can improve the utilization rate of the absorbent core and reduce material waste while maintaining the basic absorption performance of the product. It can also help reduce environmental impact and improve the user experience for consumers. Utility Model Content

[0008] Therefore, the objective of this invention is to provide an apparatus for manufacturing a partitioned absorbent core and the partitioned absorbent core thereof, thereby at least partially overcoming the shortcomings of the prior art.

[0009] To accomplish the above tasks, this utility model provides a partitioned absorbent core, which extends in both the transverse and longitudinal directions and has a thickness in a direction perpendicular to both the transverse and longitudinal directions. The absorbent core includes: - a first wrapping nonwoven layer; - a second wrapping nonwoven layer; - a core layer between the first wrapping nonwoven layer and the second wrapping nonwoven layer, wherein the core layer includes: - a first intermediate nonwoven layer; - a second intermediate nonwoven layer; and - a first polymer layer between the first and second intermediate nonwoven layers, wherein the first polymer layer contains at least partially uniformly distributed first superabsorbent polymer particles; - a second polymer layer between the first wrapping nonwoven layer and the core layer, wherein the second polymer layer contains at least partially uniformly distributed second superabsorbent polymer particles; wherein the total length of the core layer in the longitudinal direction is not less than 40% of the total length of the absorbent core in the longitudinal direction, and the absorbent core has only the second polymer layer in the front and rear regions of the core layer in the longitudinal direction.

[0010] Therefore, the partitioned absorbent core of this utility model can save material costs and reduce the impact on the natural environment caused by its disposal after use. On the other hand, since the partitioned absorbent core removes part of the layer structure in the end areas on both sides, it can reduce the material thickness between the wearer's abdomen and the wearer's skin, thereby eliminating the discomfort of stuffiness or lack of breathability to a certain extent.

[0011] As a preferred aspect, the total length of the absorbent core extending beyond the core layer in the longitudinal direction on its front side is no more than 35% of the total length of the absorbent core in the longitudinal direction.

[0012] As a preferred aspect, the total length of the absorber core extending longitudinally beyond the core layer on its rear side is no more than 25% of the total length of the absorber core in the longitudinal direction.

[0013] As a preferred aspect, the first intermediate nonwoven layer and the second intermediate nonwoven layer comprise synthetic fibers or are composed of synthetic fibers, optionally blended with natural fibers such as cellulose fibers, cotton fibers, or viscose fibers.

[0014] As a preferred aspect, the upper wrapping nonwoven layer and / or the second wrapping nonwoven layer are formed of a low-basis-weight nonwoven fiber web with a basis weight between 5 gsm and 50 gsm.

[0015] As a preferred aspect, the first superabsorbent polymer particles and the second superabsorbent polymer particles are identical, and the composite absorbent core comprises at least 40% by weight of superabsorbent polymer particles based on the total weight of the composite absorbent core, wherein the basis weight of the superabsorbent polymer particles is 100 gsm to 500 gsm.

[0016] As another aspect of this utility model, a manufacturing apparatus for a partitioned absorbent core is also disclosed, comprising: a first roll for supplying a first intermediate nonwoven layer; a first conveying mechanism for conveying the first intermediate nonwoven layer from the first roll along the machine direction; a first hopper and a second roll for supplying a second intermediate nonwoven layer sequentially arranged in front of the first roll along the machine direction, wherein the first hopper is used to supply superabsorbent material containing first superabsorbent polymer particles; a first rolling mechanism arranged in front of the second roll along the machine direction for pressing the first intermediate nonwoven layer, the superabsorbent material containing the first superabsorbent polymer particles, and the second intermediate nonwoven layer into a strip-shaped core layer; a rotary cutting mechanism arranged in front of the first rolling mechanism along the machine direction for cutting the strip-shaped core layer into multiple individual core layers of different lengths; and a second conveying mechanism for supplying a second wrapping nonwoven layer. Three reels; a second conveying mechanism for delivering the second wrapped nonwoven layer from the third reel along the machine direction; a transfer mechanism adjacent to the rotary cutting mechanism for transferring multiple individual core layers spaced apart from each other to the top side of the second wrapped nonwoven layer; a second hopper and a fourth reel for supplying the first wrapped nonwoven layer, sequentially arranged along the machine direction in front of the third reel, wherein the second hopper is used to continuously supply superabsorbent material containing second superabsorbent polymer particles to the second wrapped nonwoven layer; a second pressing mechanism arranged along the machine direction in front of the third reel for laminating the second wrapped nonwoven layer, multiple spaced-apart individual core layers, and the first wrapped nonwoven layer into the elongated absorbent core; and a cutting station arranged along the machine direction in front of the second pressing mechanism for cutting the elongated absorbent core into multiple individual partitioned absorbent cores.

[0017] This allows for the efficient manufacture or production of the aforementioned partitioned absorber core with its unique structure using an online, continuous process.

[0018] As a preferred aspect, the transfer mechanism is a transfer hub with a negative pressure adsorption mechanism.

[0019] As a preferred aspect, the first hopper and / or the second hopper are configured as bulk solids pumps or feeders capable of maintaining a consistent flow of superabsorbent polymer particles during free fall.

[0020] As a preferred aspect, it also includes an adhesive spray nozzle disposed between a third roll for supplying the second wrapped nonwoven layer and a second hopper, for applying adhesive to the top side of the second wrapped nonwoven layer unwound from the third roll. Attached Figure Description

[0021] Figure 1This is a schematic diagram of the manufacturing equipment for the partitioned absorbent core according to the present invention;

[0022] Figure 2 This is a schematic cross-sectional view of an existing absorber core;

[0023] Figure 3 This is a schematic enlarged view of an existing absorber core;

[0024] Figure 4 This is a schematic cross-sectional view of the partitioned absorption core according to the present invention;

[0025] Figure 5 This is a schematic enlarged view of the partitioned absorption core according to the present invention.

[0026] Explanation of reference numerals in the attached figures

[0027] 100 - Manufacturing equipment; 101 - First intermediate nonwoven layer; 102 - Second intermediate nonwoven layer;

[0028] 103-First feeding hopper; 104-First conveying mechanism; 105-Vessel cutting mechanism;

[0029] 106 - Transfer mechanism; 107 - Second hopper; 108 - First nonwoven wrapping layer;

[0030] 109 - Second wrapping nonwoven layer; 110 - Adhesive spray nozzle; 200 - Core layer;

[0031] 11-Upper nonwoven layer; 12-Lower nonwoven layer; 13-Intermediate reinforcing layer;

[0032] 21 - Upper core layer; 22 - Lower core layer; G - Void; X - Machine direction or longitudinal direction; Y - Vertical direction; Detailed Implementation

[0033] Those skilled in the art will understand that the following detailed description of embodiments is merely an illustration of exemplary models and is not intended to limit the broader aspects of this disclosure.

[0034] Certain directional terms used in the description of the accompanying drawings below, such as “inner,” “outer,” “upper,” “lower,” and other directional terms, shall be understood to have their normal meaning and refer to those directions involved when normally viewing the drawings. Unless otherwise specified, the directional terms used in this specification are generally in accordance with the conventional directions understood by those skilled in the art.

[0035] The terms “first,” “first,” “second,” “second,” and similar terms used in this utility model do not indicate any order, quantity, or importance, but are used to distinguish one component from other components.

[0036] Terminology Definition

[0037] The terms “disposable” or “reusable” are used herein to describe absorbent articles that are not typically intended to be washed or otherwise restored to or reused as absorbent articles (e.g., they are designed to be discarded after a single use and may also be configured to be recyclable, compostable, or disposed of in other environmentally compatible ways). The absorbent pants described herein are examples of disposable absorbent articles.

[0038] The term "pant-style absorbent garment" (also known as "menstrual pants," "pant-style absorbent garment," and "menstrual pants") refers herein to a disposable absorbent garment designed for use by an adult wearer, having a continuous perimeter waist opening and side-opposite continuous perimeter leg openings. For the avoidance of confusion, adult incontinence garments can be in the form of absorbent pants. Pants may be constructed to have a continuous or closed waist opening, such as a package, and at least one continuous closed leg opening before the wearer puts on the garment. Pants may be pre-formed using a variety of techniques, including but not limited to using any reusable fastening closure and / or permanent closure (e.g., stitching, thermal bonding, pressure welding, adhesives, glue bonding, mechanical fasteners, etc.) to join the parts of the garment together. Pants may be pre-formed at any location around the waist area of ​​the garment (e.g., side-fastening or seam-fastening, front waistband fastening or seam-fastening, back waistband fastening or seam-fastening, or combinations thereof).

[0039] Regarding structural terminology, the terms “set up” or “equipped” are used herein to indicate that one or more elements are located in a particular place or position as part of a macroscopic overall structure with other elements or as separate elements joined to another element.

[0040] As used herein, the term "joint" includes a configuration in which an element is directly secured to another element by directly attaching the element to the other element, and a configuration in which an element is indirectly secured to another element by attaching the element to an intermediate member (which in turn is attached to the other element).

[0041] As used herein, “integral” means a configuration in which an element is generated from or derived from a component or part of an article, as opposed to an element being joined to a component. “Integral formation” means generating an element from an underlying material or part thereof by, for example, molding, forming, and / or remodeling the underlying material.

[0042] "Proximal" and "distal" refer to the position of an element that is relatively close to or far from the longitudinal or lateral centerline of the structure, respectively (for example, relative to the same longitudinal axis, the proximal edge of a longitudinally extending element is closer to the longitudinal axis than the distal edge of the same element).

[0043] "Facing the body" and "facing the clothing" refer to the relative positions of components or the relative positions of the surfaces of a component or group of components, respectively. "Facing the body" means that during wear, a component or surface is closer to the wearer than some other components or surfaces. "Facing the clothing" means that during wear, a component or surface is further away from the wearer than some other components or surfaces (i.e., the component or surface is closer to the wearer's clothing, which may be worn over a disposable absorbent material).

[0044] The term "opening" refers to the initial separation of opposite waist areas before or during the wearing of an article, thus not forming a continuous waist and leg opening.

[0045] The term "closure" refers to the permanent or repeatable secure joining of opposing waist areas during encapsulation to form a continuous waist opening and leg opening.

[0046] The terms "nonwoven" or "non-woven fabric" herein refer to a material or material web formed without the aid of a weaving or knitting process. The material or material web may have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers"), which may be interlocked, but in a manner distinct from that found in knitted fabrics. Nonwoven materials or webs can be formed by a variety of processes, including, but not limited to, meltblowing, spunbonding, and carding processes.

[0047] As used herein, the term "bonding" refers to the joining, adhesion, connection, attachment, etc., of two elements. Two elements are considered to be bonded together when they are joined, adhered, connected, attached, etc., directly or indirectly to each other, such as when bonded to an intermediate element. Bonding can be performed via, for example, adhesives, pressure bonding, thermal bonding, ultrasonic bonding, splicing, stitching, and / or welding.

[0048] First of all Figure 2-3 The diagram illustrates the structure of a double-layer composite core in the prior art. For example... Figure 2 As best shown, the bilayer composite core has a thickness along the vertical Y direction and comprises, from top to bottom: a liquid-permeable upper wrapping layer 11, for example, made of a nonwoven sheet or nonwoven fabric; a lower wrapping layer 12, for example, made of a nonwoven sheet or nonwoven fabric; an intermediate reinforcing layer 13 between the upper wrapping layer 11 and the lower wrapping layer 12; a first polymer layer between the upper wrapping layer 11 and the intermediate reinforcing layer 13, wherein the first polymer layer contains at least partially uniformly distributed first superabsorbent polymer particles (SAP or SAM); and a second polymer layer between the intermediate reinforcing layer 13 and the lower wrapping layer 12, wherein the second polymer layer contains at least partially uniformly distributed second superabsorbent polymer particles.

[0049] Here, Figure 2-3The intermediate reinforcing layer 13 of the bilayer composite core shown is designed to be highly bulky. The term "highly bulky" refers to a low-density, loosely woven fabric compared to a flat, paper-like fabric, characterized by a relatively high porosity. This means that there are relatively large amounts of void space between its fibers, in which superabsorbent polymer particles can be distributed.

[0050] The intermediate reinforcement layer 13 is preferably a nonwoven fabric, but other types of high-loft materials are not excluded. The intermediate reinforcement layer 13 may contain or be composed of synthetic fibers, optionally blended with natural fibers such as cellulose fibers, cotton fibers, or viscose fibers. The intermediate reinforcement layer 13 may be substantially free of free cellulose fibers that are not bonded to other fibers of the nonwoven fabric. The amount of such free cellulose fibers in the absorbent core may be less than 10% of the total absorbent core weight, or less than 5% of the total absorbent core weight, or less than 1% of the total absorbent core weight, or may be completely free of such free cellulose fibers. The high-loft material may contain at least 10%, 30%, 50%, 70%, 90%, and up to 100% synthetic fibers by weight of the high-loft layer.

[0051] The fibers forming the intermediate reinforcing layer 13 can be made partly or entirely of relatively elastic synthetic fibers, particularly polypropylene (PP), polyamide (PA, such as nylon), or polyethylene terephthalate (PET) fibers. The diameter of the fibers can be, for example, in the range of 0.01 mm to 0.50 mm.

[0052] The thickness, basis weight, and density of the intermediate reinforcing layer 13 are generally uniform in both the transverse and longitudinal directions. The fiber orientation in the intermediate reinforcing layer 13 can be non-uniform, for example, in carded nonwoven fabrics. Furthermore, the fiber orientation of the intermediate reinforcing layer 13 in the thickness direction z can differ from the dominant orientation in one or both directions x and / or y. As an example, the basis weight of a high-loft intermediate reinforcing layer 13 can be, for example, from 15 gsm to 500 gsm, particularly from 30 gsm to 200 gsm, such as from 50 gsm to 120 gsm. The values ​​for the intermediate reinforcing layer 13 indicated herein are considered specifically for high-loft materials, i.e., before the application of adhesives to the SAP particles. When the absorbent core comprises two or more high-loft intermediate layers, these intermediate reinforcing layers 13 can be the same or different.

[0053] like Figure 2As shown, a high-loft intermediate reinforcing layer 13 is sandwiched between an upper wrapping layer 11 and a lower wrapping layer 12. Generally, the upper wrapping layer 11 is positioned on the wearer-facing side of the bilayer absorbent core, closest to the absorbent article, allowing fluid to easily pass through it to the intermediate reinforcing layer 13 during use. The lower wrapping layer 12 is positioned on the opposite side of the intermediate reinforcing layer 13. The bottom layer can be liquid-permeable or liquid-impermeable. The top and bottom layers provide coverage on both sides of the intermediate layer to prevent SAP particles from detaching from the high-loft material during the preparation of the bilayer absorbent core and article and / or during use of the absorbent article.

[0054] The upper wrapping layer 11 and the lower wrapping layer 12 can be made of relatively thin and inexpensive materials, such as those commonly used in the production of conventional cores. The upper wrapping layer 11 and the lower wrapping layer 12 can be, for example, thin paper (breathable felt or wet-laid web) having a basis weight range of, for example, 5 to 100 gsm, particularly 10 to 40 gsm. The upper wrapping layer 11 and the lower wrapping layer 12 can also be formed from low-basis-weight nonwoven fiber webs with a basis weight between 5 gsm and 50 gsm, such as carded nonwovens, spunbond nonwovens (“S”), or meltblown nonwovens (“M”), and laminates of any of these. For example, spun melt polypropylene nonwovens are suitable, particularly nonwovens with a laminated web structure of SMS or SMMS or SSMMS and a basis weight range of about 5 gsm to 20 gsm.

[0055] like Figure 2 As shown, a first polymer layer is sandwiched between the upper coating layer 11 and the intermediate reinforcing layer 13, and a second polymer layer is sandwiched between the intermediate reinforcing layer 13 and the lower coating layer 12. It is known that the first polymer layer may be composed of a polymer material consisting of first superabsorbent polymer particles and fluff pulp, or solely of polymers containing planarly laid first superabsorbent polymer particles, meaning that the first polymer layer contains at least partially uniformly distributed first superabsorbent polymer particles (SAP or SAM). Similarly, the second polymer layer may be composed of a polymer material consisting of second superabsorbent polymer particles and fluff pulp, or solely of polymers containing planarly laid second superabsorbent polymer particles, meaning that the second polymer layer contains at least partially uniformly distributed second superabsorbent polymer particles (SAP or SAM). Preferably, the first and second superabsorbent polymer particles are identical.

[0056] In this document, the term “superabsorbent polymer” (abbreviated as “SAP” in both singular and plural forms) refers to an absorbent material capable of absorbing at least 10 times its weight in a 0.9% saline solution, as measured by centrifugal retention capacity (CRC) test (EDANA method NWSP 241.0.R2(19)). SAP preferably has a CRC value of at least 15 g / g.

[0057] SAP particles can be relatively small in their dry state (their longest dimension is less than 1 mm) and can be generally spherical in shape, but granules, fibers, flakes, spheres, powders, plates, and other shapes and forms are also known to those skilled in the art. Typically, SAP can be in the form of spherical particles. Therefore, the absorbent material can consist of or be substantially composed of SAP distributed within a high-loft nonwoven fabric. The absorbent core comprises at least 60% by weight of superabsorbent polymer particles based on the total weight of the absorbent core, wherein the superabsorbent polymer particles have a basis weight of 100 gsm to 500 gsm.

[0058] Therefore, in Figure 3 The diagram shows a schematic of such a double-layer absorber core in the prior art, wherein the side of the upper encapsulation layer 11 and the middle reinforcement layer 13 closest to it (including the SAP) can be regarded as the upper core layer 21, and the side of the lower encapsulation layer 12 and the middle reinforcement layer 13 closest to it (including the SAP) can be regarded as the lower core layer 22. Figure 2 As shown, the upper core layer 21 and the lower core layer 22 are essentially the same length. This results in the following drawback: when assembled into absorbent clothing such as baby diapers, the two ends of this double-layer absorbent core in the longitudinal direction can extend to the wearer's abdomen and upper buttocks, respectively. During actual use, the wearer's bodily fluids are constrained by gravity and the limited fluid diffusion of the absorbent core, resulting in fluid leakage at both ends of the absorbent core ( Figure 3 The area near the red box (as shown in the image) is often not used to absorb and retain bodily fluids. Because the absorbent core is composed of multiple layers of superabsorbent particles and multiple layers of nonwoven fabric, this design results in high material costs and material waste. Furthermore, since the absorbent core is for single use, it also puts significant pressure on the environment. Additionally, because the two ends of the absorbent core are closer to the wearer's skin than the groin area, it can cause discomfort such as stuffiness or lack of breathability.

[0059] In response to this, the inventors of this utility model, after discovering the shortcomings of the double-layer absorbent core design and considering the technical requirements for online mass production of absorbent cores, took the lead in proposing to reduce the need for rotary cutting transfer. Figure 3 The red box in the image indicates the area with very low SAM usage, thereby reducing product production costs and minimizing environmental pollution.

[0060] Manufacturing equipment for partitioned absorber cores

[0061] As a specific technical solution to the above-mentioned inventive concept, Figure 1 The diagram shows a manufacturing apparatus 100 for a partitioned absorber core according to the present invention.

[0062] like Figure 1 The manufacturing equipment 100 for the partitioned absorbent core according to the present invention includes a frame (not shown), wherein a first roll for supplying a first intermediate nonwoven layer 101 to the manufacturing equipment is first provided on the frame along the machine direction X. Figure 1 (Not shown in the figure), wherein the first intermediate nonwoven layer 101 from the first roll is delivered along the machine direction X by a first conveying mechanism 104, such as a conveying roller. Further, a first hopper 103 and a second roll for supplying the second intermediate nonwoven layer 102 are sequentially arranged in front of or downstream of the first conveying mechanism 104 along the machine direction X. Figure 1 (Not shown in the figure). Optionally in this invention, the first intermediate nonwoven layer 101 and / or the second intermediate nonwoven layer 102 may comprise or be composed of synthetic fibers, optionally mixed with natural fibers such as cellulose fibers, cotton fibers, or viscose fibers.

[0063] In this embodiment, the first hopper 103 may be a bulk solids pump or feeder, configured to maintain a consistent flow of, for example, superabsorbent polymer particles during free fall. The flow rate of the superabsorbent polymer particles exiting the first hopper 103 can be adjusted so that the first hopper 103 can deliver different amounts of superabsorbent polymer particles, thereby producing superabsorbent materials with different basis weights in the core layer 200, which is described in detail below. Preferably, the superabsorbent polymer particles have a basis weight of 100 gsm to 500 gsm. This difference in basis weight of the superabsorbent material allows the formed core layer 200 to be used for different absorbent end uses, such as for diapers, feminine hygiene products, adult care clothing, bandages, etc.

[0064] After superabsorbent polymer particles from the first feed hopper 103 are deposited or bonded onto the first intermediate nonwoven layer 101, the second intermediate nonwoven layer 102 from the roll supplied with the second intermediate nonwoven layer 102 is positioned above the deposited superabsorbent polymer particles. Preferably, before the second intermediate nonwoven layer 102 is positioned onto the deposited superabsorbent polymer particles, an adhesive can be sprayed onto the second intermediate nonwoven layer 102 using a spray nozzle (not shown). This spray nozzle can be located in front of the first feed hopper 103 or both in front of and behind the first feed hopper 103 to mix the adhesive and the deposited superabsorbent polymer particles together, as described below. However, it should be understood that the spray nozzle is merely optional and may even be absent in some embodiments. When present, the adhesive applied by the spray nozzle is operable to more tightly bond the second intermediate nonwoven layer 102 to the deposited superabsorbent polymer particles and / or further fix the superabsorbent material within the formed core layer 200.

[0065] In a preferred aspect, the combination of the first intermediate nonwoven layer 101, the deposited superabsorbent material from the first feed hopper 103, and the second intermediate nonwoven layer 102 can be aided in compressing these components together by one or more first rolling mechanisms. Generally, the first rolling mechanism can apply a pressure of 0.5 pounds per linear inch (PLI) (88 N / m) to 1.5 PLI (263 N / m), or 0.75 PLI (131 N / m) to 1.25 PLI (219 N / m), to the combination of the first intermediate nonwoven layer 101, the deposited superabsorbent material from the first feed hopper 103, and the second intermediate nonwoven layer 102. Such pressure helps to further bond the deposited superabsorbent material to the first and second intermediate nonwoven layers 101, 102. While not required in all embodiments, it may be preferred that the first rolling mechanism be positioned relatively close to the second intermediate nonwoven layer 102, such that when the combination of the first intermediate nonwoven layer 101, the deposited superabsorbent material, and the second intermediate nonwoven layer 102 is passed through the rolling mechanism, it forms a long strip-shaped core layer 200 that is firmly bonded together. Here, as a preferred aspect, the first intermediate nonwoven layer 101 and the second intermediate nonwoven layer 102 may comprise synthetic fibers or be composed of synthetic fibers, optionally blended with natural fibers such as cellulose fibers, cotton fibers, or viscose fibers.

[0066] Next, as Figure 1 As shown, a rotary cutting mechanism 105, such as a slitting roller, is arranged downstream of the roll supplying the second intermediate nonwoven layer 102 in the machine direction X, so that the combination of the pressed first intermediate nonwoven layer 101, the deposited superabsorbent material, and the second intermediate nonwoven layer 102 from the rolling mechanism can be transferred to the rotary cutting mechanism 105. At this rotary cutting mechanism 105, the pressed, continuous strip-shaped combination of the first intermediate nonwoven layer 101, the deposited superabsorbent material, and the second intermediate nonwoven layer 102 is cut as needed into multiple individual core layers 200 of different lengths. These individual core layers 200 can then be used in the manufacturing process of the partitioned absorbent core described herein. Specifically, by controlling the feed rate of the strip-shaped combination of the first intermediate nonwoven layer 101, the deposited superabsorbent material, and the second intermediate nonwoven layer 102 upstream of the rotary cutting mechanism 105, the strip-shaped combination can be cut into core layers 200 of different lengths as needed.

[0067] Adjacent to the rotary cutting mechanism 105 is a transfer mechanism 106, preferably a transfer hub, for further transferring core layers 200 of different lengths. The transfer hub rotates around its own axis of rotation at different speeds as needed. When it rotates to the exit position of the rotary cutting mechanism 105, it receives core layers 200 of different lengths from the rotary cutting mechanism 105 by means of a method such as negative pressure. Then, it transfers them downstream by its own rotation to the second conveying mechanism 111 to achieve the second lamination process.

[0068] like Figure 1 As shown, in the second lamination process, the second wrapping nonwoven layer 109, having a top side and a bottom side, can be wound from a third roll containing the material forming the second wrapping nonwoven layer 109. Figure 1 (Not shown in the image) Unwound and extended. The second wrapping nonwoven layer 109 may correspond to the lower wrapping nonwoven layer 12 in the absorbent core described above. However, in other embodiments, the second wrapping nonwoven layer 109 may also correspond to the previously described upper wrapping nonwoven layer 11.

[0069] As shown, the first wrapping nonwoven layer 108, having a top side and a bottom side, can also be made from the fourth roll ( Figure 1 (Not shown in the image) unwound and extended. Before attaching the first wrapped nonwoven layer 108 to the second wrapped nonwoven layer 109, superabsorbent material from the second feed hopper 107 located between the two can be dispersed onto the top side of the second wrapped nonwoven layer 109. For example, the superabsorbent material can be stored in the second feed hopper 107 and can be dispensed onto the top side of the second wrapped nonwoven layer 109 via a conduit. In some embodiments, the superabsorbent material (e.g., with...) Figure 4 The SAP particles shown, in which the superabsorbent polymer particles have a basis weight of 100 gsm to 500 gsm, are metered to such that a specified amount of superabsorbent material is deposited on the top side of the second encapsulated nonwoven layer 109.

[0070] The superabsorbent material can be dispensed from the second hopper 107 in such a manner to achieve an addition rate between approximately 90 gsm and approximately 350 gsm. Before the superabsorbent material contacts the top side of the second wrapped nonwoven layer 109, a spray nozzle 110 positioned between the spool containing the material forming the second wrapped nonwoven layer 109 and the second hopper 107 can apply adhesive to the top side of the second wrapped nonwoven layer 109. It should be noted that although the spray nozzle 110 is positioned on the front side of the second hopper 107 here, it is also feasible to position the spray nozzle 103 on both the front and rear sides of the second hopper 107 to mix the adhesive and the deposited superabsorbent polymer particles together.

[0071] Subsequently, multiple core layers 200 of varying lengths from transfer mechanism 106 are transferred one by one, spaced apart by a certain gap G, to the top side of the second wrapped nonwoven layer 109 with adhesive, thereby bonding them thereto. The second wrapped nonwoven layer 109, with multiple spaced-apart core layers 200 bonded to its top side, is then conveyed below the second discharge hopper 107 to receive SAP or SAM particles falling from it. Preferably, as the SAP or SAM particles are dispensed from the second discharge hopper 107, a conveyor belt driven by the second conveying mechanism 111 can vibrate to cause the second wrapped nonwoven layer 109, which is being conveyed thereon, to vibrate. Adding vibrational energy to the second wrapped nonwoven layer 109 can help increase the stability of the dispensed superabsorbent material throughout the second wrapped nonwoven layer 109. However, in at least some embodiments, it may not be necessary to use vacuum and / or vibrational energy to achieve the desired amount of superabsorbent material stabilization within the second wrapped nonwoven layer 109.

[0072] Next, after depositing the superabsorbent material onto a second wrapped nonwoven layer 109 having multiple spaced-apart core layers 200, a first wrapped nonwoven layer 108 is laminated onto the second wrapped nonwoven layer 109. The laminate of the second wrapped nonwoven layer 109 and the first wrapped nonwoven layer 108 can then be advanced along the machine direction through one or more second rolling mechanisms to help compress the components together. Preferably, the first wrapped nonwoven layer 108 can be formed from a low-basis-weight nonwoven fiber web with a basis weight between 5 gsm and 50 gsm, and the second wrapped nonwoven layer 109 can also be formed from a low-basis-weight nonwoven fiber web with a basis weight between 5 gsm and 50 gsm.

[0073] Generally, the second rolling mechanism can apply a pressure of 0.5 pounds per linear inch (PLI) (88 N / m) to 1.5 PLI (263 N / m) or 0.75 PLI (131 N / m) to 1.25 PLI (219 N / m) to the combination of the first wrapped nonwoven layer 108 and the second wrapped nonwoven layer 109 with a plurality of spaced-apart core layers 200. This pressure helps to further secure the plurality of spaced-apart core layers 200 between the second wrapped nonwoven layer 109 and the first wrapped nonwoven layer 108. While not required in all embodiments, it may be preferred that the second rolling mechanism be positioned relatively close to the roll from which the first wrapped nonwoven layer 108 is supplied, such that when the combination of the first wrapped nonwoven layer 108 and the second wrapped nonwoven layer 109 with a plurality of spaced-apart core layers 200 is passed through the rolling mechanism, a firmly bonded structure is formed. Figure 3The elongated absorbent core 300 shown in the figure has multiple core layers 200 with visible gaps G between them, and the SAP particles located above the multiple core layers 200 are continuously distributed.

[0074] Following one or more second rolling mechanisms, the elongated absorbent core 300 can be passed to a cutting station, where it is cut as needed into individual partitioned absorbent cores 300. These individual partitioned absorbent cores 300 can then be incorporated into the manufacturing process for producing the various absorbent articles described herein.

[0075] 300 partitioned absorption core

[0076] like Figure 4 As shown, the partitioned absorbent core 300 extends in both the lateral and longitudinal directions and has a thickness in a vertical direction perpendicular to the lateral and longitudinal directions, comprising along the vertical direction: an uppermost first wrapping nonwoven layer 108; a lowermost second wrapping nonwoven layer 109; a core layer 200 between the first wrapping nonwoven layer 108 and the second wrapping nonwoven layer 109, wherein the core layer 200 comprises: a first intermediate nonwoven layer 101; a second intermediate nonwoven layer 102; a first polymer layer between the first intermediate nonwoven layer 101 and the second intermediate nonwoven layer 102, wherein the first polymer layer contains at least partially uniformly distributed first superabsorbent polymer particles (SAP); and a second polymer layer between the first wrapping nonwoven layer 108 and the core layer 200, wherein the second polymer layer contains at least partially uniformly distributed second superabsorbent polymer particles (SAP).

[0077] Further as Figure 5 As shown, according to Figure 1 The partitioned absorbent core 300 produced by the manufacturing equipment 100 shown has a middle section defined by the core layer 200 for absorbing urine along the machine direction X. Figure 5 In the partitioned absorbent core 300 shown, the side of the partitioned absorbent core 300 facing the body (i.e., the side of the first wrapping nonwoven layer 108) is... Figure 5 Partial layer structure (not shown in the image) in Figure 5 The front and rear sides shown are removed or thinned so that the total length l of the core layer 200 in the partitioned absorber core 300 is more than 40% and more preferably more than 60% of the total length of the entire partitioned absorber core 300.

[0078] Specifically, in Figure 5In the illustrated embodiment, the intermediate nonwoven layer and polymer absorbent layer are not provided in the two end regions on both sides of the core layer 200 along the longitudinal direction (X direction). That is, the partitioned absorbent core 300 includes a portion with the core layer 200 sandwiched in the middle and a portion without the core layer 200 sandwiched in the middle. The length of the portion with the core layer 200 sandwiched in the middle is l, and the overall length of the partitioned absorbent core 300 is L. Here, the length l is at least 40% of the overall length L, and more preferably at least 60%. This can be adjusted by factors such as the cutting length of the rotary cutting mechanism 105 and the transfer timing of the transfer mechanism 106. Furthermore, the portion of the absorbent core 300 that exceeds the core layer 200 along the longitudinal direction can be distributed on the front and rear sides of the longitudinal direction (X direction), such as... Figure 5 As shown, in a preferred aspect, the total length of the absorbent core extending beyond the core layer in the longitudinal direction on its front side is no more than 35% of the total length of the absorbent core in the longitudinal direction. Furthermore, the total length of the absorbent core 300 extending beyond the core layer 200 in the longitudinal direction on its rear side can also be no more than 25% of the total length of the absorbent core in the longitudinal direction. According to the inventors' laboratory tests, this design can effectively reduce material costs without significantly increasing the possibility of urine leakage.

[0079] Therefore, on the one hand, it can save the material cost of the partitioned absorbent core 300 and the impact on the natural environment caused by its disposal after use; on the other hand, since the partitioned absorbent core 300 removes part of the layer structure in the end areas on both sides, it can reduce the material thickness between the wearer's abdomen and the wearer's skin, thereby eliminating the discomfort of stuffiness or lack of breathability to a certain extent.

[0080] After numerous experiments, the inventors found that shortening or eliminating the middle nonwoven layer and polymer absorbent layer in the end areas on both sides does not cause urine leakage. Even when the wearer urinates at a high instantaneous speed or crawls on the ground, no urine leakage will occur.

[0081] Compared to current technologies, laboratory tests conducted by the inventors have shown that products implementing this invention offer thinner and more breathable diapers for consumers. Simultaneously, it can reduce the manufacturing cost of the absorbent core to a certain extent, for example, reducing material costs by 10% to 20%.

[0082] It should also be noted that the manufacturing equipment according to this utility model is not only applicable to cores with a double-layer SAM structure, but also to composite cores using a single-layer SAM core and a single-layer plush structure.

[0083] The embodiments of this utility model have been illustrated and described herein, but those skilled in the art should understand that various modifications, omissions, and additions can be made without departing from the spirit and scope of this utility model. It should not be understood as limited to the specific embodiments described herein, but encompasses all possible embodiments embodied within the scope and equivalents of the features described in the appended claims.

[0084] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​stated. Rather, unless otherwise specified, each such dimension is intended to represent the value and a functionally equivalent range around that value. For example, a dimension disclosed as “40 mm” is intended to represent “approximately 40 mm”.

[0085] All documents referenced in the “Detailed Description” section are incorporated herein by reference in the relevant sections; no reference to any document should be construed as an admission that it is prior art concerning this utility model. In the event of any conflict between the meaning or definition of any term in this written document and the meaning or definition of any term in the referenced documents, the meaning or definition assigned to the term in this written document shall prevail.

[0086] While specific embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many other changes and modifications can be made without departing from the spirit and scope of the present invention. Therefore, the appended claims are intended to cover all such changes and modifications within the scope of the present invention.

[0087] When describing elements of the present invention or their preferred embodiments(s), the articles "a," "an," "the," and "the" are intended to indicate the presence of at least one element. The terms "comprising," "including," and "having" are intended to be inclusive and mean that additional elements may be present in addition to the listed elements. Many modifications and variations may be made to the present invention without departing from the spirit and scope thereof. Therefore, the above embodiments are not intended to limit the scope of the present invention.

Claims

1. A partitioned absorbent core, the absorbent core extending in a transverse direction and a longitudinal direction and having a thickness in a vertical direction perpendicular to the transverse direction and the longitudinal direction, characterized in that, The absorber core includes: - First wrapping nonwoven layer; -Second wrapping nonwoven layer; - A core layer between the first wrapping nonwoven layer and the second wrapping nonwoven layer, wherein the core layer comprises: - First intermediate nonwoven layer; -Second intermediate nonwoven layer; and - A first polymer layer between a first intermediate nonwoven layer and a second intermediate nonwoven layer, wherein first superabsorbent polymer particles are at least partially and uniformly distributed within the first polymer layer. - A second polymer layer between the first nonwoven wrapping layer and the core layer, wherein the second polymer layer is at least partially and uniformly distributed with second superabsorbent polymer particles. Wherein, the total length of the core layer along the longitudinal direction is not less than 40% of the total length of the absorbent core along the longitudinal direction, and the absorbent core is provided with only a second polymer layer in the front and rear regions of the core layer along the longitudinal direction.

2. The partitioned absorption core as described in claim 1, characterized in that, The total length of the absorber core extending beyond the core layer in the longitudinal direction on its front side is no more than 35% of the total length of the absorber core in the longitudinal direction.

3. The partitioned absorption core as described in claim 1, characterized in that, The total length of the absorber core extending beyond the core layer in the longitudinal direction on its rear side shall not exceed 25% of the total length of the absorber core in the longitudinal direction.

4. The partitioned absorption core as described in claim 1, characterized in that, The above The first and second intermediate nonwoven layers comprise or consist of synthetic fibers, optionally blended with natural fibers such as cellulose fibers, cotton fibers, or viscose fibers.

5. The partitioned absorption core as described in claim 1, characterized in that, The first and / or the second nonwoven wrapping layers are formed from low-basis-weight nonwoven fiber webs with a basis weight between 5 gsm and 50 gsm.

6. The partitioned absorption core as described in claim 1, characterized in that, The above The first superabsorbent polymer particles and the second superabsorbent polymer particles are identical, wherein the basis weight of the superabsorbent polymer particles is 100 gsm to 500 gsm.

7. A manufacturing apparatus for a partitioned absorbent core, wherein the partitioned absorbent core is a partitioned absorbent core according to any one of claims 1 to 6, characterized in that, include: First roll for supplying the first intermediate nonwoven layer; A first conveying mechanism for delivering a first intermediate nonwoven layer from a first roll along the machine direction; A first feed hopper and a second roll for supplying a second intermediate nonwoven layer are sequentially arranged in front of a first roll along the machine direction, wherein the first feed hopper is used to supply superabsorbent material containing first superabsorbent polymer particles; A first roller pressing mechanism is arranged along the machine direction in front of the second roll, which is used to press the first intermediate nonwoven layer, the superabsorbent material containing the first superabsorbent polymer particles, and the second intermediate nonwoven layer into a strip-shaped core layer. A rotary cutting mechanism is arranged along the machine direction in front of the first roller pressing mechanism, which is used to cut the long strip core layer into multiple individual core layers with different lengths. The third roll is used to supply the nonwoven layer of the second package; A second conveying mechanism for delivering the second packaged nonwoven layer from the third roll along the machine direction; The transfer mechanism, which is located adjacent to the rotary cutting mechanism, is used to transfer multiple individual core layers to the top side of the second wrapping nonwoven layer in a manner that is spaced apart from each other by a certain gap. A second feed hopper and a fourth roll for supplying the first wrapped nonwoven layer are arranged sequentially in front of the third roll along the machine direction, wherein the second feed hopper is used to continuously supply superabsorbent material containing second superabsorbent polymer particles to the second wrapped nonwoven layer. The second roller pressing mechanism, arranged along the machine direction in front of the third roll, is used to press the second wrapped nonwoven layer, a plurality of separate core layers spaced apart from each other, and the first wrapped nonwoven layer into a strip-shaped absorbent core. The cutting station, located in front of the second roller pressing mechanism along the machine direction, is used to cut the long strip-shaped absorbent core into multiple individual partitioned absorbent cores.

8. The manufacturing equipment as claimed in claim 7, characterized in that, The transfer mechanism is a transfer hub with a negative pressure adsorption mechanism.

9. The manufacturing equipment as claimed in claim 7, characterized in that, The first hopper and / or the second hopper are configured as bulk solids pumps or feeders capable of maintaining a consistent flow of superabsorbent polymer particles during free fall.

10. The manufacturing equipment as claimed in claim 7, characterized in that, It also includes an adhesive spray nozzle positioned between a third roll for supplying the second wrapped nonwoven layer and a second hopper, which applies adhesive to the top side of the second wrapped nonwoven layer unwound from the third roll.

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