Disposable absorbent article and apparatus for manufacturing the same

Abstract

The utility model relates to personal hygiene nursing product technical field, concretely relates to a disposable absorbent article and the equipment for manufacturing it. Disposable absorbent article has the front waist area, rear waist area and the crotch area between the front waist area and rear waist area, include: liquid-permeable top sheet, with the top sheet is connected liquid-impermeable back sheet, and the wet core between the top sheet and the back sheet, the wet core has the body surface to the wearer and the clothes surface away from the wearer, wherein, the back sheet includes inner layer and outer layer, at least a portion of the inner layer is connected to the clothes surface, the outer layer is covered with fluffy layer on the surface away from the inner layer, the fluffy layer is located in at least partial area of the front waist area, the fluffy layer roll pressure is combined to the outer layer and is formed into integral type front waist paste with compact compaction area. The front waist paste has good performance, and can be directly made in disposable absorbent article production process.

Description

Technical Field

[0001] This utility model relates to the field of personal hygiene care products, specifically to a disposable absorbent product and equipment for manufacturing it. Background Technology

[0002] Waistbands are widely used in the diaper industry and are an indispensable key component of modern diaper design. Their core function is to provide a repeatedly adjustable fit, ensuring the diaper conforms to the body of an infant or adult while maintaining ease and comfort. In diaper design, waistbands are typically used in the waistband securing area. The side waistbands (hooks) on both sides of the diaper can be combined with the front waistband (loops), allowing users to freely adjust the tightness according to their waist size, preventing leakage or discomfort caused by being too tight or too loose. Furthermore, the reusable nature of the waistbands allows for adjustments to the fit during wear without the need for replacements, improving the user experience and reducing waste.

[0003] In the prior art, CN1244108A discloses a disposable moisture-absorbing product with an integral overlapping area. This product includes a liquid-permeable top sheet, a liquid-impermeable bottom sheet connected to the top sheet, and a moisture-absorbing core located between the top and bottom sheets. The bottom sheet comprises a laminate of an inner mesh sheet and an outer mesh sheet. The outer mesh sheet includes an integral overlapping area with a portion that has been mechanically pre-deformed to create a raised component (front waist patch). This raised component can be wound onto a connecting component (side waist patch) of a complementary fastener. Furthermore, this prior art may also include a lifting element located between the inner mesh sheet and the raised portion, which provides space for the connecting component to penetrate the raised portion. However, this technical solution requires first stretching the outer mesh sheet and then placing the lifting element between the outer mesh sheet and the raised portion, making the process relatively complex.

[0004] In some existing products, separately produced non-woven fabric is glued to the outer layer of the diaper. In this method, the glued non-woven fabric is mostly made of material with a basis weight of 39gsm-50gsm. However, due to its high basis weight, this type of material is not only detrimental to environmental sustainability but also leads to high costs. Therefore, it is essential to develop an absorbent product that balances environmental friendliness with the excellent performance of the front waistband. Utility Model Content

[0005] Therefore, the purpose of this utility model is to provide a disposable absorbent product with good performance in the front waist patch area.

[0006] This utility model provides a disposable absorbent article having a longitudinal and transverse direction perpendicular to each other, and a thickness direction perpendicular to the longitudinal and transverse directions. The absorbent article has a front waist area, a back waist area, and a crotch area located between the front waist area and the back waist area along the longitudinal direction. The disposable absorbent article includes: a liquid-permeable top sheet; a liquid-impermeable bottom sheet connected to the top sheet; and a moisture-absorbing core located between the top sheet and the bottom sheet. The moisture-absorbing core has a body side facing the wearer and a clothing side facing away from the wearer. The bottom sheet includes an inner layer and an outer layer. At least a portion of the inner layer is connected to the clothing side. A fluffy layer is covered on the surface of the outer layer away from the inner layer. The fluffy layer is located in at least a portion of the front waist area. The fluffy layer is roll-pressed to the outer layer to form an integral front waist patch with a dense compacted area.

[0007] This invention involves covering the outer front waist area with a fluffy layer, which is then rolled together to form an integrated front waist patch with a dense, compacted zone. This front waist patch can be directly produced during the manufacturing process of disposable absorbent products, eliminating the need for separate production and subsequent bonding of non-woven fabric, thus effectively improving production efficiency. Simultaneously, the design of the outer composite fluffy layer gives the front waist patch a suitable thickness, fluffiness, and good mechanical properties, further enhanced by the dense, compacted zone.

[0008] In a preferred embodiment, the device further includes a side waist patch located in the lower back area, the side waist patch being detachably connected to the integrated front waist patch, wherein the disposable absorbent product is closed when the side waist patch is connected to the integrated front waist patch.

[0009] In a preferred embodiment, the side waist patch and the integrated front waist patch can generate a peel force of not less than 40 gF and a shear force of not less than 2500 gF.

[0010] In a preferred embodiment, the integrated front waistband has a pre-formed pattern rolled out, the pre-formed pattern being the portion outside the compacted area, the pre-formed pattern comprising multiple rows of pattern combinations arranged at intervals along the longitudinal direction, the pattern combinations comprising multiple circles arranged at intervals along the transverse direction, adjacent rows of the pattern combinations being staggered in the longitudinal direction, and the ratio of the area of ​​the compacted area to the area of ​​the integrated front waistband being 28% to 38%.

[0011] In a preferred embodiment, the dense compaction zone includes multiple rows of wavy patterns arranged at longitudinal intervals, the ratio of the area of ​​the wavy patterns to the area of ​​the integrated front waistband being 16% to 26%.

[0012] In a preferred embodiment, the compacted zone protrudes in a direction away from the inner layer or is recessed in a direction towards the inner layer.

[0013] In a preferred embodiment, the outer layer is made of at least one of hot-air bonded carded fiber web, multilayer spunbond nonwoven fabric, soft elastic spunbond fabric, spunbond nonwoven fabric, or spunbond-meltblown-spunbond composite nonwoven fabric, and the basis weight of the outer layer is 15-25 gsm; the fluffy layer is made of at least one of hot-air bonded carded fiber web, multilayer spunbond nonwoven fabric, soft elastic spunbond fabric, spunbond nonwoven fabric, or spunbond-meltblown-spunbond composite nonwoven fabric, and the basis weight of the fluffy layer is 15-25 gsm.

[0014] This utility model also provides an apparatus for manufacturing disposable absorbent products, wherein the disposable absorbent product is the aforementioned disposable absorbent product. The apparatus includes a transfer anvil roller, a cutter roller, a composite pressure roller, a concave pattern roller, and a convex anvil roller. The transfer anvil roller vacuum-adsorbs and rolls the fluffy layer to the cutter roller. The cutter roller rotates and cuts the fluffy layer to a preset width. The transfer anvil roller transfers the cut fluffy layer to the outer layer. The transfer anvil roller and the composite pressure roller roll the fluffy layer to the outer layer to obtain the integrated front waist patch. The concave pattern roller and the convex anvil roller roll-press a pattern onto the integrated front waist patch.

[0015] In a preferred embodiment, the concave embossing roller has a downwardly recessed first embossing feature, and the convex anvil roller has an upwardly protruding second embossing feature corresponding to the first embossing feature.

[0016] In a preferred embodiment, the device further includes a first pressure roller and a second pressure roller arranged corresponding to each other, the first pressure roller and the second pressure roller pressing the outer layer having the integrated front waist patch onto the inner layer, thereby obtaining the substrate. Attached Figure Description

[0017] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings, wherein:

[0018] Figure 1 This is a flowchart illustrating the manufacturing process of the integrated waist patch in this utility model.

[0019] Figure 2 This is a schematic diagram of the equipment used in this utility model for manufacturing disposable absorbent products;

[0020] Figure 3 yes Figure 2 Main view of the device;

[0021] Figure 4 yes Figure 3 Top view of the equipment in the middle;

[0022] Figure 5 This is a schematic diagram of the cutter roller in this utility model;

[0023] Figure 6 This is a schematic diagram of the composite pressure roller in this utility model;

[0024] Figure 7 This is a schematic diagram of the transfer anvil roller in this utility model;

[0025] Figure 8 This is a schematic diagram of the bubble pattern embossing mold in this utility model;

[0026] Figure 9 yes Figure 8 Enlarged view of point I in the middle;

[0027] Figure 10 This is a schematic diagram of the wave pattern embossing mold in this utility model;

[0028] Figure 11 This is a schematic diagram of the disposable absorbent product of this utility model.

[0029] Explanation of reference numerals in the attached figures

[0030] 11-Inner layer; 12-Outer layer; 13-Fluffing layer; 21-Transfer anvil roller; 22-Knife roller; 23-Composite pressure roller; 24-Concave pattern roller; 25-Convex anvil roller; 26-First pressure roller; 27-Second pressure roller; 28-Adhesive applicator; 29-Frame; 30-Dense compaction zone; 31-Pattern combination; 311-Circle; 32-Wave pattern; 40-Front waist area; 50-Rear waist area; 60-Crotch area; 71-Top sheet; 72-Bottom sheet; 73-Moisture-absorbing core; 80-Integrated front waist sticker; 90-Side waist sticker. Detailed Implementation

[0031] The present invention will be further described in detail below with reference to specific embodiments. The embodiments given are only for illustrating the present invention and are not intended to limit the scope of the present invention.

[0032] The schematic solutions of the technical solutions disclosed in this utility model are now described in detail with reference to the accompanying drawings. Although the drawings are provided to illustrate some embodiments of this utility model, the drawings are not necessarily drawn to the dimensions of the specific embodiments, and certain features may be enlarged, removed, or partially cut to better illustrate and explain the disclosure of this utility model. Some components in the drawings may be repositioned according to actual needs without affecting the technical effect. The phrase "in the drawings" or similar terms appearing in the specification do not necessarily refer to all drawings or examples.

[0033] Certain directional terms used in the description of the accompanying drawings below, such as “inner,” “outer,” “above,” “below,” and other directional terms, will be understood to have their normal meaning and refer to those directions as normally viewed in the accompanying 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.

[0034] 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.

[0035] Terminology Definition

[0036] In this document, "absorbent article" means an article that can be placed close to or near the wearer's body (i.e., adjacent to the body) to absorb and contain various liquid, solid, and semi-solid excretions from the body. Such absorbent articles as described herein are intended to be discarded after their limited use period, rather than washed or otherwise restored for reuse. It should be understood that, without departing from the scope of this disclosure, this disclosure applies to a variety of disposable absorbent articles, including but not limited to diapers, diaper pants, training pants, toddler pants, swim trunks, feminine hygiene products (including but not limited to menstrual pads or menstrual pants), incontinence products, medical clothing, surgical pads and bandages, and other personal care or health care clothing.

[0037] In this document, "disposable" is used to describe absorbents that are not typically intended to be washed, or restored, or reused as absorbents (e.g., they are intended to be discarded after a single use and may also be configured to be recyclable, compostable, or otherwise set up in an environmentally compatible manner).

[0038] In this article, SMS refers to composite nonwoven material, short for Spunbond-Meltblown-Spunbond, which is a three-layer structure formed by spunbond-meltblown-spunbond.

[0039] In this article, SB refers to spunbond nonwoven fabric, which is a nonwoven fabric made through melt spinning, air-laid web formation, and hot rolling reinforcement processes.

[0040] In this article, SS refers to spunbond-spunbond double-layer nonwoven composite, which is a material composed of two layers of spunbond nonwoven fabric.

[0041] In this article, TABCW refers to through-air bonded carded web.

[0042] In this article, SSSS refers to a four-layer spunbond-spunbond-spunbond-spunbond composite, also known as Spundbond, which is a material composed of four layers of spunbond nonwoven fabric.

[0043] In this article, PUB refers to a point unbonded area formed on the surface of a nonwoven fabric during the hot air and pressure bonding process, using specially designed airflow nozzles or molds. Other areas are then bonded normally by heat and pressure.

[0044] In this article, "bubble" refers to a fluffy, round shape and is used interchangeably with "round" or "circular pattern".

[0045] In this article, basis weight refers to the mass of material per unit area, usually expressed in grams per square meter (g / m²). 2 (or GSM) indicates that it is used to measure the thickness, density, or coverage of a material.

[0046] In this article, shear force refers to the ability of a waist tape to resist lateral slippage or detachment when subjected to an external force parallel to the adhesive surface.

[0047] In this article, shear refers to the force required to tear the side waist tape vertically from the front waist tape.

[0048] In this article, the term "tape tab" refers to a reusable adhesive fastener used as a closure system for disposable absorbent products. Located on both sides of the waist of the disposable absorbent product, it is mainly used to adjust the tightness and fix the position of the diaper to ensure a proper fit around the wearer's waist.

[0049] In this article, the front lumbar support (Loop) refers to the passive engagement material in the lumbar support, which achieves a repeatable fixation function through mechanical engagement with the side lumbar support material.

[0050] In this article, the term "hook" refers to the active fixing material in the lumbar support, which achieves a repeatable fixing function through mechanical engagement with the front lumbar support material.

[0051] In this article, the term "online loop" refers to a front lumbar patch that is directly integrated into the product during the manufacturing process of disposable absorbent materials.

[0052] In this paper, meltblown refers to fibers formed by extruding molten thermoplastic material through multiple thin, typically circular, die capillaries into molten wires or filaments and into a converging high-speed flow of heated gas (e.g., air). The high-speed heated gas flow thins the molten thermoplastic material filaments to reduce their diameter, which can be the diameter of a microfiber. Subsequently, the meltblown fibers are carried by the high-speed gas flow and deposited on a collecting surface to form a fiber web composed of randomly dispersed meltblown fibers.

[0053] In this document, spunbond refers to small-diameter fibers formed by extruding molten thermoplastic material as filaments from multiple fine capillaries having a circular or other configuration of spinnerets, and then rapidly reducing the diameter of the extruded filaments by conventional processes such as drawing and the process described in the following patent.

[0054] In this document, “embossing,” “rolling,” or “embossing” refers to a structural feature formed when a layer of material is compressed or pressed down at discrete locations (according to known embossing techniques) such that the embossed layer still includes some material of the embossed layer directly beneath the embossed area. Essentially, the embossed area of ​​the embossed layer is compressed to increase layer density, but without perforation. The embossed feature does not pierce the entire thickness of the embossed layer. Multiple embossed features should constitute an “embossed pattern or embossed design.” An embossed pattern or embossed design should include a series of recesses, also referred to for the purposes of this disclosure as gravure embossing, a raised pattern, or a combination of each. Gravure embossing can be considered a more conventional embossing, where, for example, when viewed from the wearer-facing surface of the article, only recesses are formed in a layer. Such recesses may extend downward along the depth direction of the article from the wearer-facing surface of the article layer to the garment-facing surface of the article layer. In this document, “embossing,” “rolling,” or “embossing” are used interchangeably.

[0055] Such gravure printing can be formed, for example, by passing sheet material through the gap between a first patterning roller (which has protrusions along its surface) and a smooth or coated matching roller, or by passing it against a matching roller having recesses corresponding to the protrusions of the first patterning roller. Letterpress printing can be formed by a patterning roller that includes recesses along its surface, or both protrusions and recesses, and is pressed against a smooth or coated matching roller.

[0056] Imprinting can be achieved by applying heat, pressure, ultrasonic energy, or a combination thereof. Examples of imprinting techniques and patterns can be found, for example, in U.S. Patents 7,686,790 to Rasmussen et al., 7,145,054 to Zander et al., and 4,333,979 to Sciaraffa et al., each of which is incorporated herein by reference in its entirety without conflict with this disclosure. In one embodiment, imprinting can be formed by a pair of closely spaced embossing rollers, which include raised or recessed features or pins on one or both of their surfaces, these features or pins being designed not to completely penetrate the layer to be imprinted. In another embodiment, such imprinting rollers may include a gap formed between a pattern roller and a smoothing roller.

[0057] In this document, 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.

[0058] In this article, the loft element refers to the nonwoven fabric covering the outer layer.

[0059] In this article, the compacted zone refers to the area where the fiber density increases after rolling.

[0060] Single absorbent products

[0061] Figure 11 This is a plan view of a disposable absorbent article, showing it in a flat, unshrinked state (i.e., stretched by elasticity), with some sections cut open to better reveal its internal structure. The portion of the disposable absorbent article in contact with the wearer is positioned away from the observer. Figure 11 The disposable absorbent article shown has mutually perpendicular longitudinal and transverse directions, and a thickness direction perpendicular to said longitudinal and transverse directions. Along said longitudinal direction, it has a front waist area 40, a back waist area 50, and a crotch area 60 located between the front waist area 40 and the back waist area 50. The waist areas may include elastic members that gather around the wearer's waist, thereby making the disposable absorbent article fit better and provide a better seal. The crotch area 60 is the portion of the disposable absorbent article located between the front waist area 40 and the back waist area 50, and when the disposable absorbent article is worn, the crotch area 60 is located between the wearer's legs.

[0062] A disposable absorbent article may include a liquid-permeable top sheet 71; a liquid-impermeable bottom sheet 72 connected to the top sheet 71; and a moisture-absorbing core 73 located between the top sheet 71 and the bottom sheet 72, the moisture-absorbing core 73 having a body side facing the wearer and a clothing side facing away from the wearer; wherein the bottom sheet 72 includes an inner layer 11 and an outer layer 12, at least a portion of the inner layer 11 being connected to the clothing side, and the outer layer 12 having a fluffy layer 13 covering the surface away from the inner layer 11, the fluffy layer 13 being located in at least a portion of the front waist area 40, the fluffy layer 13 being roll-bonded to the outer layer 12 to form an integral front waist patch 80 having a dense compacted area 30.

[0063] The top sheet 71 can be made of any woven, nonwoven, or film sheet that is easily permeable by bodily effluent that may come into contact with the body-facing surface of the top sheet 71. In various embodiments, the top sheet 71 can be constructed from various nonwoven webs such as meltblown webs, spunbond webs, hydroentangled webs, or air-permeable combined carded webs. Examples of suitable materials for the top sheet 71 include, but are not limited to, natural fiber webs (such as cotton), rayon, hydroentangled webs, polyester, polypropylene, polyethylene, nylon or other thermally bondable fibers (such as bicomponent fibers), polyolefins, copolymers of polypropylene and polyethylene, linear low-density polyethylene, and combined carded webs of aliphatic esters (such as polylactic acid). Porous membranes and mesh materials can also be used, as well as laminates of these materials or combinations thereof. An example of a suitable material for the top sheet 71 is a porous polyethylene membrane material. An example of a suitable top sheet 71 can be a combined carded web made of polypropylene and polyethylene, such as a combined carded web available from SandlerCorp., Germany. U.S. Patent 4,801,494 to Datta et al., U.S. Patent 4,908,026 to Sukiennik et al., and WO 2009 / 062998 to Texol teach a variety of other materials that can be used as top sheet 71, each of which is incorporated herein by reference in its entirety. Additional materials for top sheet 71 may include, but are not limited to, those described in U.S. Patent 4,397,644 to Matthews et al., U.S. Patent 4,629,643 to Curro et al., U.S. Patent 5,188,625 to Van Iten et al., U.S. Patent 5,382,400 to Pike et al., U.S. Patent 5,533,991 to Kirby et al., U.S. Patent 6,410,823 to Daley et al., and U.S. Publication No. 2012 / 0289917 to Abuto et al., each of which is incorporated herein by reference in its entirety.

[0064] In various embodiments, the top sheet 71 may include a plurality of holes (not shown) formed therethrough to allow bodily effluent to more easily enter the absorbent core 73. These holes may be arranged randomly or uniformly throughout the top sheet 71, or they may be located in a narrow longitudinal strip or bar arranged along the longitudinal centerline of the absorbent article 10. The size, shape, diameter, and number of holes may vary to suit the specific needs of the absorbent article.

[0065] In various embodiments, the basis weight of the top sheet 71 can range from about 5 gsm, 10 gsm, 15 gsm, 20 gsm, or 25 gsm to about 50 gsm, 100 gsm, 120 gsm, 125 gsm, or 150 gsm. For example, in one embodiment, the top sheet 71 can be constructed from an air-permeable bonded carded web with a basis weight ranging from about 15 gsm to about 100 gsm. In another example, the top sheet 71 can be constructed from an air-permeable bonded carded web with a basis weight ranging from about 20 gsm to about 50 gsm, such as air-permeable bonded carded webs readily available from nonwoven material manufacturers such as Xiamen Yanjan Industry and Beijing DaYuan Nonwoven Fabrics. Alternatively, open-cell membranes, such as those available from membrane suppliers such as Texol in Italy and Tredegar in the United States, can be used. In various embodiments, the top sheet 71 may be made of a perforated polyethylene film with a basis weight in the range of about 15 gsm to about 30 gsm. In various embodiments, the top sheet 71 may be made of cotton material and have a basis weight of about 25 gsm to about 35 gsm.

[0066] In various embodiments, the top sheet 71 is hydrophilic. The top sheet 71 may be formed of a material that is inherently hydrophilic, or it may be formed of a hydrophobic material that is then coated with a hydrophilic coating, such as a surfactant.

[0067] A moisture-absorbing core 73 may be positioned between a top sheet 71 and a bottom sheet 72. The moisture-absorbing core 73 can typically be any single-layer structure or combination of layered components, exhibiting a degree of compressibility, fit, non-irritation to the wearer's skin, and the ability to absorb and retain liquids and other bodily exudates. In various embodiments, the moisture-absorbing core 73 may be formed from a variety of different materials and may comprise any number of desired layers. For example, the moisture-absorbing core 73 may comprise one or more layers (e.g., two layers) of the following absorbent web material: cellulose fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, loosely woven webs or other stabilized structures, superabsorbent materials, binder materials, surfactants, selected hydrophobic and hydrophilic materials, pigments, detergents, odor control agents, etc., and combinations thereof. In one embodiment, the absorbent web material may comprise a matrix of cellulose fibers and may also include superabsorbent materials. Cellulose fibers may comprise blends of wood pulp fibers. An example of wood pulp fluff can be found in the trade name NB 416 of Weyerhaeuser Corp., which is a bleached, highly absorbent wood pulp containing primarily softwood fibers.

[0068] In various embodiments, the moisture-absorbing core 73 may include optional amounts of superabsorbent material, if desired. Examples of suitable superabsorbent materials may include poly(acrylic acid), poly(methacrylic acid), poly(acrylamide), poly(vinyl ether), copolymers of maleic anhydride with vinyl ether and α-olefins, poly(vinylpyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and their salts and copolymers. Other superabsorbent materials may include unmodified and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid-grafted starch, methylcellulose, deacetylated chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and natural gums such as alginate, xanthan gum, locust bean gum, etc. Mixtures of natural and wholly or partially synthetic superabsorbent polymers may also be used. The superabsorbent material may be present in the moisture-absorbing core 73 in any amount as desired.

[0069] Regardless of the combination of absorbent materials used in the moisture-absorbing core 73, the absorbent materials can be formed into a web structure using various conventional methods and techniques. For example, the absorbent web can be formed using techniques such as, but not limited to, dry forming, air forming, wet forming, foam forming, and combinations thereof. Co-formed nonwoven materials can also be used. Methods and equipment for performing such techniques are well known in the art.

[0070] The shape of the moisture-wicking core 73 can vary as needed and can include any of a variety of shapes, including but not limited to triangular, rectangular, dog-bone shaped, and oval. In various embodiments, the moisture-wicking core 73 may have a shape that generally corresponds to the overall shape of the absorbent sheet 40. The dimensions of the moisture-wicking core 73 may be substantially similar to the dimensions of the absorbent sheet 40; however, it should be understood that while the dimensions of the moisture-wicking core 73 are similar, they are generally smaller than the dimensions of the entire absorbent sheet 40 in order to be adequately accommodated therein.

[0071] For example, suitable materials and / or structures for the moisture-wicking core 73 may include, but are not limited to, those described in U.S. Patent 4,610,678 to Weisman et al., U.S. Patent 6,060,636 to Yahiaoui et al., U.S. Patent 6,610,903 to Latimer et al., U.S. Patent 7,358,282 to Krueger et al., and U.S. Publication No. 2010 / 0174260 to Di Luccio et al., the entire contents of each of which are hereby incorporated by reference.

[0072] As described above, in various embodiments, the moisture-wicking core 73 may be a single-layer structure and may include, for example, a matrix of cellulose fibers and a superabsorbent material. In various embodiments, the moisture-wicking core 73 may have at least two layers of material, such as a body-facing layer and a clothing-facing layer. In various embodiments, the two layers may be identical to each other. In various embodiments, the two layers may be different from each other. In such embodiments, the two layers may provide different absorption properties that are considered suitable for the absorbent article. In various embodiments, the body-facing layer of the moisture-wicking core 73 may be composed of an air-laid material, and the clothing-facing layer of the moisture-wicking core 73 may be composed of a compressed sheet containing a superabsorbent polymer. In such embodiments, the air-laid material may have a basis weight of about 40 gsm to about 200 gsm, and the compressed sheet containing the superabsorbent polymer may be a cellulose fiber-based material, which may be a combination of cellulose pulp and SAP encapsulated by a tissue carrier, having a basis weight of about 40 gsm to about 400 gsm.

[0073] The backing sheet 72 of an absorbent article is typically liquid-impermeable and is the part of the absorbent article facing the wearer's clothing. The backing sheet 72 allows air or vapor to pass through the absorbent article while still preventing liquid passage. Any liquid-impermeable material can typically be used to form the backing sheet 72. The specific structure and composition of the backing sheet 72 can be selected from a variety of known membranes and / or fabrics, with specific materials suitably chosen to provide desired levels of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics, etc. The backing sheet 72 can consist of a single layer or multiple layers, and these single or multiple layers can themselves comprise similar or different materials. Suitable materials that can be used include microporous polymer membranes, such as polyolefin membranes or polyethylene or polypropylene, nonwoven materials and nonwoven laminates, and membrane / nonwoven laminates. The specific structure and composition of the backing sheet 72 can be selected from a variety of known membranes and / or fabrics, with specific materials suitably chosen to provide desired levels of liquid barrier, strength, abrasion resistance, tactile properties, aesthetics, etc. In various embodiments, a polyethylene film with a thickness of about 0.2 mil or 0.5 mil to about 3.0 mil or 5.0 mil can be used. An example of substrate 72 can be a polyethylene film, such as one available from PliantCorp., Schaumburg, Illinois, USA. Another example may include a calcium carbonate-filled polypropylene film. In yet another embodiment, substrate 72 can be a hydrophobic nonwoven material with water-repellent properties, such as a nonwoven laminate, examples of which may be a spunbond, meltblown, meltblown-spunbond four-layer laminate.

[0074] In various embodiments, the backing film 72 may be a two-layer structure comprising an outer layer 12 and an inner layer 11 that can be bonded together. The outer layer 12 may be any suitable material and may be a material that provides the wearer with a substantially fabric-like texture or appearance. An example of such a material may be a 100% polypropylene bonded combed web with a diamond-patterned bonding pattern, such as 30gsm Sawabond or an equivalent material, available from Sandler AG, Germany. Another example of a suitable material for the outer layer may be a 20gsm spunbond polypropylene nonwoven web. The inner layer 11 may be vapor-permeable (i.e., “breathable”) or vapor-impermeable. The inner layer 11 may be made of a thin plastic film, but other liquid-impermeable materials may also be used.

[0075] The inner layer 11 can prevent liquid bodily waste from leaking from absorbent materials and wetting items (such as sheets and clothing) as well as the wearer and caregiver. Examples of materials used for the inner layer 11 may be printed 19gsm Berry Plastics XP-8695H film or equivalent materials commercially available from Berry Plastics Corporation, Evansville, IN, US.

[0076] Suitable film 72 may be made of materials such as those described in U.S. Patent 4,578,069 to Whitehead et al., U.S. Patent 4,376,799 to Tusim et al., U.S. Patent 5,695,849 to Shawver et al., U.S. Patent 6,075,179 to McCormack et al., and U.S. Patent 6,376,095 to Cheung et al., each of which is incorporated herein by reference in its entirety.

[0077] Furthermore, the disposable absorbent product also includes a side waist patch 90 located in the lower back area 50. The side waist patch 90 is detachably connected to the integrated front waist patch 80. When the side waist patch 80 is connected to the integrated front waist patch 80, the disposable absorbent product closes. Specifically, the side waist patch 90 has a large number of micro hooks, and the integrated front waist patch 80 has a large number of micro ring structures. When the hooks are hooked into the ring structures, the disposable absorbent product closes; when the hooks are disengaged from the ring structures, the disposable absorbent product opens.

[0078] The integrated front lumbar support 80 and side lumbar supports 90 ensure that the absorbent material is properly secured around the wearer's waist. The integrated front lumbar support 80 and side lumbar supports 90 can be opened and closed multiple times without compromising the function of the combined structure.

[0079] Specifically, existing disposable absorbent products use separately produced non-woven fabric glued to the outer layer of the diaper as an off-line loop. As shown in Table 1, the glued non-woven fabric typically uses a basis weight of 39-50 gsm. However, this type of material, due to its high basis weight, is not only detrimental to environmental sustainability but also leads to high costs. Therefore, to balance environmental protection and reduced production costs, the inventors of this application considered covering the outer layer 12 of the backing sheet 72 with a low-basis-weight loose layer 13 of a different material, and then rolling the two together. This roll-bonds the loose layer 13 to the outer layer 12, forming an integrated front loop 80 with a dense compacted area 30. Roll-forming enhances the mechanical properties of the integrated front loop 80, thereby reducing product production costs, as shown in Table 2. Specifically, the basis weight of the outer layer 12 in Table 2 is 18 gsm.

[0080] Table 1 Existing front lumbar support performance data

[0081]

[0082] Table 2 Different Types of Integrated Front Waist Pads (I)

[0083]

[0084] As shown in Table 2, the inventors of this application explored the combination of fluffy layers 13 with different materials and base weights and different embossed patterns, thereby obtaining one-piece front waist stickers 80 with different properties.

[0085] Specifically, in the bubble embossing embodiment described in Table 2, a preset pattern is formed on the integrated front waistband patch 80, which is the portion outside the dense compaction zone 30. The integrated front waistband patch 80 has multiple rows of pattern combinations 31 arranged longitudinally at intervals. Each pattern combination 31 includes multiple circles 311 arranged laterally at intervals, with adjacent rows of pattern combinations 31 arranged alternately. It is understood that the bubbles in Table 2 can be circular 311 structures. After being rolled by the concave pattern roller 24 and the convex anvil roller 25, the integrated front waistband patch 80 exhibits a dense compaction zone 30 that is recessed towards the inner layer 11. It is understood that the circular 311 has a thickness dimension greater than the dense compaction zone 30.

[0086] Figure 8 and Figure 9 One embodiment of a bubble pattern embossing mold is shown. In this specific embodiment, the mold is 54mm × 326mm = 17604mm. 2 Within the area, there are 418 6mm circular 311 bubbles, and the area of ​​the bubble embossing pattern is π (3mm). 2 =11817mm 2 The compacted area 30 occupies approximately 32.87% of the area of ​​the integrated front lumbar support 80. In other embodiments, the compacted area 30 may occupy approximately 28% to 38% of the area of ​​the integrated front lumbar support 80.

[0087] Furthermore, in embodiments involving small dot embossing, the small dots can be first circles with a diameter of approximately 0.8 mm. In this embodiment, the densely compacted area 30 occupies 8%-15% of the area of ​​the integrated front waistband 80. In embodiments involving large dot embossing, the large dots can be second circles with a diameter of approximately 1.5 mm. In this embodiment, the densely compacted area 30 occupies 8%-15% of the area of ​​the integrated front waistband 80. It is understood that the dimensions of the small and large dots in the thickness direction are greater than those of the densely compacted area 30.

[0088] In the wave embossing embodiments described in Table 2, the dense compaction zone 30 consists of multiple rows of wave-shaped patterns 32 arranged at intervals along the longitudinal direction. After the integrated front waist patch 80 is rolled by the concave flower roller 24 and the convex anvil roller 25, the wave-shaped pattern 32 protrudes in the direction away from the inner layer 11. Figure 10 One embodiment of the wavy embossing mold is shown. The dense compacted zone 30 can occupy 16%-26% of the area of ​​the one-piece front waistband 80.

[0089] The inventors of this application conducted experiments on combinations of fluffy layers 13 with different materials and base weights and different embossed patterns, obtaining the data shown in Table 2. The data shows that although some combinations exhibited good test results in terms of peel force, shear force, and fuzziness, there is still a certain gap compared to existing front flared wraps. Specifically, the side flared wrap model used in conjunction with the integrated front flared wrap 80 in Table 2 is 3M CHK07071SV.

[0090] Therefore, the inventors of this application considered combining outer layers 12 of different materials and base weights with fluffy layers 13 of different materials and different embossing patterns to obtain a one-piece front lumbar sticker 80 with superior performance, as detailed in Table 3. Among them, the side lumbar sticker model used in conjunction with the front lumbar sticker in Table 3 is Velcro HTH 02D.

[0091] Table 3 Different Types of Integrated Front Waist Patches (Part Two)

[0092]

[0093] As can be seen from the data in Table 3, the integrated front waist patch prepared by some combinations exhibits excellent mechanical properties: peel force not less than 40gF and shear force not less than 2500gF.

[0094] Specifically, in the bubble embossing implementation described in Table 3, a preset pattern is formed on the integrated front waistband patch 80, which is the portion outside the dense compaction zone 30. Specifically, the integrated front waistband patch 80 has multiple rows of pattern combinations 31 arranged longitudinally at intervals. Each pattern combination 31 includes multiple circles 311 arranged laterally at intervals, with adjacent rows of pattern combinations 31 arranged alternately. It is understood that the bubbles in Table 3 can be circular 311 structures. After being rolled by the concave pattern roller 24 and the convex anvil roller 25, the integrated front waistband patch 80 exhibits a dense compaction zone 30 that is recessed towards the inner layer 11. Figure 8 An embodiment of a bubble pattern embossing mold is shown, wherein the dense compacted area 30 can occupy 28% to 38% of the area of ​​the one-piece front waistband 80.

[0095] In the wave embossing embodiments described in Table 3, the dense compaction zone 30 consists of multiple rows of wave-shaped patterns 32 arranged longitudinally at intervals. After the integrated front waist patch 80 is rolled by the concave flower roller 24 and the convex anvil roller 25, the wave-shaped pattern 32 protrudes in the direction away from the inner layer 11. Figure 10 An embodiment of a wave-shaped embossing mold is shown, wherein the dense compacted area 30 can occupy 16%-26% of the area of ​​the one-piece front waistband 80.

[0096] In addition, the "Fluffy TABCW" material in Table 3 is slightly fluffy and softer than the "TABCW" material. Similarly, the "Fluffy SS" material is slightly fluffy and softer than the "SS" material.

[0097] Furthermore, the inventors also conducted performance tests on the integrated front waist sticker 80 obtained by combining other types of outer layer 12, fluffy layer 13 and embossed pattern, together with the matching side waist sticker 90. The relevant data are shown in Table 4.

[0098] Table 4 Different Types of Integrated Front Waist Patches (Part 3)

[0099]

[0100] As shown in Table 4, the peel force of the relevant combinations has increased, while the shear force has decreased slightly. Furthermore, the side lumbar support patch used in conjunction with the front lumbar support patch in Table 4 is model Velcro H496.

[0101] Specifically, in the bubble embossing embodiment described in Table 4, a preset pattern is formed on the integrated front waistband sticker 80, which is the portion outside the dense compaction zone 30. The integrated front waistband sticker 80 has multiple rows of pattern combinations 31 arranged longitudinally at intervals. Each pattern combination 31 includes multiple circles 311 arranged laterally at intervals, with adjacent rows of pattern combinations 31 arranged alternately. It is understood that the bubbles in Table 4 can be circular 311 structures. After being rolled by the concave pattern roller 24 and the convex anvil roller 25, the integrated front waistband sticker 80 exhibits a dense compaction zone that is recessed towards the inner layer 11. Figure 8 One embodiment of the bubble embossing mold is shown, wherein the compacted area 30 may occupy 28%-38% of the area of ​​the one-piece front waistband 80. It is understood that the circular shape 311 has a larger dimension in the thickness direction than the compacted area 30.

[0102] In the wave embossing embodiments described in Table 4, the dense compaction zone 30 consists of wave-shaped patterns 32 arranged longitudinally along the rows. After the integrated front waist patch 80 is rolled by the concave flower roller 24 and the convex anvil roller 25, the wave-shaped patterns 32 bulge outwards from the inner layer 11. Figure 10 One embodiment of the wavy embossing mold is shown. The dense compacted zone 30 can occupy 16%-26% of the area of ​​the one-piece front waistband 80.

[0103] In addition, the "Fluffy TABCW" material in Table 4 is slightly fluffy and softer than the "TABCW" material. Similarly, the "Fluffy SS" material is slightly fluffy and softer than the "SS" material.

[0104] Therefore, based on the data in Tables 2 to 4, Velcro HTH 02D is more suitable for the integrated front waist patch 80 of this invention, while high-strength SMS with a basis weight of 22 gsm can be used as the fluff layer 13 of the front waist patch. The fluff layer 13 uses a low-basis-weight nonwoven fabric, which reduces costs and is beneficial to environmental sustainability. In addition, because this SMS material has high strength, it can provide good peel and shear forces and will not cause the integrated front waist patch 80 to tear or break. For the integrated front waist patch 80, the key characteristic of the outer layer 12 is its fluffiness or thickness, not its basis weight. Even if some high-basis-weight outer layer materials meet the basis weight requirements, if they are flattened during transportation or storage, they cannot form a sufficient thickness to present a clear embossed pattern, and naturally it is difficult to guarantee good mechanical properties.

[0105] Equipment for manufacturing disposable absorbent products

[0106] Reference Figures 1 to 7 In another aspect, this utility model provides an apparatus for manufacturing the aforementioned integrated front waist patch. The apparatus includes a transfer anvil roller 21, a cutting roller 22, and a composite pressure roller 23. The transfer anvil roller 21 vacuum-adsorbs and rolls the fluffy layer 13 onto the cutting roller 22. The cutting roller 22 rotates and cuts the fluffy layer 13 to a preset width. The transfer anvil roller 21 transfers the cut fluffy layer 13 to the outer layer 12. The transfer anvil roller 21 and the composite pressure roller 23 press the fluffy layer 13 onto the outer layer 12 to obtain the integrated front waist patch 80. The width of the fluffy layer 13 refers to the width of the fluffy layer 13 within a certain range. Figure 11 The dimensions in the longitudinal direction are shown.

[0107] Specifically, the transfer anvil roller 21 has a cutting point, and the cutter roller 22 cuts the fluffy layer 13 at the cutting point.

[0108] In a preferred embodiment, the device further includes a concave embossing roller 24 and a convex anvil roller 25. The concave embossing roller 24 has a first embossing feature that is recessed downwards, and the convex anvil roller 25 has a second embossing feature that is raised upwards corresponding to the first embossing feature. The concave embossing roller 24 and the convex anvil roller 25 roll and press the integrated front waist patch 80 to form a dense compacted area 30.

[0109] Understandably, the concave embossing roller 24 is a generally cylindrical rotating component, and a first embossing feature is formed on the concave roller 24 that is recessed downwards in the direction of its rotation axis. Similarly, the convex anvil roller 25 is a generally cylindrical rotating component, and a second embossing feature is formed on the convex anvil roller 25 that is raised upwards in the direction away from its rotation axis. The second embossing feature can roll the combination of the fluffy layer 13 and the outer layer 12 into the first embossing feature, thereby obtaining an integrated front waist sticker 80 with a predetermined pattern.

[0110] exist Figure 1 In the manufacturing process diagram of the integrated waist patch shown, the positions of the concave flower roller 24 and the convex anvil roller 25 can be interchanged.

[0111] Furthermore, a similar pattern can be formed on the outer peripheral surface of the concave roller 24. Figure 8 or Figure 10 The mold shows a downwardly recessed bubble or wavy feature, and the outer peripheral surface of the convex anvil roller 25 has an upwardly raised embossed feature corresponding to this feature.

[0112] In addition, the device also includes a first pressure roller 26 and a second pressure roller 27 arranged corresponding to each other. The first pressure roller 26 and the second pressure roller 27 roll the integrated front waist patch 80 and / or the outer layer 12 onto the inner layer 11 to form the substrate 72.

[0113] Specifically, refer to Figure 1 The adhesive applicator 28 applies adhesive to the fluffy layer 13. The transfer anvil roller 21 vacuum-adsorbs and rolls the fluffy layer 13 to the cutter roller 22. The cutter roller 22 rotates and cuts the fluffy layer 13 to a preset width. The transfer anvil roller 21 continues to transfer the cut fluffy layer 13 to the outer layer 12. The transfer anvil roller 21 and the composite pressure roller 23 roll and paste the fluffy layer 13 to the outer layer 12 to obtain the integrated front waist sticker 80.

[0114] After being rolled by the concave patterned roller 24 and the convex anvil roller 25, the one-piece front waist sticker 80 is obtained with a dense compaction zone 30. The adhesive applicator 28 applies adhesive to the inner layer 11, and the first pressure roller 26 and the second pressure roller 27 roll and paste the one-piece front waist sticker 80 with the preset pattern to the inner layer 11 to form the backing film 72.

[0115] 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.

[0116] 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”.

[0117] 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.

[0118] 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.

[0119] 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 one or more elements. 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 disposable absorbent article having a longitudinal and a transverse direction perpendicular to each other, and a thickness direction perpendicular to said longitudinal and transverse directions, said absorbent article having a front waist area (40), a rear waist area (50), and a crotch area (60) located between said front waist area (40) and said rear waist area (50) along said longitudinal direction, characterized in that, This single-use absorbent product includes: A liquid-permeable top sheet (71); A liquid-impermeable backing sheet (72) connected to the top sheet (71); and A moisture-absorbing core (73) is located between the top sheet (71) and the bottom sheet (72), the moisture-absorbing core (73) having a body side facing the wearer and a clothing side facing away from the wearer; The backing sheet (72) includes an inner layer (11) and an outer layer (12). At least a portion of the inner layer (11) is connected to the fabric surface. The outer layer (12) is covered with a fluffy layer (13) on the surface away from the inner layer (11). The fluffy layer (13) is located in at least a portion of the front waist area (40). The fluffy layer (13) is rolled and bonded to the outer layer (12) to form an integral front waist patch (80) with a dense compacted area (30).

2. The disposable absorbent article according to claim 1, characterized in that, It also includes a side waist patch (90) located in the lower back area (50), the side waist patch (90) being detachably connected to the integrated front waist patch (80), and the disposable absorbent product closing when the side waist patch (90) is connected to the integrated front waist patch (80).

3. The disposable absorbent article according to claim 2, characterized in that, The side waist patch (90) and the integrated front waist patch (80) can generate a peel force of not less than 40gF and a shear force of not less than 2500gF.

4. The disposable absorbent article according to claim 1, characterized in that, The integrated front waist patch (80) has a pre-pressed pattern, which is the part outside the compacted area (30). The pre-pressed pattern includes multiple rows of pattern combinations (31) arranged at intervals along the longitudinal direction. Each pattern combination includes multiple circles (311) arranged at intervals along the transverse direction. Adjacent rows of pattern combinations (31) are staggered in the longitudinal direction. The ratio of the area of ​​the compacted area (30) to the area of ​​the integrated front waist patch (80) is 28% to 38%.

5. The disposable absorbent article according to claim 1, characterized in that, The dense compacted zone (30) includes multiple rows of wavy patterns (32) arranged at intervals along the longitudinal direction, and the ratio of the area of ​​the wavy pattern (32) to the area of ​​the integrated front waist patch (80) is 16% to 26%.

6. The disposable absorbent article according to claim 1, characterized in that, The dense compacted zone (30) protrudes in the direction away from the inner layer (11) or is recessed in the direction towards the inner layer (11).

7. The disposable absorbent article according to claim 1, characterized in that, The outer layer (12) is made of at least one of hot air bonded combed fiber web, multilayer spunbond nonwoven fabric, soft elastic spunbond fabric, spunbond nonwoven fabric or spunbond-meltblown-spunbond composite nonwoven fabric, and the basis weight of the outer layer (12) is 15-25 gsm. The material of the fluffy layer (13) is at least one of hot air bonded combed fiber web, multilayer spunbond nonwoven fabric, soft elastic spunbond fabric, spunbond nonwoven fabric or spunbond-meltblown-spunbond composite nonwoven fabric, and the basis weight of the fluffy layer (13) is 15-25 gsm.

8. An apparatus for manufacturing a disposable absorbent article, said disposable absorbent article being a disposable absorbent article according to any one of claims 1-7, characterized in that, The device includes a transfer anvil roller (21), a cutter roller (22), a composite pressure roller (23), a concave pattern roller (24), and a convex anvil roller (25). The transfer anvil roller (21) vacuum-adsorbs and rolls the fluffy layer (13) to the cutter roller (22). The cutter roller (22) rotates and cuts the fluffy layer (13) to a preset width. The transfer anvil roller (21) transfers the cut fluffy layer (13) to the outer layer (12). The transfer anvil roller (21) and the composite pressure roller (23) roll the fluffy layer (13) to the outer layer (12) to obtain the integrated front waist patch (80). The concave pattern roller (24) and the convex anvil roller (25) roll and form a pattern on the integrated front waist patch (80).

9. The device according to claim 8, characterized in that, The concave embossing roller (24) has a first embossing feature that is recessed downwards, and the convex anvil roller (25) has a second embossing feature that is raised upwards, corresponding to the first embossing feature.

10. The device according to claim 8, characterized in that, The device also includes a first pressure roller (26) and a second pressure roller (27) arranged corresponding to each other, the first pressure roller (26) and the second pressure roller (27) roll the outer layer (12) having the integrated front waist patch (80) onto the inner layer (11) to obtain the substrate (72).

Images