Disposable Absorbent Mat and Related Manufacturing Method

Abstract

The present invention relates to the field of hygiene devices, and more particularly to a disposable absorbent mat for general use to protect any surface that can come into contact with urine or other types of organic liquids. The disposable mat (100) comprises: a liquid absorption pad (1) having a predetermined length and width defining the boundary of the effective area (23); a sheet (2) of liquid-impermeable material, coupled under the absorption pad (1) so as to define a first pair (21) and a second pair (22) at opposite free edges and disposed outside the effective area (23) occupied by the absorption pad (1); a sheet (3) of liquid-permeable material, coupled on top of the absorption pad (1) on the side opposite to the sheet (2) of liquid-impermeable material; and first lateral closure means of the absorption pad (1) to counter liquid leakage. The absorption mat (100) comprises a first strip (4) and a second strip (5) of liquid-impermeable material, defining second lateral closure means of the absorption pad (1) to counter liquid leakage, disposed orthogonally to the first lateral closure means. The present invention also relates to a method for manufacturing the above-described disposable absorbent mat.

Description

Technical Field

[0001] The present invention relates to the field of hygiene devices, and more particularly to disposable absorbent mats, especially of the type for infants or adults, but of a type suitable for general use to protect any surface that may come into contact with urine or other types of organic liquids, and is also possible for animals.

[0002] The present invention also relates to a method for manufacturing the above-mentioned disposable absorbent mat.

Background Art

[0003] Conventional disposable absorbent mats have a rectangular shape and are composed of a sheet of substantially liquid-impermeable material and a sheet of liquid-permeable material, between which an absorbent pad forming the core of the mat is sandwiched and bonded together.

[0004] The above-mentioned liquid-impermeable material is generally a sheet of polyethylene and serves to stop liquids that tend to flow downward by gravity.

[0005] The above-mentioned liquid-permeable material is generally made of a hydrophilic non-woven fabric and serves to allow liquids to pass through and prevent the occurrence of allergic reactions on the user's skin.

[0006] The above-mentioned absorbent pad is technically composed of cellulose called FLUFF and is optionally mixed with granules of a superabsorbent material technically called SAP or polymer.

[0007] Cellulose is surrounded and adhered together between two layers of cellulose tissue and is added to ensure the maximum absorbency of the mat so as to be commensurate with the final cost of the product.

[0008] All the layers constituting the mat are joined together by adhesion or welding.

[0009] In a conventional absorption mat, the sheet of liquid-impermeable material and the sheet of liquid-permeable material have the same dimensions, while the absorption pad has smaller dimensions such that it is entirely contained within them and leaving respective bonding edges.

[0010] Therefore, sealing against lateral leakage of liquid is ensured only by the mutual bonding at these edges.

[0011] Unfortunately, the risk of liquid passing through and leaking from the absorption pad through the edges of the sheets that are only adhesively overlapped is high in any case. Thus, liquid can leak along all four sides of the mat.

[0012] Another example in a known absorption mat is provided to solve at least some of this drawback. It is one in which at least one pair of sides closes a pair of edges in the sheet of liquid-impermeable material in the region occupied by the absorption pad by turning them inside out under the sheet of liquid-permeable material.

[0013] Thus, the actually formed absorption mat comprises lateral closing means for counteracting liquid leakage acting on two of the four sides.

[0014] An improvement has been seen, but the above absorption mat still has limits in sealing against liquid leakage along two of the four sides.

[0015] On the other hand, due to the linear production method of the mat, it is impossible to turn over the other pair of edges that are arranged orthogonally to the forward direction in which the product is being manufactured. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0016] An object of the present invention is to eliminate the above-mentioned drawbacks and disadvantages.

[0017] Accordingly, it is an object of the present invention to provide a completely sealed absorption mat that completely prevents lateral leakage of liquid absorbed by the pad.

[0018] It is also an object of the present invention to provide an absorption mat that can be easily produced by a rapid and cost-effective manufacturing method.

Means for Solving the Problems

[0019] These objects are achieved by using a disposable absorption mat that is substantially square in shape: - a liquid absorption pad having a predetermined length and width defining the boundary of the effective area; - a sheet of liquid-impermeable material having a predetermined length and width larger than that of the absorption pad, coupled under the absorption pad so as to define a first and a second pair at the opposing free edges, and disposed outside the effective area occupied by the absorption pad; - a sheet of liquid-permeable material, coupled on the side opposite to the sheet of liquid-impermeable material and overlying the absorption pad, The first pair of free edges in the sheet of liquid-impermeable material is folded upward in the effective area occupied by the absorption pad to define a first lateral closing means of the absorption pad to counter liquid leakage. Here, the disposable absorption mat is characterized in that the sheet of liquid-permeable material has a predetermined length and width equal to the length and width of the absorption pad, and that the absorption mat comprises first and second strips of liquid-impermeable material installed across each free edge in the second pair of free edges and the liquid-permeable sheet respectively. These first and second strips are coupled to at least the second pair of free edges and are arranged orthogonal to the first lateral closing means to define a second lateral closing means in the absorption pad that counteracts liquid leakage.

[0020] Advantageously, the first pair of free edges in the sheet of liquid-impermeable material is folded upward in the liquid-permeable material.

[0021] More preferably, the first and second strips are superposed at the edge of the first side closing means formed by the first pair of free edges folded upwards.

[0022] According to a possible variant of the invention: - The first and second strips of impermeable material are made of a hydrophobic non-woven fabric; - The sheet of liquid-impermeable material is made of polyethylene; - The sheet of liquid-permeable material generally consists of a hydrophilic non-woven fabric; - The absorbent pad is a composite material and comprises at least one tissue made of a hydrophilic material and an absorbent cellulose layer. This at least one tissue faces the sheet of liquid-impermeable material, and the absorbent cellulose layer faces the sheet of liquid-permeable material.

[0023] According to another aspect of the invention, the absorbent pad, the sheet of liquid-impermeable material, the sheet of liquid-permeable material, the pair of edges, and the strips are joined together by adhesion or welding.

[0024] The invention also relates to a method for manufacturing the disposable absorbent mat described above: - Providing a web of liquid-impermeable material having a predetermined width and unwound in the forward direction; - Providing a plurality of liquid absorbent pads, each having a predetermined length and width, this width being less than the width of the above web; - Providing a plurality of sheets of liquid-permeable material, each having a predetermined length and width equal to the length and width of the above absorbent pad; - Joining the above absorbent pad and the sheet of liquid-permeable material together to produce a multi-layer absorbent panel; - Applying the above multi-layer absorbent panel successively and spaced apart on top of the web of liquid-impermeable material in the forward direction, thereby defining an effective area along the above web, a first pair of free edges facing in the forward direction, and a free area transverse to the forward direction between each multi-layer absorbent panel. - Defining a first lateral closing means of the absorbent mat, which folds upward a first pair of free edges of the web of liquid-impermeable material over the effective area occupied by the multi-layer absorbent panel to counter liquid leakage; - Providing a strip of liquid-impermeable material; - Applying the strip across at least a part of the free area in the transverse direction and the effective area occupied by the multi-layer absorbent panel to obtain a second lateral closing means for countering liquid leakage, which is arranged orthogonally to the first lateral closing means; - Cutting the web in the transverse direction to obtain a disposable absorbent mat, characterized by including the above.

[0025] In a preferred variant, the method comprises: - Providing an alternative strip of liquid-impermeable material having a width longer than the width of the free area in the transverse direction along the forward direction of the web; - Applying each of the alternative strips between two consecutive multi-layer absorbent panels; - Cutting the web in the transverse direction at the intermediate line of the alternative strip to obtain the strip above, further including the above.

[0026] Alternatively, the steps of bonding together an absorbent pad and a sheet of liquid-permeable material, applying a multi-layer absorbent panel on top of the web of liquid-impermeable material, and applying the strip include the step of adhesively bonding or welding together the above components.

[0027] The main advantage of the present invention consists in that the absorbent mat is closed and liquid-tight along all four sides.

[0028] In addition to the folded-up edges at two parallel sides of the mat, the sides orthogonal to them are also advantageously sealed, and no liquid that has not been absorbed by the pad will leak out.

[0029] Closing the four sides enables the use of a simplified absorption pad. That is, it is made of only a basic tissue paper and the top without a cellulose layer. A sheet of permeable material, the same size as this pad and attached to this pad, will act as a second top tissue.

[0030] In the configuration of the absorption pad, by enabling the saving of tissue layers, the production cost is substantially reduced.

[0031] Furthermore, in the required linear manufacturing method, it is possible to use a single strip of impermeable material to close two continuous mats. In fact, a single strip is applied between two continuous multi-layer absorption panels, occupying the entire free area and the two effective areas occupied by the two adjacent multi-layer absorption panels, and then cutting the above strip and the web of impermeable material below along the intermediate line to obtain individual mats. It is obvious that material is saved for the many strips actually used.

[0032] These and other advantages will become clearer from the following description of the preferred embodiments of the invention, made by way of non-limiting examples with reference to the figures.

Brief Description of the Drawings

[0033]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0034] Referring to FIGS. 1 to 3, the present invention relates to a disposable absorption mat having a substantially rectangular shape.

[0035] The disposable type absorption cross piece 100 is in a layered form: - a liquid absorption pad 1; - a sheet 2 of a liquid-impermeable material bonded under the liquid absorption pad 1; - a sheet 3 of a liquid-permeable material bonded on the opposite side to the sheet 2 of the liquid-impermeable material and overlapping the absorption pad 1. It comprises.

[0036] The sheet 2 of the liquid-impermeable material is made of polyethylene.

[0037] The sheet 3 of the liquid-permeable material is made of a loosely woven hydrophilic non-woven fabric.

[0038] The absorption pad 1 is a composite material and is composed of a tissue paper 6 of a hydrophilic material and a layer 7 of absorbent cellulose. Inside the absorption mat 100, the tissue paper 6 faces the liquid-impermeable material 2, and the layer 7 of absorbent cellulose faces the sheet 3 of the liquid-permeable material.

[0039] Compared with a conventional absorption pad composed of a two-layer tissue with a cellulose layer held in between, the pad that can be used in the mat of the present invention advantageously has no tissue paper layer. The function of the tissue paper layer is actually replaced by a hydrophilic non-woven fabric sheet bonded to the pad.

[0040] The absorption pad can also be obtained by using a non-woven fabric sheet and a cellulose layer mixed with superabsorbent granules or polymers as an alternative to the tissue paper.

[0041] The absorption pad 1 has a predetermined length and width that define the boundary of the effective area. The sheet 3 of liquid-permeable material has a predetermined length and width equal to the length and width of the absorption pad 1. The sheet 2 of liquid-impermeable material has a predetermined length and width greater than the length and width of the absorption pad 1, thereby defining a first pair 21 and a second pair 22 outside the effective area 23, that is, the effective absorption area occupied by the absorption pad 1.

[0042] Referring in detail to the cross-sectional view of FIG. 2, first lateral closing means in the absorption mat 100 that counteracts liquid leakage is shown.

[0043] The first pair 21 of free edges in the sheet 2 of liquid-impermeable material is folded upward in the effective area 23 represented by the absorption pad 1, accurately defining the first lateral closing means.

[0044] Referring in detail to the cross-sectional view of FIG. 3, on the other hand, second lateral closing means in the absorption mat 100 that counteracts liquid leakage is shown and is arranged orthogonally to the first lateral closing means.

[0045] The absorption mat 100 comprises fourth and fifth strips of liquid-impermeable material, each spanning a second pair 22 of free edges and a sheet 3 of liquid-permeable material orthogonal to the first pair 21 of free edges.

[0046] Specifically, the first strip 4 and the fifth strip 5 are overlapped and joined at least at the second pair 22 of free edges, defining the second lateral closing means of the absorption pad 1. Specifically, they are overlapped at the ends of the first lateral closing means formed by the first pair of the folded upward free edges 21.

[0047] The first strip 4 and the second strip 5 of impermeable material are made of a hydrophobic non-woven fabric or, preferably, the same material that makes up the liquid-impermeable sheet 2 of the absorption mat 100 installed under the absorption pad 1, that is, polyethylene.

[0048] All layers of the absorbent mat 100 shown, namely the absorbent pad 1, the sheet 2 of liquid-impermeable material, the sheet 3 of liquid-permeable material, the pairs 21, 22 of free edges, and the strips 4, 5, are joined to one another by the adhesive layer 8.

[0049] Alternatively, these layers can be joined together by known types of welding techniques.

[0050] Figure 4 shows part of the method of manufacturing the absorbent mat 100 described above.

[0051] The first step (section A) provides for unwinding a web 20 of liquid-impermeable material having a predetermined width, for example polyethylene, along the forward direction X.

[0052] Parallel to the line 9 of the unwound web, a multilayer absorbent panel is prepared.

[0053] To assemble the multilayer absorbent panel 9, the following steps follow (not shown): - providing a plurality of liquid absorbent pads 1, each having a predetermined length and width, this width being less than the width of the web 20 described above; - providing a plurality of sheets 3 of liquid-permeable material, each having a predetermined length and width equal to the length and width of the absorbent pad 1; - joining the absorbent pad 1 and the sheet 3 of liquid-permeable material together by adhesion or welding to create the multilayer absorbent panel 9;

[0054] Next, referring again to Figure 4, the multilayer absorbent panel 9 is applied above the web 20 of liquid-impermeable material, along the forward direction X, at the center of this web, continuously and spaced apart from one another (section B).

[0055] The multilayer absorption panel 9 is positioned on the web 20 so as to define an effective absorption area 23 and a first pair of free edges 21 facing each other along the forward direction X, and a transverse free area 24 with respect to the forward direction X between each multilayer absorption panel 9, along the web 20.

[0056] A subsequent step relates to the structure of the first lateral closing means in the absorption mat 100 that counteracts liquid leakage (section C).

[0057] In fact, these operations include the step of continuously folding upwards the first pair of free edges 21 in the web 20 of liquid-impermeable material over the effective area 23 occupied by the multilayer absorption panel 9.

[0058] Referring to sections D and E of FIG. 4, the step of creating a second lateral closing means of the absorption mat 100 that counteracts liquid leakage and is arranged orthogonally to the first lateral closing means is shown. That is: - providing an alternative strip 10 of liquid-impermeable material; - applying the alternative strip 10 between the transverse free area 24 and the effective area 23 occupied by the multilayer absorption panel 9 (section D); - cutting the web 20 transversely to obtain a disposable absorption mat 100 provided with the second lateral closing means (section E), which is.

[0059] Specifically, the alternative strip 10 of liquid-impermeable material has a width greater than the width of the transverse free area 24 measured along the forward direction X of the web 20, whereby each strip 10 entirely occupies the transverse free area 24 until it overlaps two consecutive effective areas 23.

[0060] The transverse cut of the web 20 at the center line of the strip 10 separates the mat 100 and divides the strip 10 into two strips 4, 5 each, which form the second lateral closing means.

[0061] Alternatively, to create the second side closure means, strips 4, 5 of liquid-impermeable material having a width that overlaps only a part of the effective region 23 and the free region 24 in the transverse direction can be used so that the cutting step affects only the web 20.

Claims

1. A disposable absorbent mat (100) having a substantially square shape, comprising: a liquid absorbent pad (1) having a predetermined length and width defining the boundary of the effective area (23); a sheet (2) of liquid-impermeable material having a predetermined length and width larger than that of the absorbent pad (1), joined under the absorbent pad (1) so as to define a first pair (21) and a second pair (22) at the opposing free edges, and disposed outside the effective area (23) occupied by the absorbent pad (1); a sheet (3) of liquid-permeable material joined to overlap the absorbent pad (1) on the side opposite to the sheet (2) of liquid-impermeable material; the first pair (21) of free edges of the sheet (2) of liquid-impermeable material is folded upward in the effective area (23) occupied by the absorbent pad (1) to define first side closure means of the absorbent pad (1) to resist liquid leakage; wherein the disposable absorbent mat (100) has the sheet (3) of liquid-permeable material having a predetermined length and width equal to the length and width of the absorbent pad (1), and the absorbent mat (1) comprises a first strip (4) and a second strip (5) of the liquid-impermeable material installed across each free edge at the second pair (22) of free edges and the sheet (3) of liquid-permeable material, respectively, the first strip (4) and the second strip (5) being joined at least to the second pair (22) of free edges and disposed orthogonally to the first side closure means to define second side closure means of the absorbent pad (1) to resist liquid leakage.

2. The disposable absorbent mat (100) according to claim 1, wherein the first pair (21) of free edges of the sheet (2) of liquid-impermeable material is folded upward in the liquid-permeable material (3).

3. The disposable absorbent mat (100) according to claim 2, wherein the first strip (4) and the second strip (5) are overlapped at the ends of the first side closure means formed by the first pair (21) of free edges folded upward.

4. The disposable absorbent mat (100) according to any one of claims 1 to 3, wherein the first strip (4) and the second strip (5) of the liquid-impermeable material are made of a hydrophobic non-woven fabric.

5. The disposable absorbent mat (100) according to any one of claims 1 to 4, wherein the sheet (2) of the liquid-impermeable material is made of polyethylene.

6. The disposable absorbent mat (100) according to any one of claims 1 to 5, wherein the sheet (3) of the permeable material is made of a hydrophilic non-woven fabric.

7. The absorbent pad (1) is a composite material, and includes at least one tissue (6) made of a hydrophilic material and an absorbent cellulose layer (7). At least one of the tissues (6) faces the sheet (2) of the liquid-impermeable material, and the absorbent cellulose layer (7) faces the sheet (3) of the liquid-permeable material. The disposable absorbent mat (100) according to any one of claims 1 to 6.

8. The disposable absorbent mat (100) according to any one of claims 1 to 7, wherein the absorbent pad (1), the sheet (2) of the liquid-impermeable material, the sheet (3) of the liquid-permeable material, the pair of edges (21, 22), and the strips (4, 5) are joined together by an adhesive (8) or welding.

9. A method for manufacturing the disposable absorbent mat (100) according to any one of claims 1 to 8, providing a web (20) of liquid-impermeable material having a predetermined width and unwound in the forward direction (X); providing a plurality of liquid absorbent pads (1), each having a predetermined length and width, the width being less than the width of the web (20); providing a plurality of sheets (3) of liquid-permeable material, each having a predetermined length and width equal to the length and width of the absorbent pad (1); joining the absorbent pad (1) and the sheet (3) of the liquid-permeable material together to produce a multi-layer absorbent panel (9); Apply the multilayer absorption panel (9) sequentially and spaced apart on top of the web (20) of the liquid-impermeable material along the forward direction (X), thereby defining an effective area (23) along the web (20), a first pair (21) of opposing free edges along the forward direction (X), and a transverse free area (24) in the transverse direction with respect to the forward direction (X) between each of the multilayer absorption panels (9). In the effective area (23) occupied by the multilayer absorption panel (9), fold back the first pair (21) of free edges in the web (20) of the liquid-impermeable material upward to define the first lateral closure means of the absorption mat (100) against liquid leakage. Providing strips (4, 5) of liquid-impermeable material. Apply the strips (4, 5) across at least a part of the transverse free area (24) and the effective area (23) occupied by the multilayer absorption panel (9) to obtain second lateral closure means against liquid leakage arranged orthogonally to the first lateral closure means. Cut the web (20) transversely to obtain the disposable absorption mat (100). A method for manufacturing a disposable absorption mat (100), characterized by comprising the above steps.

10. Providing an alternative strip (10) of liquid-impermeable material having a width longer than the width of the transverse free area (24) along the forward direction (X) of the web (20). Applying each of the alternative strips (10) between two consecutive multilayer absorption panels (9). Cut the web (20) transversely at the intermediate line of the alternative strip (10) to obtain the strips (4, 5). Characterized by further comprising the above steps. The step of bonding the absorption pad (1) and the sheet (3) of the liquid-permeable material together, the step of applying the multilayer absorption panel (9) on top of the web (20) of the liquid-impermeable material, and the step of applying the strips (4, 5, 10) include the step of bonding or welding the components together. A method for manufacturing a disposable absorption mat (100) according to claim 9.

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