sanitary products

Abstract

For example, the present invention provides sanitary articles for use in personal care absorbent products such as nappies or diapers, training pants, sanitary napkins, incontinence garments, wound aids, personal protective equipment, face masks, protective clothing, head and shoe covers, which are renewable and sustainably produced, and are made from materials not derived from petrochemicals. [Solution] A sanitary article is provided that includes a fiber composition comprising a combination of wool fibers and polymer fibers, wherein the polymer fibers are not derived from one or more petrochemical products.

Description

Technical Field

[0001] The present invention is directed to hygiene articles for use in personal care absorbent products such as, for example, nappies or diapers, training pants, sanitary napkins, incontinence garments, wound aids, personal protective equipment, face masks, prophylactic clothing, head and shoe covers, etc. More particularly, the hygiene article is a non-woven wool-containing hygiene article.

Background Art

[0002] A variety of hygiene products are available in the market. Many of these products contain materials that are not renewable or not sustainably produced, such as absorbent polymer materials derived from virgin petrochemical products.

[0003] Wool has been used in durable products that are washable and / or long-lasting, such as clothing, carpets and upholstery for chairs, as well as insulating building materials. Wool has inherent properties such as heat regulation, odor control, breathability, and comfort. In light of environmental concerns in consumer goods, wool has the ability to be used to fill the gap in sustainable disposable hygiene non-woven products or articles.

[0004] The object of the present invention is to provide a renewable and sustainably produced hygiene article composed of materials not derived from petrochemical products, or at least to provide the public with an environmentally creditable and useful alternative.

Summary of the Invention

[0005] In a first aspect, the present invention provides a hygiene article comprising a fiber composition composed of a combination of wool fibers and polymer fibers, wherein the polymer fibers are hygiene articles not derived from one or more petrochemical products.

[0006] In one embodiment, the hygiene article is a non-woven product. In one embodiment, the polymer fibers are sustainably produced and are biodegradable or compostable.

[0007] In one embodiment, the wool fibers are washed wool fibers. In one embodiment, the wool fibers are approximately 16 to 40 microns thick. In another embodiment, the wool fibers are approximately 18 to 40 microns thick. In yet another embodiment, the wool fibers are approximately 30 to 40 microns thick.

[0008] In one embodiment, the length of the wool fibers is approximately 25 mm to 130 mm. In another embodiment, the length of the wool fibers is approximately 25 mm to 75 mm. In one embodiment, the sanitary article is composed of an acquisition distribution layer, a filter layer, a moisture-resistant fabric, an antimicrobial fabric, a top sheet, or an absorbent core layer. In one embodiment, the sanitary article is composed of an acquisition distribution layer. In one embodiment, the sanitary article is composed of a filter layer suitable for use in face masks and the like. In one embodiment, the sanitary article is composed of a moisture-resistant fabric suitable for use in personal protective wearables such as protective clothing, shoe covers, or head covers, but not limited to these. In one embodiment, the sanitary article is composed of an antimicrobial fabric for use in personal protective wearables such as protective clothing, shoe covers, or head covers, but not limited to these.

[0009] In one embodiment, the fiber composition comprises about 20-99% wool fibers and about 1-80% polymer fibers. In a preferred embodiment, the fiber composition comprises about 20-97% wool fibers and about 3-80% polymer fibers. In a more preferred embodiment, the fiber composition comprises about 30-95% wool fibers and about 5-70% polymer fibers.

[0010] In one embodiment, the fiber composition may further contain up to 25% fiber binder. In one embodiment, the polymer fiber is derived from, but is not limited to, viscose, rayon, bagasse, hemp, eucomis (pineapple plant) fiber, flax, cotton, eucalyptus, silk, sugarcane, corn starch, soybeans, rice waste, recycled fiber, milk fiber, and reprocessed fiber. In one embodiment, the polymer fiber is selected from polylactic acid fiber, cellulosic polymer fiber, or a combination thereof.

[0011] In another embodiment, the polymer fibers are approximately 30-40 mm in length. In one embodiment, the fiber composition comprises about 20-70% wool fibers and about 80-30% polylactic acid fibers. In a preferred embodiment, the fiber composition comprises about 40-60% wool fibers and about 60-40% polylactic acid fibers. In a more preferred embodiment, the fiber composition comprises about 45-55% wool fibers and about 55-45% polylactic acid fibers. In the most preferred embodiment, the fiber composition comprises about 50% wool fibers and about 50% polylactic acid fibers.

[0012] In one embodiment, the fiber composition comprises about 20-70% wool fibers and about 80-30% cellulosic fibers. In a preferred embodiment, the fiber composition comprises about 30-45% wool fibers, about 30-45% cellulosic fibers, and about 10-40% fiber binder.

[0013] In one embodiment, the cellulose fibers are approximately 30-40 mm in length. In one embodiment, the cellulosic fiber is a viscose fiber. In another embodiment, the fiber composition comprises about 20-99% wool fibers and about 1-80% viscose fibers. In yet another embodiment, the fiber composition comprises about 80-98% wool fibers and about 2-20% viscose fibers. In a more preferred embodiment, the fiber composition comprises about 90-96% wool fibers and about 4-10% viscose fibers. In the most preferred embodiment, the fiber composition comprises about 95% wool fibers and about 5% viscose fibers.

[0014] In one embodiment, the viscose fibers are approximately 30-40 mm in length. In one embodiment, the weight of the sanitary material is approximately 30 to 200 grams / square meter. In a preferred embodiment, the weight of the sanitary material is approximately 50 to 100 grams / square meter. In another preferred embodiment, the weight of the sanitary material is approximately 60 grams / square meter.

[0015] In one embodiment, the thickness of the sanitary article is approximately 0.5 to 2.0 mm. In a preferred embodiment, the thickness of the sanitary article is approximately 1.0 to 1.5 mm. In a more preferred embodiment, the thickness of the sanitary article is approximately 1.0 mm.

[0016] In one embodiment, the sanitary article is composed of a collection / distribution layer, a filter layer, a moisture-resistant fabric, an antimicrobial fabric, a top sheet, or an absorbent core layer. In one embodiment, the sanitary article is composed of a collection / distribution layer. In one embodiment, the sanitary article is composed of a filter layer suitable for use in face masks and the like. In one embodiment, the sanitary article is composed of a moisture-resistant fabric suitable for use in personal protective wearables such as protective clothing, shoe covers, or head covers, but not limited to these. In one embodiment, the sanitary article is composed of an antimicrobial fabric for use in personal protective wearables such as protective clothing, shoe covers, or head covers, but not limited to these.

[0017] In a second aspect, the present invention provides a method for manufacturing a sanitary article as defined above, the method comprising the following steps: (a) A step of providing a fiber composition by combining wool fibers and polymer fibers, (b) A process of joining the combined fibers, Includes.

[0018] In one embodiment, the method includes a further step of applying a wetting agent to the fiber composition either before or after the bonding step. In one embodiment, the wetting agent is Cirrasol® 910XS-LQ (CRODA).

[0019] In one embodiment, the hygiene article is the acquisition and distribution layer, the topsheet, or the absorbent core layer. In one embodiment, the hygiene article is the acquisition and distribution layer. In one embodiment, the step of combining wool fibers and polymer fibers together to obtain a fiber composition is achieved by dry technology (e.g., carding), airlaid technology, or wet technology.

[0020] In one embodiment, the method includes a further step of drying the fiber composition after the wetting agent is applied. In one embodiment, the joining step is selected from a thermal joining step, a mechanical joining step, or a chemical joining step. In one embodiment, the mechanical joining step is a water jet entanglement step, or a spunlace step, or an airlaid step.

[0021] In one embodiment, the joining step is a thermal joining step performed at about 130°C. In one embodiment, the thermal joining step is performed for about 1 minute. In one embodiment, the hygiene article is a non-woven product.

[0022] In a third aspect, the present invention provides a method for manufacturing a hygiene article as defined above, the method comprising the following steps: (a) a step of combining wool fibers and polymer fibers together to provide a fiber composition; (b) a step of spunlacing the combined fibers; and.

[0023] In one embodiment, the step of combining wool fibers and polymer fibers together to obtain a fiber composition is achieved by dry technology (e.g., carding), airlaid technology, or wet technology. In one embodiment, the fiber composition is formed into a web-like structure.

[0024] In one embodiment, the spunlacing step is performed at about 7.0 to 10.0 MPa (about 70 to 100 bar). In one embodiment, the spunlacing step is performed in two passes.

[0025] In one embodiment, the sanitary material is a collection and distribution layer, a top sheet, or an absorbent core layer. In one embodiment, the sanitary material is a collection and distribution layer. In one embodiment, the sanitary article is a nonwoven fabric product.

[0026] Further aspects and embodiments of the present invention will become apparent from the following description and examples provided below. The present invention is disclosed in more detail below with reference to drawings and embodiments provided herein in a non-limiting manner. [Brief explanation of the drawing]

[0027] [Figure 1] Figure 1 shows a schematic top view of a collection and distribution layer located in a sanitary product, specifically a diaper or sanitary pad. [Figure 2] Figure 2 shows a photograph of a sanitary item, an exemplary collection and distribution layer, rolled in a format for use in diaper manufacturing. [Figure 3] Figure 3 shows photographs of examples of nonwoven sanitary articles. The green articles represent nonwoven collection and distribution articles made from synthetic fibers. The white nonwoven articles are bio-composite nonwoven fabrics containing wool and viscose, and wool and polylactic acid (PLA). [Figure 4] Figure 4 shows an overall diagram of one embodiment of the process of the present invention for manufacturing nonwoven sanitary articles according to the present invention. [Modes for carrying out the invention]

[0028] The following description includes numerous exemplary configurations and parameters. However, it should be noted that such descriptions are not intended to limit the scope of the invention, but rather are provided as illustrative embodiments.

[0029] definition In the examples, embodiments, and examples of the present invention as described herein, terms such as “comprising” and “including” should be read broadly and not limitingly.

[0030] Therefore, unless the context clearly requires a different interpretation, throughout the specification and claims, words such as "comprise" and "comprising" should be interpreted in a comprehensive sense, as opposed to an exclusive sense, that is, "includes, but is not limited to."

[0031] As used herein, the terms “about” or “approximately” usually mean within 20%, more preferably within 10%, and most preferably within 5% of a given value or range. Alternatively, the term “about” means within a logarithmic (i.e., single-digit) range, preferably within twice the given value.

[0032] As used herein, the term “article” refers to any three-dimensional solid material capable of collecting and storing bodily fluids discharged from the body. Preferred articles according to the present invention include, but are not limited to, disposable fluid-absorbing articles such as face masks designed to be worn in contact with the user’s body, protective clothing, shoe covers, or head coverings, personal protective wearables, disposable fluid-absorbing panty liners, sanitary napkins, menstrual (catamenials), incontinence inserts / pads, diapers, training pants, breast pads, and interlabial inserts / pads.

[0033] As used herein, the term “body fluid” means any fluid produced and expelled by the body of a human or animal, such as urine, menstrual fluid, feces, and vaginal secretions. As used herein, the term “cellulose polymer fiber” means any naturally produced or mechanically manufactured fiber derived from a cellulose source, including, but not limited to, cotton, wood or wood pulp, linen, hemp, bagasse, flax, eucalyptus, sugarcane, corn starch, soybean, rice waste, rayon, viscose, jute fiber, eucomycete fiber, reprocessed fiber and recycled fiber, and combinations thereof.

[0034] As used herein, the term “layer” refers to a fibrous composition whose main dimensions are its length and width. It should be understood that the term “layer” is not necessarily limited to a single layer or sheet of composition. Therefore, a layer may include a laminate, composite, or combination of several sheets or webs of different fibrous materials. [Examples]

[0035] The examples described herein are provided for illustrative purposes only to illustrate specific embodiments of the invention and are not intended to limit the invention in any way. Those skilled in the art can use the disclosures and teachings herein to generate other embodiments and variations without excessive experimentation. All such embodiments and variations are considered to be part of the invention.

[0036] Techniques for consolidating or joining fibers within a layer or web include mechanical bonding, thermal bonding, and chemical bonding. In the mechanical bonding process, fibers are mechanically intertwined, for example, by a water jet (spunlace) or barbed needle (needle punch), causing them to fuse together and achieve web integrity. Thermal bonding is achieved by increasing the temperature in the presence of a low-melting-point thermoplastic material, such as polylactic acid, which melts at a specific temperature to join fibers within the layer or web. Chemical bonding is achieved by using a wet chemical binder to join fibers in a web-like structure.

[0037] Preferred means for enhancing integrity include thermal bonding, needle punching, through-air bonding, and / or spunlacing. The structure and integrity of the sanitary article remain stable when wet. In summary, the addition of thermoplastic materials improves the fluid permeability of discharged bodily fluids, thus resulting in improved collection properties.

[0038] A preferred thermal bonding technique is achieved by applying hot air to the surface of a fibrous fabric. The hot air circulates directly above the fibrous fabric but does not penetrate it. The bonding site is formed between the wool fibers and polymer fibers. It is assumed that suitable binders, such as crystalline binder fibers, two-component composite binder fibers, and powders, may be used during the thermal bonding process. When crystalline binder fibers or powders are used, the binder melts completely, forming molten droplets throughout the cross-section of the nonwoven fabric. Bonding occurs at these points during cooling. Products manufactured using a through-air oven tend to be bulky, open, soft, strong, stretchable, breathable, and absorbent.

[0039] In the case of thermal bonding, thermoplastic material may also be added to the fibers. During heat treatment, at least a portion of this thermoplastic material melts and migrates to the fiber intersections caused by capillary effect. These intersections solidify after cooling, joining the sites and improving the integrity of the fiber matrix.

[0040] Suitable thermoplastic materials include polylactic acid and any other biodegradable, heat-sensitive polymer. Spunlacing (also known as "water entanglement") is a further method for increasing the integrity of a web. The formed web of carded or loose fibers (usually airlaid or wet) is first compressed and pre-moistened to remove air pockets. Spunlacing techniques use multiple rows of fine, high-speed jets of water to slap the web onto a porous belt or to move a perforated or patterned screen, thereby binding the fibers together. The water pressure generally increases from the first to the last jet. Pressures as high as 15.0 MPa (150 bar) are used to guide the water jet onto the web. This pressure is sufficient for most nonwoven fibers, but higher pressures are used for special applications.

[0041] Spunlace is a nonwoven fabric manufacturing system that uses water jets to intertwine fibers, thereby achieving fabric integrity. Softness, drape, conformability, and relatively high strength are the main characteristics of spunlace nonwovens.

[0042] Chemical bonding is performed by using a chemical binder to bond fibers in a web-like structure. A chemical bonding agent, such as OC-BioBinder® Oak 33XX from OrganoClick, may be applied during the chemical bonding process. The chemical bonding process may involve a continuous process of moving the fibrous web-like structure through an impregnation bath or sprayer containing the binder. It should be understood that modifications to the chemical bonding technique can be used, such as adding a wetting agent to the impregnation bath containing the binder. The chemical bonding time must be sufficient for fiber impregnation to occur in order to allow the fibers to form a chemical bond with the bonding agent, thereby enhancing the physical integrity of the resulting fiber composition.

[0043] sanitary goods The sanitary articles of the present invention, including but not limited to collection and distribution layers, are preferably constructed to efficiently transfer and distribute discharged bodily fluids to other areas or layers of the composition in which the bodily fluids are immobilized and stored.

[0044] Sanitary items include wool fibers and polymer fibers. Wool fibers can be fixed to enhance the strength and integrity of the article. Techniques for solidifying fibers within the web include mechanical bonding, thermal bonding, and chemical bonding. Preferred sanitary articles contain wool fibers and polymer fibers dispersed within them.

[0045] Therefore, as an example, a suitable sanitary article comprises 50-99% by weight of wool material and 1-50% by weight of polymer fibers, preferably 50-80% by weight of wool material and 20-50% by weight of polymer fibers.

[0046] When sanitary materials are configured as collection and distribution layers, the weight range of the materials is 20-200 g / m², depending on the proportion of polymer fibers. 2 Most preferably 40-80 g / m² 2 It would be within that range. The process for producing the sanitary articles of the present invention is schematically shown in Figure 4. This process involves combining washed raw wool and polymer fibers in a ratio such as 50% wool fibers and 50% polylactic acid fibers, and forming these fibers together into a web-like structure. The fibers are then joined (either thermally, chemically, or mechanically) to create physical connections or bonding between the polymer fibers and wool fibers and to enhance the integrity of the composition. A wetting agent may be applied to the resulting wool / polymer fiber composition before or after the joining step. The wetting step is performed to make the wool fibers hydrophilic. If a wetting agent is applied to the fiber composition, the fiber composition requires further drying to allow the water applied during the application of the wetting agent to dry. The final step requires winding the fiber composition.

[0047] The following examples will be described without limiting the present invention. Example 1 The first fiber composition was manufactured using 50% washed New Zealand wool having a fiber length of approximately 25-130 mm and a wool diameter of approximately 18-40 microns, preferably approximately 34-39 microns, and 50% two-component polylactic acid (PLA) composite fibers having a fiber length of approximately 38 mm and a density of 2.2 dtex. The PLA was supplied directly from Ingeo Fibres. The separated fibers were laminated and blended using a Frenaught fiber opener. The fibers were carded together in a two-pass process using a carding machine (0.5 m Single Cylinder Tatham Card). In the first pass, the blended fibers were passed through the card to further blend the fibers. In the second pass, the carded fiber web was rotated 90 degrees to reorient the fibers in the second carding pass in order to produce a uniform and homogeneous web. Next, the resulting carding fiber web was heat-bonded using a hot press at approximately 140°C for a total of approximately 20 seconds (10 seconds on one side, then the sample was flipped over and pressed again for another 10 seconds). It should be understood that alternative heat bonding techniques can be used, such as a flatbed laminator or a ventilated oven with a top and bottom conveyor. The heat bonding time must be sufficient to heat the PLA so that the PLA fiber sheath can flow, and then allow an effective cooling period for the fiber composition to solidify before any winding process. Before winding, the wool and PLA fiber composition may be moistened with a wetting agent to make the wool hydrophilic. In this example, a 1% solution (diluted with water) of the wetting agent, specifically Cirrasol® 910XS-LQ (supplied by CRODA International Plc), was used. After applying a wetting agent, the fiber composition was subjected to a drying process using a Spooner ventilated oven at approximately 80°C and a fan speed of 50% for approximately 2 minutes or for a period sufficient to remove the water. Higher temperatures may be used in the drying process, however, the temperature should not affect the integrity of the fiber composition. Once the fiber composition was prepared, it was subjected to various tests to determine its properties, as outlined below. The tests were carried out according to the standard nonwoven fabric procedure.

[0048] result: The results of the collection and distribution layer manufactured according to Example 1, as described above, are shown in Table 1 below. These results are also compared with commercially available collection and distribution layers (see Table 2).

[0049] [Table 1]

[0050] [Table 2]

[0051] From the attached documents, it can be seen that the abrasion and rewetting characteristics of the collection and distribution layer manufactured according to Example 1, as well as the process outlined in Figure 2, are comparable to those of commercially available collection and distribution layers.

[0052] Example 2 The second fiber composition was manufactured using 40% washed New Zealand wool having a fiber length of approximately 25-130 mm and a wool fiber diameter of approximately 20-40 microns, preferably approximately 34-39 microns, and 40% viscose (1.3 dtex) having a fiber length of approximately 38 mm. The viscose fibers were supplied directly from Lenzing. The separated fibers were laminated and blended using a Frenaught fiber opener. The fibers were carded together in a two-pass process using a carding machine (0.5 m Single Cylinder Tatham Card). In the first pass, the blended fibers were passed through the card to further blend the fibers. In the second pass, the carded fiber web was rotated 90 degrees to reorient the fibers in the second carding pass in order to produce a uniform and homogeneous web. A binder was applied before the heat bonding process. Next, the resulting fiber web was heat-bonded using a hot press at approximately 140°C for a total of approximately 20 seconds (10 seconds on one side, then the sample was flipped over and pressed again for another 10 seconds). It should be noted that alternative heat bonding techniques, such as a flatbed laminator or a ventilated oven with an up-and-down conveyor, can be used. The heat bonding time must be sufficient to heat the viscose so that the viscose fiber sheath can flow, and then allow an effective cooling period for the fiber composition to solidify before any further processes. Before winding, the wool and viscose fiber composition may be moistened with a wetting agent to make the wool hydrophilic. In this example, a 1% solution (diluted with water) of the wetting agent, specifically Cirrasol® 910XS-LQ (supplied by CRODA International Plc), was used. After applying the wetting agent, the fiber composition was subjected to a drying process using a Spooner ventilated oven at approximately 80°C and a fan speed of 50% for approximately 2 minutes or a length of time sufficient to remove the water. Higher temperatures may be used in the drying process, however, the temperature should not affect the integrity of the fiber composition. Once the drying process was complete, the binder was applied to the fiber composition to form the remaining 20% ​​of the composition. The binder, OC-BioBinder Oak, was supplied by OrganoClick.The binder was applied using a single-pass padding method at a pressure of 0.1 MPa (1 bar) and a padding rate of 1 m / min (Roaches padder). A drying process was then performed using a 100°C air oven, passing the material through once for 2 minutes at a fan speed of 40%. Once the fiber compositions were prepared, they were subjected to various tests to determine their properties, as outlined below. The tests were conducted according to standard nonwoven fabric procedures.

[0053] result: The results of the collection and distribution layer manufactured according to Example 2, as described above, are shown in Table 3 below.

[0054] [Table 3]

[0055] The results showed that the increased surface area and wettability due to the viscose fiber content contributed to improved tensile and elongation properties (comparable to those measured for commercially available samples shown in Table 2). However, re-wetting and abrasion results were negatively affected at a 40% viscose fiber content.

[0056] Example 3 The third fiber composition was manufactured using 95% washed New Zealand wool with a fiber length of approximately 25–130 mm and 5% viscose (1.3 dtex) with a fiber length of approximately 38 mm. The viscose fibers were supplied directly from Lenzing. The separated fibers were stacked and blended using a Frenaught fiber opener. The fibers were carded together in a two-pass process using a carding machine (0.5 m Single Cylinder Tatham Card). In the first pass, the blended fibers were passed through the card to further blend the fibers. In the second pass, the carded fiber web was rotated 90 degrees to reorient the fibers in the second carding pass in order to produce a uniform and homogeneous web. The resulting fiber web was then spin-laced / water-entangled in two passes at approximately 7.0 MPa (70 bar) for a total of approximately 20 seconds (10 seconds on one side, then the sample was flipped over, and then water-entangled again for another 10 seconds). Following the water entanglement process, the fiber composition was subjected to a drying process using a Spooner ventilated oven at approximately 80°C and 50% fan speed for approximately 2 minutes or a length sufficient to remove the water. Higher temperatures may be used in the drying process, however, the temperature should not affect the integrity of the fiber composition. Once the fiber composition was prepared, it was subjected to various tests to determine its properties, as outlined below. The tests were carried out according to the standard nonwoven fabric procedure and compared with the properties of commercially available products (see Table 2).

[0057] [Table 4]

[0058] Example 4 The fourth fiber composition was manufactured using 60% washed New Zealand wool, 15% cotton, 5% viscose (1.3 dtex), and 20% biobinder, with fiber lengths of approximately 25-130 mm. The cotton and viscose fibers had a fiber length of approximately 38 mm. The viscose fibers were supplied directly from Lenzing. The cotton fibers were supplied from TJ Beall Co. The separated fibers were stacked and blended using a Frenaught fiber opener. The fibers were carded together in a two-pass process using a carding machine (0.5 m Single Cylinder Tatham Card). In the first pass, the blended fibers were passed through the card to further blend the fibers. In the second pass, the carded fiber web was rotated 90 degrees to reorient the fibers in the second carding pass in order to produce a uniform and homogeneous web. In the first pass, the blended fibers were passed through the card to further blend the fibers. In the second pass, the carded fiber web was rotated 90 degrees to reorient the fibers in the second carding pass in order to produce a uniform and homogeneous web. A binder (OC-BioBinder® Oak 33XX from OrganoClick) was applied during the chemical bonding process. The resulting fiber web was then chemically bonded. The chemical bonding process involves a continuous process of moving the fibrous web structure through an impregnation bath or sprayer containing the binder. It should be understood that modifications to the chemical bonding technique can be used, such as adding a wetting agent to the impregnation bath containing the binder. The chemical bonding time must be sufficient for fiber impregnation to occur. The cotton and viscose fiber compositions were dried before winding the wool. Once the fiber compositions were prepared, they were subjected to various tests to determine their properties, as outlined below. Two slightly different weight samples (Sample 1 and Sample 2) were prepared using the same process. The tests were carried out according to the nonwoven standard procedure and compared to the properties of commercially available products (see Tables 5 and 6).

[0059] [Table 5]

[0060] [Table 6]

[0061] Example 5 SGS in Wisconsin, USA, independently tested two prototype collection and distribution layer samples against a well-functioning commercial incontinence product for collection and re-wetting rates. The tests were conducted according to ISO 17025 accreditation. Prototype sample 1 weighed 60 grams / m² and contained 85% wool fibers and 15% viscose. Prototype sample 2 weighed 60 grams / m² and contained 80% wool and 20% Lenzing viscose (1.3 dtex, 38 mm fiber length). To ensure a clear comparison between the commercial product and the prototypes, the collection and distribution layer of the commercial product was removed and replaced with either prototype 1 or prototype 2. The results are shown in Table 7 below.

[0062] [Table 7]

[0063] Example 6 The top sheet layer may also be configured to have a weight of approximately 15-50 grams / square meter, which is suitable for diapers or sanitary items that come into contact with the skin. The top sheet layer could have the same composition as prototype samples 1 and 2 described above in Example 5. For the top sheet layer, it is expected that low-micron fibers, such as 24-30 micron fibers, could be used for the wool used for further flexibility.

[0064] It should also be understood that the sanitary article could be configured to include a combination of one or more sanitary articles. For example, the sanitary article could be configured to include a top sheet layer and a collection / distribution layer.

[0065] It should also be understood that other sanitary articles, such as nonwoven wipes, materials suitable for face masks, and absorbent cores for broad absorption purposes, could be developed and constructed from variations of prototype sample 1 or prototype sample 2. Those skilled in the art would be able to construct a desired sanitary article if its characteristics and functional requirements were known.

[0066] Each and all disclosures of the patents, patent applications, and publications cited herein are incorporated herein by reference in their entirety. While this disclosure has been described with reference to certain aspects, it will be apparent that other aspects and variations can be devised by those skilled in the art without departing from the true intent and scope of this disclosure. The appended claims are intended to be construed as including all such aspects and equivalent variations. Any patent, publication, or other disclosure material referred to as being incorporated herein by reference is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material contained herein. Accordingly, to the extent necessary, disclosures expressly contained herein supersede any conflicting material incorporated herein by reference.

[0067] While this disclosure has been specifically shown and described with reference to its preferred embodiments, it will be understood by those skilled in the art that various modifications of form and detail can be made without departing from the scope of this disclosure as encompassed by the appended claims.

[0068] Exemplary Embodiments Embodiment 1: (a) A step of combining wool fibers and polymer fibers to form a web-like structure, wherein the combined fibers consist of (i) 30-97% wool fibers and (ii) 3-70% polymer fibers, and the polymer fibers are not derived from petrochemical products, and the step of forming the web, (b) A step of mechanically, thermally, or chemically joining the wool fibers and polymer fibers in the web-like structure. A method for producing a fiber composition for use in sanitary articles, including [the specified element]. Embodiment 2: The fiber composition is 95% wool fibers and 5% viscose fibers, or 90-96% wool fibers and 4-10% viscose fibers, or 80% ± 5% wool fibers and 20% ± 5% viscose fibers, or 70% ± 5% wool fibers and 30% ± 5% viscose fibers, or 40% ± 5% wool fibers and 40% ± 5% viscose fibers, or 50% ± 5% wool fibers and 50% ± 5% polylactic acid fibers The method according to Embodiment 1, comprising: Embodiment 3: The wool fiber is a sheep's wool fiber. The wool fibers mentioned above are washed wool fibers. The length of the wool fibers is 25mm to 130mm. The length of the wool fibers is 25mm to 75mm. The wool fibers have a thickness of 16 to 40 μm. The polymer fibers are 16 to 40 mm in length, and The polymer fibers are 30 to 40 mm in length. The method according to Embodiment 1, further comprising one or more of the following. Embodiment 4: The method according to Embodiment 1, wherein the web-like structure is manufactured by carding. Embodiment 5: The method according to Embodiment 1, further comprising the step of applying a wetting agent to the fiber composition either before or after the bonding. Embodiment 6: The method according to Embodiment 5, further comprising the step of drying the fiber composition after the wetting agent has been applied. Embodiment 7: The method according to Embodiment 1, further comprising the step of drying the fiber composition after the bonding. Embodiment 8: The thermal bonding is performed at a temperature of 130°C or within 10% of this temperature. The mechanical joining process includes a water entanglement process or a needle punching process, or The method according to Embodiment 1, wherein chemical bonding is performed using a binder. Embodiment 9: The method according to Embodiment 1, further comprising the step of adding a binder after bonding. Embodiment 10: A sanitary article containing a fiber composition, wherein the fiber composition comprises 30-97% wool fibers and 3-70% polymer fibers not derived from petrochemical products, the wool fibers and polymer fibers in the fiber composition form a web-like structure, and the wool fibers and polymer fibers are mechanically, thermally, or chemically bonded to each other. Embodiment 11: The fiber composition is 95% wool fibers and 5% viscose fibers, or 90-96% wool fibers and 4-10% viscose fibers, or 80% ± 5% wool fibers and 20% ± 5% viscose fibers, or 70% ± 5% wool fibers and 30% ± 5% viscose fibers, or 40% ± 5% wool fibers and 40% ± 5% viscose fibers, or 50% ± 5% wool fibers and 50% ± 5% polylactic acid fibers A sanitary article according to Embodiment 10, having the following characteristics. Embodiment 12: The wool fiber is a sheep's wool fiber. The wool fibers mentioned above are washed wool fibers. The length of the wool fibers is 25mm to 130mm. The length of the wool fibers is 25mm to 75mm. The wool fibers have a thickness of 16 to 40 μm. The polymer fibers are 16 to 40 mm in length, and The polymer fibers are 30 to 40 mm in length. The sanitary article according to Embodiment 10, further comprising one or more of the following. Embodiment 13: The weight of the sanitary article is 50-70 grams / square meter, 15-50 grams / square meter, 40-80 grams / square meter, 60 grams / square meter, or 20±5%-200±5% grams / square meter, and / or The sanitary article according to Embodiment 10, wherein the thickness of the sanitary article is 0.5 to 2.0 mm, 1.0 to 1.5 mm, or 1.0 mm. Embodiment 14: The sanitary article according to Embodiment 10, wherein the sanitary article is composed of an acquisition distribution layer, a top sheet, an absorbent core layer, a filter layer, or an antimicrobial fabric. Embodiment 15: The sanitary article according to Embodiment 10, wherein the sanitary article is configured as personal protective equipment. Embodiment 16: The sanitary article according to Embodiment 10, wherein the sanitary article comprises a face mask, protective clothing, shoe covers, head covers, panty liners, sanitary napkins, menstrual products, incontinence pads, incontinence clothing, diapers, toilet training pants, nonwoven wipes, breast pads, or interlabial pads.

Claims

[Claim 1] The invention described in the specification.

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