Carbon fiber core, method for manufacturing the same, and use

Abstract

The present invention discloses a carbon fiber core including a carbon fiber core body, the carbon fiber core body comprising a flow guide layer, adhesive layer I, coating layer I, adhesive layer II, carbon fiber layer, fluff pulp layer, water-absorbent resin layer, adhesive layer III, and coating layer II arranged in order from top to bottom, with liquid permeable and ventilated holes provided in the coating layer and core layer. The present invention has a rational structure and, while guaranteeing absorption and penetration prevention performance, further possesses excellent deodorizing and antibacterial properties, and can be applied to incontinence pads and sanitary napkin products. The manufacturing process of the present invention enables mass production of cores and applied products, solving the problems of low production quality and slow production speed that exist in conventional sanitary products made with activated carbon.

Description

Technical Field

[0001] This application claims the priority of Patent Application No. CN2023105831462 (Title of Invention: Carbon Fiber Core, Its Manufacturing Method and Use) filed with the China Patent Office on May 21, 2023, and all of its content is incorporated herein by reference.

[0002] The present invention relates to the field of disposable hygiene products, and particularly to a carbon fiber core, its manufacturing method and use.

Background Art

[0003] The main performances of conventional personal hygiene products have focused on features such as leakage prevention, comfortable use feeling, convenience, dryness, and light weight. As the requirements for people's quality of life increase, the number of people with sensitive skin is also increasing. In addition to the requirements for conventional basic performances, the deodorizing performance and antibacterial performance of hygiene products have increasingly become the focus of customer attention.

[0004] In recent years, in the hygiene product industry, many technical researches and patent achievements have been published regarding the antibacterial and deodorizing functions of sanitary napkins and incontinence products, but many are realized by means such as the addition of chemical antibacterial components and odor masking components. Currently, some products are trying to apply methods such as using activated carbon or adding antibacterial agents to hygiene products in order to obtain deodorizing and antibacterial functions, but there are problems such as the discoloration of activated carbon, which affects customers' use, and low antibacterial and deodorizing effects.

[0005] The performance of the core has the greatest impact on the performance of adult incontinence pad products. Therefore, the present invention has developed a functional core sheet with new deodorizing and antibacterial functions. Thereby, it not only solves the deodorizing and antibacterial problems of incontinence pads and sanitary napkin products, but also realizes good production process control, continuous production, and the elimination of pollution problems.

Summary of the Invention

[0006] To overcome the shortcomings of conventional technology, the present invention provides a carbon fiber core, a method for manufacturing the same, and a method for using the same. The functional carbon fiber core of the present invention has a rational structure, ensures absorption and backflow prevention performance, and further possesses excellent deodorizing and antibacterial properties, and can be used in incontinence pads and sanitary napkin products.

[0007] The technical means employed by the present invention to solve its technical problems are as follows: The carbon fiber core includes the carbon fiber core body. The carbon fiber core body includes a flow guide layer I, an adhesive layer I, a coating layer I, an adhesive layer II, a carbon fiber layer, a fluff pulp layer, a water-absorbent resin layer, an adhesive layer III, and a coating layer II arranged in order from top to bottom, and multiple liquid-permeable and ventilating holes are provided throughout the coating layer I, the coating layer II, and the core layers between them.

[0008] As an improvement to the above technical means, the mass ratio of each component of the carbon fiber core body is as follows: The ratio of the flow guide layer, adhesive layer I, coating layer I, adhesive layer II, carbon fiber layer, fluff pulp layer, water-absorbing resin layer, adhesive layer III, and coating layer II is 10-80%, 0.5-5.0%, 2-40%, 0.5-5.0%, 2-90%, 0-95%, 0-25%, 0.5-5.0%, and 5-60%.

[0009] As an improvement to the above technical means, the flow guide layer is manufactured by a hot air process using two-component fibers.

[0010] As an improvement to the above technical means, the flow guide layer is bonded to the coating layer I via an adhesive layer I.

[0011] As an improvement to the above technical means, the adhesive layers I, II, and III employ the same type of petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or water-based EVA adhesive.

[0012] As an improvement to the above technical means, the carbon fiber layer, the fluff pulp layer, and the water-absorbent resin layer are uniformly fused between coating layer I and coating layer II and laminated flat.

[0013] As an improvement to the above technical means, the carbon fiber layer is manufactured from activated carbon fiber material with an iodine adsorption capacity of 800-1600 mg / g, the fiber length is controlled to 0.2-30 mm, and the amount added is 2-30 g / m. 2 It is controlled by [something].

[0014] As an improvement on the above technical means, the fluff pulp layer is manufactured from fully treated, partially treated, or untreated fluff pulp.

[0015] As an improvement to the above technical means, the superabsorbent resin is sodium polyacrylate with a water absorption ratio > 5 and an absorption ratio of > 20 or more in 0.9% physiological saline solution, and the particle size is 0.5-2 mm.

[0016] As an improvement to the above technical means, the liquid vent hole is a semi-pressure-filled circular dot, square, or rhombic emboss, and the diameter range of the press-fitting dot or emboss is 0.5-60 mm.

[0017] An object of the present invention is also to provide a method for manufacturing the above-described carbon fiber core, which includes the following steps.

[0018] S1: Fabrication of the guide layer The flow guide layer is manufactured by a hot air process using two-component fibers, and its material is two types from PP, PE, PET, PLA, and PBAT, with a basis weight in the range of 10-60 gsm and a fiber fineness of 6-12D.

[0019] S2: Manufacturing of coating layer I and coating layer II The aforementioned coating layers I and II are manufactured from ordinary toilet paper, wet-strength toilet paper, or nonwoven fabric material, with a basis weight in the range of 10-40 gsm. Here, coating layer I and coating layer II may be made of the same material or different materials. The toilet paper is made of wood pulp or bamboo pulp materials, and the non-woven fabric is made mainly of PE or PP. When the coating layer II is made of ordinary toilet paper or wet paper strength-enhanced toilet paper, the basis weight ranges from 10 to 20 gsm.

[0020] S3: Use of Adhesive The adhesive layer I, adhesive layer II, and adhesive layer III employ the same type of petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or aqueous EVA adhesive.

[0021] S4: Adhesion I The flow guiding layer and the coating layer I are adhered through the adhesive layer I by a spiral or spray coating process.

[0022] S5: Manufacture of Deodorant and Antibacterial Layer The carbon fiber layer is made of activated carbon fiber material with an iodine adsorption amount of 800 - 1600 mg / g, the fiber length is controlled to be 0.2 - 30 mm, and the addition amount is controlled to be 2 - 30 g / m 2 and is controlled to be The fluff pulp layer is made of fully processed, semi-processed or unprocessed fluff pulp, and the moisture is controlled to be < 10% or less. The water-absorbing resin uses sodium polyacrylate with a water absorption ratio > 5 and an absorption ratio for 0.9% physiological saline > 20 or more, and the particle size of its particles is 0.5 - 2 mm. The carbon fiber layer, fluff pulp layer, and water-absorbing resin layer are uniformly fused and flatly arranged between the coating layer I and the coating layer II. The usage ratios of carbon fiber, fluff pulp, and water-absorbing resin in the deodorant and antibacterial layer are 30 - 100%: 0 - 50%: 0 - 20%.

[0023] S6: Adhesion II The coating layer I and the deodorant and antibacterial layer, and the deodorant and antibacterial layer and the coating layer II are adhered through the adhesive layer II and the adhesive layer III respectively by a spiral or spray coating process. The operating temperature is 100 - 180 °C, and the viscosity during operation is 1700 cps - 15000 cps.

[0024] S7: Manufacturing of Liquid and Air Permeation Holes The whole composed of coating layer I, adhesive layer II, carbon fiber layer, fluff pulp layer, water-absorbing resin layer, adhesive layer III and coating layer II is pressed by a press roll to form a plurality of liquid and air permeation holes. The liquid and air permeation holes may be semi-indentation circular points, or square or diamond embossments. The diameter range of the semi-indentation circular points or embossments is 0.5 - 60 mm.

[0025] An object of the present invention is also to provide the use of a carbon fiber core in disposable care sanitary products.

[0026] As an improvement of the above technical means, the disposable care sanitary product includes an incontinence pad, a paper diaper, a pant-type paper diaper, a comfort pad or a menstrual napkin product.

[0027] As an improvement of the above technical means, the disposable care sanitary product needs to have good downward permeability and anti-backflow property. The downward permeability index of a menstrual napkin should be < 60 s, and the backflow amount should be < 1 g. The downward permeability index of an incontinence product should be < 15 s each time, and the backflow amount should be < 2 g.

[0028] Beneficial Effects of the Present Invention 1. The carbon fiber core and formulation provided by the present invention have antibacterial and deodorizing functions and effects, and can effectively suppress the bacteria and odor of excrement in the product. 2. The carbon fiber core structure provided by the present invention reasonably contains a core with antibacterial and deodorizing effects, and good penetration and drying performance can be achieved when the core is applied to the product. 3. The carbon fiber core product of the present invention can be ideally applied to products such as functional menstrual napkins and incontinence pads, and can solve the problems of the odor of excrement during women's menstrual periods and for incontinence patients. 4. Through the manufacturing process of the carbon fiber core of the present invention, mass production of the core and application products can be realized, and the problems of low production quality and slow production speed existing in the sanitary products conventionally manufactured using activated carbon can be solved. [Brief explanation of the drawing]

[0029] The present invention will be described in more detail below with reference to the drawings and specific embodiments. [Figure 1] This is a schematic diagram of the carbon fiber core structure of Example 1. [Figure 2] This is a schematic diagram of the carbon fiber core of Example 1. [Modes for carrying out the invention]

[0030] The technical solutions in embodiments of the present invention will be described clearly and completely below with reference to the drawings of the embodiments. Clearly, the embodiments described are only a selection of embodiments of the present invention, not all embodiments. All other embodiments that can be obtained by those skilled in the art without any creative work based on embodiments of the present invention are also within the scope of the protection of the present invention.

[0031] Example 1 Carbon fiber core including the carbon fiber core body As shown in Figures 1 and 2, the carbon fiber core body includes a flow guide layer 1, an adhesive layer I2, a coating layer I3, an adhesive layer II4, a carbon fiber layer 5, a fluff pulp layer 6, a water-absorbing resin layer 7, an adhesive layer III8, and a coating layer II9 arranged in order from top to bottom. Multiple liquid and air vents 10 are provided in the coating layer I3, the coating layer II9, and the core layer between them.

[0032] As an improvement to the above embodiment, the mass ratio of each component of the carbon fiber core body is as follows. The ratios of the flow guide layer 1, adhesive layer I, 2, coating layer I, 3, adhesive layer II, 4, carbon fiber layer 5, fluff pulp layer 6, water-absorbing resin layer 7, adhesive layer II, 8, and coating layer II are 10-80%, 0.5-5.0%, 2-40%, 0.5-5.0%, 2-90%, 0-95%, 0-25%, 0.5-5.0%, and 5-60%.

[0033] As an improvement to the above embodiment, the flow guide layer 1 is manufactured by a hot air process using two-component fibers, and its material is any two types of fibers selected from PP, PET, PE, PLA, and PBAT.

[0034] As an improvement to the above embodiment, the flow guide layer 1 is bonded to the coating layer I3 via the adhesive layer I2.

[0035] As an improvement to the above embodiment, the adhesive layers I2, II4, and III8 are made of the same type of petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or water-based EVA adhesive, for example, poly adhesive T137.

[0036] As an improvement to the above embodiment, the carbon fiber layer 5, the fluff pulp layer 6, and the water-absorbing resin layer 7 are uniformly fused and arranged flat between the coating layer I3 and the coating layer II9, the fluff pulp and carbon fiber material are uniformly mixed and arranged flat, and the water-absorbing polymer is uniformly dispersed between the fluff pulp and carbon fiber mixture.

[0037] As an improvement to the above embodiment, the carbon fiber layer 5 is manufactured from activated carbon fiber material with an iodine adsorption capacity of 800-1600 mg / g, the fiber length is controlled to 0.2-30 mm, and the amount added is 2-30 g / m 2 It is controlled by [something].

[0038] As an improvement to the above embodiment, the fluff pulp layer 6 is manufactured from fully treated, partially treated, or untreated fluff pulp.

[0039] As an improvement to the above embodiment, the superabsorbent resin is sodium polyacrylate with a water absorption ratio > 5 and an absorption ratio of > 20 or more in 0.9% physiological saline solution, and the particle size is 0.5-2 mm.

[0040] As an improvement to the above embodiment, the liquid vent hole 10 is a semi-pressure-filled circular dot, square, or diamond emboss, and the diameter range of the semi-pressure-filled circular dot or emboss is 0.5-60 mm.

[0041] Example 2 The method for manufacturing a carbon fiber core described in Example 1 includes the following steps S1 to S7.

[0042] S1: Manufacturing of guide layer 1 The flow guide layer 1 is manufactured by a hot air process using two-component fibers, with a basis weight in the range of 10-60 gsm and a fiber fineness of 6-12D, and its material is any two types of fibers selected from PP, PET, PE, PLA, and PBAT.

[0043] S2: Manufacturing of coating layer I3 and coating layer II9 The aforementioned coating layers I3 and II9 are manufactured from ordinary toilet paper, wet-strength toilet paper, or nonwoven fabric material, with a basis weight in the range of 10-40 gsm. Here, coating layer I3 and coating layer II9 may be made of the same material or different materials. Toilet paper is manufactured from wood pulp or bamboo pulp, while nonwoven fabrics are manufactured primarily from PE or PP. When coating layer II9 is ​​manufactured using regular toilet paper or wet-strength toilet paper, the basis weight is in the range of 10-20 gsm.

[0044] S3: Use of adhesives The adhesive layers I2, II4, and II8 can be of the same type: petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or water-based EVA adhesive.

[0045] S4:Adhesion I The flow guide layer 1 and the coating layer I3 are bonded together via the adhesive layer I2 by a spiral or spray coating process.

[0046] S5: Manufacturing of deodorizing and antibacterial layers The carbon fiber layer 5 is made from activated carbon fiber material with an iodine adsorption capacity of 800-1600 mg / g, with a fiber length controlled to 0.2-30 mm, and an additive amount of 2-30 g / m. 2 It is controlled by [something]. The fluff pulp layer 6 is manufactured from fully processed, partially processed, or unprocessed fluff pulp, with its moisture content controlled to <10% or less. Sodium polyacrylate, with a water absorption ratio >5 and an absorption ratio >20 or higher in 0.9% physiological saline solution, is used as the water-absorbing resin, and its particle size is 0.5-2 mm. The carbon fiber layer 5, the fluff pulp layer 6, and the water-absorbent resin layer 7 are uniformly fused together and arranged flat between the coating layer I3 and the coating layer II9. Particular attention should be paid to ensuring that they are uniformly and flatly arranged. The proportions of carbon fiber, fluff pulp, and superabsorbent polymer used in the deodorizing and antibacterial layer are 30-100%, 0-50%, and 0-20%. The deodorizing and antibacterial layer can achieve both deodorizing and antibacterial effects. It has been verified that the reduction rate of odor concentration for indole, hydrogen sulfide, acetic acid, methyl mercaptan, and ammonia gas is greater than 70%, and the antibacterial rate against E. coli, Staphylococcus aureus, and Candida is greater than 70%.

[0047] S6: Adhesion II The coating layer I3 and the deodorizing / antibacterial layer, and the deodorizing / antibacterial layer and coating layer II9 are bonded via adhesive layers II4 and III8, respectively, by a spiral or spray coating process. Particular attention must be paid to the adhesive performance of the carbon fiber material. The operating temperature was 100-180°C, and the viscosity during operation was 1700 cps-15000 cps.

[0048] S7: Manufacturing of liquid and air vent holes 10 The entire core layer, consisting of coating layer I3, adhesive layer II4, carbon fiber layer 5, fluff pulp layer 6, water-absorbent resin layer 7, adhesive layer III8, and coating layer II9, was pressed with a press roll to form multiple liquid-permeable and ventilated holes 10. The liquid and air vent holes 10 are semi-pressure-fitted circular dots, but they may also be square or diamond-shaped embossed. The diameter of the pressure point is determined based on the width of the selected material, and the diameter range for the semi-press-in circular point or emboss is 0.5-60 mm.

[0049] Example 3 Use of the carbon fiber core described in Example 1, manufactured by the manufacturing method described in Example 2, in disposable care hygiene products.

[0050] Disposable care hygiene products that can be manufactured using the carbon fiber core include, but are not limited to, incontinence pads, diapers, pull-up style diapers, incontinence pads, or sanitary napkin products.

[0051] The aforementioned disposable care hygiene products must possess not only antibacterial and deodorizing properties, but also good backflow prevention properties. Here, the backflow index of sanitary napkins must be <60s and the amount of backflow must be <1g, while the backflow index of incontinence products must be <15s each time and the amount of backflow must be <2g.

[0052] The above are merely preferred embodiments of the present invention and do not limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art can still modify the technical solutions described in each of the above embodiments or make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be within the scope of protection of the present invention.

Claims

1. A carbon fiber core including a carbon fiber core body, The carbon fiber core body includes a flow guide layer I, an adhesive layer I, a coating layer I, an adhesive layer II, a carbon fiber layer, a fluff pulp layer, a water-absorbing resin layer, an adhesive layer III, and a coating layer II arranged in order from top to bottom, and multiple liquid-permeable and ventilating holes are provided throughout the coating layer I, the coating layer II, and the core layer between them. The mass ratio of each component of the carbon fiber core body is as follows: A carbon fiber core characterized in that the flow guide layer, adhesive layer I, coating layer I, adhesive layer II, carbon fiber layer, fluff pulp layer, water-absorbing resin layer, adhesive layer III, and coating layer II are in the following proportions: 10-80%: 0.5-5.0%: 2-40%: 0.5-5.0%: 2-90%: 0-95%: 0-25%: 0.5-5.0%: 5-60%.

2. The flow guide layer is manufactured using a two-component fiber by a hot air process. The carbon fiber core according to claim 1, characterized in that the flow guide layer is bonded to the coating layer I via an adhesive layer I.

3. The carbon fiber core according to claim 1, characterized in that the adhesive layers I, II, and III employ the same type of petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or aqueous EVA adhesive.

4. The carbon fiber layer, the fluff pulp layer, and the water-absorbing resin layer are uniformly fused and arranged flat between coating layer I and coating layer II. The carbon fiber layer is manufactured from activated carbon fiber material with an iodine adsorption capacity of 800-1600 mg / g, with a fiber length controlled to 0.2-30 mm, and an additive amount of 2-30 g / m. ２ Controlled by, The aforementioned fluff pulp layer is manufactured from fully treated, partially treated, or untreated fluff pulp. The carbon fiber core according to claim 1, characterized in that the superabsorbent resin is sodium polyacrylate with a water absorption ratio > 5 and an absorption ratio of > 20 or more in 0.9% physiological saline solution, and the particle size is 0.5-2 mm.

5. The carbon fiber core according to claim 1, characterized in that the liquid and air vent holes are semi-pressure-filled circular dots, square or rhombic embossings, and the diameter range of the press-fitting dots or embossings is 0.5-60 mm.

6. A method for manufacturing a carbon fiber core according to any one of claims 1 to 5, comprising the following S1 to S7: S1: Manufacturing of the flow guide layer The aforementioned flow guide layer is manufactured by a hot air process using two-component fibers, and its material is two types from PP, PE, PET, PLA, and PBAT, with a basis weight in the range of 10-60 gsm and a fiber fineness of 6-12D. S2: Manufacturing of coating layer I and coating layer II The aforementioned coating layers I and II are manufactured from ordinary toilet paper, wet-strength toilet paper, or nonwoven fabric material, and have a basis weight in the range of 10-40 gsm. Here, coating layer I and coating layer II may be made of the same material or different materials. When the coating layer II is manufactured using regular toilet paper or wet-strength toilet paper, the basis weight is in the range of 10-20 gsm. S3: Use of adhesives The adhesive layers I, II, and III employ the same type of petroleum-based hot melt pressure-sensitive adhesive, polyolefin-based hot melt non-pressure-sensitive adhesive, or water-based EVA adhesive. S4: Adhesion I The flow guide layer and the coating layer I are bonded together via the adhesive layer I by a spiral or spray coating process. S5: Manufacturing of deodorizing and antibacterial layers The carbon fiber layer is made from activated carbon fiber material with an iodine adsorption capacity of 800-1600 mg / g, the fiber length is controlled to 0.2-30 mm, and the amount added is 2-30 g / m. ２ Controlled by, The fluff pulp layer is manufactured from fully treated, partially treated, or untreated fluff pulp, with the moisture content controlled to <10% or less. The superabsorbent polymer used is sodium polyacrylate with a water absorption ratio > 5 and an absorption ratio > 20 or higher in 0.9% physiological saline solution, and its particle size is 0.5-2 mm. A carbon fiber layer, a fluff pulp layer, and a water-absorbent resin layer are uniformly fused together and arranged flat between coating layer I and coating layer II. S6: Adhesion II By a spiral or spray coating process, coating layer I and the deodorizing / antibacterial layer, and the deodorizing / antibacterial layer and coating layer II are bonded via adhesive layers II and III, respectively. The operating temperature is 100-180°C, and the viscosity during operation is 1700 cps-15000 cps. S7: Manufacturing of liquid-conducting and vent holes The entire structure, consisting of coating layer I, adhesive layer II, carbon fiber layer, fluff pulp layer, water-absorbent resin layer, adhesive layer III, and coating layer II, is pressed with a press roll to form multiple liquid-permeable and ventilated holes. A manufacturing method characterized in that the liquid vent holes may be semi-pressure-filled circular dots, square or diamond-shaped embossing, and the diameter range of the semi-pressure-filled circular dots or embossing is 0.5-60 mm.

7. Use of a carbon fiber core according to any one of claims 1 to 5 or a carbon fiber core manufactured by the method of claim 6 in a disposable care hygiene product.

8. The use according to claim 7, wherein the disposable care hygiene product includes incontinence pads, diapers, pull-up style diapers, insufficient pads, or sanitary napkin products.

9. The disposable care hygiene product must have good permeability and backflow prevention properties, the permeability index of the sanitary napkin must be <60s and the amount of backflow must be <1g, and the permeability index of the incontinence product must be <15s each time and the amount of backflow must be <2g, as described in claim 7.

Images