KR20100033209A - Method for manufacturing unwooven web perforated without phisical or thermal deformation and absorbent articles comprising the unwooven web - Google Patents

Abstract

PURPOSE: A method for manufacturing non-woven fabric on which a hole is formed and an absorbing product having the same are provided to prevent increase of fiber density of the non-woven fabric, and to reduce damage of the fiber. CONSTITUTION: An absorbing product(100) includes the following: a surface sheet(110) transmitting liquid discharged from a body of a user; an absorbing body(130) retaining and absorbing liquid permeated from the surface sheet; a rear sheet(140) arranged on the bottom of the absorbing body to prevent leakage of the contained liquid; and a surge layer(115) rapidly transferring the liquid to the absorbing body. An elastic body(150) surrounds legs of an infant. The surge layer is arranged between the surface sheet and the absorbing body.

Description

TECHNICAL FIELD OF MANUFACTURING UNWOOVEN WEB PERFORATED WITHOUT PHISICAL OR THERMAL DEFORMATION AND ABSORBENT ARTICLES COMPRISING THE UNWOOVEN WEB}

The present invention relates to a method of making a perforated nonwoven fabric without physical or thermal deformation and to an absorbent product having the nonwoven fabric, and more particularly, to quickly capture a large amount of liquid discharged from a user's body and deliver it to an absorbent body. It relates to absorbent articles such as diapers, feminine sanitary napkins or liners with perforated nonwoven fabrics without physical or thermal deformation to facilitate this.

1 is a cross-sectional view of a general absorbent article. As shown in Fig. 1, the absorbent article 10 includes a liquid permeable body side surface sheet 2, a liquid impermeable outer back sheet 4, a back sheet, a surface sheet 2 and a back sheet ( 4) an absorber 6 disposed between them, and a surge layer 8 disposed between the surface sheet 2 and the absorber 6.

The surface sheet 2 provides softness to make the user feel comfortable in contact with the skin of the user. The absorbent body 6 has a function of absorbing and retaining liquid discharged from the user's body, and is preferably made of superabsorbent particles and pulp fibers. Under the absorbent body 6, the back sheet 4 which consists of a liquid impermeable film material is arrange | positioned so that the liquid collected by the absorber 6 may not discharge to the outside.

The surge layer 8 functions to quickly absorb the liquid, transfer the absorbed liquid to the absorber, and prevent the user's skin from getting wet. In order to maximize this function of the surge layer 8, the material is preferably made of a nonwoven fabric having a low fiber density and a high bulkiness, but a high basis weight of material is consumed in the manufacture of the surge layer 8 Therefore, there is a problem that the manufacturing cost rises. In order to maintain or improve its performance while reducing manufacturing costs, the surge layer 8 may be constructed of perforated nonwoven fabric.

According to the prior art, the surge layer consists of a nonwoven fabric perforated with a pin that is physically cut out or heated with a device such as a punch after bonding the fibers. Since the nonwoven fabric is mainly formed with a protrusion on one side and passes through two rolls having a recess on the other side to form a perforation, the nonwoven fabric can be deformed by physical or thermal pressure. Therefore, there is a problem that the density of the nonwoven fabric is increased (at the same time the bulkiness is lowered) and the fiber density around the perforation is increased. In addition, there is a problem that may be caused by damage to the fiber and stiffness of the surge layer by the physical or thermal pressure applied during the drilling.

The present invention is to solve the above problems, the present invention is to prevent the increase in the fiber density of the nonwoven fabric during the drilling process by applying the physical or thermal pressure to the nonwoven fabric, to reduce the damage of the fiber and improve the softness To provide a method for producing a perforated nonwoven fabric without any possible physical or thermal deformation and an absorbent article having the nonwoven fabric.

According to one embodiment of the present invention, a perforated nonwoven fabric without physical or thermal deformation includes mixing fibers, opening the mixed fibers, carding the opened fibers, and physically carding the carded fibers. Or through perforation without thermal deformation, bonding the perforated fibers, and finishing the bonded fibers.

Preferably, the perforating step consists of pushing the fiber around the perforation while forming perforation by intermittently supplying a constant air pressure to the fiber.

Alternatively, the perforating may be performed simultaneously with the carding, in which case the opened fiber is carded onto a conveyor on which protrusions are formed to form a perforated web. Bonding is done by applying air pressure or pressure through variable contact in the upper, lower or upper layers of the web.

Absorbent article according to an embodiment of the present invention is a liquid-permeable surface sheet, a liquid-impermeable back sheet, an absorber disposed between the surface sheet and the back sheet to absorb the liquid penetrating the surface sheet, and the surface And a surge layer disposed between the sheet and the absorbent to transfer liquid passing through the surface sheet to the absorbent, the surge layer consisting of a perforated nonwoven fabric without physical or thermal deformation.

Absorbent article according to another embodiment of the present invention is a liquid permeable surface sheet, a liquid impermeable back sheet, an absorbent disposed between the surface sheet and the back sheet to absorb the liquid that has passed through the surface sheet, and the surface And a surge layer disposed between the sheet and the absorbent to transfer liquid passing through the surface sheet to the absorbent material, wherein the surface sheet is made of a perforated nonwoven fabric without physical or thermal deformation.

Absorbent article according to another embodiment of the present invention is a liquid permeable surface sheet, a liquid impermeable back sheet, disposed between the surface sheet and the back sheet, the absorber for absorbing the liquid penetrating the surface sheet, and A surge layer disposed between the surface sheet and the absorber to transfer the liquid that has passed through the surface sheet to the absorber, wherein the surge layer comprises a nonwoven fabric not perforated on the upper or lower surface of the perforated nonwoven fabric without physical or thermal deformation. It consists of a laminate nonwoven fabric formed by laminating.

Preferably, the perforated area is 5 to 80% of the total area of the nonwoven fabric. Preferably, the diameter of the perforations is 2-30 mm. More preferably, the diameter of the perforations is 5-10 mm. Preferably, the weight of the perforated nonwoven is 20 to 400 gsm.

According to an absorbent article according to an embodiment of the present invention, by forming a perforation in the nonwoven fabric without physical or thermal deformation, it is possible to prevent an increase in fiber density around the perforation and thereby reduce stiffness. Thus, the user may feel soft when attached to the user's skin.

In addition, the nonwoven fabric has a low density and has an increased void volume, so that the liquid discharged from the user can be quickly delivered to the absorbent body.

In addition, since a nonwoven fabric having the same thickness can be formed using a smaller amount of fibers than a nonwoven fabric having the same thickness, a nonwoven fabric having the same thickness can be formed even at a low basis weight. Therefore, the cost can be reduced.

If the size of the perforation is large enough, the surface sheet becomes concave at the perforated portion, thereby reducing the area where the skin and the surface sheet contact. In addition, since the distance between the surface sheet and the absorber in the perforated portion is shortened, the absorber can absorb the moisture contained in the surface sheet by capillary action. Therefore, the absorbent product can be kept soft as the area in contact with the skin of the user is reduced and the moisture contained in the surface sheet is reduced.

If the ratio of perforation is high, the strength of the nonwoven fabric is lowered and the perforated nonwoven fabric may be deformed during the process. Thus, a non-perforated nonwoven fabric may be laminated and used on the upper or lower surface of the perforated nonwoven fabric, whereby the nonwoven fabric may be drilled without deteriorating the strength of the nonwoven fabric. You can increase the ratio.

Hereinafter, a method of manufacturing a perforated nonwoven fabric without physical or thermal deformation according to an embodiment of the present invention and an absorbent product having the nonwoven fabric will be described in detail.

Figure 2 is a perspective view of an absorbent article according to an embodiment of the present invention, Figure 3 is a cross-sectional view taken along line III-III of Figure 2, Figure 4 is a perspective view of a nonwoven fabric according to an embodiment of the present invention.

2 and 3, the absorbent product 100 according to an embodiment of the present invention is a surface sheet 110 and the surface sheet 110 for transmitting the liquid discharged from the user's body in contact with the skin of the user Absorber 130, which functions to absorb and retain the liquid transmitted from the sheet), a back sheet 140 disposed below the absorber 130 so that the liquid retained in the absorber 130 does not leak outward, and a surface thereof. A surge layer 115 is disposed between the sheet 110 and the absorber 130 to quickly transfer the liquid that has passed through the surface sheet 110 to the absorber 130. As shown in FIG. 2, when the absorbent product 100 is used as a diaper, the absorbent product 100 further includes an elastic body 150 that can cover the legs of the infant and a waistband 160 for fixing to the waist. can do.

The surface sheet 110 (also referred to as a "liner") is a surface in direct contact with the user's skin and functions to allow the liquid discharged from the user's body to be quickly moved to the absorber 130. Thus, the surface sheet 110 advantageously has wettability, hydrophilicity and porosity. Preferably, the surface sheet 110 is made of a relatively low density and bulky nonwoven material, and the nonwoven material is composed of a single fiber such as polyester or polypropylene, or has a low melting point component and a high melting point component. It can be composed of components or composite fibers. For example, the fibers may comprise nylon, polyester, cotton, acrylic fibers or combinations thereof, and the bicomponent fibers may comprise a polyester core and a polyethylene sheath.

The absorber 130 is positioned between the surface sheet 110 and the back sheet 140 to quickly absorb and retain the liquid. In general, absorbent 130 should be compressible, compliant, and non-irritating to the user's skin. For example, the absorber 130 may be made of pulp fibers or pulp fibers mixed with superabsorbent particles.

The back sheet 140 is disposed below the absorber 130. The back sheet 140 is made of a liquid impermeable film material in order to prevent the liquid collected from the absorber 130 is discharged to the outside so as not to contact the underwear of the user.

The surge layer 115 is disposed between the surface sheet 110 and the absorber 130. The surge layer 115 quickly absorbs the liquid that has penetrated the surface sheet 110, transfers the absorbed liquid to the absorber 130, and prevents the liquid from seeping out of the skin. The surge layer 115 may be an adhesive carding web or an airlaid web made of natural or synthetic fibers. For example, the adhesive carding web may be a powder adhesive carding web, an infrared carding web, or a through air bonded carded web (TABCW) nonwoven layer. The perforated nonwoven fabric 120 may be used as the surge layer 115 without physical or thermal deformation in accordance with an embodiment of the present invention to improve the absorption rate and the softness performance of the surge layer 115. Perforated nonwoven fabric 120 without physical or thermal deformation in accordance with one embodiment of the present invention may also be used as the surface sheet 110.

Additionally, the perforated nonwoven fabric 120 without physical or thermal deformation in accordance with one embodiment of the present invention may be laminated with an unperforated nonwoven fabric (not shown) and used as the surge layer 115. In this case, the non-perforated nonwoven fabric may be disposed between the surface sheet 110 and the perforated nonwoven fabric 120 or between the perforated nonwoven fabric 120 and the absorber 130. The type of nonperforated nonwoven is not particularly limited and may be a general spunbond, adhesive carding web, airlaid, breathable carding web nonwoven layer. Preferably, the non-perforated nonwoven has a basis weight of 10 to 30 gsm.

The surface sheet 110, the nonwoven fabric 120, the absorber 130, and the back sheet 140 may be assembled into various absorbent articles well known using conventional techniques known in the art. For example, the components can be attached to each other by thermal or ultrasonic bonding, hot melt adhesives, and the like.

4 is a perspective view of a perforated nonwoven fabric without physical or thermal deformation in accordance with one embodiment of the present invention. As shown, a plurality of perforations 122 are formed in the body 121 of the nonwoven fabric 120. The nonwoven fabric 120 according to an embodiment of the present invention comprises the steps of mixing the fibers, opening the mixed fibers, carding the opened fibers, and physically or thermally It is manufactured by drilling without deformation, bonding the punched fibers, and finishing the bonded fibers.

The mixing, the opening, the opening, the carding, the bonding, and the finishing may be performed using conventional techniques known in the art.

Preferably, the perforated area of the nonwoven is 5 to 80% of the total area of the nonwoven. Preferably, the diameter of the perforations is 2-30 mm. More preferably, considering the absorption time, the diameter of the perforation is 5 to 10 mm. Preferably, the weight of the perforated nonwoven 120 is 20 to 400 gsm.

FIG. 5A is a view showing a perforation through carding, and FIG. 5B is an enlarged view of portion A of FIG. 5A.

5A and 5B, the nonwoven fabric 120 may be perforated using a constant air pressure after carding. In order to puncture the carded fibers 121a, the pneumatic pipe 170 is disposed in a direction perpendicular to the surface of the carded fibers 121a, thereby intermittently supplying constant air pressure to the carded fibers 121a so that the carded fibers are surrounded by Pushed away. As a result, the unbonded perforations 122a are formed in the carded fibers 121a and bonded to form the perforations 122 as shown in FIG. 4.

Perforating and carding the nonwoven fabric 120 may be performed at the same time. A circular protrusion may be formed on the carding conveyor to form a perforated web by carding the fiber so that the fiber does not settle on the protrusion. At the end of the carding step, bonding is done by applying air pressure or pressure through variable contact in the upper, lower or upper layers of the web. After the bonding step, a perforation 122 having a shape and a size corresponding to the protrusion may be formed in the nonwoven fabric 120 as shown in FIG. 4.

According to the above-described perforation method, there is no loss of fiber in the manufacturing of the nonwoven fabric 120, and in this process, deformation due to physical or thermal pressure of the nonwoven fabric 120 does not occur. However, the aforementioned nonwoven fabric perforation method is not limited thereto as an exemplary embodiment, and may be perforated in various ways that do not involve deformation by physical or thermal pressure.

Table 1 shows the measured values for the thickness and density of the perforated nonwoven fabric using air pressure in accordance with one embodiment of the present invention:

 Code c  CODE G  Code F  Thickness (mm)  1.87  1.69  1.86  Density (g / cm 3)  0.043  0.041  0.037

Code C: Unperforated TABCW material nonwoven fabric (80 gsm);

Code G: unperforated TABCW material nonwoven fabric (70 gsm);

Code F: TABCW material nonwoven fabric (70 gsm) perforated using air pressure.

As can be seen from Table 1, reducing the basis weight of the nonwoven fabric under the same conditions (comparison of code C and code G) results in a decrease in density while thinning in thickness. However, the perforated nonwoven fabric (code F) according to the present invention has a substantially lower density and substantially the same thickness as code C using less basis weight material than code C. In addition, the perforated nonwoven fabric (code F) according to the invention has a thickness greater than code G and has a significantly lower density, using the same basis weight material as code G. Therefore, the perforated nonwoven fabric (code F) according to the present invention has improved thickness and density in spite of the use of relatively small basis weight materials as compared to codes C and code G, thereby realizing the reduction of raw materials.

Table 2 shows the results for the liquid absorption time (sec) and water evaporation (g / s / m ² ) of the absorbent product composed of all the components except the nonwoven fabric under the same conditions.

 Code c  Code F  Primary absorption time (sec)  19.08  17.08  Second absorption time (sec)  24.92  20.60  Tea absorption time (sec)  26.72  23.42 Water evaporation (g / s / m ² )  21.87  18.59

Code C: Absorbent product with unperforated TABCW material nonwoven fabric (80 gsm);

Code F: Absorbent product using TABCW nonwoven fabric (70 gsm) perforated using air pressure.

As can be seen from Table 2, the absorption time of the absorbent article (code F) using the perforated nonwoven fabric is reduced by about 10 to 17% compared to code C. In addition, the moisture evaporation of the absorbent article (code F) using the perforated nonwoven fabric is increased by about 15% compared to code C. Therefore, the absorbent product according to the present invention can maintain the smoothness because the absorption of the liquid discharged from the user's body is fast and the amount of moisture evaporation per unit time is large.

The present invention described above is not limited to the above-described embodiment and the accompanying drawings, and it is common in the field of the present invention that various substitutions, modifications, and changes can be made without departing from the technical spirit of the present invention. It will be evident to those who have knowledge of.

1 is a cross-sectional view of an absorbent article according to an example of the prior art.

2 is a perspective view of an absorbent article according to an embodiment of the present invention.

3 is a cross-sectional view taken along the line III-III of FIG. 2.

Figure 4 is a perspective view of a nonwoven fabric used in the absorbent article according to an embodiment of the present invention.

Figure 5a is a view showing a state of drilling through the carding step.

FIG. 5B is a partial view of portion A of FIG. 5A.

<Description of the symbols for the main parts of the drawings>

100: Absorbent product

110: surface sheet

120: nonwoven fabric

130: absorber

140: back sheet

Claims (24)

Mixing the fibers, Opening the mixed fiber; Carding the opened fiber; Perforating the carded fiber without physical or thermal deformation; Bonding the perforated fibers; Finishing the bonded fiber A method of making a perforated nonwoven fabric without physical or thermal deformation. The method of claim 1, wherein the perforating step pushes the carded fibers around the perforations while forming perforations by intermittently supplying a constant air pressure to the carded fibers. A method of making a perforated nonwoven fabric without physical or thermal deformation. The method of claim 1, wherein the carding and the perforating are performed at the same time, and the opened fiber is carded on a conveyor having a protrusion to form a perforated web, The bonding step is to apply a constant air pressure or a variable pressure in the upper, lower or upper and lower layers of the web. A method of making a perforated nonwoven fabric without physical or thermal deformation. A perforated nonwoven fabric without physical or thermal deformation produced by the method of any one of claims 1 to 3. The perforated nonwoven fabric of claim 4, wherein the perforated area is 5 to 80% of the total area of the perforated nonwoven fabric. The nonwoven fabric of claim 4, wherein the diameter of the perforation is between 2 and 30 mm. The nonwoven fabric of claim 6, wherein the diameter of the perforation is between 5 and 10 mm. The perforated nonwoven fabric of claim 4, wherein the perforated nonwoven fabric has a weight of 20 to 400 gsm. Liquid permeable surface sheets, Liquid impermeable backsheet, An absorbent body disposed between the surface sheet and the back sheet to absorb a liquid that has passed through the surface sheet; A surge layer disposed between the surface sheet and the absorber to transfer liquid passing through the surface sheet to the absorber, The surge layer is an absorbent article made of a nonwoven fabric perforated without physical or thermal deformation of claim 4. 10. The absorbent article as in claim 9, wherein said perforated area is 5 to 80% of the total area of said nonwoven fabric. 10. The absorbent article as in claim 9, wherein said aperture has a diameter of 2 to 30 mm. 12. The absorbent article as in claim 11, wherein said aperture has a diameter of 5 to 10 mm. 10. The absorbent article as in claim 9, wherein the perforated nonwoven fabric has a weight of 20 to 400 gsm. Liquid permeable surface sheets, Liquid impermeable backsheet, An absorber disposed between the surface sheet and the back sheet to absorb a liquid that has passed through the surface sheet; A surge layer disposed between the surface sheet and the absorber to transfer liquid passing through the surface sheet to the absorber, The surge layer is an absorbent article consisting of a laminated nonwoven fabric laminated with an unperforated nonwoven fabric on a perforated nonwoven fabric without physical or thermal deformation of claim 4. 15. The absorbent article as in claim 14, wherein said perforated area is 5 to 80% of the total area of said nonwoven fabric. 15. The absorbent article as in claim 14, wherein said aperture has a diameter of 2 to 30 mm. 17. The absorbent article as in claim 16, wherein said aperture has a diameter of 5-10 mm. 15. The absorbent article as in claim 14, wherein the perforated nonwoven fabric has a weight of 20 to 400 gsm. 15. The absorbent article as in claim 14, wherein the weight of said unperforated nonwoven fabric is 10-30 gsm. Liquid permeable surface sheets, Liquid impermeable backsheet, An absorber disposed between the surface sheet and the back sheet to absorb a liquid that has passed through the surface sheet; A surge layer disposed between the surface sheet and the absorber to transfer liquid passing through the surface sheet to the absorber, The surface sheet is an absorbent article made of a nonwoven fabric perforated without physical or thermal deformation of claim 4. 21. The absorbent article as in claim 20, wherein said perforated area is between 5 and 80% of the total area of said nonwoven fabric. 21. The absorbent article as in claim 20, wherein said aperture has a diameter of 2 to 30 mm. 23. The absorbent article as in claim 22, wherein said aperture has a diameter of 5-10 mm. 21. The absorbent article as in claim 20, wherein the perforated nonwoven fabric has a weight of 20 to 400 gsm.

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