专利摘要:
UNITARY ABSORBENT STRUCTURES UNDERSTANDING AN ABSORBENT CORE AND / OR AN ACQUISITION AND DISPERSION LAYER FOR ABSORBENT ARTICLES. The present invention relates to a unitary absorbent structure and method for the same, wherein said unitary absorbent structure comprises an absorbent core (5) and / or an acquisition layer (2) and dispersion (3), said core absorbent (5) and / or an acquisition layer (2) and dispersion (3) comprising at least one layer of fibrous non-woven substrate (23) having an empty volume suitable for penetration by superabsorbent particles, characterized by the fact that the said superabsorbent particles are dispersed in the substrate layer (23) according to a size distribution gradient along the depth direction or z direction of said absorbent core (5) and / or acquisition layers (2) and dispersion (3 ).
公开号:BR112014025010B1
申请号:R112014025010-3
申请日:2012-04-13
公开日:2021-02-02
发明作者:Dany Michiels;Tanika Degrande
申请人:Libeltex;
IPC主号:
专利说明:

FIELD OF THE INVENTION
[001] The present invention relates to absorbent structures comprising absorbent cores and / or acquisition and dispersion systems, said absorbent core and / or acquisition and dispersion system comprising a dispersion of superabsorbent particles. The invention also relates to absorbent articles comprising said absorbent structures, the absorbent article is preferably a disposable absorbent article such as toilet paper, panty liners, baby diapers, incontinence pads, training pants, armpit pads, medical wound bandaging and the like. BACKGROUND OF THE INVENTION
[002] Conventional absorbent articles are manufactured by combining an upper (1) liquid-permeable or permeable, hydrophilic or semi-hydrophilic layer, a fibrous material, an absorbent core (5) and a lower layer of impermeable or impervious liquid material (6 ). Upper layer (1) and lower layer (6) refer to the relative position of said layers with respect to the absorbent core (5).
[003] Absorbent cores are generally composed of fluffy and superabsorbent polymer particles (SAP) (Super Absorbent Polymer) (21). Multilayer absorbent articles may comprise additional acquisition (2) and dispersion (3, 4) layers or conventional ADL (Acquisition and Dispersion Layers) (19), having at least 3 functions. The upper layer is an acquisition layer (2), which is suitable for quickly acquiring the liquid and transmitting it to the distribution layers (3, 4) located below the acquisition layer (2). Said distribution layers allow the liquid to migrate away from the user. A third function is to prevent further wetting by the liquid.
[004] A multilayer ADL is disclosed in the Belgian patent BE 1 018 052 which refers to an improved multilayer ADL system comprising 3 layers of acquisition (2) and distribution (3.4) perfecting the distribution of the liquid (Figure 2 ). The acquisition layers (2) are generally composed of thick hydrophilic or hydrophobic fibers that rapidly transmit the liquid through capillarity to the dispersion layers. Said dispersion layers generally comprise suitable hydrophilic material and fibers in hygiene articles such as profiled or shaped multilob fibers ranging from 0.7 to 30 dtex and preferably from 1.5 to 7 dtex. SAP PARTICLES
[005] Typical SAP particles (21) are composed of chains of cross-linked hydrophilic polymers capable of absorbing about 10 times water absorption based on the weight of the dry particles. Hydrophilic polymers are natural or synthetic polymers or a mixture of both types. Common natural polymers include cellulose-based polymer such as cellulose or starch eventually modified by additional hydrophilic functions, for example, carboxylates, phosphonate or sulfoxylate. Synthetic hydrophilic polymers are generally a polymer based on a polyether or a polyacrylate.
[006] SAP particles (21) can be advantageously coated or partially coated. The additional coating improves or provides additional properties for the SAP particles (21) such as a better absorption capacity of body fluid, a better adhesion of the surrounding particles, an increased capacity for transporting liquids or better mechanical properties. ABSORBENT CORES
[007] The absorbent cores generally comprise a mixture of SAP particles (21) and a substrate (23) such as fibers, layers, fluff or any combination thereof.
[008] When the absorbent core is moistened, the SAP particles (21) are capable of absorbing a large amount of liquid; however, wet SAP particles (21) are swelled in this way forming a gel with the adjacent swollen SAP particles (21). Said gel formation can block the transmission of liquid into the absorbent core.
[009] As a consequence, blocking with gel leads to potential leakage and / or new wetting issues. To prevent gel blockage and to improve the fluid-absorbing capacity of the absorbent core, individual SAP particles (21) must be sufficiently distant from each other. This is usually achieved by mixing the SAP particles (21) with cellulose-based fluff.
[0010] Thinner absorbent core can also be obtained by reducing the amount of fluff used in the composition of the absorbent core. For example, US 5,763,331 discloses a lint-free absorbent core comprising granular SAP material such as acrylate or a biodegradable material firmly bonded to a backing layer such as paper or non-woven fabric. The adhesive used to glue the superabsorbent granular component to the main backing layer is applied by spraying.
[0011] US 2003/175418 and US 2002/0090453 are known for a method for preventing particle loss and agglomeration. These patents disclose a process for stably fixing SAP powder on substrates such as a layer, film, foam or fiber treated with a curable liquid resin or curable resin solution such as a thermoplastic resin powder. SAP powder is applied to the surface of a polymeric material and coated with a curable liquid resin and then cured by heating. The absorbent film obtained has reduced particle agglomeration and particle loss. Alternatively, the SAP powder is coated with a resinous material and applied to the surface of a polymeric and cured material. The absorbent film obtained can therefore be interposed between layers to form an absorbent core.
[0012] WO 03/092757 also discloses a method for preparing a fluff-free absorbent core composed of layers of SAP particles and plasticizer. The plasticizer is sprayed onto the SAP particles followed by thermal pressing. The plasticizer enhancing the flexibility and structural integrity for the layer without impairing the new wetting capacity and acquisition rates of the absorbent core. The disclosed method also facilitates the manufacture of absorbent articles.
[0013] It is also known from US 4,232,674 a liquid absorbent device where superabsorbent polymer particles are deposited in predetermined patterns, such as parallel strips to leave areas without coverage for capillary flow of liquid from saturated to unsaturated areas of the layer.
[0014] In order to improve the liquid retention of absorbent articles, it is also known to prepare a multilayer absorbent core. For example, US 2003/135178 discloses an absorbent laminated core comprising an upper and a lower layer and inner layers where one of the inner layers is a central fibrous layer such as tow fibers containing SAP. The other inner layer is a layer selected from an acquisition layer, a distribution layer, an additional fibrous layer optionally containing SAP, an absorption layer, a storage layer or combinations and fragments thereof.
[0015] Multilayer absorbent core can also be obtained by combining an absorbent layer or storage layer with a conventional ADL (19) in a unitary structure to form an absorbent core. Unit absorbent core can also generally be reduced in thickness and facilitate the processing of absorbent articles.
[0016] Some examples of unit absorbent cores are disclosed in WO 92/11831. It is known from this document an absorbent article comprising a liquid-permeable upper layer, a liquid-impervious back layer and a multilayer absorbent core positioned between the upper layer and the lower layer. Said absorbent core comprising a multilayer absorbent body comprising acquisition / distribution layers and a positioned storage layer underlying each acquisition layer and comprising an absorbent gelling material. A rolled multilayer absorbent body is obtained by wrapping the multilayer absorbent with fluid transport winding.
[0017] WO 91/11163 discloses an absorbent structure having an ADL comprising bonding means and chemically stiffened cellulosic fibers, preferably rolled up and a fluid storage layer positioned below each ADL comprising SAP particles with an average diameter of 400 to 700 microns and carrier media for SAP particles.
[0018] WO 00/41882 discloses an absorbent structure with 2 folds, each fold comprises SAP particles in different concentration and dispersed or homogeneously within a fiber matrix and binder or placed in different places or zones such as strips within the structure . Each fold is made up of several strata in liquid communication. The different density of the two folds creates a gradient of capillary tension between the folds.
[0019] US2008 / 312625, US 2008/312632 and US 2008/3126621 disclose a substantially cellulose-free absorbent core comprising 2 absorbent layers each having a substrate comprising SAP particles and thermoplastic adhesive covering the SAP particles. The 2 absorbent layers are joined so that a portion of the thermoplastic adhesive of the 2 absorbent layers is in contact. The 2 absorbent layers being combined in such a way that the respective patterns of polymer material in absorbent particle are compensated for each other.
[0020] It is known from US 2007/027436 a thin, conformable and flexible absorbent article, comprising a fluid-permeable upper layer, a lower layer joined to said upper layer more or less on the periphery of said absorbent article and a core disposed between the said top layer and said bottom layer, said core comprising a storage layer containing superabsorbent material and an acquisition / storage layer containing superabsorbent material.
[0021] With respect to the aforementioned prior art there is a need to improve unitary absorbent structures that provide comfort to users, greater absorption ability, mechanical stability, fineness, low rewetting capacity and that are easy to process into an absorbent article . SUMMARY OF THE INVENTION
[0022] The present invention relates to an improved unitary absorbent structure comprising an absorbent core (5) having a permanent liquid holding capacity and / or an acquisition layer (14) and dispersion (16) having a holding capacity of temporary liquid, said absorbent core (5) and / or acquisition layer (14) and dispersion (16) comprising at least one non-woven material such as a layer of fibrous substrate (23) having an empty volume suitable for penetration with superabsorbent particles (SAP particles) (21), and adhesives, and said superabsorbent particles are dispersed in the substrate layer (23) according to a size distribution gradient along the depth or z direction of said core absorbent (5) and / or unit acquisition layer (14) and dispersion (16). Figures 9, 10, 11, 21, 22 and 23 illustrate different modalities comprising a distribution of SAP particles (21) on a substrate (23). In a second aspect, the invention relates to a method for producing said absorbent core and / or ADL.
[0023] It is an objective of the present invention to reduce the thickness of absorbent articles by reducing the amount of fluff generally used in absorbent core, generally comprised in the range of 40 to 60% by weight, without impairing the ability to absorb body fluid, absorption speed and new wetting capacity of the absorbent core. In addition, the absorbent structures according to the invention are fluffless; where without fluff it should be understood that the layer comprises less than about 4% by weight of fluff, advantageously the absorbent structures do not comprise any fluff at all and where fluff refers to a cellulose fluff.
[0024] In a further aspect, the invention relates to an absorbent structure having a high body fluid absorbing capacity without being subjected to the issue of gel blocking.
[0025] In a further aspect, the invention relates to an absorbent structure that includes an ADL to form an improved multilayer absorbent core where the ADL and the absorbent layer are unitary and integrated.
[0026] In a further aspect the invention relates to absorbent structures or absorbent structures in multilayer combined with an additional conventional ADL (19) with or without a fluid holding capacity.
[0027] It is an additional object of the invention to provide an integrated ready-to-use absorbent structure capable of being directly incorporated into absorbent articles. DESCRIPTION OF THE DRAWINGS
[0028] Figure 1: is a cross-sectional view of a typical absorbent article comprising from top to bottom a liquid-permeable top layer (1) and a liquid-impervious bottom layer (6), an acquisition and distribution system (2 , 3 and 4), an absorbent core (5) generally composed of a mixture of fluff and SAP; typically, the amount of SAP ranges from 0 to 60% by weight.
[0029] Figure 2: is a cross-sectional view of a conventional 3-layer ADL (19) comprising from top to bottom an acquisition layer (2) and 2 distribution layers (3) and (4).
[0030] Figure 3: is a cross-sectional view of a substrate comprising from top to bottom a triple layer of acquisition layers (14), again wetting (15) and distribution (16).
[0031] Figure 4: is a cross-sectional view of a substrate comprising a triple layer of acquisition layers (14), distribution (16) and new wetting (15).
[0032] Figure 5: is a cross-sectional view of a substrate comprising from top to bottom a triple layer of acquisition layers (14) and a new wetting layer (15).
[0033] Figure 6: is a cross-sectional view of a substrate comprising from top to bottom a triple layer of acquisition layers (14), distribution (16) and new wetting (15) with the third partially hydrophobic layer.
[0034] Figure 7: is a cross-sectional view of a substrate comprising from top to bottom a triple layer of acquisition (14), distribution (16) and absorption (17) layers.
[0035] Figure 8: is a cross-sectional view of a substrate comprising from top to bottom a mixed triple layer of polyester and polyolefin defining an empty volume gradient (18a, 18b, 18c).
[0036] Figure 9: is a cross-sectional view of a substrate comprising from top to bottom an upper layer of acquisition and dispersion (19), a layer of new moistening of space structure of smaller empty volume preventing the loss of particles of SAP (21) and a lower layer having a very large void space comprising SAP particles (21) and a cover layer covering the lower section of the absorbent core.
[0037] Figure 10: is a cross-sectional view of a triple layer substrate where the fibers defining an empty volume distribution gradient (18a, 18b, 18c) partially filled with SAP particles (21) and the bottom of the structure is covered by an additional layer.
[0038] Figure 11: is a cross-sectional view of SAP particles (21) fully penetrated into a substrate having an empty volume distribution gradient (18a, 18b, 18c). The core is covered by non-woven layers at the top and bottom (22).
[0039] Figure 12: is a cross-sectional image of SAP particles (21) partially penetrated in a substrate having an empty volume distribution gradient (18a, 18b, 18c).
[0040] Figures 13: is a schematic of a method of producing a structure according to the invention.
[0041] Figure 14: is a schematic of a dosing system for SAP particles (21), illustrating the deposition of SAP particles (21) along the y direction, or lateral dimension, of the non-woven substrate.
[0042] Figure 15: is a cross-sectional view of a discontinuous application of SAP particles (21) on a substrate for the production of multiple absorbent cores. The core is covered with a heat melt adhesive and a core covering layer (11). The cut line for individual core formation is also indicated.
[0043] Figure 16: is a cross-sectional image of 3 individual profiled absorbent cores.
[0044] Figure 17: is a detailed view of the supply roller used for spreading SAP particle powder (21) to create a profiled core.
[0045] Figure 18: is a cross-sectional image of an absorbent core profiled along the x-direction or longitudinal dimension.
[0046] Figure 19: is a top view of a layer of absorbent core standardized in the x-y plane.
[0047] Figure 20: illustrates the deposition of SAP particles (21) on a non-woven substrate before the application of the Fibroline process and the dispersion profile of said particles along the z direction after the application of the Fibroline process.
[0048] Figure 21: illustrates an ADL comprising particles of SAP (21) dispersed according to the invention, said ADL is positioned on top of a conventional absorbent core.
[0049] Figure 22: illustrates an absorbent structure according to the invention covered by a layered cover (22).
[0050] Figure 23: illustrates a conventional ADL (19) positioned on top of an absorbent core according to the invention.
[0051] Figure 24: is a top view of an absorbent article with a body shape.
[0052] Figure 25: is a view of the SAP particles (21) deposited on a non-woven substrate with a directional profile x and y after dispersion using the Fibroline method.
[0053] Figure 26: illustrates the process of sealing (24) an individual core with a core winding material (25). DETAILED DESCRIPTION OF THE INVENTION
[0054] A liquid according to the invention comprises, but is not limited to, any body fluid such as urine or blood. The inventors have developed a lint-free absorbent structure comprising an absorbent core and / or ADL. Said absorbent structure comprising SAP particles (21) having a size distribution and a hydrophilic or hydrophobic non-woven fibrous substrate (23), said SAP particles (21) being dispersed within the fibrous substrate (23) based on their size distribution. The absorbent structure obtained is further coated with a covering layer (22) such as a continuous heat-sealed filament, PE film, PET film, polyolefin, multilayer films, co-extruded films, non-woven carded or any suitable material and maintained on the core with adhesive.
[0055] In addition to the high holding capacity of body fluid and the fineness of the absorbent article, there are some other advantages in using the absorbent structure of the invention such as better conversion, improved performance and reliability due to the dispersion of SAP particles (21 ) in a specific part of the absorbent structure and the absence of fluff. It is also economically advantageous to use such a core and / or ADL since fluff is no longer required and extra method steps such as hammer grinding to prepare the fluff are unnecessary, yet storage and packaging cost is reduced as well as the cost of transport.
[0056] Advantageously, an absorbent structure according to the invention is a multilayer structure comprising an upper layer ensuring good acquisition and distribution of the liquid; a suitable intermediate layer to prevent liquid from returning to the surface, said intermediate layer is non-porous, where non-porous is defined as an empty volume value ranging from about 10 to about 600 cm3 of empty volume per m2 of substrate (23). The absorbent structure also comprises a porous fibrous lower layer, where porous according to the invention is defined by an empty volume ranging from about 0.1 to 20000 cm3 of empty space / m2 of substrate (23), preferably about 600 about 6000 cm3 of empty space / m2 of substrate (23). Said fibrous lower layer comprising coated or uncoated SAP particles (21), thereby forming a SAP layer below the intermediate layer. SAP particles (21) composing the SAP layer are dispersed within the lower layer, based on the SAP particle size distribution gradient (21), where the smaller SAP particles (21) are embedded deeper in the lower layer and the larger particles remain on the outside of the bottom layer. A suitable non-porous core covering layer (22) having an empty volume value ranging from about 10 to about 600 cm3 of empty volume per m2 of substrate (23) is used to prevent the release of SAP particles (21 ), said core cover layer material (22) is maintained in the absorbent structure through adhesive means, ultrasonic welding and / or any other suitable method (Figure 26).
[0057] The absorbent structures of the invention comprise SAP particles (21), where at least 90%, preferably 95% or 98%, of the SAP particles (21) have a particle size diameter ranging from about 45 to about 850 μm, preferably from about 100 to about 800 μm. Smaller SAP particles (21) are able to penetrate deeply, that is, along the z direction, into the bottom of the substrate (23) while the larger SAP particles (21) remain on the outside of the substrate ( 23) or remain on the surface of said substrate (23), thereby forming an absorbent layer based on the SAP particle size gradient (21).
[0058] The absorbent structure of the invention comprising a layer of SAP particles (21) completely integrated within the absorbent core and / or ADL allows the preparation of absorbent articles thinner than the conventional absorbent cores known to the inventors since said Kernels generally require a fluff-absorbing distribution layer or other cellulose-based fiber system, for example, ring fibers or a standard ADL system (19) in combination with a fluffed retention core.
[0059] It has been found that the absorbent cores according to the invention have an excellent liquid-absorbing property and low re-wetting capacity. SAP particles (21) dispersed on the substrate (23) with a size distribution gradient are supposed to be able to prevent gel formation when the SAP particles (21) are in a swollen state. SUPERABSORVENT PARTICLES
[0060] According to the invention, the SAP particles (21) are either uncoated, partially or fully coated. Commercial uncoated SAP particles available (21) suitable for the invention are polymer grade Ecotec EK-X EM 67, which is generally used in absorbent cores comprising SAP and fluff in a ratio of up to 80% by weight of SAP fillers; Evonik; Favox SXM 10000, Favor 9155.
[0061] The SAP particles (21) can be either incorporated into the absorbent layer or in the ADL or in both the absorbent layers and the ADL. ABSORBENT CORE
[0062] An absorbent core according to the invention can be obtained by fully penetrating a non-woven substrate (23) with SAP particles (21), in this way an additional conventional ADL (19) would be used, as illustrated in Figure 23.
[0063] A substrate (23) completely penetrated with the SAP particles (21) according to the invention comprises up to 1000 g / m2 of SAP, preferably about 300 to about 500 g / m2 of SAP particles (21) depending on the body's fluid retention capacity.
[0064] To avoid gel blocking, the swollen SAP particles (21) must be sufficiently distant to be permeable enough to allow liquids, such as body fluids, to pass through the absorbent layer. This was achieved by the inventors by distributing the SAP particles (21) within the substrate (23) based on the SAP particle size gradient. Without being limited by any theory, it is believed that only smaller SAP particles (21) penetrate deeply into the substrate (23), along the z direction, while larger SAP particles (21) remain on the outside of the substrate (23) . Since smaller SAP particles (21) are sufficiently distant from each other, they prevent the issue of gel blocking, while larger SAP particles (21) are able to progressively absorb excess body fluids. Preferably, the absorbent structure of the invention can be combined with a conventional ADL (19).
[0065] Figure 23 illustrates an absorbent core according to the invention comprising a non-woven substrate (23) and a dispersion of SAP particles (21) within the substrate (23), depending on the SAP particle size gradient ( 21). The absorbent core is further combined with a conventional ADL (19) on top of the absorbent core.
[0066] Figure 12 also illustrates an absorbent article according to the invention using a 3-layer ADL structure with SAP particles (21) in a swollen state after absorbing liquid. ACQUISITION, DISPERSION, LAYERS (ADL)
[0067] In a second embodiment, specific quantity and size of SAP particles (21) are dispersed, based on their size dispersion gradient, on a substrate (23) comprising an ADL structure, so that the substrate ( 23) is partially penetrated with the SAP particles (21). Figures 9 and 10 illustrate this second embodiment.
[0068] According to the invention, an ADL comprising a sufficient quantity of SAP particles (21) to absorb liquids or body fluids can be directly used as a unitary absorbent structure (Figures 9 and 22), said structure comprising a section of ADL and an absorbent section comprising the dispersed SAP particles (21). In general up to 1000 g / m2, preferably from about 300 to about 500 g / m2 of SAP particles (21), is sufficient to combine an ADL and an absorbent core in one element.
[0069] The ADL can also comprise a small amount of SAP particles (21) that serves as a temporary storage or transfer layer (20) (Figure 21). In general between 0.1 to 300 g / m2, preferably from about 100 to about 200 g / m2, a low amount of SAP particles is considered (21). In the latter case, an additional absorbent core has to be combined with an ADL. Adequate ADL should absorb water or liquids and slowly release it to the absorbent core.
[0070] Typically, ADL are multilayer structures comprising an acquisition layer (2) and dispersion layers (3, 4). In a preferred mode, the ADL comprising a dispersion of SAP particles (21) is a 3-layer structure composed of an acquisition layer (2) and 2 diffusion layers (3).
[0071] In a particular embodiment, a triple layer ADL according to the invention can comprise an acquisition layer (14), a new wetting layer (15) and a distribution layer (16) which are illustrated in Figure 3 .
[0072] The upper layer is a very porous acquisition layer (14) allowing fluids to easily penetrate the structure.
[0073] The intermediate layer is a non-porous diffusion layer preventing the fluid from returning to the upper surface. Non-porous according to the invention is defined by an empty volume ranging from about 10-600 cm3 of empty space / m2 of substrate (23). The diffusion layer is also very hydrophilic, so that the liquid is spread over the core.
[0074] The lower layer comprises profiled fibers, or multilobals, to improve the distribution of liquid in the absorbent core. Non-limiting examples of commercially available multilob fibers are 4DG 6dn, 4T 3dn, trilobal 6dn, pentalobal 6 dn, quadfill 7dt, preferably the fiber is a trilobal 6dn or pentalobal 6dn fiber and other shapes.
[0075] In another embodiment according to the invention, triple-layered ADL comprising acquisition (14), distribution (16) and again wetting (15) layers, as illustrated in Figure 4.
[0076] The upper layer is a very porous acquisition layer (14), thus allowing fluid to penetrate the absorbent core.
[0077] The intermediate layer is a dispersion layer comprising profiled fibers, thus improving the distribution of the liquid to the lower layer.
[0078] The bottom layer is a non-porous layer comprising very fine fibers, preventing liquid from returning to the surface. It is also very hydrophilic, so that the liquid is spread over the nucleus.
[0079] In another embodiment according to the invention, a triple ADL layer comprising 2 acquisition layers (14) and a new wetting layer (15) is illustrated in Figure 5.
[0080] The upper layer is a very porous acquisition layer (14) allowing fluid to penetrate the absorbent structure.
[0081] The intermediate layer is also an acquisition layer (15) that is semi-porous, where semi-porous according to the invention is defined by a void volume ranging from about 300 to about 500 cm3 of void volume / m2 of substrate (23), however, said intermediate layer is characterized by an empty volume distribution gradient (18a, 18b, 18c), thereby creating a funnel for the transport of liquid towards the core.
[0082] The bottom layer is non-porous and composed of very fine fibers preventing liquid from returning to the surface. Preferably, the bottom layer is calendered, to further reduce the void volume on the surface, preventing the liquid from the core from returning to the surface. Said bottom layer is preferably hydrophilic, allowing the liquid to spread in the core.
[0083] In another embodiment according to the invention, the absorbent structure comprises triple layered ADL also comprising acquisition layers (14), distribution (16) and new wetting (15), as illustrated in Figure 6.
[0084] The upper layer is a very porous acquisition layer (14) suitable to allow body fluids to penetrate the absorbent structure.
[0085] The intermediate layer is a layer suitable for the distribution and spreading of the liquid to the lower layer and to the core.
[0086] The bottom layer is a non-porous layer composed of a mixture of hydrophilic and thin hydrophobic fibers, blocking the liquid from returning to the surface.
[0087] In another embodiment according to the invention, the absorbent structure comprises a triple layer, acquisition layers (14), distribution (16) and absorption (17) as shown in Figure 7.
[0088] The upper layer is a very porous acquisition layer (14) allowing body fluids to penetrate the absorbent core.
[0089] The intermediate layer is a distribution layer (16) comprising fibers to ensure that the entire surface of the distribution layer (16) is used.
[0090] The lower layer comprises a mixture of fibers including viscose absorbing fibers, to temporarily store the liquid in said lower layer, thereby creating a plug before the liquid is transferred to the absorbent core.
[0091] In another embodiment illustrated in Figure 8 the triple layer ADL comprises a mixture of polyester fibers and polyolefins defined a triple layer system defining an empty volume gradient (18a, 18b, 18c) of 3000, 1000 and 300 cm3 empty volume / m2 of substrate surface (23), said empty volume gradient (18a, 18b, 18c) creating a funnel for the liquid. This results in a faster liquid absorption speed.
[0092] The fibers used provide good resilience and resistance to pressure, creating a distance between the core and the top of the diaper, resulting in a dry surface.
[0093] ADLs suitable for the invention are fluff free and ensure fast liquid absorption, and good rewetting properties, so that liquid is prevented from coming back to the surface and keeps the upper surface dry. It also ensures that the liquid is well spread and distributed, so that the total core is used to its maximum. ABSORBENT STRUCTURES
[0094] An absorbent structure according to the invention can combine an absorbent section and an acquisition section (14) and dispersion section (16). In these specific embodiments, illustrated in Figure 22, the absorbent structure is composed of a fibrous non-woven substrate in mono or multilayer (23) such as polyester or poly polyethylene (PET), polyethylene (PE), polypropylene (PP), coPP , PET / PE, PET / PP, PET / cop, PP / PE, PLA, PLA / PP, PVA, viscose, cotton, wool, PET / coPET, acetate, PTE, PVC, Bamboo, PBT, PA, Acryl, Modacryl and / or regenerated fibers forming an interpenetrating network and SAP particles (21) and from about 0.1 to 50 g / m2, preferably from 0.7 to 25 g / m2 and more preferably from about 2 to 7 g / m2 m2 of adhesive. Preferably the absorbent structure does not comprise fluff in any way. It is possible to incorporate a large quantity of SAP particles (21) within the absorbent layer due to the fibrous nature that allows the absorption of liquids without being subjected to gel block due to the swelling of the SAP particles (21). In a preferred embodiment of the invention, the absorbent structure comprises from about 25 to 300 g / m2, but preferably from about 60 to 150 g / m2 of ADL and / or substrate (23); from about 0.1 to 1000 g / m2 of SAP particles (21), a preferred amount of SAP particles (21) for infant diapers or adult incontinence ranges from 100 to 500 g / m2, from 10 to 200 g / m2 in intimate pads and about 200 to 400 g / m2 for dressing. In general, the absorbent structure comprises from about 10 to 60 g / m2 of a core covering layer (22).
[0095] Examples of commercially available fibers suitable for making the nonwoven substrate (23) are Acryl Amicor 3.0n; Asota L10D; Eastlon SN-3450CMP1 4.0dn; Fibervisions ES-C Cure 2.2dt; Fibervisions ES-DELTA REPEAT II 5.7 dt 40 mm; Grisuten 22 3.3 dt 60 mm; Huvis LMF U16 6dn 51mm; Huvis LMF V16 4dn 51 mm; Huvis OEPO1 N215 2.0dn; Ingeo PLA SLN2660E2 6.0 dn; Invest 295 6.0dn; Meraklon PP Blend PH / HW 4,4dt; PES Greenfiber 6.7dt; Tesil 84M 6.7dt; Trevira 200 6.0dt; Viscocel 3.3dt 40mm; Wellman H1295 7dt; Wellman T0745 17dt 60mm; Wellman H7112 12dt; Wellman H8015 7dt 60mm.
[0096] An absorbent structure according to the invention has a lateral dimension ranging from 0.1 to 800 mm, but not limited to those dimensions. Depending on the different application, said absorbent structure typically has a side dimension of 50 to 180 mm for infant diaper products; 30 to 250 mm for adult incontinence products; 30 to 90 mm for intimate pads and 100 per 100 mm2 or 200 per 300 mm3 for dressing.
[0097] Preferably, the fibrous non-woven substrate (23) is a triple layer substrate (23) comprising an upper layer, which has acquisition (14) and dispersion (16) functions for fast liquid acquisition and good distribution of the liquid on the total surface of the intermediate layer. The intermediate layer is preferably very hydrophilic so that the liquid is able to spread to the core. Said intermediate layer is also non-porous, to prevent the fluid from returning to the upper surface and to keep the SAP particles (21) inside the lower layer during application, but also during the use of the absorbent article, once the particles of SAP (21) are swollen by liquid.
[0098] The lower layer is a very porous structure suitable to be penetrated with SAP particles (21), said lower layer serves as a storage layer (20) (Figure 9).
[0099] In other embodiments, SAP particles (21) penetrate the empty volume gradient (18a, 18b, 18c) of the fiber network. Smaller particles will penetrate deeper than larger particles due to the empty fiber volume gradient (18a, 18b, 18c). The upper part of the fibrous structure will be substantially free of SAP particles (21) and can also serve as an acquisition layer (14), distribution (16) and new wetting (15).
[00100] In an additional embodiment, SAP particles (21) can completely penetrate a monolayer or multilayer, preferably double or triple layer structure. The upper and lower parts of the structure being covered by a covering layer (22) such as a heat-sealed, non-woven, hydroentanglement filament or a film of polypropylene, polyethylene or PET, to prevent said SAP particles (21) from transferring to the outside of the pad.
[00101] In a preferred embodiment, the multilayer substrate (23) has a porous upper layer suitable to allow the penetration of SAP particles (21) into the substrate (23) while the lower layer, or one of the intermediate layer, is not porous to prevent loss of SAP particles (21) by transfer through the substrate (23). Advantageously, at least one additional cover layer (22) is used to prevent any loss of SAP particles (21). In order to have more coverage 2 additional layers can be used.
[00102] If two layers are used, the edges of said covering layers (22) are glued to seal the structure. If a structure cover layer (22) is used, said layer is folded to wrap the structure and the edges are glued to seal the structure. METHOD FOR PREPARING AN ABSORBENT STRUCTURE
[00103] A method for preparing an absorbent structure suitable for the invention is illustrated in Figure 13 and comprises the step of: • unwinding (11) of the fibrous substrate (7). Covering the substrate (7) with SAP particles (21) through powder dispersion (8) or drum formation, using vacuum technology of a standard diaper line. • Application of an alternative electric field to ensure a homogeneous distribution of the SAP particles (21), this method is also known as the Fibroline method (9) described in EP 1 526 214 or EP 2 165 015, each incorporated here by way of of reference. The SAP particles (21) are then dispersed on the substrate (7) and the SAP particles (21) are maintained on the fibrous substrate (7) through entrapment or entanglement and / or after an optional bonding step where the SAP particles (21) are bonded to the non-woven fibers by adding glue. • Uncoiling (11) of a core covering layer material (22). • Application of an adhesive (10) on the inner face of the core covering layer (22) and / or the substrate surface (7). • Covering the substrate (7) with said core covering layer material (22). • Guarantee of adhesion through pressure (12). • Winding of the absorbent structure (13). • Optionally, calendering the product to create a channel structure in the longitudinal direction.
[00104] A device suitable for the Fibroline method comprises a system of 2 electrodes face to face protected by a dielectric material and connected to an alternating high voltage generator (10 to 50 kV), where: The mixture of SAP particles (21 ) and adhesive is placed between the two dielectric materials and a strong alternative electric field is applied.
[00105] The devices (Figure 13) suitable for carrying out the method of preparing an absorbent structure can be used either in line or off line from an ADL and / or core production line or from a diaper or absorbent production line intimate. Preferably, the coated or uncoated SAP particles (21) are glued to the fibers of the ADL layers. Non-limiting bonding method includes powder coating and thermal bonding, heat treatment, spray coating, powder spreading, reactive glue (activation and curing) or any combination thereof.
[00106] SAP particles (21) in diameter ranging from about 45 μm to about 850 μm, preferably from about 100 to about 800 μm, and having an average diameter size of about 300 to 600 μm are preferred since the small particles effectively penetrate the ADL while larger particles remain on the outer side of the diffusion layer then forming a storage layer (20). ADHESIVE
[00107] Suitable glue according to the invention must provide good adhesion, must be permeable to liquids in order to allow the liquids to reach the absorbent layer and must have an elongation at break of at least 100%, preferably of 600 to 1800% in order to prevent gel blocking issue when SAP particles (21) are swollen by body fluids. Preferred glues are water-based glue and solid powder glue, which are sprayed to bond the SAP particles (21). Suitable commercially available adhesives are, but are not limited to, Bostik H4245; Bostik H20028; Bostik H4322 or Füller Full-Care 8400A. METHOD TO PRODUCE MULTIPLE AND / OR ADL ABSORBENT NUCLEUS
[00108] A method for producing an absorbent structure comprising an absorbent core and / or an ADL according to the invention is described in Figures 13 and 26. Advantageously, said method can be adapted to produce profiled absorbent core and / or an ADL .
[00109] The unrolled substrate layer (7) has to be wide enough to process several absorbent structures in parallel. It is then possible to spread and deliver SAP particles (21) in a discontinuous way in the width or lateral dimension or y direction of the substrate (7), as shown in Figure 14.
[00110] The method comprises the step of: • unwinding the fibrous substrate (7). Depending on the empty volume distribution of the substrate (7), the substrate (7) can be kept face up during the process in order to prevent the loss of SAP particles (21). • Partially deposit a quantity of SAP particles (21) on the substrate (7) on the side, or y direction, of the substrate (7) by spreading dust (8), • Application of an alternative electric field (9) to ensure a homogeneous distribution of the SAP particles (21). Said SAP particles (21) penetrate the substrate (7) and are maintained on the fibrous substrate (7) through entrapment or entanglement and / or after an optional bonding step where the SAP particles (21) are attached to the non-fibers woven through the addition of glue. • Application of a heat melting adhesive (10) on the substrate surface (7) and / or on the core covering layer (22). • Uncoiling (11) of a core covering layer material. • Covering the substrate (7) with said core covering layer (22). Where SAP particles (21) are present, the heat melt adhesive will bond the cover layer (22) to the substrate (7), bonding the SAP particles in their entirety (21). Where the substrate (7) is free of particles, the adhesive will bond the core covering layer material (22) to the substrate layer (7) in the substrate part (7) essentially free of SAP particles (21) in this way, sealing the absorbent core. The seal prevents SAP particles (21) from falling when this cut occurs and prevents SAP particles (21) from moving sideways.
[00111] Cut the layer where the substrate (7) is essentially free of SAP particles (21) to obtain individual cores as illustrated in Figure 15.
[00112] Also, since a little migration will occur to the sides during the Fibroline process (Figure 20), it is possible to create a dispersion profile of the SAP particles (21) in the lateral dimension of the absorbent structure (Figure 16), creating a larger SAP particle concentration zone (21) in the middle part of the absorbent structure and a smaller SAP particle concentration zone (21) on the sides, thus providing a greater body fluid storage capacity in the center of the structure absorbent preventing the possibility of leakage.
[00113] Advantageously, a SAP particle distribution profile (21) can be obtained along the length or longitudinal dimension or x direction of the absorbent structure. Said distribution profile is made by creating a profile on the supply roll used to deposit the SAP particles (21) on the substrate (7) through a powder spreading step. Figure 17 illustrates a supply roll according to the invention where the front, middle and rear sections of the substrate (7) will receive a specific quantity of SAP departments (21).
[00114] The transition between sections of different concentrations will be homogenized when applying the Fibroline process.
[00115] As illustrated in Figure 18, an absorbent structure profiled along the longitudinal dimension (x direction) can be obtained, using said supply roll, said structure comprising a larger quantity of SAP particles (21) in the front and in the middle and a smaller amount of SAP on the back of the diaper.
[00116] The profiled absorbent structure obtained therefore comprises an absorbent part comprising particles of SAP (21) partially penetrated in a non-woven substrate (23) and an upper part serving as an ADL covered with a covering layer (22) and maintained by a heat-melting adhesive. In this way, the profiled absorbent structure can be used directly on absorbent articles.
[00117] Preferably, the deposit of SAP particles (21) on the non-woven substrate (23) has a lateral and a longitudinal profile as shown in Figure 25. After the dispersion of the SAP particles (21) through the Fibroline process, the absorbent structure obtained will have an optimized absorption ability due to the amount of SAP particles (21) dispersed within the substrate (23).
[00118] In a preferred embodiment, the SAP particles (21) are also dispersed in different zones along the x and / or y directions of the substrate (23), each different zone being separated from each other (Figure 19). Following the Fibroline process, the resulting absorbent core and / or ADL comprises different motifs such as strips or channels free of SAP particles (21), thereby facilitating the flow and absorption of the fluid (Figures 19 and 20).
[00119] The absorbent structure can be used as a ready-to-use absorbent structure for absorbent articles (Figure 26) and can be easily adjusted on body-shaped absorbent articles (Figure 24). EXAMPLES
[00120] Examples of SAP particles (21) suitable for the invention are FAVOR SXM 10000 and FAVOR SXM 9155 from Evonik.
[00121] FAVOR SXM 10000 is a partially neutralized cross-linked sodium polyacrylate polymer having a size dispersion of approximately:

[00122] FAVOR SXM 9155 is a sodium polyacrylate polymer with a size dispersion of approximately:
权利要求:
Claims (14)
[0001]
1. Unit absorbent structure comprising an absorbent core (5) having a permanent liquid holding capacity and an acquisition layer (14) and dispersion (16) having a temporary liquid holding capacity, said absorbent core (5) or said layer of acquisition (14) and dispersion (16) comprising at least one layer of fibrous non-woven substrate (23) having an empty volume suitable to be penetrated by the superabsorbent particles (21), said superabsorbent particles have a size distribution and are dispersed within the layer of fibrous non-woven substrate (23) according to its particle size distribution gradient along the depth direction or z direction of said absorbent core (5) or acquisition layers (14) and dispersion (16), characterized due to the fact that at least 90% of the superabsorbent particles have a particle size diameter ranging from 45 to 850 μm, said absorbent structure comprises less than 4% of fluff and is still covered by a covering layer (22), and in which superabsorbent particles (21) of smaller size are able to penetrate, along the z direction, in the lower part of the substrate (23) while the superabsorbent particles (21) of greater size remain on the outside or on the substrate surface (23).
[0002]
2. Absorbent structure according to claim 1, characterized by the fact that the size distribution of the superabsorbent particles (21) is varying from 45 to 850 μm.
[0003]
Absorbent structure according to any one of claims 1 and 2, characterized in that said substrate layer (23) has an empty volume ranging from 0.1 to 20000 cm3 / m2 of substrate surface (23).
[0004]
Absorbent structure according to any one of claims 1 to 3, characterized in that said layer of fibrous non-woven substrate (23) is a multilayer substrate (23).
[0005]
Absorbent structure according to claim 4, characterized in that said substrate layer (23) is a triple layer comprising: - upper acquisition (14) and dispersion (16) layers, - an intermediate layer, the said intermediate layer having an empty volume value ranging from 10 to 600 cm3 per m2 of substrate (23); and - a lower layer having an empty volume varying from 10 to 600 cm3 per m2 of substrate (23).
[0006]
Absorbent structure according to any one of claims 1 to 5, characterized in that (i) the superabsorbent particles (21) are distributed depending on a profile along the longitudinal dimension or x direction of said absorbent structure and / or (ii) the superabsorbent particles (21) are deposited depending on a profile along the lateral direction or y direction of said absorbent structure.
[0007]
Absorbent structure according to any one of claims 1 to 6, characterized in that the superabsorbent particles (21) are dispersed in different zones on the fibrous non-woven substrate (23) separated from each other, thereby facilitating the flow and absorption of the fluid along the x and / or y direction of said absorbent structure.
[0008]
8. Method for preparing an absorbent structure as defined in any one of claims 1 to 7, characterized in that it comprises the step of: • unwinding the fibrous non-woven substrate (23); • cover, at least partially, the substrate (23) with superabsorbent particles (21); • apply an alternate electric field to ensure a homogeneous distribution of the superabsorbent particles (21), • unroll a core cover layer material (22), • apply an adhesive over the inner face of the core cover layer material (22 ) and / or the substrate surface (23), • cover the fibrous non-woven substrate (23) with said core covering layer material (22), • ensure adhesion through pressure.
[0009]
Method according to claim 8, characterized by the use of dust spreading or drum formation by means of vacuum technology in the step of covering the surface of the fibrous non-woven substrate (23) with superabsorbent particles (21).
[0010]
10. Absorbent article characterized by the fact that it comprises at least one absorbent structure as defined in claims 1 to 7.
[0011]
An absorbent article according to claim 10, characterized in that it comprises: (a) a liquid-pervious top layer; (b) a liquid-impervious bottom layer; (c) an absorbent structure, as defined in any one of claims 1 to 7, positioned between (a) and (b).
[0012]
Absorbent article according to claim 11, characterized in that it comprises additional acquisition (2) and dispersion (3) layers positioned on top of said absorbent structure; or comprising an additional absorbent core positioned below said absorbent structure.
[0013]
13. Absorbent article according to any one of claims 10 to 12, characterized in that said article is selected from the group consisting of a diaper, a diaper for light and / or strong incontinence, an intimate absorbent and panty liner or a dressing.
[0014]
Absorbent article according to claim 13, characterized by the smell that (i) said absorbent article is a diaper or diaper for light and / or strong incontinence comprising from 0.1 to 1000 g / m2 of superabsorbent particles; (ii) said absorbent article is an intimate absorbent or panty liner comprising from 0.1 to 1000 g / m2 of superabsorbent particles; or (iii) said absorbent article is a dressing comprising from 0.1 to 1000 g / m2 of superabsorbent particles.
类似技术:
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BR112016014185B1|2022-01-11|ABSORBENT ARTICLE
同族专利:
公开号 | 公开日
EP2836178B1|2016-11-02|
CA2869870A1|2013-10-17|
EP2836178A1|2015-02-18|
CA2869985C|2018-07-03|
CA2869870C|2017-11-28|
CN104470478B|2017-11-21|
KR101778357B1|2017-09-26|
WO2013153235A1|2013-10-17|
JP6181151B2|2017-08-16|
ES2611905T3|2017-05-11|
MX347251B|2017-04-20|
RU2014145517A|2016-06-10|
CN104470478A|2015-03-25|
PL2836179T3|2017-06-30|
CN104470477B|2017-04-05|
EP2836179B1|2017-01-04|
JP6490773B2|2019-03-27|
RU2608535C2|2017-01-19|
PH12014502234B1|2014-12-15|
RU2014145514A|2016-06-10|
PH12014502235B1|2014-12-15|
CO7170187A2|2015-01-28|
CN104470477A|2015-03-25|
WO2013152809A1|2013-10-17|
KR101770018B1|2017-08-21|
MX2014012259A|2015-05-11|
HUE031297T2|2017-06-28|
HUE031544T2|2017-07-28|
MY173898A|2020-02-26|
US20150342799A1|2015-12-03|
PL2836178T3|2017-06-30|
IN2014DN09133A|2015-05-22|
US20150065974A1|2015-03-05|
IN2014DN09132A|2015-05-22|
PH12014502235A1|2014-12-15|
CA2869985A1|2013-10-17|
KR20150014922A|2015-02-09|
CL2014002730A1|2015-06-19|
JP2015512732A|2015-04-30|
JP2015512729A|2015-04-30|
KR20150014923A|2015-02-09|
JP6258294B2|2018-01-10|
EP2836179A1|2015-02-18|
US10772772B2|2020-09-15|
MX2014012258A|2015-06-23|
PH12014502234A1|2014-12-15|
JP2018020196A|2018-02-08|
US10905604B2|2021-02-02|
ES2613437T3|2017-05-24|
MX347250B|2017-04-20|
RU2625434C2|2017-07-13|
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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
2020-02-18| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
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申请号 | 申请日 | 专利标题
PCT/EP2012/056859|WO2013152809A1|2012-04-13|2012-04-13|Unitary absorbent structures comprising an absorbent core and/or an acquisition and dispersion layer for absorbent articles|
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