Patent Application
20130211358
The present invention relates to an absorbent article such as a disposable diaper, an absorbent pad, and a sanitary napkin.
There has been known the above type of absorbent articles including a liquid permeable topsheet which forms a skin-facing face, a liquid impermeable backsheet which forms a non-skin-facing face, and an absorbent member arranged between both the sheets. Further, there has been known the absorbent member which is structured to include an absorbent core containing cellulose fibers such as pulp and/or absorbent polymer and a core wrap sheet which covers the absorbent core. The core wrap sheet functions as a sheet for receiving an absorbent core forming material such as absorbent polymer when manufacturing the absorbent member and functions to form a shape as wrapping the absorbent core after manufacturing. Traditionally, a permeable sheet such as nonwoven and paper has been used as the core wrap sheet.
Traditionally, numerous attempts have been performed as targeting improvement of fit against a body of a wearer and liquid absorbability for such a kind of absorbent articles. Examples of an effective method to improve fit include a method to lessen a thickness of an absorbent member (absorbent core) as decreasing a usage amount of cellulose fibers being bulky absorbent core forming materials. When the absorbent member is thinned, flexibility of the absorbent member is improved and fit is improved thereby. For example, Patent Literature 1 discloses an absorbent article having the abovementioned structure with an absorbent core structured to include a trapping system in which cellulose fibers are not substantially contained.
With the absorbent article including a thin-type absorbent core which does not substantially contain cellulose fibers as disclosed in Patent Literature 1, a distance between the absorbent core forming material such as absorbent polymer absorbing and retaining bodily discharge liquid and a skin of a wearer is short while wearing the absorbent article compared to an absorbent article including a relatively thick absorbent core which is mainly structured with cellulose fibers. Accordingly, liquid remaining is more likely to occur at a topsheet which forms a skin-facing face and a dry feeling at the topsheet is more likely to be decreased. Thus, there is a fear to cause a trouble such as a skin rash.
The present invention is directed to an absorbent article including: a topsheet which forms a skin-facing face; a backsheet which forms a non-skin-facing face; and an absorbent member which is arranged between both the sheets, in which the absorbent member is structured to include an absorbent core which contains absorbent polymer without substantially containing hydrophilic fibers, an upper core wrap sheet which covers a skin-facing face of the absorbent core, and a lower core wrap sheet which covers a non-skin-facing face of the absorbent core, and the upper core wrap sheet includes a thick region having a larger thickness than the lower core wrap sheet.
The present invention provides an absorbent article having excellent fit and a dry feeling at a skin-facing face.
a) and 4(b) are sectional views schematically illustrating sections in the lateral direction respectively of other embodiments of an absorbent member according to the present invention.
a) to 5(d) are sectional views further illustrating sections schematically in the lateral direction respectively of other embodiments of the absorbent member according to the present invention.
a) is a perspective view illustrating an example of a concave-convex region of an upper core wrap sheet according to the present invention and
a) is a perspective view illustrating another example of the concave-convex region of the upper core wrap sheet according to the present invention and
The present invention relates to an absorbent article having excellent fit and a dry feeling at a skin-facing face.
In the following, an absorbent article of the present invention will be described with reference to the drawings based on a disposable diaper being a preferred embodiment thereof. As illustrated in
As illustrated in
In the present specification, the longitudinal direction denotes a direction along a long side of an absorbent article (disposable diaper) or a structural member thereof (e.g., absorbent core) and the lateral direction denotes a direction being perpendicular to the longitudinal direction. In the drawings, a direction indicated by reference X denotes the longitudinal direction of the diaper 1 (absorbent member 4) and a direction indicated by reference Y denotes the lateral direction of the diaper 1 (absorbent member 4). Further, the skin-facing face denotes a face of an absorbent article (disposable diaper) or a structural member thereof facing to a skin side of a wearer while the absorbent article (disposable diaper) is worn. The non-skin-facing face denotes a face of the absorbent article (disposable diaper) or the structural member thereof facing to a side (clothing side) being opposite to the skin side while the absorbent article (disposable diaper) is worn.
As illustrated in
Further, as illustrated in
Further, a fastened region 9 formed of a female member of the mechanical Hook-and-Loop fastener is formed at the non-skin-facing face of the front section B of the diaper 1. The fastened region 9 is formed by joining and fixing the female member of the mechanical Hook-and-Loop fastener to the non-skin-facing face of the backsheet 3 with known joining means (e.g., adhesive or heat seal) and the fastening portion 81 of the fastening tape 8 can be fastened thereto as being detachably attachable.
In the following, the absorbent member 4 will be described in detail. As illustrated in
The absorbent core 40 contains absorbent polymer and does not contain hydrophilic fibers substantially. Here, in addition to a case that the absorbent core does not contain hydrophilic fibers at all, “substantial non-containing of hydrophilic fibers” includes a case that a minute amount of hydrophilic fibers are contained, specifically, a case that hydrophilic fiber content of the absorbent core is 5% or less by mass. Here, fibers having hydrophilic surfaces may be used as the hydrophilic fibers and examples thereof include cellulose fibers and synthetic fibers on which a hydrophilicity process is performed with a surface acting agent or the like as needed. Examples of the cellulose fibers include natural cellulose fibers being wood pulp such as softwood kraft pulp and hardwood kraft pulp and non-wood pulp such as cotton pulp and straw pulp, and regenerated cellulose fibers such as rayon and cupra. Further, examples of the synthetic fibers include hydrophilic synthetic fibers such as polyvinyl alcohol fibers and polyacrylonitrile fibers, polyethylene terephthalate (PET) fibers, polyethylene (PE) fibers, polypropylene (PP) fibers, and polyester fibers. Since the absorbent core containing absorbent polymer without substantially containing hydrophilic fibers as described above is thin while retaining practically sufficient liquid absorbability, excellent fit against a body of a wearer is obtained with high flexibility.
The absorbent core 40 is structured mainly with absorbent polymer. Content of absorbent polymer is 95% or more by mass against the total mass of the absorbent core 40 preferably and is in a range of 99% to 100% by mass more preferably. Various types traditionally used in the technical field may be used as the absorbent polymer without specific limitations. Examples thereof include sodium polyacrylate, (acrylic acid-vinyl alcohol) copolymer, crosslinked sodium polyacrylate, (starch-acrylic acid) graft polymer, (isobutylene-maleic acid anhydride) copolymer and saponification thereof, potassium polyacrylate, and cesium polyacrylate. Here, one type may be used solely or two or more types may be used as being mixed. Although a particle type is used as the absorbent polymer normally, a fiber type may be used as well. In view of difference in shape, particle types of the absorbent polymer include an indeterminate type, a block type, a barrel type, a particle aggregation type, and a ball type. Here, any type thereof may be used.
A basis weight of the absorbent core 40 is appropriately set in accordance with usage application and the like of an absorbent article (disposable diaper) to which the absorbent core 40 is assembled. For example, in a case that the diaper 1 is a paper diaper for an infant (young month age infant), from a viewpoint of balance among thinning, flexibility and liquid absorbability, it is preferable that the basis weight of the absorbent core 40 is in a range of 80 to 400 g/m2, and particularly, in a range of 150 to 300 g/m2. When the absorbent core 40 is made only of absorbent polymer, the basis weight of the absorbent core 40 is the same as a dispersal amount of the absorbent polymer.
In the present embodiment, in consideration of that absorbent polymer is contained and hydrophilic fibers are not substantially contained being a feature of the absorbent core 40, relation between thicknesses of the upper core wrap sheet 45 and the lower core wrap sheet 46 which cover the absorbent core 40 is devised. Specifically, the upper core wrap sheet 45 includes a thick region having a larger thickness than lower core wrap sheet 46. As illustrated in
Normally, an absorbent core in such an absorbent article is structured to include hydrophilic fibers such as cellulose fibers along with absorbent polymer. Here, when hydrophilic fibers is reduced in amount from such a normal absorbent core as targeting thinning and improving of fit and the like, a distance between the absorbent core (absorbent polymer) in a wet state as absorbing and retaining liquid and a skin of a wearer becomes short while wearing the absorbent article compared to that before reducing the hydrophilic fibers. Accordingly, there is a fear to cause a trouble such as a skin rash with decrease of a dry feeling at a topsheet. Further, when the lower core wrap sheet which covers the non-skin-facing face of the absorbent core becomes excessively thick, liquid leakage is more likely to occur as described below. When the thickness of the lower core wrap sheet becomes large, liquid is to be retained in the lower core wrap sheet. Here, since the skin-facing face side of the lower core wrap sheet at which liquid is retained is contacted to absorbent polymer which structures the absorbent core, liquid retained at the skin-facing face side is immobilized finally at the absorbent polymer. However, since liquid retained at the non-skin-facing face side of the lower core wrap sheet remains without being immobilized at the absorbent polymer, liquid leakage is more likely to occur. In the present embodiment, in consideration of the above, the thick region having a larger thickness than the lower core wrap sheet 46 is formed at the upper core wrap sheet 45. With the above, decrease of a dry feeling at the skin-facing face (topsheet 2) of the diaper 1 caused by reduction of hydrophilic fibers is prevented and improvement is achieved in leakage prevention. Thicknesses of core wrap sheets are measured as follows.
First, adhesive contained in a product (diaper) is dissolved by soaking the product (diaper) into cleaning solvent (mixed solvent of butyl acetate and hexane) and the product is carefully disassembled into structural members. The respective structural members are taken out from the cleaning solvent so as not to be stretched and are dried at room temperature. Subsequently, a load of 5.9 Pa is applied to a dried core wrap sheet by placing an acrylic plate having a 50 millimeters square shape (weight: 14. 8 g) thereon. The thickness of the core wrap sheet is measured with a laser type thickness indicator.
Here, in a case that the upper core wrap sheet includes a concave-convex region where a concave-convex shape is formed as the upper core wrap sheet 45 illustrated in
From a viewpoint to reliably produce an operational effect due to the abovementioned thickness ingenuity of the core wrap sheets 45, 46, a ratio (t1/t2) between the thickness t1 (see
Further, the basis weight of the upper core wrap sheet 45 is in a range of 13 to 30 g/m2 preferably and in a range of 15 to 20 g/m2 more preferably. The basis weight of the lower core wrap sheet 46 is in a range of 7 to 30 g/m2 preferably and in a range of 10 to 15 g/m2 more preferably. In general, a basis weight and a thickness of a sheet are mutually related. The thickness becomes larger with increase of the basis weight.
The upper core wrap sheet 45 and the lower core wrap sheet 46 are integrated as being mutually joined with joining means (adhesive) such as hot-melt type adhesive. More specifically, both the sheets 45, 46 are mutually joined with adhesive (not illustrated) adherent to the absorbent core 40 (absorbent polymer), so that both the sheets 45, 46 and the absorbent core 40 are integrated with the adhesive.
A sheet which is structured mainly with fibers (a sheet with fiber content preferably being 90% or more by mass) may be adopted respectively as the upper core wrap sheet 45 and the lower core wrap sheet 46. Examples thereof include paper such as crepe paper, nonwoven such as spunbond nonwoven, meltblown nonwoven, thermalbonded nonwoven, needle-punched nonwoven, spanlaced nonwoven and airlaid nonwoven, and a combined sheet with two types or more of the sheets laminated. Not being structured with the respective sheets structuring the combined sheet mutually stuck with adhesive, the combined sheet is preferably to be in one sheet while the respective sheets are integrated with entanglement and/or thermal adhesion of mutual structural fibers of the respective sheets like a laminated body of nonwoven described later. Both the sheets 45, 46 may be the same sheets or different sheets.
It is preferable that each of the upper core wrap sheet 45 and the lower core wrap sheet 46 is formed of a laminated body with one or more of spunbond nonwoven layers and one or more of meltblown nonwoven layers. The laminated body (core wrap sheets 45, 46) is one sheet of nonwoven in which the respective nonwoven layers are integrated as being mutually joined. Not being integrated as being mutually stuck with adhesive, adjacent nonwoven layers in the laminated body are integrated with entanglement and/or thermal adhesion of mutual structural fibers of the respective nonwoven layers. With a laminated body in which adjacent nonwoven layers are mutually stuck with adhesive, liquid is more likely to be collected at a boundary face which exists between nonwoven layers as a boundary between the nonwoven layers. Therefore, it is not exactly ideal for a core wrap sheet according to the present invention.
A spunbond nonwoven layer is a layer formed of spunbond nonwoven which is manufactured with a known spunbond method. A meltblown nonwoven layer is a layer formed of meltblown nonwoven which is manufactured with a known meltblown method. For example, the spunbond nonwoven can be obtained by that thermal-fused synthetic resin spins out from a nozzle, a number of generated filaments are amassed on a conveyer to be a web, and the respective filaments are joined with a process such as thermal compression bonding and mechanical interlacing on the web. Further, for example, meltblown nonwoven can be obtained by forming a self-joining fiber web while melted synthetic resin is blown onto a conveyer from a die chip of an extruding machine with high-speed air-flow. Examples of constituent fibers for spunbond nonwoven and meltblown nonwoven include fibers made solely of polyolefin resin such as polyethylene and polypropylene, polyester resin such as polyethylene terephthalate or the like, or conjugate fibers composed of a plurality of such resins (a sheath/core conjugate type, a side-by-side type or the like).
Specifically preferable examples of the laminated body (core wrap sheets 45, 46) include spunbond-meltblown-spunbond (SMS) nonwoven being nonwoven integrated in a state that one meltblown nonwoven layer is placed between two spunbond nonwoven layers or spunbond-meltblown-meltblown-spunbond (SMMS) nonwoven being nonwoven integrated in a state that two meltblown nonwoven layers are placed between two spunbond nonwoven layers.
In addition to that the upper core wrap sheet 45 is formed of a laminated body of one or more of spunbond nonwoven layers and one or more of meltblown nonwoven layers, it is preferable that a basis weight of the spunbond nonwoven layer of the upper core wrap sheet 45 is larger than that of the meltblown nonwoven layer. Here, “the basis weight” denotes a sum of basis weights of the respective nonwoven layers. For example, in a case that two spunbond nonwoven layers exist in the laminated body (upper core wrap sheet 45) including a case that another nonwoven layer exists between the two spunbond nonwoven layers as well as a case that the two spunbond nonwoven layers are mutually contacted, it denotes a sum of the respective basis weights of the two spunbond nonwoven layers. From a viewpoint of improving a dry feeling at the topsheet 2, it is desired that the upper core wrap sheet 45 placed between the topsheet 2 and the absorbent core 40 has a large free-water retention amount. In general, spunbond nonwoven has a feature of having a large thickness as being bulky and a large free-water retention amount compared to meltblown nonwoven. Therefore, it is preferable for the upper core wrap sheet 45 formed of the laminated body that a basis weight of the spunbond nonwoven layer is relatively large.
Further, in addition to that the lower core wrap sheet 46 is formed of a laminated body of one or more of spunbond nonwoven layers and one or more of meltblown nonwoven layers, it is preferable that a basis weight of the meltblown nonwoven layer of the lower core wrap sheet 46 is larger than that of the spunbond nonwoven layer. Here, “the basis weight” denotes as described above. The lower core wrap sheet 46 is placed between the absorbent core 40 and the backsheet 3. From a viewpoint of leakage prevention, it is preferable that a free-water retention amount of the sheet 46 itself is small. Therefore, it is preferable for the lower core wrap sheet 46 that a basis weight of the spunbond nonwoven layer being superior in free-water retention capability is relatively small by relatively enlarging a basis weight of the meltblown nonwoven layer.
In the upper core wrap sheet 45 formed of the laminated body, a basis weight ratio between the spunbond nonwoven layer and the meltblown nonwoven layer (the former/the latter) is in a range of 5 to 15 preferably and in a range of 7 to 10 more preferably. Further, in the lower core wrap sheet 46 formed of the laminated body, a basis weight ratio between the spunbond nonwoven layer and the meltblown nonwoven layer (the former/the latter) is in a range of 0.05 to 0.2 preferably and in a range of 0.1 to 0.15 more preferably.
It is preferable that the upper core wrap sheet 45 and the lower core wrap sheet 46 are different in hydrophilicity as well as in thickness. More specifically, a hydrophilic degree of the upper core wrap sheet 45 is higher than that of the lower core wrap sheet 46. That is, from a viewpoint that bodily discharge liquid such as urine is quickly permeated to the absorbent core 40 side, it is preferable that the upper core wrap sheet 45 has a relatively high hydrophilic degree. Further, from a viewpoint of leakage prevention, liquid spreading acceleration in the absorbent core 40 and the like, it is preferable that the lower core wrap sheet 46 has hydrophobicity or slight hydrophilicity on the order not to retain free water (bodily discharge liquid). A hydrophilic degree of a sheet can be evaluated by a water passing time measured with a method described below. The shorter the water passing time is, the higher the hydrophilic degree of the sheet is evaluated. The water passing time of the upper core wrap sheet 45 is different from that of the lower core wrap sheet 46. The water passing time of the upper core wrap sheet 45 having a relatively-high hydrophilic degree is shorter than 15 seconds preferably and is shorter than 10 seconds more preferably. The water passing time of the lower core wrap sheet 46 having a relatively-low hydrophilic degree is 15 seconds or longer preferably and is 60 seconds or longer more preferably.
As illustrated in
Examples of a method of relatively increasing the hydrophilic degree of the upper core wrap sheet 45 and relatively decreasing the hydrophilic degree of the lower core wrap sheet 46 include a method to perform a hydrophilization process only on the upper core wrap sheet 45 without performing the hydrophilization process on the lower core wrap sheet 46 when both the core wrap sheets 45, 46 are nonwoven. Examples of a method of the hydrophilization process include a method to perform a process (immersing, spraying, gravure coating, printing or the like) on a sheet (nonwoven) with hydrophilization oil solution and a method for kneading hydrophilization oil solution into resin being a material of nonwoven and bleeding out.
The diaper 1 of the present embodiment will be further described. As illustrated in
From a viewpoint that the operational effects (improvement of a dry feeling at the topsheet, and the like) due to the abovementioned absorbent member 4 are to be reliably produced, it is preferable that the skin-facing face (upper core wrap sheet 45) of the absorbent member 4 in 30% or more of the total area, particularly in a range of 50% to 60%, is not covered with another member like the sublayer sheet 5 which is arranged between the topsheet 2 and the absorbent member 4. When the entire area of the skin-facing face of the absorbent member 4 (100% of the total area of the skin-facing face) is covered with the sublayer sheet 5, there is a fear that the above-mentioned ingenuity of the core wrap sheets 45, 46 is not utilized.
A sheet which is structured mainly with hydrophilic fibers (preferably, a sheet with content of the hydrophilic fibers being 90% or more by mass) may be adopted as the sublayer sheet 5. Examples of the sheet include paper, nonwoven, and a web. Fibers having hydrophilic surfaces may be used as the hydrophilic fibers without any specific limitation as long as being capable of forming a sheet with a high degree of freedom of mutual fibers in a wet state. In addition to cellulose fibers, hydrophilic synthetic fibers and synthetic fibers on which a hydrophilicity process is performed as described above, examples of the hydrophilic fibers include denatured (cellulose) fibers disclosed in JP 2010-526632A exemplifying kneaded and/or curled (curly) chemically-stiffened (cellulose) fibers, and kneaded and/or curled (curly) chemically-stiffened bridged cellulose or synthetic polymer fibers. Here, the fiber may be used solely or two or more of the fibers may be used as being mixed.
In addition to hydrophilic fibers, the sublayer sheet 5 may include other constituents such as absorbent polymer and deodorant. A basis weight of the sublayer sheet 5 is in a range of 40 to 300 g/m2 preferably and in a range of 60 to 200 g/m2 more preferably. Further, a thickness of the sublayer sheet 5 with no load is in a range of 1 to 10 mm preferably and in a range of 3 to 5 mm more preferably.
Materials for forming respective components of the diaper 1 will be descried. A variety types of materials traditionally used in the art may be used as the topsheet 2 and the backsheet 3. The topsheet 2 may adopt a variety of liquid permeable sheet materials such as nonwoven and a perforated film. The backsheet 3 may adopt a variety of materials being non-permeable or water-repellent such as a non-permeable resin film, a permeable resin film with fine holes, nonwoven like water-repellent nonwoven or the like, a laminated body of the above and other sheets, or the like. Further, the side sheet 62 may adopt a material being similar to that of the backsheet 3.
In a case that a resin film is used as the backsheet 3, it is preferable that a permeable resin film (e.g., a resin film with fine holes) is used as the resin film to decrease a damp feeling of a wearer. Particularly, to reduce a damp feeling to the extent possible, it is preferable that higher permeability is provided to the resin film for the backsheet 3. As a method to improve permeability of a resin film with fine holes, traditionally, there have been known a method to stretch the resin film (a method to increase the number of fine holes of the resin film compared to that before being stretched by appropriately adjusting stretching conditions and the like), a method to form fine holes which are slightly larger than normal fine holes, and the like. However, with a resin film having permeability increased with such a traditional method, there is a fear that water-pressure resistance is slightly decreased. In a case that such a resin film with reduced water-pressure resistance is used in the diaper 1 as the backsheet 3, there is a fear of inconvenience that liquid absorbed and retained at the absorbent core 40 leaks to the outside as passing through the backsheet 3 when a body weight of a wearer is applied largely to the diaper 1. In contrast, since liquid is less likely to move to the backsheet 3 side by decreasing a hydrophilic degree of the lower core wrap sheet 46 and applying slight hydrophilicity or hydrophobicity on the order not to retain free water (bodily discharge liquid) to the lower core wrap sheet 46 as described above, the abovementioned fear can be swept away. In particular, when the lower core wrap sheet 46 has hydrophobicity, liquid leakage from the backsheet 3 side can be effectively prevented. The water passing time of the lower core wrap sheet 46 having hydrophobicity is 15 seconds or longer preferably and is 60 seconds or longer more preferably.
The diaper 1 of the present embodiment is used similarly to a known open-style type disposable diaper. In the diaper 1 of the present embodiment, since the absorbent member 4 is structured to include the absorbent core 40 which contains absorbent polymer without substantially containing hydrophilic fibers, it is possible to design thinly compared to a traditional absorbent member which mainly contains hydrophilic fibers such as cellulose fibers. Owing to adopting of such a thin type absorbent member, excellent fit can be obtained against a body of a wearer. There may be a fear that thinning of the absorbent core 40 due to substantial non-usage of hydrophilic fibers causes decrease of a dry feeling at the skin-facing face (topsheet 2). However, in the diaper 1 of the present embodiment, since the thick region being thicker than the lower core wrap sheet 46 is formed at the upper core wrap sheet 45, decrease of a dry feeling at the skin-facing face is less likely to occur and a trouble such as a skin rash can be effectively prevented.
As described above, the absorbent member according to the present invention can be designed thinly. The thickness of the thin absorbent member with no load is in a range of 1 to 5 mm preferably and in a range of 2 to 4 mm more preferably.
Not being limited to the abovementioned embodiment, the absorbent member according to the present invention can adopt a variety of types without departing from the spirit of the present invention. Other embodiments of the absorbent member according to the present invention are illustrated in
In absorbent members 4A, 4B illustrated in
As illustrated in
In absorbent members 4C to 4F illustrated in
As illustrated in
As illustrated in
As illustrated in
In the upper core wrap sheet 45 which has the concave-convex region P and the flat region Q, the thickness (apparent thickness) of the concave-convex region P is only required to be larger than the thickness of the lower core wrap sheet 46 at least. That is, it is only required that the concave-convex region P is the thick region. Here, it does not matter whether the thickness of the flat region Q is larger or smaller than the thickness of the lower core wrap sheet 46. Further, the concave-convex region P exists over the absorbent core 40 in a range of 30% to 100% of the entire width (entire length in the lateral direction Y) preferably and in a range of 50% to 100% more preferably.
A known solid processing method used for providing a concave-convex shape to a sheet in the art can be used as a method to form the concave-convex region P (concave-convex shape) at the upper core wrap sheet 45. Examples thereof include embossing process such as embossing process with heat and/or pressure and ultrasonic embossing process, tooth groove process for a sheet using tooth groove rollers (a pair of gear rollers with tooth grooves engaged like gears) (e.g., see JP 2009-201964A, JP 2009-50538A, JP 2009-160032A and the like), creping process (e.g., see JP 2004-305771A, JP 8-126663 A, JP 8-260328A and the like), and strain-free process (e.g., see JP 8-502181A, JP 10-502423A, JP 2002-320640A, JP 2006-320730A and the like).
Not being limited to the abovementioned embodiments, the present invention may be appropriately modified without departing from the spirit of the present invention. For example, although the sublayer sheet 5 is arranged from the front section B to the crotch section C in the abovementioned embodiment, the arrangement position of the sublayer sheet 5 is not specifically limited. For example, it is possible to be arranged from the rear section A to the crotch section C or to be arranged only at the crotch section C. Alternatively, the sublayer sheet 5 may not be arranged.
Further, other than an open-style type disposable diaper with a fastening tape, the absorbent article of the present invention may be an underpants type disposable diaper which is previously formed in an underpants shape, an absorbent pad, a sanitary napkin, or the like. In relation to the abovementioned embodiments, additional subjects (absorbent articles) are further disclosed.
[1] An absorbent article, including a topsheet which forms a skin-facing face, a backsheet which forms a non-skin-facing face, and an absorbent member which is arranged between both the sheets, wherein the absorbent member is structured to include an absorbent core which contains absorbent polymer without substantially containing hydrophilic fibers, an upper core wrap sheet which covers a skin-facing face of the absorbent core, and a lower core wrap sheet which covers a non-skin-facing face of the absorbent core, and the upper core wrap sheet includes a thick region having a larger thickness than the lower core wrap sheet.
[2] The absorbent article according to subject [1], wherein content of the hydrophilic fibers of the absorbent core is 5% or less by mass.
[3] The absorbent article according to subject [1], wherein the absorbent core does not contain the hydrophilic fibers at all.
[4] The absorbent article according to any one of subjects [1] to [3], wherein the hydrophilic fibers are one or more of fibers selected from a group consisting of cellulose fibers and synthetic fibers on which a hydrophilicity process is performed.
[5] The absorbent article according to subject [4], wherein the cellulose fibers are one or more of fibers selected from a group consisting of natural cellulose fibers and regenerated cellulose fibers.
[6] The absorbent article according to subject [5], wherein the natural cellulose fibers are one or more of fibers selected from a group consisting of wood pulp and non-wood pulp.
[7] The absorbent article according to subject [6], wherein the wood pulp is one or more of pulps selected from a group consisting of softwood kraft pulp and hardwood haft pulp.
[8] The absorbent article according to subject [6] or subject [7], wherein the non-wood pulp is one or more of pulps selected from a group consisting of cotton pulp and straw pulp.
[9] The absorbent article according to any one of subjects [5] to [8], wherein the regenerated cellulose fibers are one or more of fibers selected from a group consisting of rayon and cupra.
[10] The absorbent article according to any one of subjects [4] to [9], wherein the synthetic fibers are one or more of fibers selected from a group consisting of hydrophilic synthetic fibers, polyethylene terephthalate fibers, polyethylene fibers, polypropylene fibers, and polyester fibers.
[11] The absorbent article according to subject [10], wherein the hydrophilic synthetic fibers are one or more of fibers selected from a group consisting of polyvinyl alcohol fibers and polyacrylonitrile fibers.
[12] The absorbent article according to any one of subjects [1] to [11], which is used for a paper diaper for an infant, and a basis weight of the absorbent core is in a range of 80 to 400 g/m2.
[13] The absorbent article according to subject [12], wherein the basis weight of the absorbent core is in a range of 150 to 300 g/m2.
[14] The absorbent article according to any one of subjects [1] to [13], wherein a ratio (t1/t2) between a thickness t1 of the thick region of the upper core wrap sheet and a thickness t2 of the lower core wrap sheet is in a range of 1.5 to 20.
[15] The absorbent article according to subject [14], wherein the ratio (t1/t2) between the thickness t1 of the thick region of the upper core wrap sheet and the thickness t2 of the lower core wrap sheet is in a range of 2 to 10.
[16] The absorbent article according to any one of subjects [1] to [15], wherein a basis weight of the upper core wrap sheet is in a range of 13 to 30 g/m2.
[17] The absorbent article according to subject [16], wherein the basis weight of the upper core wrap sheet is in a range of 15 to 20 g/m2.
[18] The absorbent article according to any one of subjects [1] to [17], wherein a basis weight of the lower core wrap sheet is in a range of 7 to 30 g/m2.
[19] The absorbent article according to subject [18], wherein the basis weight of the lower core wrap sheet is in a range of 10 to 15 g/m2.
[20] The absorbent article according to any one of subjects [1] to [19], wherein the upper core wrap sheet includes a concave-convex region where a concave-convex shape is formed.
[21] The absorbent article according to any one of subjects [1] to [20], wherein each of the upper core wrap sheet and the lower core wrap sheet is a sheet made mainly of fibers.
[22] The absorbent article according to subject [21], wherein each of the upper core wrap sheet and the lower core wrap sheet is a sheet with fiber content being 90% or more by mass.
[23] The absorbent article according to subject [21] or subject [22], wherein each of the upper core wrap sheet and the lower core wrap sheet is a sheet selected from a group consisting of paper and nonwoven.
[24] The absorbent article according to subject [21] or subject [22], wherein each of the upper core wrap sheet and the lower core wrap sheet is a combined sheet formed by laminating two or more of sheets selected from a group consisting of paper and nonwoven.
[25] The absorbent article according to subject [23] or subject [24], wherein the paper is crepe paper.
[26] The absorbent article according to any one of subjects [23] to [25], wherein the nonwoven is one or more of nonwovens selected from a group consisting of spunbond nonwoven, meltblown nonwoven, thermalbonded nonwoven, needle-punched nonwoven, spanlaced nonwoven and airlaid nonwoven.
[27] The absorbent article according to any one of subjects [1] to [20], wherein each of the upper core wrap sheet and the lower core wrap sheet is formed of a laminated body with one or more of spunbond nonwoven layers and one or more of meltblown nonwoven layers, a basis weight of the spunbond nonwoven layer is larger than that of the meltblown nonwoven layer in the upper core wrap sheet, and a basis weight of the meltblown nonwoven layer is larger than that of the spunbond nonwoven layer in the lower core wrap sheet.
[28] The absorbent article according to subject [27], wherein adjacent nonwoven layers in the laminated body are integrated with entanglement and/or thermal adhesion of mutual structural fibers of the respective nonwoven layers not being integrated as being mutually stuck with adhesive.
[29] The absorbent article according to subject [27] or subject [28], wherein the spunbond nonwoven layer is formed of spunbond nonwoven and the spunbond nonwoven is obtained by that synthetic resin spins out from a nozzle with thermal fusion, a number of generated filaments are amassed on a conveyer to be a web, and the respective filaments are joined with a thermal compression bonding process or a mechanical interlacing process on the web.
[30] The absorbent article according to any one of subjects [27] to [29], wherein the meltblown nonwoven layer is formed of a meltblown nonwoven and the meltblown nonwoven is obtained by blowing melted synthetic resin onto a conveyer from a die chip of an extruding machine with high-speed air-flow to form a self-joining fiber web.
[31] The absorbent article according to any one of subjects [27] to [30], wherein the laminated body is nonwoven integrated in a state that one layer of the meltblown nonwoven layer is placed between two layers of the spunbond nonwoven layers.
[32] The absorbent article according to any one of subjects [27] to [30], wherein the laminated body is nonwoven integrated in a state that two layers of the meltblown nonwoven layers are placed between two layers of the spunbond nonwoven layers.
[33] The absorbent article according to any one of subjects [1] to [32], wherein a hydrophilic degree of the upper core wrap sheet is higher than that of the lower core wrap sheet.
[34] The absorbent article according to any one of subjects [1] to [33], wherein the lower core wrap sheet has hydrophobicity.
[35] The absorbent article according to any one of subjects [1] to [34] used for a disposable diaper.
[36] The absorbent article according to any one of subjects [1] to [34] used for an open-style type disposable diaper with a fastening tape.
In the following, the present invention will be described more specifically with examples. Here, the present invention is not limited to such examples.
A sample for example 1 was prepared as an open-style type disposable diaper having a basic structure being similar to the diaper 1 illustrated in
A sample for example 2 was prepared as an open-style type disposable diaper similarly to example 1 except for that the lower core wrap sheet adopted hydrophobic SMMS nonwoven having a thickness of 0.1 mm (a basis weight of 10 g/m2) and water passing time of 63 seconds with a basis weight ratio of the respective layers (S:M:M:S) being “4:1:1:4”.
Samples for comparison examples 1 and 2 were prepared as an open-style type disposable diaper similarly to example 1 except for that thicknesses (basis weights) of the upper core wrap sheet and the lower core wrap sheet were equaled.
A sample for comparison example 3 was prepared as an open-style type disposable diaper similarly to comparison example 1 except for that the sublayer sheet was arranged between the topsheet and the absorbent member as being hydrophilic SMMS nonwoven having a thickness of 0.1 mm (a basis weight of 10 g/m2) with a basis weight ratio of the respective layers (S:M:M:S) being “4:1:1:4”. The sublayer sheet is arranged to the front side of the absorbent member.
A sample for comparison example 4 was prepared as an open-style type disposable diaper similarly to example 1 except for interchanging thicknesses (basis weights) of the upper core wrap sheet and the lower core wrap sheet.
A sample for comparison example 5 was prepared as an open-style type disposable diaper similarly to example 1 except for that the absorbent core adopted an absorbent core substantially containing hydrophilic fibers (cellulose fibers) as well as absorbent polymer (SAP) (flap pulp (NBKP) web with 50 g/m2 was overlapped on SAP with 75 g/m2).
Liquid return amounts were measured with a method described below using samples (disposable diapers) of examples and comparison examples. The result thereof is indicated below in table 1. The extent of the liquid return amount is closely related to absorption performance of a disposable diaper, especially, to a dry feeling at the skin-facing face (topsheet). The less liquid return amount provides higher rating with higher absorption performance of a disposable diaper as being superior in dry feeling.
An acrylic plate with a cylindrical inlet portion is placed on a topsheet at the center part of an absorbent member in a state that a disposable diaper being a measurement target is planarly expanded and is fixed on a horizontal surface with the skin-facing face (topsheet) faced upward. The inlet portion arranged at the acrylic plate is cylindrical having an inner diameter of 20 mm. A penetration hole having an inner diameter of 10 mm which provides communication between the inside of the cylindrical inlet portion and a face of the acrylic plate faced to the topsheet is formed at the acrylic plate while the center axis line of the cylindrical inlet portion is matched with the center thereof in the longitudinal direction and the lateral direction. Subsequently, the acrylic plate is arranged so that the center axis of the cylindrical inlet portion is matched with the center part of the absorbent member in plane view. Then, artificial urine of 30 g is poured from the cylindrical inlet portion and is to be absorbed by the disposable diaper. After the artificial urine is powered, the acrylic plate is removed. After one minute of pouring, twenty sheets of filter paper (hard filter paper 4A manufactured by ADVANTEC CO., LTD) of 10 centimeters square are overlapped and placed on the poured position on the skin-facing face (topsheet) of the disposable diaper. Then, pressurization is performed for thirty seconds with a load of 0.7 kPa or below 0.1 kPa. Thus, artificial urine liquid-returned with pressurization is absorbed by the filter paper. A weight of the filter paper increased with the absorption is measured and the difference against a weight of the filter paper before the absorption is taken as the liquid return amount.
As clearly seen from the result indicated in table 1, it is revealed that the disposable diapers of the examples (the present invention) have less liquid return amounts in both cases of the load at measuring the liquid return amount being 0.7 kPa and being below 0.1 kPa. The load of 0.7 kPa corresponds to a load applied to a diaper in a state that a young month age infant wearing the diaper lies on his/her back. When the liquid return amount is below 2 g at the load of 0.7 kPa, liquid is not moved along a skin in a case that liquid exists between a skin of a wearer and the topsheet. Further, the load below 0.1 kPa reflects a feeling of touching a surface (skin-facing face) of a diaper without substantially little pressurization to the diaper. When the liquid return amount is below 0.2 g at the load below 0.1 kPa, a wearer hardly feels wet. In contrast, any of the respective comparison examples does not satisfy both conditions that liquid is not moved along a skin and that a wet feeling does not exist at a surface of a diaper. In comparison examples 1 to 4, the upper core wrap sheet does not include the thick region having a larger thickness than the lower core wrap sheet. Further, in comparison example 5, the absorbent core substantially contains hydrophilic fibers. The comparison examples are different from the examples in the abovementioned points. The above reveals that the following is important for improving a dry feeling at the skin-facing face of an absorbent article, that is, 1) the upper core wrap sheet includes the thick region having a larger thickness than the lower core wrap sheet and 2) the absorbent core does not substantially contain hydrophilic fibers.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-233376 | Oct 2010 | JP | national |
| 2011-226510 | Oct 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/073841 | 10/17/2011 | WO | 00 | 4/4/2013 |
