Sanitary pad for women

Abstract

A sanitary napkin for women includes a permeable inner sheet, which comes into contact with the skin of a wearer to thus allow secretions to pass therethrough, an outer sheet fused to the inner sheet, and an absorption pad disposed between the inner sheet and the outer sheet to absorb the secretions passed through the inner sheet, the outer sheet being a nanolaminate film composed of a nanomembrane formed by electrospinning a polymer solution and a strength-reinforcing nonwoven fabric laminated on one side of the nanomembrane.

Claims

1. A sanitary napkin for women, comprising: a permeable inner sheet, which comes into contact with skin of a wearer to thus allow secretions to pass therethrough; an outer sheet fused to the inner sheet; an absorption pad disposed between the inner sheet and the outer sheet to absorb the secretions passed through the inner sheet, wherein the outer sheet is a nanolaminate film composed of a nanomembrane formed by electrospinning a polymer solution and a strength-reinforcing nonwoven fabric laminated on one side of the nanomembrane, and the nanomembrane of the nanolaminate film has a weight of 2.0 g/m.sup.2 to 6.0 g/m.sup.2, a thickness of 4.0 m to 18.0 μm, and air permeability of 1.5 CFM or more at 125 Pa, wherein the nanomembrane and the strength-reinforcing nonwoven fabric are adhered to each other using 4.0 to 16 g/m2 of a moisture-curable hot-melt adhesive.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a top plan view showing the outer appearance of a sanitary napkin for women according to the present invention;

(2) FIG. 2 is an exploded cross-sectional view showing the structure of FIG. 1;

(3) FIG. 3 is an exploded perspective view showing the structure of an outer sheet according to the present invention;

(4) FIG. 4A is photographs showing the measuring device of the unit weight of a nanomembrane according to the present invention;

(5) FIG. 4B photographs showing the measurement result of the unit weight of a nanomembrane according to the present invention;

(6) FIG. 5A is photographs showing the measuring device of the thickness of the nanomembrane according to the present invention;

(7) FIG. 5B is photographs showing the measurement result of the thickness of the nanomembrane according to the present invention;

(8) FIG. 6A is photographs showing the measuring device of the waterproofness of a sanitary napkin for women according to the present invention;

(9) FIG. 6B is photographs showing the specifications of sample for measuring of the waterproofness of a sanitary napkin for women according to the present invention; and

(10) FIG. 7 is a comparison photograph for confirming the air permeability of the sanitary napkin for women according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(11) FIG. 1 is a top plan view showing the outer appearance of a sanitary napkin for women according to the present invention, and FIG. 2 is an exploded cross-sectional view showing the structure of the sanitary napkin of FIG. 1.

(12) As shown in FIG. 2, the sanitary napkin of FIG. 1 is configured to include a permeable inner sheet 100, which comes into contact with the skin of a wearer to thus allow secretions to pass therethrough, an outer sheet 200, fused at edges to the inner sheet 100, and an absorption pad 300, disposed between the inner sheet 100 and the outer sheet 200 to absorb the secretions passed through the inner sheet 100.

(13) The inner sheet 100, which comes into contact with the skin of a wearer, is configured to absorb secretions such as menstrual blood and the like to thus pass therethrough, and is thus mainly formed of polyethylene or cotton, which is soft and has high permeability.

(14) Also, the absorption pad 300, which absorbs and stores the secretions such as menstrual blood and the like, is disposed between the inner sheet 100 and the outer sheet 200, and is made of nonwoven fabric or pulp having high flexibility and liquid storage ability.

(15) The inner sheet 100 and the absorption pad 300 are generally used and known, and a detailed description of materials or manufacturing methods thereof is thus omitted.

(16) The main feature of the present invention is the outer sheet 200 in the configuration of FIGS. 1 and 2.

(17) As shown in FIG. 3, the outer sheet 200 of the sanitary napkin for women according to the present invention comes into contact with the underwear such as panties, and the edges thereof are adhered to the inner sheet 100.

(18) The outer sheet 200 is a nanolaminate film.

(19) As illustrated in FIG. 3, the outer sheet 200 includes a nanomembrane 210, obtained by electrospinning a polymer solution, and a strength-reinforcing nonwoven fabric 220, laminated on one side of the nanomembrane 210, and the nanomembrane 210 and the strength-reinforcing nonwoven fabric 220 are laminated with each other by means of a hot-melt adhesive 230 that is cured under predetermined humidity.

(20) As described above, when the nanolaminate film using nanofiber having electromagnetic-wave-shielding effects or an ion-permeable membrane is applied to the outer sheet 200 of the sanitary napkin for women by the present applicant, different and excellent effects, which have not been recognized conventionally, may be exhibited.

(21) Hereinafter, the configuration of the outer sheet 200 of the sanitary napkin for women according to the present invention and the method of manufacturing the same (Preparation Example) are described in detail.

Preparation Example

1. Formation of Nanomembrane 210

(22) A nanomembrane is manufactured by electrospinning an electrospinning solution comprising a dissolved polymer (a solution obtained by dissolving a polymer in a solvent at a weight ratio of 1:1) at room temperature at a flow rate of 0.02 to 0.05 ml/min using an electrospinning device under the conditions that a spinning part and a stacking part are spaced apart from each other at a distance of 10 to 30 cm and that the applied voltage is adjusted in the range of 10 to 55 kV.

(23) The polymer for use in the preparation of nanofiber is selected from the group consisting of polyurethane (PU), polyacrylonitrile (PAN), polyvinylalcohol (PVA), nylon, polyvinylidene fluoride (PVdF), polyhydroxybutyrate (PHB), polyethersulfone (PES), polyetherimide (PEI), polycaprolactone (PCL), polylactic acid (PLA), poly-L-lactic acid (PLLA), and combinations thereof.

(24) Also, the solvent for dissolving the above polymer in order to perform electrospinning is selected from the group consisting of DMA (dimethyl acetamide), DMF (N,N-dimethylformamide), NMP (N-methyl-2-pyrrolidinone), DMSO (dimethyl sulfoxide), THF (tetrahydrofuran), DMAc (di-methylacetamide), EC (ethylene carbonate), DEC (diethyl carbonate), DMC (dimethyl carbonate), EMC (ethyl methyl carbonate), PC (propylene carbonate), water, acetic acid, formic acid, chloroform, dichloromethane, acetone, ethanol, and combinations thereof.

(25) Used in the outer sheet 200 of the sanitary napkin for women according to the present invention, the nanomembrane 210 includes silver nanoparticles, which are known to have strong antimicrobial activity.

(26) The silver nanoparticles are contained in the nanomembrane by adding silver nitrate in a predetermined amount upon preparation of the polymer solution.

(27) Silver nitrate is present in ionized forms such as silver ions and nitrate ions in the polymer solution, and nitrate ions are volatilized and the solution in which only the silver ions are present is electrospun.

2. Formation of Strength-Reinforcing Nonwoven Fabric 220

(28) Used in the sanitary napkin for women according to the present invention, the outer sheet 200 is obtained by laminating a strength-reinforcing nonwoven fabric 220 on one side of a nanomembrane 210.

(29) The strength-reinforcing nonwoven fabric 220 is provided in order to reinforce the nanomembrane 210 because the nanomembrane 210 configured to allow only air, but not liquid, to pass therethrough is vulnerable to tearing.

(30) The strength-reinforcing nonwoven fabric 220 is made of PP, PE, PET, etc.

(31) In the present embodiment, a strength-reinforcing nonwoven fabric for use in the nanolaminate film of the outer sheet 220 is manufactured through a spun-bond process using polypropylene (PP).

(32) PP pellets are sequentially placed in a water bath, a hopper and a screw extruder.

(33) Extruder sleeve partition heating, melting with a continuous prefilter, slicing using an extruder and rotating in a rotary box are performed.

(34) Accurate measurement using a metering pump, quantitative introduction of a melt using a spinning nozzle, and continuous melt flow through spraying using the openings of the nozzle are performed, thus forming raw fiber.

(35) The raw fiber is absorbed by a monomer, followed by cooling using cold air, air drafting, and filament formation. The filament is uniformly perforated through a pendulum roller, is sent to a hot-rolling machine by a conveyor curtain using air flows having positive and negative pressure, and is evenly laid on a net curtain that forms a spun sticky web through heat bonding by the hot-rolling machine.

3. Hot-Melt Adhesive

(36) The outer sheet 200 of the present invention is configured such that the nanomembrane 210 and the strength-reinforcing nonwoven fabric 220 are adhered to each other by means of the hot-melt adhesive.

(37) The hot-melt adhesive is an adhesive which is thermoplastic, which is changed into a liquid phase by heat, and which has a characteristic of curing at a humidity of 80% or higher, and an acrylic resin may be used.

(38) The solid adhesive is heated to a liquid phase and applied onto the surface of an engraved roller to thus be applied onto one side of the strength-reinforcing nonwoven fabric 220.

(39) The hot-melt adhesive is applied in dot or line form onto one side of the strength-reinforcing nonwoven fabric 220, and the nanomembrane 210 is laminated thereon and then pressed.

(40) Examples of a process of applying the hot-melt adhesive onto the surface of the strength-reinforcing nonwoven fabric may include a spraying process, a roller process and a blanket transformation process, but no particular limitation is imposed thereon, so long as the inherent functions of the nanomembrane are not damaged after bonding.

(41) The weight of the adhesive that is transferred to the nonwoven fabric varies depending on the kind of nonwoven fabric. Preferably, the adhesive is used in an amount of about 4 to 10 g/m.sup.2 for a nonwoven fabric having a flat surface, and is used in an amount of about 16 g/m.sup.2 for a nonwoven fabric having a rough surface.

(42) Accordingly, the weight of the hot-melt adhesive applied on the nonwoven fabric falls in the range of 4 to 16 g/m.sup.2.

(43) If the weight of the hot-melt adhesive is less than 4 g/m.sup.2, adhesion of the nanomembrane 210 and the strength-reinforcing nonwoven fabric 220 may decrease and thus the nanomembrane 210 and the strength-reinforcing nonwoven fabric 220 are liable to separate from each other. On the other hand, if the weight thereof exceeds 16 g/m.sup.2, air permeability may decrease, the total weight of the nanolaminate film may increase, and the adhesive may leak out.

(44) Hence, it is important that the weight of the adhesive fall within the above numerical range.

4. Formation of Nanolaminate Film

(45) A nanolaminate film is manufactured by engaging and rotating a first roller, on which the nanomembrane is wound, a second roller, on which the strength-reinforcing nonwoven fabric is wound, and an engraved roller, which rotates together with the second roller in contact therewith, followed by pressing.

(46) Specifically, a hot-melt adhesive is melted at a temperature of about 1900 in an extruder, and is then applied onto the surface of an engraved roller. Here, the adhesive is applied at a uniform thickness on the surface of the engraved roller by means of a blade.

(47) Thereafter, a strength-reinforcing nonwoven fabric is placed between the engraved roller and the second roller, whereby the adhesive applied on the engraved roller is transferred to the surface of the strength-reinforcing nonwoven fabric, and the nonwoven fabric on which the adhesive was applied is laminated with the nanomembrane fed from the first roller, and then passes through a pressing roller, thereby completing a nanolaminate film.

(48) The engraved roller functions to press the strength-reinforcing nonwoven fabric at a pressure of 3 to 5 kg/cm.sup.2, and the surface of the engraved roller is maintained at a temperature of 1900.

Experimental Example

(49) The outer sheet 200 of a sanitary napkin for women according to the present embodiment was manufactured as described in the above Preparation Example, and the unit weight, thickness, air permeability and waterproofness thereof were measured under the following experimental conditions. As the Comparative Example, the outer sheets of commercially available sanitary napkins for women were tested under the same experimental conditions.

1. Weight of Nanomembrane

(50) The weight of the outer sheet 200 of a sanitary napkin for women is the main factor that determines the fit with a wearer. The lighter the outer sheet, the better the fit.

(51) A test sample was manufactured in a rectangular shape having a width of 250 mm and a length of 200 mm, and the weight thereof was measured in accordance with ASTM D 3886, and is represented in units of g/m.sup.2.

(52) FIG. 4A shows photographs of the measuring device of the unit weight and FIG. 4B shows photographs captured during the measurement of the unit weight.

2. Thickness of Nanomembrane

(53) The thickness of a nanomembrane was measured in accordance with ASTM D 1777, and is represented in units of μm. When the thickness is thinner to 100% point or more, effects are regarded as excellent.

(54) FIG. 5A shows photographs of the measuring device of the thickness of the outer sheet.

(55) FIG. 5B shows photographs captured during the measurement of the thickness of the outer sheet.

3. Measurement of Air Permeability of Nanolaminate Film

(56) Air permeability was measured in accordance with ASTM D 737-04 (2008).

(57) As such, the air permeability of the nanolaminate film comprising the nanomembrane and the strength-reinforcing nonwoven fabric, which were laminated together, was directly measured.

(58) The strength-reinforcing nonwoven fabric has no effect on air permeability because the pore size of the nanomembrane is hundreds of times larger.

(59) A sample was spread on an air permeability meter (Textest FX 3300), and was then fixed by pressing down a circular chamber having a diameter of 15 cm.

(60) The set pressure was 125 Pa and the measured value was CFM (Cubic Feet per Minute). Briefly, the set pressure wad applied to the product and the amount of air passed through the sample was measured. The values at three diagonally distributed points for one sample were measured, and were then averaged.

(61) Here, the weight of the nanomembrane according to the present invention was 4.0 g/m.sup.2, and the thickness thereof was 7.0 μm, and air permeability was determined by measuring the amount of air passing therethrough using a flow meter at an air pressure of 125 Pa.

4. Measurement of Waterproofness (Water Repellency) of Nanolaminate Film

(62) Waterproofness (water repellency) was measured in accordance with JIS L 1092 (2009).

(63) A sample was cut into a square shape having a width and length of 200 mm each, placed on a holder with a diameter of 11.5 cm, fixed with a frame, and then pressurized.

(64) Here, the nanolaminate film was disposed such that the surface thereof contacting water was a nanomembrane and the surface opposite thereto was a strength-reinforcing nonwoven fabric.

(65) The water pressure was slowly increased while applying water pressure. While the water pressure was increased, the pressure at which the third droplet, among droplets, emerged from the gap in the outer sheet was measured.

(66) When a third droplet was not observed even at a water pressure of 5000 mmH.sub.2O, waterproofness was judged not to be problematic, and no further measurements were made.

(67) FIG. 6A is photographs showing the measuring device of waterproofness of the nanolaminate.

(68) FIG. 6B is photographs showing the state (specification) of sample for measuring waterproofness.

5. Experimental Results (Comparative Example)

(69) TABLE-US-00001 TABLE 1 Unit LEMON A Company B Company C Company D Company E Company Thickness μm    8   34   62   78   98   150 Basis Weight g/m.sup.2    4.0   33   60   80   100   130 Air permeability CFM,    2.0    0.0001    0.0001    0.0001    0.0001    0.0001 @125 pa Water repellency mmH.sub.2O 5,000↑ 5,000↑ 5,000↑ 5,000↑ 5,000↑ 5,000↑

(70) As is apparent from the above experimental results, the thickness of the nanomembrane used in the present invention is only 5.3% to 23.5% of that of the outer sheet of each of the commercially available sanitary napkins, the basis weight thereof is 3.0% to 12%, and the air permeability is as high as twenty thousand times thereof.

(71) Particularly, an experiment that may actually confirm air permeability along with waterproofness was performed as shown in FIG. 7.

(72) FIG. 7 shows an actual testing photograph of a finished product of the sanitary napkin for women according to the present invention and commercially available sanitary napkins.

(73) Specifically, as shown in the photograph of FIG. 7, for the sanitary napkin of the present invention, tested in a manner in which water was positioned on the top of the outer sheet and air was blown from the bottom thereof, it was confirmed that air bubbles were formed while the air from the bottom passed through the outer sheet and proceeded to the top without water leaking at all, whereas all of the remaining sanitary napkins were thus confirmed to have no air permeability because no air bubbles were formed.

(74) If the weight of the nanomembrane exceeds 6.0 g/m.sup.2 and the thickness of the nanomembrane exceeds 18.0 m, waterproofness is relatively improved, but air permeability is considerably lowered, which leads to discomfort in wearing and inconvenience due to the weight.

(75) In the experiment of the present application, the air permeability of the nanomembrane having a weight of 7.0 g/m.sup.2 and a thickness of 20 m was measured to be 0.7 CFM, which is regarded as a numerical value having a critical meaning taking into consideration that the air permeability of the nanomembrane having a weight of 6.0 g/m.sup.2 and a thickness of 18.0 m was 1.5 CFM.

(76) On the other hand, if the weight of the nanomembrane is less than 2.0 g/m.sup.2 and the thickness of the nanomembrane is less than 4.0 m, air permeability is improved and thus the alleviation of rash and the fit are observed to improve, but a large number of droplets are formed within about 5 sec from the start of the experiment, waterproofness being measured to be about 500 to 1000 mmH.sub.2O.

(77) In the case of a nanomembrane having a weight less than 2.0 g/m.sup.2 and a thickness less than 4.0 μm, leakage may occur in the sanitary napkin, on which basis it is judged that the same is not usable as a product.

(78) Although the sanitary napkin for women according to the present invention has been described in the preferred embodiments, it is intended to facilitate understanding of the present invention and is not intended to limit the scope of the invention.

(79) It will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the invention.