JP2002369841A - Method of manufacturing throw-away diaper having pattern sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a throw-away diaper which is capable of minimizing the mispositioning between a pattern and the diaper and is capable of freely dealing with the change of the position where the pattern is attached when a pattern is attached to a portion of the diaper. SOLUTION: A pattern sheet 15 of a square shape is affixed to the inner side of an exterior sheet of the throw-away diaper 1 and this pattern sheet 15 is printed with the one-point pattern 17. This pattern 17 is so formed as to be visible through the exterior sheet. The one-point pattern 17 can be positioned and attached exactly to an arbitrary position of the diaper 1 by using this pattern sheet 15.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a disposable diaper, and more particularly to a method of manufacturing a disposable diaper having a pattern sheet in which a pattern such as multicolor printing can be viewed only on a part of the back or front of the diaper. .

[0002]

2. Description of the Related Art In so-called open-type disposable diapers for babies and infants or disposable diapers preformed in a pants-type, a pattern such as a figure of an animal or a character is generally made to appear on the outer diaper. It is.

[0003] As a conventional method of applying the pattern, a continuous pattern or a repetitive pattern is printed in advance on a film serving as an outer sheet (back sheet) of a diaper, and the diaper is continuously formed by an automatic machine using the outer sheet. Manufacture is common.

Japanese Patent Application Laid-Open No. 3-90602 discloses a hot-melt type adhesive having a color using a transparent outer sheet (back sheet) and a third member inside the outer sheet. Are joined through. Then, while applying the hot-melt adhesive in the form of dots, a region having a high dot density is formed with the hot-melt adhesive, and a pattern or pattern is expressed in the region having a high dot density. Through the exterior sheet.

[0005]

As described above, in the method of manufacturing a diaper using a film on which a pattern is printed in advance as an exterior sheet, an absorbent layer and a liquid-permeable inner sheet are provided on the strip-shaped exterior sheet. (Top sheet), followed by a step of separating into individual diapers. for that reason,
In a disposable diaper after completion, it is practically impossible to control which pattern or design is located at which position on the diaper exterior. Therefore, printing of the exterior sheet is limited to the continuous pattern or the repetitive pattern as described above, and the degree of freedom in selecting the design of the pattern appearing on the exterior is limited. In addition, since it is necessary to perform printing on the entire film serving as the exterior sheet, the manufacturing cost of the exterior sheet (the film having a printed pattern) is increased. For example, if the pattern is expressed by multicolor printing, the cost is increased. Extremely high.

[0006] In the method disclosed in JP-A-3-90602, a colored hot-melt adhesive is applied to an exterior sheet using a roll coater, and the hot-melt adhesive is applied by dot application. Since the pattern is expressed, a clear pattern cannot be obtained, and of course, it is impossible to express a multicolored pattern. Further, in FIG. 1 of the above publication, the pattern is made to appear only on a part of the diaper. However, the method of applying the pattern by the roll coater as described above is disadvantageous in that misalignment between the completed diaper and the pattern is likely to occur. There is.

The present invention has been made to solve the above-mentioned conventional problems, and it is possible to apply a pattern to only a part of a diaper at a low cost. For example, even when a multicolor printing pattern is used, the cost is greatly increased. An object of the present invention is to provide a method of manufacturing a disposable diaper capable of preventing the occurrence of diapers.

Further, the present invention provides a disposable diaper and a method of manufacturing the disposable diaper which can minimize the positional deviation between the pattern and the diaper when the pattern is applied to a part of the diaper, and can freely cope with a change in the position where the pattern is applied. It is intended to provide a way.

[0009]

According to the present invention, there is provided an exterior sheet directed to the outside, a liquid-permeable inner sheet directed to the liquid receiving side, and an absorbing layer positioned between the outer sheet and the inner sheet. In a method for manufacturing a disposable diaper having a front part applied to the abdomen of the wearer, an intermediate part applied to the crotch part, and a rear part applied to the back, (a) transparent Affixing a pattern sheet having an area smaller than that of the exterior sheet and having a pattern on the surface thereof at a predetermined position on the inner surface of the exterior sheet with the surface facing the exterior sheet; Placing the absorbing layer and the inner sheet inside the outer sheet.

[0010] Preferably, the pattern sheet is formed by printing a pattern on a resin film, and more preferably,
The pattern sheet is moisture-permeable.

In the step (a), it is preferable that the pattern sheet is adhered to the exterior sheet by using an adhesive randomly applied to the inner surface of the exterior sheet.

In the present invention, both sides of the front portion and both sides of the rear portion are joined to form a waist opening and a pair of leg openings, and a waist is formed by an elastic member provided in the waist opening. The gathers are a method of manufacturing a pants-type disposable diaper in which leg gathers are formed by elastic members provided in the leg openings, respectively, and in the step (a), the pattern sheet is formed with the waist gathers. It can be configured to be attached to an area that does not touch both of the leg gathers.

[0013] Alternatively, both sides of the front part and both sides of the rear part are joined to form a waist opening and a pair of leg openings, and a gather continuous around the waist from the front part to the rear part is formed. In the method for manufacturing a formed pants-type disposable diaper, in the step (a), the pattern sheet may be configured to be adhered to a region not to be caught by the gathers.

Further, an impermeable sheet or a hydrophobic sheet which covers the inside of the exterior sheet is overlapped between the step (a) and the step (b), and the exterior sheet and the liquid impermeable sheet or the hydrophobic sheet are overlapped. And a step of sandwiching the pattern sheet between the conductive sheet and the conductive sheet.

It is preferable that the exterior sheet is a nonwoven fabric. Furthermore, when the disposable diaper in a state where the intermediate portion is bent so that the front portion and the rear portion are in contact with each other is viewed from the back or the front, the pattern sheet is, for example, 50% or less of the area of the diaper.

The disposable diaper of the present invention may be a so-called open type, or may be formed in advance in a pants type.

When the disposable diaper is viewed from the back and when viewed from the front, the disposable diaper is crushed into a flat shape so that the front part and the rear part are in close contact with each other without the diaper being worn on a human body. , Means a state viewed from the rear side or the front side. Alternatively, the disposable diaper has a three-dimensional shape in a state in which the diaper is worn on a human body. In this case, the projection shape means a projection shape when the diaper is viewed from the back side and when viewed from the front side. In other words, the condition that the area occupied by the pattern sheet is smaller than the area (projected area) of the diaper may be satisfied under either one of the state in which the diaper is crushed and the state in which the diaper is formed into a three-dimensional shape.

The pattern sheet is, for example, polygonal, circular or elliptical.

As described above, when a breathable and moisture-permeable sheet is used as the pattern sheet, the exterior sheet becomes
In the case of moisture permeability, the ventilation sheet and the moisture permeability function of the exterior sheet are not hindered by attaching the pattern sheet. However, if the pattern sheet is as small as 50% or less than the area of the exterior sheet when viewed from the back or front, even if the pattern sheet does not have air permeability or moisture permeability, The influence on the prevention of stuffiness of the diaper as a whole can be reduced.

For example, the exterior sheet is a non-woven fabric,
A liquid-impermeable sheet or a hydrophobic sheet is superimposed on the inside of the exterior sheet, and the pattern sheet is attached between the exterior sheet and the liquid-impermeable sheet or the hydrophobic sheet. .

Alternatively, the exterior sheet may be a film, and the pattern sheet may be adhered to an inner surface of the film.

In the manufacturing method of the present invention, if the accuracy in attaching the pattern sheet to the exterior sheet is ensured, the pattern can be attached at a predetermined position of the diaper without shifting the position. Further, it is possible to easily cope with a change in the position where the pattern is attached and a change in the size of the pattern.

[0023]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a perspective view showing a pants-type disposable diaper manufactured by one embodiment of the manufacturing method of the present invention, and FIG. 2 is a pants-type disposable diaper II-II shown in FIG. 5 and 6 are perspective views showing an example of a method for manufacturing the disposable diaper.

The disposable diaper 1 shown in FIG. 1 is formed in a pants shape in advance, and has a so-called hourglass shape in a deployed state before the forming. The diaper 1 has a front surface 2A applied to the abdomen of the wearer during use, a rear surface 2C applied to the buttocks and / or back during use, and an intermediate portion 2B applied to the crotch during use.

The lateral side 4A of the front part 2A and the lateral side 4C of the rear part 2C are joined to each other. As a result, a waist opening 5 is formed by the waist end 3A of the front surface 2A and the waist end 3C of the rear surface 2C. Further, leg openings 6 are formed on the left and right sides of the front part 2A, the intermediate part 2B, and the rear part 2C.

An elastic member (elastic band) 7 is attached to the waist ends 3A and 3C in the lateral direction, and as shown in FIG. Gathers are formed. An elastic member (elastic band) 8 is attached around the leg opening 6, and as shown in FIG. 1, a leg gather (around the leg side) around the leg opening 9 by the elastic contraction force of the elastic member 8. Cuff) is formed.

In the sectional view of FIG. 2, the lower side in the figure is the outer surface side of the diaper 1, and the inner side is the inner surface side of the diaper 1. The laminated structure of the diaper includes a waterproof sheet 12 (a liquid-impermeable sheet) formed of a breathable and moisture-permeable film inside an exterior sheet 11 formed of a nonwoven fabric which is a breathable and moisture-permeable material.
Are superimposed. Further, an absorbent layer 13 is superposed on the inside of the waterproof sheet 12, and a liquid-permeable inner sheet 14 is superposed on the innermost side. And the exterior sheet 1
A rectangular piece-shaped pattern sheet 15 is sandwiched between the waterproof sheet 1 and the waterproof sheet 12.

A hot-melt adhesive 16a is applied to the inner surface of the exterior sheet 11 in a random shape such as a wavy shape, and the exterior sheet 11 and the waterproof sheet 12 are adhered by the hot-melt adhesive 16a. ing. The pattern sheet 15 is adhered and fixed to the exterior sheet 11 by the hot melt adhesive 16a.

The inner surface of the waterproof sheet 12 and the absorbent layer 13
The hot melt type adhesives 16b and 16c are also randomly applied to the inner surface of the waterproof sheet 12, the waterproof sheet 12 and the absorbing layer 13 are bonded, and the absorbing layer 13 and the inner sheet 14 are bonded.

The outer sheet 11, the inner sheet 14, and the waterproof sheet 12 have the same hourglass shape when the diaper 1 is deployed. However, the waterproof sheet 12
Only the outer sheet 11 and the inner sheet 14 may be smaller in shape. The absorbing layer 13 has an hourglass shape smaller than the outer sheet 11 and the inner sheet 14. The outer sheet 11 and the inner sheet 14 (and the waterproof sheet 12) are located at positions deviating from the periphery of the absorbent layer 13, that is, the lateral sides 4 of the front surface 2A.
A, the lateral side 4C of the rear surface 2C, the waist ends 3A and 3C, and the periphery of the waist opening 5 are adhered to each other by the hot melt adhesives 16a and 16b.

On the other hand, the pattern sheet 15 occupies a sufficiently smaller area than the exterior sheet 11 and has, on its outer surface, figures such as animal faces, characters, plants, and the like.
Alternatively, patterns 17 such as symbols and characters are printed.
In the illustrated embodiment, a one-point pattern 17 is printed on one pattern sheet 15. Further, any combination of the figures, symbols, and characters may be printed as the pattern 17. Since the pattern sheet 15 is in the shape of a small square piece, the area of the margin around the pattern 17 is small. Therefore, the pattern sheet 15 can be manufactured at low cost. Further, since the pattern sheet 15 is small and the dimensions of the pattern 17 are also small, even if the pattern 17 is printed in multiple colors, a significant increase in cost can be suppressed.

The pattern sheet 15 is a resin film such as polyethylene or polypropylene, a paper material, a laminate material of a paper material and a resin film, and the like, and is preferably a material capable of printing the pattern 17 vividly. However, in the case where the pattern sheet 15 is formed of a resin film, if a gas permeable and moisture permeable film is used, the gas permeability and the gas permeability of the portion where the pattern sheet 15 is attached will not be impaired. The pattern sheet 15 may be made of a nonwoven fabric such as a point bond, a spun bond, and a spun lace. The pattern sheet 15 formed of this nonwoven fabric is air-permeable and moisture-permeable.

The exterior sheet 11 is a non-woven fabric and has a light transmittance that can be visually confirmed by seeing through the pattern 17, and is, for example, a point bond, an air-through, a spun bond, a spun-lace non-woven fabric, or the like. is there.

The waterproof sheet 12 is a breathable and moisture-permeable resin film such as polyethylene or polypropylene. The absorbent layer 13 is formed of an absorbent material, for example, ground pulp or a mixture of ground pulp and a superabsorbent polymer, and the ground pulp or a mixture of ground pulp and the superabsorbent polymer is wrapped in an absorbent sheet such as a tissue. It is a thing.

The inner sheet 14 is liquid-permeable and formed of hydrophobic fibers, hydrophilic fibers, etc., which have been subjected to hydrophilic treatment. Alternatively, the inner sheet 14 may be formed by stacking a cushion layer made of a bulky nonwoven fabric on the nonwoven fabric.

The pattern sheet 15 is attached to the rear surface 2C of the diaper 1, or the pattern sheet 15 is moved from the rear surface 2C to the intermediate portion 2B.
Mounted over. In this case, when the disposable diaper 1 is viewed from the back ((i) direction) in the same three-dimensional state as worn on the human body as shown in FIG.
The disposable diaper 1 is crushed into a flat state so that the front part 2A and the rear part 2C are in close contact with each other, and the back ((i) direction).
When viewed from above, it is preferable that the area occupied by the pattern sheet 15 is smaller than the entire visual area of the diaper, and it is preferable that the area occupied by the pattern sheet 15 relative to the entire visual area be 50% or less.

The pattern sheet 15 is attached to the front part 2A of the diaper 1, or is moved from the front part 2A to the middle part 2A.
B may be attached. In this case, when the diaper 1 is viewed from the front ((ii) direction) in the three-dimensional state of the diaper 1 or in a state where the diaper 1 is crushed, the area 15 occupied by the pattern sheet 15 with respect to the entire visual area of the diaper 1 Is sufficiently small, and the area ratio is preferably 50% or less.

The pattern sheet 15 can be attached to both the front surface 2A and the rear surface 2C.

The pattern sheet 15 can be attached to an arbitrary position, but around the waist opening 5,
It is preferable to attach the waist gather formed by the elastic member 7 and the region around the leg opening 6 to both the leg gathers formed by the elastic member 8 so as not to be hung. Further, even in the case where a gather continuous from the front part 2A to the rear face part 2C is formed around the waist, it is preferable that the pattern sheet 15 be attached to a position where the gather does not catch the gather.

When the pattern sheet 15 is attached at a position where it does not catch on the gathers, the pattern sheet 15 can be kept relatively flat, and the pattern 17 can be prevented from being distorted.

Further, it is preferable that the pattern sheet 15 is attached to a position avoiding a joint between the lateral side 4A of the front part 2A and the lateral side 4C of the rear part 2C.
The joining of the side portion 4A and the side portion 4C is realized by thermal welding, but if the pattern sheet 15 is present at this joining portion, the joining by the thermal welding will be hindered.

Next, a method of manufacturing the disposable diaper 1 shown in FIGS. 1 and 2 will be described.

After applying the hot melt adhesive 16a to the non-woven fabric to be the exterior sheet 11, as shown in FIG. 5, the pattern sheet 15 on which the pattern 17 has been printed in advance is positioned so as to have a predetermined interval. Place on non-woven fabric. The pattern sheet 15 is cut into a predetermined size from a belt-like sheet (tape-like sheet) 15A. At this time, the pattern sheets 15 are cut at regular intervals so that the patterns 17 appear uniformly on the individual pattern sheets 15 cut out, and are sequentially placed on the nonwoven fabric.

The waterproof sheet 12 is placed on the exterior sheet 11.
Are laminated and heated by the heating roller 20, and heat is applied, so that the individual pattern sheets 15 are sandwiched and bonded between the nonwoven fabric as the exterior sheet 11 and the film as the waterproof sheet.

Next, a hot melt type adhesive 16b is applied to the upper surface of the bonded body of the nonwoven fabric forming the exterior sheet 11 and the film forming the waterproof sheet 12. Then, as shown in FIG. 6, an absorbent layer 13 is provided on the joined body so as to be spaced apart from each other and to be aligned with the pattern sheet 15. A hot melt adhesive 16c is applied to the surface of the absorption layer 13.

Then, a non-woven fabric serving as a top sheet 14 is overlaid on the absorbent layer 13, and these laminates are sandwiched between heating rollers, and the respective layers are adhered to each other. Thereafter, the leg opening is cut along the cutting line L1 and the cutting line L2
, Individual fronts 2A, rear 2C
And a laminate having an intermediate portion 2B. Further, the lateral side 4A of the front part 2A and the lateral side 4C of the rear part 2C are joined to form the pants type shown in FIG.

In the above steps, the description of the step of attaching the elastic members 7 and 8 is omitted.

FIGS. 3 and 4 are sectional views showing another embodiment of the structure of the laminated body forming the disposable diaper 1. FIG.

In FIG. 3, a nonwoven fabric 21, which is a hydrophobic sheet having air permeability and moisture permeability, is overlaid on the inside of the exterior sheet 11. The sheet 15 is sandwiched and adhered. The nonwoven fabric 21 is, for example, a spunbonded nonwoven fabric formed of polypropylene fibers, or a sheet in which a spunbonded nonwoven fabric, a meltblown nonwoven fabric, and a spunbonded nonwoven fabric are stacked.

In FIG. 4, a waterproof film is used as the exterior sheet 22. This waterproof film is a resin film such as polyethylene or polypropylene, and has air permeability and moisture permeability. The waterproof film is transparent or translucent and has a light transmittance enough to allow the pattern 17 of the pattern sheet 15 to be seen through.

A hot-melt adhesive 16a is applied to the inner surface of the outer sheet 22 of the waterproof film, and the pattern sheet 15 is overlaid and adhered. And pattern sheet 1
5, the absorption layer 13 is located.

Next, FIGS. 7A and 7B show the pattern sheet 1.
It is a rear view which shows the modification of the attachment position of No. 5.

In FIG. 7 (A), the pattern sheet 15 is mounted on the rear surface 2C of the disposable diaper 1 at a position offset to the right and in a well-balanced position as a whole. In the example shown in FIG. 7B, two pattern sheets 15 on which different patterns are printed are divided into right and left portions and attached to well-balanced positions on the rear surface 2 </ b> C.

As described above, in the present invention, the pattern 17 can be attached to an arbitrary position of the diaper 1 and in an arbitrary number.
The degree of freedom in design can be increased.

The pattern sheet 15 is not limited to a square or a rectangle, but may be a circle or an ellipse in addition to a polygon such as a triangle or a pentagon.

The disposable diaper of the present invention is not limited to the pants type shown in FIG. 1, but may be an hourglass type so-called open type.

[0057]

As described above, according to the present invention, a pattern can be provided at an arbitrary position. Further, since a pattern sheet having a relatively small area is used, there is little waste of sheet material such as a resin film forming the pattern sheet. Further, since the pattern is printed on the pattern sheet having a small area, the cost of printing the pattern can be reduced. Further, since the printing cost can be reduced as compared with the case where a continuous pattern or a repeated pattern is printed on the entire exterior sheet as in the related art, the pattern can be printed in multiple colors.

In addition, a one-point or several-point pattern can be positioned and attached to the diaper with high precision, and pattern displacement hardly occurs.

Further, it is possible to easily cope with a change in the pattern to be applied to the diaper and a change in the position where the pattern is applied.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a pants-type diaper manufactured by the manufacturing method of the present invention;

FIG. 2 is a sectional view taken along line II-II of the pants-type diaper shown in FIG.

FIG. 3 is a cross-sectional view showing another embodiment of the laminated structure;

FIG. 4 is a cross-sectional view showing another embodiment of the laminated structure;

FIG. 5 is a perspective view showing a method for manufacturing a disposable diaper according to the present invention;

FIG. 6 is a perspective view showing a method for manufacturing a disposable diaper according to the present invention;

FIGS. 7A and 7B are rear views showing a modification of a position where a pattern is applied to a diaper;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Disposable diaper 2A Front part 2B Intermediate part 2C Rear part 3A Front waist part 3C Rear waist part 5 Waist opening part 6 Leg opening part 7,8 Elastic member 11 Exterior sheet 12 Waterproof sheet 13 Absorption layer 14 Inner sheet 15 Pattern sheet 17 Pattern 16a, 16b, 16c hot melt adhesive

Continued on the front page (72) Inventor Tohru Sasaki 1531-7, Wadahama Takasuka, Toyohama-cho, Mitoyo-gun, Kagawa Prefecture Inside the Unicharm Corporation Technical Center (72) Inventor Hiroki Yamamoto 1531- Takasuga, Wadahama, Toyohama-cho, Mitoyo-gun, Kagawa Prefecture 7 Unicharm Corporation Technical Center F-term (reference) 3B029 BC07 BD07 BD10 BD13 BF05 BF06 BF07 4C098 AA09 CC03 CC11 CC12 DD10 DD25

Claims (9)

[Claims] An exterior sheet directed to the outside, a liquid-permeable inner sheet directed to the liquid receiving side, and an absorbing layer located between the exterior sheet and the inner sheet, and In a method for manufacturing a disposable diaper in which a front part applied to the abdomen, an intermediate part applied to the crotch part, and a rear part applied to the back side are formed, (a) a predetermined inner surface of the exterior sheet that can be seen through; At a position, a step of attaching a pattern sheet having an area smaller than the exterior sheet and having a pattern on the surface, with the surface facing the exterior sheet,
(B) installing the absorbent layer and the inner sheet inside the outer sheet. 2. The method for manufacturing a disposable diaper according to claim 1, wherein the pattern sheet is a pattern formed by printing a pattern on a resin film. 3. The method for manufacturing a disposable diaper according to claim 1, wherein the pattern sheet is moisture-permeable. 4. The process according to claim 1, wherein in the step (a), the pattern sheet is adhered to the exterior sheet using an adhesive randomly applied to an inner surface of the exterior sheet.
The method for producing a disposable diaper according to any one of the above. 5. A waist opening and a pair of leg openings are formed by joining both sides of the front part and both sides of the rear part, and a waist gather is formed by an elastic member provided in the waist opening. A method of manufacturing a pants-type disposable diaper in which a leg gather is formed by an elastic member provided in the leg opening, wherein in the step (a), the pattern sheet is formed by combining the waist gather and the leg. The method for producing a disposable diaper according to any one of claims 1 to 4, wherein the disposable diaper is attached to an area that does not cover both gathers. 6. A waist opening and a pair of leg openings are formed by joining both sides of the front part and both sides of the rear part, and a gather continuous around the waist from the front part to the rear part is formed. It is a manufacturing method of the formed underpants type disposable diaper, The disposable diaper according to any one of claims 1 to 4, wherein in the step (a), the pattern sheet is adhered to an area not to be gathered. Diaper manufacturing method. 7. A method according to claim 1, wherein said step (a) and said step (b)
7. The method according to claim 1, further comprising: stacking an impermeable sheet or a hydrophobic sheet covering the inside of the exterior sheet, and sandwiching the pattern sheet between the exterior sheet and the liquid impermeable sheet or the hydrophobic sheet. The method for producing a disposable diaper according to any one of the above. 8. The method according to claim 1, wherein the exterior sheet is a non-woven fabric.
8. The method for producing a disposable diaper according to any one of items 7 to 7. 9. When the disposable diaper in a state where the intermediate portion is bent so that the front portion and the rear portion are in contact with each other is viewed from the back or the front, the pattern sheet is 50% or less of the area of the diaper. A method for producing a disposable diaper according to any one of claims 1 to 8.