CN109477271B - Method and apparatus for forming through-hole in nonwoven fabric sheet for absorbent article - Google Patents

Method and apparatus for forming through-hole in nonwoven fabric sheet for absorbent article Download PDF

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Publication number
CN109477271B
CN109477271B CN201680087922.8A CN201680087922A CN109477271B CN 109477271 B CN109477271 B CN 109477271B CN 201680087922 A CN201680087922 A CN 201680087922A CN 109477271 B CN109477271 B CN 109477271B
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China
Prior art keywords
fabric sheet
pin member
rotating body
nonwoven fabric
hole
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CN201680087922.8A
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Chinese (zh)
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CN109477271A (en
Inventor
石川慎一
杷野翔大
石川宜秀
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Unicharm Corp
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Unicharm Corp
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C29/00—Finishing or dressing, of textile fabrics, not provided for in the preceding groups

Abstract

The present invention provides a method of forming through holes h, h.... when a nonwoven fabric sheet 1m passes between a first rotating body 55 and a second rotating body 51, which rotate with their respective outer circumferential surfaces facing each other, in a thickness direction of the nonwoven fabric sheet 1m, a through hole h, h.... was formed in the nonwoven fabric sheet 1 m. The method comprises the following steps: a step for forming a through hole h, h.... when the pin member 55p, 55p.... is inserted into the hole portion 51h, 51h.... a, by pressing the pin member 55p, 55p.... into the nonwoven fabric sheet 1m, the pin member being formed as a protrusion on the outer circumferential surface of the rotating first rotating body 55, the hole portion being formed in the outer circumferential surface of the rotating second rotating body 51; and a step for urging gas to flow between the pin member 55p and the hole portion 51h when the pin member 55p, 55p.

Description

Method and apparatus for forming through-hole in nonwoven fabric sheet for absorbent article
Technical Field
The present invention relates to a method and apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article such as a disposable diaper.
Background
Conventionally, in a manufacturing line for an absorbent article, such as a disposable diaper that absorbs excrement such as urine, there is a case where a process for forming through holes in a nonwoven fabric sheet as a constituent material is performed for the purpose of imparting breathability to the absorbent article. As one example of a method for forming such through-holes, PTL 1 discloses that through-holes are formed in a nonwoven fabric sheet by pin members that protrude from the outer circumferential surface of a rotating roller to be pressed into the nonwoven fabric sheet in the thickness direction.
[ list of citations ]
[ patent document ]
[PTL 1]JP2003-171866A
Disclosure of Invention
[ problem ] to
However, with this method, a burr (flip-ups) protruding in a direction of pressing in the pin member is formed at an edge portion of the through hole. If the protruding height of these burrs is large, there is a risk of deterioration in the texture of the nonwoven fabric sheet, and eventually the texture of the absorbent article as a product is impaired.
The present invention has been achieved in view of the conventional problems as described above, and an object of the present invention is to reduce the protrusion height of burrs formed at edge portions of through-holes when forming the through-holes in a nonwoven fabric sheet for an absorbent article.
[ solution of problem ]
The main aspect of the present invention is a method of forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the method comprises the following steps:
a step for forming the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on the outer circumferential surface of the rotating first rotating body,
the hole portion is formed in the outer circumferential surface of the rotating second rotating body; and
a step for urging gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion.
Further, an apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the device comprises:
in a mechanism, a mechanism is provided,
the mechanism forms the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on the outer circumferential surface of the rotating first rotating body,
the hole portion is formed in the outer circumferential surface of the rotating second rotating body, and
the mechanism causes gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion.
Other features of the present disclosure will become apparent from the description of the present specification with reference to the accompanying drawings.
[ advantageous effects of the invention ]
According to the present invention, the protruding height of the burr formed at the edge portion of the through-hole when the through-hole is formed in the nonwoven fabric sheet for an absorbent article can be reduced.
Drawings
Fig. 1 is a schematic perspective view of a pants-shaped state of a three-piece type disposable diaper 1 as viewed from the front side, the three-piece type disposable diaper 1 being one example of an absorbent article.
Fig. 2 is a schematic plan view of the diaper 1 in a developed state as viewed from the skin side.
Fig. 3 is a sectional view taken along III-III in fig. 2.
Fig. 4A is a schematic plan view of an intermediate product 1m before the process for forming the through-hole h of the first embodiment is performed by the forming apparatus 50.
Fig. 4B is a schematic plan view of the intermediate product 1m after the above-described processing.
Fig. 5 is a schematic side view of a forming device 50, in which forming device 50 parts of the configuration are shown in longitudinal section.
Fig. 6 is a partially enlarged view taken along arrows VI-VI in fig. 5.
Fig. 7 is a view showing an arrangement pattern of the pin members 55p on the outer circumferential surface of the intermediate roller 55.
Fig. 8 is a view showing an arrangement pattern of the hole portions 51h in the outer circumferential surface of the upstream roller 51.
In fig. 9, fig. 9A is an enlarged view of a portion IXa in fig. 7, and fig. 9B is a view taken along an arrow B-B in fig. 9A.
Fig. 10 is a schematic enlarged view showing that a protruding burr B is formed at an edge portion of the air hole h when the pin member 55p is pressed into the intermediate product 1m to form the air hole h.
Fig. 11 is a view showing innovations of the first embodiment for reducing the projection height of the burr B.
Fig. 12 is a view showing an example in which the receiving portion 55r is integral with the pin member 55p and is inseparable from the pin member 55p.
Fig. 13 is a view showing the innovation of the second embodiment.
Fig. 14 is a view showing still another embodiment.
Fig. 15 is a view showing still another embodiment.
Detailed Description
A method of forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the method comprises the following steps:
a step for forming the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on the outer circumferential surface of the rotating first rotating body,
the hole portion is formed in the outer circumferential surface of the rotating second rotating body; and
a step for urging gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, when a gas flows between the pin member and the hole portion, a part of the gas may flow between the pin member and the nonwoven fabric sheet by, for example, passing through gaps between fibers of the nonwoven fabric sheet. Therefore, due to the flow of the passing gas, frictional resistance that may be generated between the pin member and the nonwoven fabric sheet when the pin member is pressurized can be reduced. In other words, the pulling of the edge portion of the through hole in the direction of pressing into the pin member during this pressing can be suppressed. As a result, the protrusion height of the burr that can be formed at the edge portion of the through-hole can be reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The nonwoven fabric sheet has thermoplastic resin fibers and
the gas is a heated gas heated by a heating device.
According to the method of forming through holes in a nonwoven fabric sheet for an absorbent article, the gas is a heated gas. For this reason, the thermoplastic resin fibers of the nonwoven fabric sheet can be softened by the flow of the heated gas, thereby making it easier to form through holes in the nonwoven fabric sheet. Specifically, when the pin member is pressed in, the thermoplastic resin fibers can be easily moved or deformed in the direction for increasing the hole diameter. Therefore, the frictional resistance that can be generated between the pin member and the nonwoven fabric sheet during this pressing can be further reduced, and as a result, the protruding height of the burr can be further reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The nonwoven fabric sheet has thermoplastic resin fibers and
the pin member is heated by a heating device.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, the thermoplastic resin fibers of the nonwoven fabric sheet can be softened by the heated pin members. Therefore, when the pin member is pressed into the nonwoven fabric sheet, the thermoplastic resin fibers are easily pressed circumferentially outward. Therefore, the frictional resistance that can be generated between the pin member and the nonwoven fabric sheet during this pressing can be further reduced, and as a result, the protruding height of the burr can be further reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The gas flows from the hole portion toward the pin member.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, gas flows from the hole portion of the second rotating body toward the pin member of the first rotating body, and thus the gas flows in a direction opposite to the direction in which the pin member is pressed, that is, in a reverse direction against pressurization. Therefore, the protrusion height of the burr that may protrude in the direction of press-in at the edge portion of the through-hole may also be reduced by the pressure of the flowing gas.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The gas flows from the pin member toward the hole portion.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, gas flows from the pin member of the first rotating body toward the hole portion of the second rotating body. Specifically, the gas flows in the same forward direction as the direction in which the pin member is pressed. Here, as described above, a part of the gas may flow between the pin member and the nonwoven fabric sheet by passing through the gaps between the fibers of the nonwoven fabric sheet. Therefore, due to the flow of the passing gas, frictional resistance that may be generated between the pin member and the nonwoven fabric sheet when the pin member is pressurized can be reduced. As a result, the protrusion height of the burr that can be formed at the edge portion of the through-hole can be reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The gas is a heated gas heated by a heating device,
the second rotating body is heated by the heating gas,
the nonwoven fabric sheet is wrapped on the outer circumferential surface of the second rotating body via a predetermined wrapping angle on an upstream side of a closest position with respect to a rotating direction of the second rotating body,
the closest position is the position of the second rotating body closest to the first rotating body, and
the non-woven fabric sheet is heated by the second rotating body by being wrapped on the outer circumferential surface.
According to the method of forming the through-hole in the nonwoven fabric sheet for the absorbent article, the nonwoven fabric sheet is heated and softened by being wrapped on the outer circumferential surface of the second rotating body. Then, the nonwoven fabric sheet in this softened state reaches the closest position in the rotational direction, and at the closest position, the pin member is pressed into the nonwoven fabric sheet to form the through-hole. During the pressurization, the thermoplastic resin fibers may be easily moved or deformed due to being softened. For this reason, the frictional resistance that may be generated between the pin member and the nonwoven fabric sheet during pressurization can be further reduced, and as a result, the protruding height of the burr can be further reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The heated air is ejected from the hole portion in the second rotating body when the hole portion passes through a range of the wrapping angle in the rotating direction of the second rotating body.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, heated air is ejected from the hole portions toward the portions of the nonwoven fabric sheet wrapped on the second rotating body through the winding angle. Therefore, the portion of the nonwoven fabric sheet can be further softened by the heated air, and as a result, the frictional resistance that can be generated between the pin member and the nonwoven fabric sheet when the pin member is pressed into the hole portion can be further reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
A plurality of receiving portions are formed as protrusions on the outer circumferential surface of the first rotating body,
the receiving portions each have a holding face capable of receiving and holding one surface of the nonwoven fabric sheet without penetrating the nonwoven fabric sheet, and
a gap is provided between at least two of the receiving portions that are adjacent to each other.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, the nonwoven fabric sheet is received and held not only by the pin members but also by the receiving portions. Therefore, the nonwoven fabric sheet can be stably held in place in the rotational radial direction of the first rotating body as a whole.
Also, a gap is provided between two of the receiving portions on the outer circumferential surface of the first rotating body. The gap may function as a passage for gas on the outer circumferential surface of the first rotating body. Therefore, in the case where the gas flows from the hole portion of the second rotating body toward the pin member of the first rotating body, the gas reaching the pin member passes through the gap on the outer circumferential surface of the first rotating body, and thereby can be quickly discharged from the outer circumferential surface of the first rotating body to the surrounding external space. In contrast, in the case where the gas flows from the pin member of the first rotating body toward the hole portion of the second rotating body, the gas passes through the gap on the outer circumferential surface of the first rotating body, and thereby the gas in the space surrounding the outer circumferential surface of the first rotating body can be quickly supplied to the pin member. In other words, regardless of the direction of the gas flow, a situation in which the flow of the gas is obstructed on the outer circumferential surface of the first rotating body can be avoided. As a result, difficulty in the flow of gas between the hole portion and the pin member can be efficiently prevented.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
A receiving portion among the receiving portions is formed to be integral with the pin member and inseparable from the pin member.
According to this method of forming the through-hole in the nonwoven fabric sheet for an absorbent article, the receiving portion and the pin member are formed to be integral and inseparable, and thus the receiving portion can receive the nonwoven fabric sheet in the vicinity of the pin member. Therefore, a substantially constant pressing amount of the nonwoven fabric sheet by the pin member can be maintained, thereby making it possible to suppress variations in the hole diameter of the through-hole.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
A receiving portion among the receiving portions is separated from the pin member.
According to this method of forming the through-hole in the nonwoven fabric sheet for an absorbent article, the receiving portion and the pin member are separated from each other. Therefore, compared to the case where the receiving portion is formed to be integral with the pin member and inseparable from the pin member, the receiving portion and the pin member can be formed with simpler shapes, and as a result, the receiving portion and the pin member can be formed with higher dimensional accuracy.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
The gas is a heated gas heated by a heating device, and
when the heated gas flows at a position between the pin member and the hole portion, the temperature of the heated gas is greater than or equal to the softening point of the thermoplastic resin fibers contained in the nonwoven fabric sheet and less than the melting point of the thermoplastic resin fibers.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, the temperature of the heated gas is greater than or equal to the softening point of the thermoplastic resin fibers of the nonwoven fabric sheet and less than the melting point of the thermoplastic resin fibers of the nonwoven fabric sheet. Therefore, by setting the temperature to be lower than the melting point, thermal damage to the nonwoven fabric sheet caused by the heated gas can be suppressed. In addition, by setting the temperature to be greater than or equal to the softening point, the frictional resistance generated when the through-holes are formed in the nonwoven fabric sheet can be reliably reduced.
In such a method of forming through-holes in a nonwoven fabric sheet for an absorbent article, it is desirable that
A plurality of the pin members are provided on the outer circumferential surface of the first rotating body,
a plurality of the hole portions are provided on the outer circumferential surface of the second rotating body, and
the hole portions are provided such that only one of the pin members is inserted into each of the hole portions when the pin members are inserted into the hole portions.
According to this method of forming through-holes in a nonwoven fabric sheet for an absorbent article, the hole portions are provided such that only one pin member is inserted into each hole portion when the pin member is inserted into the hole portions. Therefore, the gas can more reliably flow between the pin member and the nonwoven fabric sheet than in the case where a plurality of pin members are inserted into one hole portion. Thus, the gas may more efficiently contribute to reducing frictional resistance that may be generated between the pin member and the nonwoven fabric sheet when the pin member is pressurized.
An apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the device comprises:
in a mechanism, a mechanism is provided,
the mechanism forms the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on the outer circumferential surface of the rotating first rotating body,
the hole portion is formed in the outer circumferential surface of the rotating second rotating body, and
the mechanism causes gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion.
According to the apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article, actions and effects similar to those of the above-described forming method can be achieved.
First embodiment
The method and apparatus 50 for forming the through-holes h in the nonwoven fabric sheet 1m for an absorbent article according to the first embodiment of the present invention are used in a manufacturing line for manufacturing a disposable diaper 1, which disposable diaper 1 is one example of an absorbent article. Fig. 1 is a schematic perspective view of a pants-shaped state of a three-piece diaper 1 as viewed from the front side, the three-piece diaper 1 being one example of a disposable diaper 1. Also, fig. 2 is a schematic plan view of the diaper 1 in a developed state as viewed from the skin side. Fig. 3 is a sectional view taken along III-III in fig. 2.
In the pants-shaped state shown in fig. 1, the diaper 1 has a vertical direction, a lateral direction, and a front-rear direction as three directions orthogonal to each other. Hereinafter, the upper side and the lower side in the up-down direction in the pants-shaped state will also be referred to as "waist opening side" and "crotch side", respectively, and the front side and the rear side in the front-back direction in the pants-shaped state will also be referred to as "front side" and "rear side", respectively.
Also, in the developed state shown in fig. 2 and 3, the diaper 1 has a longitudinal direction, a lateral direction, and a thickness direction as three directions orthogonal to each other. Hereinafter, one side and the other side in the longitudinal direction in the developed state will also be referred to as "front side" and "rear side", respectively, and one side and the other side in the thickness direction will also be referred to as "skin side" and "non-skin side", respectively.
It is noted that the transverse direction has the same meaning in the pant-shaped state and in the unfolded state. Also, the longitudinal direction in the developed state coincides with the up-down direction in the pants-shaped state, and the thickness direction in the developed state coincides with the front-back direction in the pants-shaped state.
Further, in the unfolded state shown in fig. 2 and 3, the diaper 1 is shown in a state of being stretched out to such an extent that the elastic cords 16, 35 and 45 do not exert any contractive force at all anyway, the elastic cords 16, 35 and 45 serving as elastic members for imparting stretchability to the diaper 1 described later.
Since the diaper 1 is a so-called three-piece diaper, in the unfolded state shown in fig. 2, the diaper 1 has the absorbent main body 10 for absorbing excrement as a first component, the front belt member 31 as a second component, and the back belt member 41 as a third component. Specifically, in a state where the front belt member 31 and the rear belt member 41 are arranged parallel to each other in the longitudinal direction with a gap therebetween, the absorbent main body 10 spans between the member 31 and the member 41, and the end portions 10ea and 10eb of the absorbent main body 10 in the longitudinal direction are respectively joined and fixed to the closest belt member of the belt members 31 and 41, thereby having a substantially H-shaped appearance in plan view.
In this substantially H-shaped unfolded state, the absorbent body 10 is folded in half at a folded position which is a predetermined position CL10 in the longitudinal direction of the absorbent body 10 (which is a position corresponding to the center position CL1 in the longitudinal direction of the diaper 1), and when the belt members 31 and 41 facing each other in this folded state are joined in the lateral end portions 31e and 41e by welding, the belt members 31 and 41 are joined together to form a ring shape, thereby obtaining the diaper 1 in a pant-shaped state in which the waist opening BH and the pair of leg openings LH are formed as shown in fig. 1.
Note that, in the developed state shown in fig. 2 and 3, the absorbent main body 10 is substantially rectangular in plan view. The longitudinal direction of the absorbent main body 10 coincides with the longitudinal direction. Further, the absorbent main body 10 includes an absorbent body 11, a top sheet 13 covering the absorbent body 11 from the skin side, and a back sheet 15 covering the absorbent body 11 from the non-skin side.
The absorbent body 11 has an absorbent core 11c that absorbs liquid, and a core wrap sheet that is made of tissue paper or the like (not shown) and covers the outer circumferential surface of the core 11 c. The absorbent core 11c is a molded body made of a predetermined liquid absorbent material and having a substantially hourglass shape in plan view, as one example of a predetermined shape. Examples of the liquid absorbent material include liquid absorbent fibers such as pulp fibers and liquid absorbent particles made of super absorbent polymer (so-called SAP) or the like.
The topsheet 13 is a liquid-permeable sheet made of nonwoven fabric and having a planar dimension according to which the liquid-permeable sheet protrudes from the absorbent body 11 in the longitudinal direction and the transverse direction. The back sheet 15 is also a sheet having a planar dimension according to which the sheet protrudes from the absorbent body 11 in the longitudinal direction and the transverse direction, and one example is a two-layer structural laminate sheet 15 shown in fig. 3. Specifically, the laminate sheet 15 has a liquid impermeable leakproof sheet 15a made of a polyethylene film (PE) or a polypropylene film (PP) on the skin side and an outer sheet 15b made of a nonwoven fabric on the non-skin side.
When the absorbent body 11 is sandwiched between the top sheet 13 and the back sheet 15, portions of the top sheet 13 and the back sheet 15 protruding from the absorbent body 11 in the longitudinal direction and the transverse direction are joined together by an adhesive, welding, or the like to obtain a frame-like shape, thereby forming the absorbent main body 10. Note that the outer sheet 15b may be omitted, and the back sheet 15 may have only the leakage-preventing sheet 15 a.
Also, as shown in this example in fig. 2, the portion 10LG of the absorbent main body 10 laterally outward from the absorbent body 11 may be provided with leg gathers LG that expand and contract in the longitudinal direction. These leg gathers LG constitute a part of the leg opening LH. Also, the leg gathers LG are imparted with stretchability by fixing an elastic member 16 (elastic cord or the like) extending in the longitudinal direction to the portion 10LG in a state stretched in the longitudinal direction. Note that, in addition to these leg gathers LG, in order to prevent lateral leakage, so-called barrier cuffs (not shown) may be provided as leakage preventing wall portions on both lateral sides of the absorbent main body 10.
Also, as shown in fig. 2, the front belt member 31 is a sheet member having a substantially rectangular shape in plan view and composed of nonwoven fabric sheets 32 and 33. In this example, as shown in fig. 3, the front belt member 31 is formed by joining two superposed nonwoven fabric sheets 32 and 33 together using a hot melt adhesive. Also, as shown in fig. 2 and 3, the widthwise central portion of the front belt member 31 is covered from the non-skin side and joined to the front longitudinal end portion 10ea of the absorbent main body 10.
The rear belt member 41 is also a sheet member having a substantially rectangular shape in plan view and composed of nonwoven fabric sheets 42 and 43, similarly to the front belt member 31, and in this example, as shown in fig. 3, the rear belt member 41 is formed by joining two superposed nonwoven fabric sheets 42 and 43 together using a hot melt adhesive. Also, as shown in fig. 2 and 3, the widthwise central portion of the back belt member 41 is covered from the non-skin side and joined to the rear longitudinal end portion 10eb of the absorbent main body 10.
Note that the following description is the same for both the front belt member 31 and the rear belt member 41. For this reason, only the front belt member 31 is described below as representative of both, and the corresponding portion of the rear belt member 41 is indicated only in parentheses.
As shown in fig. 2 and 3, a plurality of elastic members (elastic strings, etc.) 35, 35.. said. (45, 45.. said..) extending in the transverse direction are inserted side by side in the longitudinal direction between the two nonwoven fabric sheets 32 and 33(42 and 43) of the front belt member 31(41), and are joined and fixed to the nonwoven fabric sheets 32 and 33(42 and 43) using a hot-melt adhesive in a state of being stretched in the transverse direction. Therefore, the front belt member 31(41) is imparted with stretchability in the lateral direction.
Also, in this example, as shown in fig. 4, the elastic member 35(45) is discontinuous in a portion (e.g., a laterally central portion) of the front belt member 31(41) that overlaps with the absorbent body 11, so as to prevent wrinkles, for example, from being formed in the absorbent body 11. Therefore, this portion is not imparted with stretchability. But there is no limitation thereto in any way.
Further, in this example, as shown in fig. 3, the planar size of the nonwoven fabric sheet 33(43) on the non-skin side in the thickness direction as one of the two nonwoven fabric sheets 32 and 33(42 and 43) is a size according to which the nonwoven fabric sheet 33(43) protrudes longitudinally outward from the nonwoven fabric sheet 32(42) on the skin side. Moreover, the protruding portions of the nonwoven fabric sheet 33(43) are folded back inward in the longitudinal direction, and the folded portions 33B (43B) cover the longitudinal end portions 32Le (42Le) of the nonwoven fabric sheet 32(42) from the skin side, but there is no limitation thereto in any way.
Also, as shown in fig. 2, in each of both lateral sides of the front belt member 31(41), there is a portion 31s (41s) (hereinafter, also referred to as a non-absorbent body portion 31s (41s)) which is not overlapped by the absorbent main body 10. In order to improve the air permeability in the non-absorbent body section 31s (41s), a plurality of air holes h (h) passing through the non-absorbent body section 31s (41s) are discretely formed in a predetermined arrangement pattern, and these air holes h (h) form an air hole group Gh31(Gh41), which is a group of air holes h. Specifically, in this example, in each of the non-absorbent body portions 31s (41s), a plurality of air holes h, h..... (h, h........) are formed side by side at a portion between a pair of the elastic members 35(45) disposed side by side in the longitudinal direction at a predetermined formation pitch, and thus these air holes h, h..... (h, h........) form air hole rows Rh31(Rh41) extending in the transverse direction. Also, pairs of the air hole rows Rh31(Rh41) adjacent in the longitudinal direction are shifted from each other by half the forming pitch in the lateral direction. Thus, the air holes h, h..... (h, h......) form an air hole group Gh31(Gh41) having a substantially staggered arrangement. Note that there is no limitation to this in any way. For example, the air holes h, h.
Further, in this example, the air holes h, h. The diameters of such non-perfect circular air holes h vary depending on the positions of the air holes h on the circumference, but even so the varying diameters fall within the range of 0.2mm to 3mm, for example. Therefore, the pores h can rapidly exhibit the intended air permeability. It should be noted that the target opening shape of the air hole h is not limited to the above-described perfect circle in any way. For example, the target opening shape may be any polygon, such as an equilateral triangle or square.
Also, in this example, the two nonwoven fabric sheets 32 and 33 for the front belt member 31 and the two nonwoven fabric sheets 42 and 43 for the rear belt member 41 are each made of a spunbond nonwoven fabric. It should be noted that this is not restricted in any way and different types of nonwoven can be used, for example SMS (spunbond/meltblown/spunbond) nonwoven. Also, as a representative example of the thermoplastic resin, a separate fiber made of polypropylene (PP) is used as the fiber constituting the nonwoven fabric, but there is no limitation thereto in any way. For example, a separate fiber made of another type of thermoplastic resin (e.g., Polyethylene (PE)) may be used, and in addition, a composite fiber containing PE and PP having a core-sheath structure can be used.
The diaper 1 is manufactured in a manufacturing line. In this manufacturing line, the intermediate products 1m of the diapers 1 are conveyed in a predetermined conveying direction. During this conveyance, various types of processing are performed on the intermediate product 1m, whereby the shape of the intermediate product 1m is successively changed each time the processing is performed, and finally, the diaper 1 shown in fig. 1 is completed. The forming device 50 for forming the through hole h of the first embodiment performs one of these steps.
Fig. 4A and 4B are schematic plan views of the intermediate product 1m, and show a process for forming the through-hole h of the first embodiment, which is performed by the forming apparatus 50. Note that fig. 4A shows an intermediate product 1m before processing, and fig. 4B shows an intermediate product 1m after processing. Moreover, fig. 5 is a schematic side view of the forming device 50, wherein portions of the configuration (the upstream roller 51 and the downstream roller 58) are shown in longitudinal cross-section. Further, fig. 6 is a partially enlarged view taken along arrows VI-VI in fig. 5. Note that, hereinafter, the width direction of the manufacturing line is also referred to as "CD direction". Further, in this example, the CD direction coincides with the horizontal direction. In this manufacturing line, the conveying direction in which the intermediate product 1m is conveyed is any direction in a plane orthogonal to the CD direction. In other words, the conveying direction is a direction defined by both a vertical up-down direction and a horizontal front-rear direction. Note that the terms "up-down direction" and "front-back direction" used herein are directions that are different from and not directly related to the terms "up-down direction" and "front-back direction" used in the above description of the diaper 1.
As can be understood from a comparison of the state before the process of fig. 4A and the state after the process of fig. 4B, in this forming apparatus 50 for forming the through-holes h, the aforementioned air holes h, h. Here, in the manufacturing line, the intermediate product 1m is conveyed using so-called side stream conveyance. Specifically, the intermediate product 1m is conveyed in an orientation such that the lateral direction of the diaper 1 coincides with the conveying direction and the longitudinal direction coincides with the CD direction. For this reason, as shown in fig. 4A, when fed from an upstream step to the forming device 50, the intermediate product 1m is basically constituted by one sheet-like member 1m in which a front belt member continuous body 31a having a plurality of front belt members 31 connected in the transverse direction and a rear belt member continuous body 41a having a plurality of rear belt members 41 connected in the transverse direction are connected as a single body in the CD direction.
More specifically, the sheet-like member 1m has a nonwoven continuous sheet 1mw1 and a nonwoven continuous sheet 1mw 2: the continuous nonwoven fabric sheet 1mw1 has a dimension in the CD direction corresponding to the sum of the longitudinal dimension of the nonwoven fabric sheet 32 of the front belt member 31 and the longitudinal dimension of the nonwoven fabric sheet 42 of the rear belt member 41; and the continuous nonwoven fabric sheet 1mw2 has a dimension in the CD direction corresponding to the sum of the longitudinal dimension of the nonwoven fabric sheet 33 of the front belt member 31 and the longitudinal dimension of the nonwoven fabric sheet 43 of the rear belt member 41. The continuous sheets 1mw1 and 1mw2 are joined to each other using a hot melt adhesive or the like in a state of being overlapped with each other, so as to be overlapped in the thickness direction. Further, the elastic member continuous bodies 35a and 45a forming the aforementioned elastic members 35 and 45 are inserted side by side in the CD direction between the continuous sheets 1mw1 and 1mw2 and fixed to the continuous sheets 1mw1 and 1mw2 in a state stretched in the conveying direction and continuous in the conveying direction. Further, among the two continuous sheets 1mw1 and 1mw2, one continuous sheet 1mw2 has a larger dimension in the CD direction than the other continuous sheet 1mw1, and therefore one continuous sheet 1mw2 has portions 1mw2p1 and 1mw2p2 protruding from the other continuous sheet 1mw1 on both sides in the CD direction. These protruding portions 1mw2p1 and 1mw2p2 are folded inward in the CD direction, thereby forming portions corresponding to the aforementioned folded portions 33B and 43B.
Then, in the forming device 50, in an area thereof on one side in the CD direction as shown in fig. 4B, a pair of air hole groups Gh31 belonging to the front belt member 31 are repeatedly formed in an intermediate product 1m shown in fig. 4A, which intermediate product 1m is a sheet-like member 1m, at a product pitch P1 in the conveying direction. Further, in the area on the other side, a pair of air hole groups Gh41 belonging to the rear belt member 41 is formed at a product pitch P1 in the conveying direction. Note that the product pitch P1 referred to herein is a value substantially the same as the total lateral lengths L31 and L41 of the front belt member 31 and the rear belt member 41 in the unfolded state shown in fig. 2.
As shown in fig. 5, the forming device 50 has three rollers 51, 55, and 58, and the three rollers 51, 55, and 58 are driven to rotate about a rotation axis extending in the CD direction. Specifically, the rollers 51, 55, and 58 are arranged side by side in this order from upstream to downstream in the conveying direction as an upstream roller 51 (corresponding to the second rotating body), an intermediate roller 55 (corresponding to the first rotating body), and a downstream roller 58. Also, the intermediate roller 55 is disposed adjacent to the upstream roller 51 and the downstream roller 58 such that the outer circumferential surfaces thereof face each other. Due to the rotating operation of these three rollers 51, 55 and 58, the intermediate product 1m sent to the forming device 50 is conveyed along a substantially Ω -shaped conveying route. Specifically, intermediate product 1m is first conveyed along arcuate first conveyance route R51 for becoming wrapped on upstream roller 51, then conveyed along arcuate second conveyance route R55 for becoming wrapped on intermediate roller 55, and finally conveyed along arcuate third conveyance route R58 for becoming wrapped on downstream roller 58. Thereafter, the intermediate product 1m is separated from the downstream roller 58 and sent to the downstream step.
Note that the upstream roller 51 and the intermediate roller 55 are closest to each other at a predetermined position P51 in the rotating direction Dc51 of the upstream roller 51, and this closest position P51 (corresponding to the closest position; hereinafter referred to as the closest position) is a position at which the first conveying route R51 is switched to the second conveying route R55. Similarly, the intermediate roller 55 and the downstream roller 58 are closest to each other at a predetermined position P55 in the rotational direction Dc55 of the intermediate roller 55, and the closest position P55 is a position at which the second conveyance route R55 is switched to the third conveyance route R58.
The intermediate roller 55 has a plurality of pin members 55p, 55p. The pin members 55p, 55p. Specifically, as shown in the enlarged view of fig. 6, in this example, the pin members 55p each include a conical portion 55pa on the tip end side and a cylindrical portion 55pb on the base end side, the cylindrical portion 55pb having the same diameter as that of the bottom face of the conical portion 55pa, and these portions are integrated with each other. Also, hole portions 51h, 51h. Specifically, the hole portion 51h has a diameter larger than that of the conical portion 55pa of the pin member 55p within the range of insertion of the pin member 55p. Also, the hole portions 51h are formed to correspond to the pin members 55P such that only one pin member 55P is inserted into each hole portion 51h at the above-described closest position P51.
Therefore, when the formation target portion of the intermediate product 1m located on the upstream roller 51 shown in fig. 5, at which the air holes h are to be formed, passes through the closest position P51, the corresponding pin member 55P is inserted into the hole portion 51h of the upstream roller 51, as shown in fig. 6. Therefore, the pin member 55p is smoothly pressed into the formation target portion of the intermediate product 1m, so that the air hole h is rapidly formed in the formation target portion.
Also, the apex angle of the conical portion 55pa in fig. 6 is selected, for example, from the range of 20 ° to 45 °, and is 36 ° in this example. Also, the height of the conical portion 55pa is selected, for example, from the range of 3mm to 8mm, and is 4.6mm in this example. Note that there is no limitation to this in any way. Further, although the edge portion of the hole portion 51h is chamfered in this example, there is no limitation to this in any way, or in other words, the edge portion need not be chamfered.
Also, in this example, the intermediate roller 55 in fig. 5 is a larger diameter roller having a circumferential length corresponding to about twice the above-described product pitch P1, so that two pairs of air hole groups Gh31 and two pairs of air hole groups Gh41 corresponding to the two diapers shown in fig. 4B can be formed over one full rotation. Further, the upstream roller 51 in fig. 5 is a smaller diameter roller having a circumferential length substantially corresponding to the product pitch so that a pair of air hole groups Gh31 and a pair of air hole groups Gh41 corresponding to one diaper shown in fig. 4B can be formed over one full rotation. Note that there is no limitation to this in any way.
Fig. 7 is a view showing an arrangement pattern of the pin members 55p on the outer circumferential surface of the intermediate roller 55, and fig. 8 is a view showing an arrangement pattern of the hole portions 51h on the outer circumferential surface of the upstream roller 51. Note that these two views show the outer circumferential surfaces of the rollers 55, 51 in a state of being stretched flat. Also, in order to prevent complexity in view, a later-described receiving portion 55r is not shown in fig. 7.
As shown in fig. 7, the pin members 55p are provided corresponding to the gas hole groups Gh31 and Gh41 formed in the aforementioned intermediate product 1 m. Specifically, as shown in fig. 4B, in the area of the intermediate product 1m on one side in the CD direction, a pair of air hole groups Gh31 for the front belt member 31 will be formed in each diaper, and therefore, as shown in fig. 7, in the area of the outer circumferential surface of the intermediate roller 55 on one side in the CD direction, a pair of pin member groups G55p1 are provided side by side in the rotation direction Dc55, each of the pin member groups G55p1 having pin members 55p in the same staggered arrangement as the air hole groups Gh 31. Similarly, in the area of the intermediate product 1m on the other side in the CD direction, a pair of air hole groups Gh41 for the rear belt member 41 will be formed in each diaper, and therefore, in the area of the outer circumferential surface of the intermediate roller 55 on the other side in the CD direction, a pair of pin member groups G55p2 are provided side by side in the rotation direction Dc55, each of the pin member groups G55p2 having the pin members 55p in the same staggered arrangement as the air hole groups Gh 41.
Also in this example, as previously described, the intermediate roller 55 is provided with air holes h corresponding to two diapers for each full rotation. Therefore, in order to make one pin member group set SG55p1(SG55p2) one set of two pin member groups G55p1, G55p1(G55p 2) juxtaposed in the rotation direction Dc55, the outer circumferential surface of the intermediate roller 55 is provided with two pin member group sets SG55p1, SG55p1(SG55p2) juxtaposed at a uniform pitch of 180 ° in the rotation direction Dc 55.
Further, fig. 9A shows an enlarged view of a portion XVIIa in fig. 7, and fig. 9B shows a view taken along an arrow B-B in fig. 9A. As shown in fig. 9A, a receiving portion 55r separated from the pin members 55p is formed as a protrusion in the outer circumferential surface of the intermediate roller 55 at a position between the adjacent pin members 55p. Also, as shown in fig. 9B, the receiving portions 55r are each a substantially cylindrical body having a top surface 55rt (corresponding to a holding surface) facing outward in the rotational radial direction Dr55 of the intermediate roller 55 at a front end portion. Therefore, the intermediate product 1m is received and supported not only by the pin member 55p but also by the receiving portion 55 r. For this reason, the intermediate product 1m can be stably supported at a proper position of the intermediate roller 55 in the rotational radial direction Dr55 as a whole. Also, at this time, the top surface 55rt of the receiving portion 55r receives one surface of the intermediate product 1m without penetrating the intermediate product 1m, and thereby also efficiently contributes to stably supporting the intermediate product 1m in position.
Also, in this example, as shown in fig. 9A, the receiving portions 55r are provided at four positions around each pin member 55p, thereby enabling the intermediate product 1m to be reliably received, but there is no limitation whatsoever as to the four positions. For example, the number of positions may be smaller if the arrangement space cannot be secured, or on the other hand, the number of positions may be larger if the arrangement space can be secured.
Further, in the example shown in fig. 9B, the position of the top surface 55rt of the receiving portion 55r is inward in the rotational radial direction Dr55 of the intermediate roller 55 with respect to the position of the apex of the pin member 55p. Therefore, this prevents the receiving portion 55r from interfering with the process for forming the air holes h using the pin member 55p. Note that here, it is desirable that the top surface 55rt of the receiving portion 55r is located near the bottom face of the conical portion 55pa of the pin member 55p, and for example, it is desirable that the position of the top surface 55rt in the rotational radial direction Dr55 is within a range of ± 2mm centered on the position of the bottom face. In this example, the top surface 55rt matches the bottom surface of the conical portion 55 pa. Therefore, the receiving portion 55r can reliably receive the intermediate product 1m without interfering with the process for forming the air holes h using the pin members 55p. Therefore, the pin member 55p can quickly form the air holes h in the intermediate product 1 m.
Also, in this example, the top surface 55rt of the receiving portion 55r is shaped as a perfect circle having a diameter selected from the range of 2mm to 5mm, for example, but there is no limitation thereto in any way. For example, the top surface 55rt of the receiving portion 55r may be shaped as a polygon such as an equilateral triangle or square, or may have other shapes.
Also, as shown in fig. 8, a hole portion 51h in the outer circumferential surface of the upstream roller 51 is provided corresponding to the pin member 55p. Specifically, as shown in fig. 7, in the area of the outer circumferential surface of the intermediate roller 55 on the one side in the CD direction, two pin member groups G55p1 are provided side by side in the rotation direction Dc55, and therefore, in correspondence with this, in the area of the outer circumferential surface of the upstream roller 51 on the one side in the CD direction, two hole section groups G51h1 are provided side by side in the rotation direction Dc51, each of the hole section groups G51h1 having a plurality of hole sections 51h in a staggered arrangement. Similarly, as shown in fig. 15, in the area of the outer circumferential surface of the intermediate roller 55 on the other side in the CD direction, two pin member groups G55p2 are provided side by side in the rotation direction Dc55, and therefore, in correspondence with this, in the area of the outer circumferential surface of the upstream roller 51 on the other side in the CD direction, two hole section groups G51h2 are provided side by side in the rotation direction Dc51, each of the hole section groups G51h2 having a plurality of hole sections 51h in a staggered arrangement.
It should be noted that, as described previously, the upstream roller 51 contributes to forming the air holes h corresponding to one diaper for each full rotation, and therefore, in order for one hole section group set SG51h1(SG51h2) to be one set of two hole section groups G51h1, G51h1(G51h 2) side by side in the rotation direction Dc51, the outer circumferential surface of the upstream roller 51 is provided with only one hole section group set SG51h1(SG51h 2).
Also, the configuration of the downstream roller 58 in fig. 5 is substantially the same as that of the upstream roller 51. For example, the outer circumferential surface of the downstream roller 58 is provided with hole part groups G58h1 and G58h2, which hole part groups G58h1 and G58h2 have the same specifications as the hole part groups G51h1 and G51h2 in the outer circumferential surface of the upstream roller 51. Therefore, when the intermediate product 1m is received from the intermediate roller 55, the pin members 55p of the intermediate roller 55 are smoothly inserted into the hole portions 58h in the hole portion groups G58h1 and G58h2, thereby making it possible to receive the intermediate product 1m without changing the shape of the air holes h formed in the intermediate product 1m to a large extent.
Also, as shown in the schematic enlarged view in fig. 10, when the pin member 55p is pressed into the intermediate product 1m to form the air hole h, a burr B protruding in a direction of pressing the pin member 55p is formed at an edge portion of the air hole h. If the protruding height of the burr B is large, there is a risk that the texture of the nonwoven fabric sheet of the intermediate product 1m deteriorates, and eventually the texture of the diaper 1 as a product is impaired. The higher the frictional resistance F between the pin member 55p and the intermediate product 1m, the larger the projection height of the burr B is considered to be.
In view of this, in the first embodiment, an innovation for reducing the frictional resistance F has been devised. Fig. 11 is an explanatory view of this innovation, and shows a schematic enlarged view of the state of the pin member 55P and the hole portion 51h at the aforementioned closest position P51 in the rotating direction Dc51 on the upstream roller 51.
In the first embodiment, as in the above innovation, when the hole portions 51h pass at least the closest position P51 in the rotating direction Dc51, as one example of the gas, air is ejected from the hole portions 51h in the upstream roller 51 in fig. 5 as shown in fig. 11. Specifically, in this example, as the hole portion 51h passes through the range θ e of ± 5 ° centered on the closest position P51 in the rotational direction Dc51, air is ejected from the hole portion 51h. Therefore, when the pin member 55p is inserted into the hole portion 51h to form the air hole h in the intermediate product 1m, air flows from the hole portion 51h toward the pin member 55p.
Therefore, as shown in fig. 11, a part of this air may flow between the pin member 55p and the intermediate product 1m by, for example, passing through gaps between fibers of the nonwoven fabric sheet forming the main body of the intermediate product 1 m. Due to this flow of the passing air, the frictional resistance F that may be generated between the pin member 55p and the intermediate product 1m when the pin member 55p is pressurized can be reduced. In other words, it is possible to suppress a situation in which the edge portion of the air hole h formed in the intermediate product 1m during this pressing is pulled in the direction of pressing into the pin member 55p. As a result, the protruding height of the burr B that may be formed at the edge portion of the air hole h can be reduced.
Also, in the case of the example shown in fig. 11, the air flows in the direction opposite to the direction in which the pin member 55p is pressed. In other words, the flow is a counter flow against the pressurization. Therefore, the protruding height of the burr B can also be reduced with the pressure of the airflow.
Note that, for example, the following configuration is adopted so as to eject air outward from the hole portion 51h in the outer circumferential surface of the upstream roller 51 only in the range θ e in the rotating direction Dc 51. First, inside the upstream roller 51 in fig. 5, a plurality of chambers 51C (not shown) are provided side by side in the rotation direction Dc51 at positions near the outer circumferential surface. Each chamber 51C communicates only with the hole portions 51h located nearby. Also, on the end surface in the CD direction of the upstream roller 51, the flow passage communicating with the blower 52B is arranged so as to face only the range θ e in the rotation direction Dc 51. Therefore, as the chamber 51C passes through the range θ e, the chamber 51C is placed in communication with the flow passage of the blower 52B, and the pressurized air is supplied from the blower 52B to the chamber 51C, and thus, the air is ejected from the hole portion 51h. However, as the chamber 51C passes through a position outside the range θ e in the rotation direction Dc51, the chamber 51C does not communicate with the flow passage of the blower 52B, pressurized air is not supplied from the blower 52B to the chamber 51C, and therefore, air is not ejected from the hole portion 51h.
It should be noted that the range θ e for ejecting air is not limited to the range of ± 5 ° described above in any way. In other words, the range may be narrower than ± 5 ° or wider. For example, there can be a configuration in which the range θ e is expanded to 360 ° in the rotation direction Dc51, and therefore, air is ejected from the hole portion 51h when the hole portion 51h passes through any position in the rotation direction Dc 51.
Further, the intermediate roller 55 has a plurality of receiving portions 55r in addition to the pin members 55p on the outer circumferential surface as described above, and a gap S55r is provided between at least two of the receiving portions 55r adjacent to each other as shown in fig. 9A. Specifically, in this example, a gap S55r is provided between all pairs of adjacent receiving portions 55 r. These gaps S55r may function as passages for the above-described air on the outer circumferential surface of the intermediate roller 55.
Therefore, as shown in fig. 11, when the air flows from the hole portion 51h in the upstream roller 51 toward the pin member 55p on the intermediate roller 55, the air reaching the pin member 55p passes through the gap S55r on the outer circumferential surface of the intermediate roller 55, and thereby can be promptly discharged from the outer circumferential surface of the intermediate roller 55 to the outside space. In other words, a situation in which the flow of air is obstructed at the outer circumferential surface of the intermediate roller 55 can be avoided. As a result, difficulty in air flow between the hole portion 51h and the pin member 55p can be prevented efficiently.
Also, in some cases, the receiving portion 55r may be formed so as to be integral with the pin member 55p and inseparable from the pin member 55p. Fig. 12 is a view showing this example. In this example, the area of the top face of the cylindrical portion 55pb ' of the pin member 55p ' is larger than the area of the bottom face of the conical portion 55pa ', and therefore, the top face projects laterally from the bottom face. Also, the protruding portion 55pbp 'of the top surface functions as the receiving portion 55 pbp'. Therefore, by using the pin member 55p 'having the integrated receiving portion 55 pbp', it is possible to omit the receiving portion 55r having a single function as shown in fig. 9B, and thereby it is possible to secure an even larger gap S55 r. Also, the protruding portion 55pbp ' may receive the intermediate product 1m near the conical portion 55pa ' of the pin member 55p '. Therefore, a substantially constant pressing amount of the intermediate product 1m by the conical portion 55pa 'of the pin member 55 p' can be reliably maintained, thereby making it possible to suppress variations in the hole diameter of the air hole h.
Here, it is desirable that the air used as the above-mentioned gas is heated air that has been heated by a heating device 52H such as an electrothermal heater. For example, as substantially shown by the two-dot chain dashed line in fig. 5, a heating device 52H may be provided in the flow passage between the blower 52B and the upstream roller 51, and thereby the air flowing in the flow passage is heated. According to this configuration, due to this flow of the heated air, it is possible to soften the thermoplastic resin fibers of the nonwoven fabric sheet constituting the main body of the intermediate product 1m, and as a result, the pores h are more easily formed in the intermediate product 1 m. Specifically, when the pin member 55p is pressed in, the thermoplastic resin fibers can be easily moved or deformed in the direction for widening the hole diameter. Therefore, the frictional resistance F that may be generated between the pin member 55p and the intermediate product 1m during this pressurization can be further reduced, and as a result, the protruding height of the burr B can be further reduced.
Note that the temperature of the heated air is desirably set as follows. Specifically, as shown in fig. 11, it is desirable that the temperature of the heated air is greater than or equal to the softening point of the thermoplastic resin fibers and less than the melting point of the thermoplastic resin fibers in the nonwoven fabric sheet of the intermediate product 1m when the heated air flows at the position between the pin member 55p and the hole portion 51h. According to this configuration, by setting the temperature to be lower than the melting point, thermal damage to the nonwoven fabric sheet of the intermediate product 1m caused by the heated air can be suppressed. In addition, by setting the temperature to be equal to or higher than the softening point, the aforementioned frictional resistance F generated when the pores h are formed in the nonwoven fabric sheet can be reliably reduced.
Also, if a plurality of types of thermoplastic resins are used to form the nonwoven fabric sheet and these different types of thermoplastic resins have different softening points, the lowest softening point may be selected as the above-described softening point, but it is desirable to select the highest softening point. Similarly, if different types of thermoplastic resins have different melting points, the highest melting point may be selected as the above-described melting point, but it is desirable to select the lowest melting point. According to this configuration, the above-described action and effect can be reliably achieved.
Note that the softening point can be obtained by TMA (thermo-mechanical analysis) according to JIS K7196 (test method for testing the softening temperature of thermoplastic films and sheets by thermo-mechanical analysis). Also, the melting point can be obtained by DSC (differential scanning calorimetry) according to JIS K7121 (test method for transition temperature of plastics). Specifically, the melting peak temperature defined in the DSC description in JISK 7121 may be used as the above-mentioned melting point.
Further, in the case of using the heated air as described above, the intermediate product 1m is preheated before the air holes h are formed in the intermediate product 1m, thereby making it possible to further improve the effect of reducing the protruding height of the burrs B. This will be described in detail below.
First, the upstream roller 51 in fig. 5 is heated by the heated air flowing in the chamber 51C or the like therein. Further, as shown in fig. 5, the intermediate product 1m is wrapped on the outer circumferential surface of the upstream roller 51 on the upstream side of the closest position P51 in the rotating direction Dc51 by a predetermined wrapping angle θ w, and the intermediate product 1m is heated and softened by the upstream roller 51 at this time. Then, the intermediate product 1m in this softened state reaches the closest position P51 in the rotating direction Dc51, and at this closest position P51, the pin members 55P of the intermediate roller 55 are pressed thereinto to form the air holes h. Therefore, during this pressing, the thermoplastic resin fibers are easily moved or deformed due to being softened, thereby making it possible to further reduce the frictional resistance F that can be generated between the pin member 55p and the intermediate product 1m during the pressing. As a result, the protruding height of the burr B can be further reduced.
Note that it is desirable that the wrapping angle θ w is selected from the range of 20 ° to 180 °. By selecting from this range, the above-described effect of preheating can be reliably achieved. Also, from the viewpoint of further promoting softening of the thermoplastic resin fibers, it is desirable to eject the heated air from the hole portions 51h of the upstream roller 51 when the hole portions 51h pass through the range of the wrapping angle θ w in the rotating direction Dc51 of the roller 51.
Also, in some cases, there can be a configuration in which a heating device (not shown) such as an electrothermal heater is provided inside the intermediate roller 55 in fig. 5 and the pin member 55p of the intermediate roller 55 is heated by the heating device. According to this configuration, by using the heated pin member 55p, the thermoplastic resin fibers constituting the nonwoven fabric sheet of the intermediate product 1m can be made softer. Thus, when the pin member 55p is pressed into the intermediate product 1m, the thermoplastic resin fibers are easily pushed circumferentially outward, thereby making it possible to further reduce the frictional resistance F that may be generated between the pin member 55p and the intermediate product 1m during this pressing. As a result, the protruding height of the burr B can be further reduced. It should be noted that one example of the criterion for heating in this case is that the temperature of the pin member 55p is greater than or equal to the softening point of the aforementioned thermoplastic resin and less than the melting point thereof.
Second embodiment
Fig. 13 is a view showing the second embodiment, and corresponds to fig. 11 in the above-described first embodiment.
As shown in fig. 11, in the first embodiment described above, air serving as gas is ejected from the hole portions 51h in the outer circumferential surface of the upstream roller 51, but the main difference in the second embodiment is that the hole portions 51h suck air instead of ejecting air, as shown in fig. 13. Other aspects are substantially the same as those in the first embodiment described above. Therefore, the same or similar configurations are indicated by the same reference numerals and will not be described again. Also, fig. 5 and 9A used in the first embodiment will also be used for convenience in the following description of the second embodiment.
In the second embodiment in fig. 13, as described above, the hole portions 51h in the outer circumferential surface of the upstream roller 51 suck air into the roller 51. Therefore, as the air hole h formation target portion of the intermediate product 1m passes the aforementioned closest position P51 (fig. 5) in the rotating direction Dc51 of the upstream roller 51, air flows from the pin member 55P of the intermediate roller 55 toward the hole portion 51h of the upstream roller 51, as shown in fig. 13. Therefore, when the pin member 55p is inserted into the hole portion 51h, a part of the air can flow between the pin member 55p and the intermediate product 1m by passing through the gaps between the fibers of the nonwoven fabric sheet of the intermediate product 1m, and at this time, due to this flow of the passing air, the frictional resistance F that can be generated between the pin member 55p and the intermediate product 1m when the pin member 55p is pressurized can be reduced. As a result, the protrusion height of the burr B that may be formed at the edge portion of the air hole h in the intermediate product 1m can be reduced.
Also, in this example, as shown in fig. 5, as the hole portion 51h of the upstream roller 51 passes through the range θ e of ± 5 ° centered on the closest position P51 in the rotational direction Dc51 of the roller 51, the hole portion 51h of the upstream roller 51 sucks air, but there is no limitation thereto in any way. Specifically, it is desirable that the hole portions 51h of the upstream roller 51 suck air at least when the hole portions 51h pass the closest position P51 in the rotating direction Dc 51. Therefore, the range θ e of air suction may be narrower than a range of ± 5 ° or wider. For example, there can be a configuration in which the range θ e is expanded to 360 ° in the rotation direction Dc51, and therefore, when the hole portion 51h passes any position in the rotation direction Dc51, air is sucked through the hole portion 51h.
Note that, it is apparent that by reversing the blowing direction (air blowing direction) of the blower 52B (fig. 5) in the above-described first embodiment, the suction of air through the hole portions 51h of the upstream roller 51 can be achieved, and therefore, this will not be described further.
Also, as shown in fig. 13, also in the second embodiment, similarly to the above-described first embodiment, the intermediate roller 55 may have a plurality of receiving portions 55r in addition to having the pin members 55p on the outer circumferential surface. In this case, as shown in fig. 9A, it is desirable that a gap S55r is provided between at least two of the receiving portions 55r adjacent to each other. For example, it is desirable to provide a gap S55r between all pairs of adjacent receiving portions 55 r.
According to this configuration, as shown in fig. 13, even when air flows from the pin member 55p of the intermediate roller 55 toward the hole portion 51h of the upstream roller 51, the air passes through the gap S55r at the outer circumferential surface of the intermediate roller 55, thereby enabling the air in the space surrounding the outer circumferential surface of the intermediate roller 55 to be promptly supplied to the pin member 55p. In other words, a situation in which the air flow is obstructed at the outer circumferential surface of the intermediate roller 55 can be avoided. As a result, difficulty in air flow between the hole portion 51h and the pin member 55p can be prevented efficiently.
Further, also in the second embodiment, there can be a configuration in which a heating device (not shown) such as an electrothermal heater is provided inside the intermediate roller 55 and the pin member 55p of the intermediate roller 55 is heated by the heating device. According to this configuration, by using the heated pin member 55p, the thermoplastic resin fibers constituting the nonwoven fabric sheet of the intermediate product 1m can be made softer. Thus, when the pin member 55p is pressed into the intermediate product 1m, the thermoplastic resin fibers are easily pushed circumferentially outward, thereby enabling the protruding height of the burr B to be further reduced by reducing the frictional resistance F that can be generated between the pin member 55p and the intermediate product 1m during this pressing.
According to this configuration having the heating device, when air flows through the outer circumferential surface of the intermediate roller 55 as shown in fig. 13, the air is heated via the pin member 55p of the intermediate roller 55. Then, the heated air flows toward the intermediate product 1 m. Therefore, the heated air can also promote softening of the thermoplastic resin fibers of the nonwoven fabric sheet of intermediate product 1m, and this also efficiently contributes to reducing the protruding height of the burrs B.
Further, according to this configuration, the upstream roller 51 sucks the heated air through the hole portion 51h, and therefore, the upstream roller 51 is heated by the heated air, and the intermediate product 1m is wrapped on the upstream roller 51 over the predetermined wrapping angle θ w, as shown in fig. 5. Therefore, the intermediate product 1m is wrapped around the upstream roller 51 and heated by the upstream roller 51, thereby softening the thermoplastic resin fibers of the nonwoven fabric sheet of the intermediate product 1 m. Therefore, this also efficiently contributes to reducing the projecting height of the burr B.
Other embodiments
Although the embodiments of the present disclosure have been described above, the above-described embodiments of the present disclosure are only for facilitating understanding of the present disclosure, and are not to be construed as limiting the present disclosure in any way. The present disclosure may be variously changed or modified without departing from the gist thereof, and includes equivalents thereof. For example, there can be variations as will be described below.
In the first embodiment described above, air is used as an example of the gas ejected from the hole portion 51h in the outer circumferential surface of the upstream roller 51, as shown in fig. 11, but there is no limitation thereto in any way. For example, nitrogen or an inert gas may be injected.
Each of the pin members 55p of the intermediate roller 55 has a conical portion 55pa and a cylindrical portion 55pb as shown in an enlarged view of the relevant portion in fig. 6, but there is no limitation thereto in any way. For example, instead of the conical portion 55pa, each of the pin members 55p of the intermediate roller 55 may have a pyramidal portion having a polygonal cross section, for example, a triangular pyramid shape or a quadrangular pyramid shape, and instead of the cylindrical portion 55pb, each of the pin members 55p of the intermediate roller 55 may have a cylindrical portion having a polygonal cross section, for example, a triangular prism or a quadrangular prism.
In the second embodiment described above, when the pin member 55p of the intermediate roller 55 is inserted into the hole portion 51h of the upstream roller 51 as shown in fig. 13, since the hole portion 51h of the upstream roller 51 sucks air, the air flows from the pin member 55p of the intermediate roller 55 toward the hole portion 51h of the upstream roller 51, but there is no limitation thereto in any way. Fig. 14 is a schematic side view showing another example thereof. Note that fig. 14 shows a cross-sectional view of the pin member 55p and the like.
In this example, injection holes 55ph for injecting gas such as air are formed in the outer surface of the conical portion 55pa of the pin member 55p of the intermediate roller 55. When the pin member 55p is inserted into the hole portion 51h of the upstream roller 51, air is injected from the injection hole 55ph into the hole portion 51h of the upstream roller 51. Here, it is noted that the ejection of air from the ejection holes 55ph of the pin member 55p can be achieved using the mechanism for ejecting air from the hole portions 51h of the upstream roller 51 in the above-described first embodiment, that is, by applying the same mechanism having the blower 52B of fig. 5 or the like to the intermediate roller 55. Therefore, the intermediate roller 55 will not be further described below. Also, in some cases, the injection holes 55ph may be provided in the outer circumferential surface of the cylindrical portion 55pb of the pin member 55p. Further, similarly to the case where the air injected from the hole portion 51H of the upstream roller 51 is heated in advance using the heating device 55H in the above-described first embodiment, the air injected from the injection hole 55ph of the pin member 55p may also be heated in advance using a heating device (not shown) in this example.
In the above-described embodiment, as shown in fig. 5, the intermediate product 1m is wrapped around both the upstream roller 51 and the intermediate roller 55, but there is no limitation thereto in any way. Specifically, as shown in fig. 15, the intermediate product 1m may pass between the roller 51 and the roller 55 without being wrapped on the roller 51 corresponding to the upstream roller 51 and the roller 55 corresponding to the intermediate roller 55.
The air holes h in the front belt member 31 and the rear belt member 41 are described as examples of the through holes h formed in the nonwoven fabric sheet in the above-described embodiment, but there is no limitation thereto in any way. For example, when the through-holes h having applications other than improving air permeability are to be formed in the front belt member 31 and the rear belt member 41, the forming method and the forming apparatus 50 for forming the through-holes h of the present invention may be applied.
Although the three-piece type disposable diaper 1 is shown as an example of the absorbent article in the above-described embodiment, there is no limitation thereto in any way. For example, when the through-holes are formed in a nonwoven fabric sheet as a material for constituting a two-piece disposable diaper, the method and apparatus 50 for forming the through-holes h of the present invention may be applied. It should be noted that the two-piece disposable diaper is a type of diaper having an outer sheet having a front portion, a crotch portion and a rear portion as a first member, and an absorbent main body 10 as a second member fixed to a skin-side surface of the outer sheet. Also, in this case, the continuous sheet of the exterior sheet is formed of two overlapped nonwoven fabric sheets, and when the through-holes h are formed in the nonwoven fabric sheets, the method and apparatus 50 for forming the through-holes h of the present invention are used.
Further, the two-piece diaper may be a so-called tape-type disposable diaper. Note that the tape type disposable diaper is a type of diaper which uses a fastening tape so as to connect a front portion covering the front side of a torso portion of a wearer to a rear portion covering the rear side of the torso portion.
Further, the absorbent article is not limited to the disposable diaper 1 in any way. Specifically, the method and apparatus 50 for forming the through-holes h of the present invention are applied when manufacturing any absorbent article manufactured by using a nonwoven fabric sheet. For this reason, the concept of the absorbent article also includes urine-absorbing pads, sanitary napkins, and the like.
[ list of reference numerals ]
1a disposable diaper (absorbent article),
1m of the intermediate product (nonwoven sheet),
1mw1 continuous sheet, 1mw2 continuous sheet,
a 1mw2p1 moiety, a 1mw2p2 moiety,
10 an absorbent main body which is provided with a plurality of layers,
10LG portion, 10ea end portion, 10eb end portion, 11 absorbent body,
11c an absorbent core having a core surface,
13 a top sheet, 15a back sheet,
15a, 15b outer sheets,
16 an elastic member for elastically urging the elastic member,
31a front belt member, 31a continuous body, 31e end portions,
a 31s non-absorbent body portion, a 32 nonwoven fabric sheet, a 32Le end portion,
33 nonwoven fabric sheet, 33B folded portion, 35 elastic member, 35a continuous body,
41a rear belt member, 41a continuous body, 42 nonwoven fabric sheet, 41Le end portion, 43 nonwoven fabric sheet,
50 to form a device, the device is,
51 upstream roller (second rotating body), 51C chamber, 51h hole portion,
a 52B blower, a 52H heating device,
55 intermediate rolls (first rotating bodies), 55H heating means,
a 55p pin member, a 55pa tapered portion, a 55pb cylindrical portion,
55p ' pin member, conical portion 55pa ', cylindrical portion 55pb ',
55 pbp' projection, 55ph injection hole,
55r receiving portion, 55rt top surface (retaining surface),
58 downstream, 58h bore sections,
BH waist opening, LH leg opening, LG leg gather,
the center position of CL1, the predetermined position of CL10,
h air holes (through holes), B burrs,
gh31 air hole group, Rh31 air hole row,
gh41 air hole group, Rh41 air hole row,
the group of G51h1 aperture segments, the group of G51h2 aperture segments,
a group of G55p1 pin members, a group of G55p2 pin members,
the group of G58h1 aperture segments, the group of G58h2 aperture segments,
the P51 closest position, the P55 closest position,
thetae range, thetaw wrap angle, S55r gap,
SG51h1 aperture group set, SG51h2 aperture group set,
SG55p1 pin member set, SG55p2 pin member set,
r51 first conveying route, R55 second conveying route, R58 third conveying route

Claims (13)

1. A method of forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the method comprises the following steps:
a step for forming the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on an outer circumferential surface of the rotating first rotating body,
the hole portion is formed in an outer circumferential surface of a second rotating body that rotates; and
a step for urging gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion,
a plurality of receiving portions are formed as protrusions on an outer circumferential surface of the first rotating body,
the receiving portions each having a holding face capable of receiving and holding one surface of the nonwoven fabric sheet without penetrating the nonwoven fabric sheet,
on the outer circumferential surface of the first rotating body, the receiving portions are each located at a position different from a position where the pin member is formed, and
a gap is provided between at least two of the receiving portions that are adjacent to each other.
2. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1,
the nonwoven fabric sheet has thermoplastic resin fibers and
the gas is heated air heated by a heating device.
3. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 2, wherein,
the nonwoven fabric sheet has thermoplastic resin fibers and
the pin member is heated by a heating device.
4. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 2, wherein,
the gas flows from the hole portion toward the pin member.
5. A method of forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the method comprises the following steps:
a step for forming the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on an outer circumferential surface of the rotating first rotating body,
the hole portion is formed in an outer circumferential surface of a second rotating body that rotates; and
a step for urging gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion,
the gas flows from the pin member toward the hole portion.
6. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 5,
the gas is heated air heated by a heating device,
the second rotating body is heated by the heated air,
the nonwoven fabric sheet is wrapped on the outer circumferential surface of the second rotating body at a predetermined wrapping angle on the upstream side of the closest position with respect to the rotating direction of the second rotating body,
the closest position is the position of the second rotating body closest to the first rotating body, and
the non-woven fabric sheet is heated by the second rotating body by being wrapped on the outer circumferential surface.
7. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 6,
the heating air is ejected from the hole portion in the second rotating body when the hole portion passes through a range of the wrapping angle in the rotating direction of the second rotating body.
8. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 5,
the receiving portion is formed integrally with the pin member and inseparable from the pin member.
9. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 5,
the receiving portion is separate from the pin member.
10. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 5,
the gas is heated air heated by a heating device, and
when the heated air flows at a position between the pin member and the hole portion, the temperature of the heated air is greater than or equal to the softening point of the thermoplastic resin fibers contained in the nonwoven fabric sheet and less than the melting point of the thermoplastic resin fibers.
11. The method of forming through-holes in a nonwoven fabric sheet for an absorbent article according to claim 1 or 5,
a plurality of pin members are provided on the outer circumferential surface of the first rotating body,
a plurality of hole portions are provided on the outer circumferential surface of the second rotating body, and
the hole portions are provided such that only one of the pin members is inserted in each of the hole portions when the pin member is inserted in the hole portions.
12. An apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the device comprises:
in a mechanism, a mechanism is provided,
the mechanism forms the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on an outer circumferential surface of the rotating first rotating body,
the hole portion is formed in an outer circumferential surface of a second rotating body that rotates, and
the mechanism causes gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion,
a plurality of receiving portions are formed as protrusions on an outer circumferential surface of the first rotating body,
the receiving portions each having a holding face capable of receiving and holding one surface of the nonwoven fabric sheet without penetrating the nonwoven fabric sheet,
on the outer circumferential surface of the first rotating body, the receiving portions are each located at a position different from a position where the pin member is formed, and
a gap is provided between at least two of the receiving portions that are adjacent to each other.
13. An apparatus for forming through-holes in a nonwoven fabric sheet for an absorbent article,
the through-hole is formed in the non-woven fabric sheet in a thickness direction of the non-woven fabric sheet when the non-woven fabric sheet passes between the first rotating body and the second rotating body,
the first rotating body and the second rotating body rotate with their respective outer circumferential surfaces facing each other,
the device comprises:
in a mechanism, a mechanism is provided,
the mechanism forms the through-hole by pressing the pin member into the nonwoven fabric sheet when the pin member is inserted into the hole portion,
the pin member is formed as a protrusion on an outer circumferential surface of the rotating first rotating body,
the hole portion is formed in an outer circumferential surface of a second rotating body that rotates, and
the mechanism causes gas to flow between the pin member and the hole portion when the pin member is inserted into the hole portion,
the gas flows from the pin member toward the hole portion.
CN201680087922.8A 2016-07-29 2016-07-29 Method and apparatus for forming through-hole in nonwoven fabric sheet for absorbent article Active CN109477271B (en)

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