CN116829112A

CN116829112A - Method for manufacturing wearing article

Info

Publication number: CN116829112A
Application number: CN202180080539.0A
Authority: CN
Inventors: 梅林丰志
Original assignee: Zuiko Corp
Current assignee: Zuiko Corp
Priority date: 2020-12-01
Filing date: 2021-11-22
Publication date: 2023-09-29
Also published as: JPWO2022118691A1; JP7457159B2; WO2022118691A1

Abstract

The purpose of the present invention is to provide a method for manufacturing a wearing article that can change the form between an initial developed form and a pants-type form, and that can improve wearing comfort. The method for manufacturing the wearing article comprises the following steps: a step of manufacturing a waistline member (10), wherein the waistline member (10) is provided with a waistline body (16) and a male buckle (12) which can extend and retract in the width direction; and a step of joining the absorber (20) to the waistline body (16), wherein the step of manufacturing the absorber (20) includes the steps of: the core is manufactured by holding the SAP in the 1 st nonwoven fabric on the core side in such a manner that the 1 st low-density region which holds the SAP at a lower density than the holding region for holding the SAP and is adjacent to both end portions in the orthogonal direction of the holding region in the orthogonal direction is formed; the coupling of the 1 st coupling portion and the 2 nd coupling portion is released.

Description

Method for manufacturing wearing article

Technical Field

The present invention relates to a method for manufacturing a wearing article.

Background

Patent documents 1 to 3 disclose wearing articles which can be unfolded from an initial pants-type form to a predetermined unfolded form and which can be assembled from the unfolded form to the pants-type form. These wearing articles include: a belt-shaped waist portion disposed at the waist of the wearer; and an absorber extending from the front abdomen to the back via the crotch of the wearer. The waist portion has elasticity stretchable in the width direction of the belt shape. The absorber is joined to the waist portion and extends from the joined portion so as to be orthogonal to the width direction of the waist portion.

In a state before use, both end portions of the waist portion are detachably coupled to the distal end portion of the absorber. Thus, the wearing article can be put on like pants.

When the wearing state of the wearing article is adjusted during use, the wearing article can be unfolded by releasing the both end portions of the waist portion from the distal end portion of the absorber.

Further, by re-coupling the both end portions of the waist portion to the distal end portion of the absorber, the wearing article can be assembled into underpants from the unfolded state.

However, according to patent documents 1 to 3, although the form of the wearing article can be changed between the original pants-type form and the developed form, there is no way to improve wearing comfort in consideration of the touch feeling of the portion of the wearing article that directly contacts the skin. Therefore, improvement of such a portion directly contacting the skin is demanded to improve wearing comfort.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open publication No. 2008-73216

Patent document 2: japanese patent public-exterior publication No. 2003-527152

Patent document 3: U.S. Pat. No. 8343127 Specification

Disclosure of Invention

The present invention has been made in view of the above-described problems, and an object thereof is to provide a method for manufacturing a wearing article which can change the form between an initial developed form and a pants-type form and can improve wearing comfort.

The method for manufacturing a wearing article for solving the above-described problems is a method comprising: a waistline member disposed at a waistline of a wearer; an absorber joined to the waist member and extending from a joining portion with the waist member in an orthogonal direction orthogonal to a width direction so as to be arranged from a back portion of a wearer to a front abdomen portion via a crotch portion, the manufacturing method comprising: a process for producing the waistline member, the waistline member comprising: a waist body extending in the width direction, having elasticity capable of expanding and contracting in the width direction, and disposed at a waist of a wearer; a 1 st coupling portion provided on a surface of both end portions in the width direction of the waist body on a skin surface side facing a wearer; a step of manufacturing the absorber, the absorber comprising: a core for absorbing body fluids; a surface sheet body provided on a skin surface side of the core body facing a wearer; a back sheet body provided on an outer surface side of the core opposite to the skin side so as to sandwich the core between the back sheet body and the front sheet body; a 2 nd coupling portion provided on an outer surface of the back sheet opposite to a surface facing the skin surface, and detachable from the 1 st coupling portion; and a joining step of joining the absorber to the joining portion of the waist body so as to extend in the orthogonal direction from the waist body, wherein the step of manufacturing the absorber includes a step of manufacturing the core, the step of forming a holding region and a 1 st low-density region, the 1 st low-density region holding the water-absorbent polymer having a lower density than the holding region and being adjacent to both end portions of the holding region in the orthogonal direction, the 1 st coupling portion and the 2 nd coupling portion being released from coupling.

A wearing article which can change the mode between an initial developed mode and a pants mode and can improve wearing comfort can be provided.

Drawings

Fig. 1 is a front view showing an assembled external appearance of an unfolding type wearing article.

Fig. 2 is a rear view showing an assembled external appearance of the developed type wearing article.

Fig. 3 is an expanded view of the expanded wearing article.

Fig. 4 is an exploded perspective view of the unfolded wearing article.

Fig. 5A is a plan view showing a distribution state of SAP in cores continuous in the waistline orthogonal direction.

Fig. 5B is a cross-sectional view taken along section line 5B-5B of fig. 5A.

FIG. 5C is a cross-sectional view taken along section line 5C-5C of FIG. 5A.

Fig. 6A is a top view showing another distribution state of SAP in a core.

Fig. 6B is a cross-sectional view taken along section line 6B-6B of fig. 6A.

Fig. 6C is a cross-sectional view taken along section line 6B-6B of fig. 6A, showing the core bent in an inverted V-shape.

Fig. 6D is a cross-sectional view taken along section line 6B-6B of fig. 6A, showing the core bent in a V-shape.

Fig. 7A is a plan view showing another distribution state of SAP in a core.

Fig. 7B is a top view showing another distribution state of SAP in a core.

Fig. 7C is a top view showing another distribution state of SAP in a core.

Fig. 8 is a system diagram of a process for manufacturing an expanded wearing article.

Fig. 9 is a plan view of the production conditions of steps 1 to 2.

Fig. 10 is a plan view of the production conditions of steps 3 to 7.

Fig. 11 is a schematic view of the surface sheet manufacturing apparatus.

Fig. 12A is a schematic view showing a process of forming the uneven shape of the surface sheet, in which the surface 1 st nonwoven fabric and the surface 2 nd nonwoven fabric are wound around the outer peripheral surface of the 1 st roll.

Fig. 12B is a schematic view showing a process of forming the uneven shape of the surface sheet, in which the surface 1 st nonwoven fabric and the surface 2 nd nonwoven fabric are pressed into the concave portion of the 1 st roll.

Fig. 12C is a schematic view of a process of forming the uneven shape of the surface sheet, and shows a case where the uneven shape is formed only on the 1 st nonwoven fabric on the surface side.

Fig. 13 is a schematic view of a core manufacturing apparatus.

Fig. 14 is a schematic view of a process of manufacturing a core by laminating the 1 st nonwoven fabric on the core side and the 2 nd nonwoven fabric on the core side.

Fig. 15A is a cross-sectional view showing a process of manufacturing the core, and shows a state before the fuzzing of the 1 st nonwoven fabric on the core side and the 2 nd nonwoven fabric on the core side.

Fig. 15B is a cross-sectional view showing a process of manufacturing the core, and shows a state after the napping of the 1 st nonwoven fabric on the core side and the 2 nd nonwoven fabric on the core side.

Fig. 15C is a cross-sectional view showing a manufacturing process of the core, and shows a state in which SAP is supported by the 1 st nonwoven fabric on the core side and the 2 nd nonwoven fabric on the core side.

Fig. 15D is a cross-sectional view showing a process of manufacturing the core, and shows a state in which the 1 st nonwoven fabric on the core side and the 2 nd nonwoven fabric on the core side are laminated to form a laminate.

Fig. 15E is a cross-sectional view showing a manufacturing process of the core, and shows a state in which the thin paper is provided to the laminate.

Fig. 15F is a cross-sectional view showing a manufacturing process of the core body, and shows a state in which the laminate is covered with the tissue paper.

Fig. 16 is a plan view of the production conditions of steps 8 to 13.

Fig. 17A is a cross-sectional view of a main part in the manufacturing process of step 1, showing a case of conveying the outer sheet.

Fig. 17B is a cross-sectional view of a main part in the manufacturing process of step 1, showing a case where the waist elastic member is disposed on the outer sheet.

Fig. 17C is a cross-sectional view of a main part in the manufacturing process of step 2, showing a case where the inner sheet is conveyed so as to cover the upper portions of the outer sheet and the waist elastic member.

Fig. 18A is a cross-sectional view of a main part of the manufacturing process in step 3, showing a case where the lift flap sheet is cut.

Fig. 18B is a cross-sectional view of a main part in the manufacturing process of step 3, showing a case where the cut standing flaps are separated in the width direction at a predetermined interval.

Fig. 18C is a cross-sectional view of a main part in the manufacturing process of step 3, showing a case where a three-dimensional corrugated elastic member is disposed on a standing flap.

Fig. 18D is a cross-sectional view of a main part of the manufacturing process in step 3, showing a case where a three-dimensional fold is manufactured by joining a three-dimensional fold elastic member to an in-turned portion of a standing flap.

Fig. 18E is a cross-sectional view of a main part of the manufacturing process in step 3, showing a case where three-dimensional wrinkles are joined to the surface sheet.

Fig. 18F is a cross-sectional view of a main part of the manufacturing process in step 6, showing a case where an absorber semi-finished product is formed in which the surface sheet semi-finished product formed in step 3, the core formed in step 4, and the back sheet semi-finished product formed in step 5 are combined.

Fig. 19A is a cross-sectional view of a main part of the manufacturing process of steps 8 and 9, showing a case where the absorber turned in a predetermined direction after the step 7 is joined to the waistline continuous body.

Fig. 19B is a cross-sectional view of a main part of the manufacturing process of step 10, showing the case where the protruding portion is folded back.

Fig. 19C is a cross-sectional view of a main part of the manufacturing process from step 11 to step 13, showing a state in which the wearing article is folded in half.

Detailed Description

Embodiments of the present invention will be described below with reference to the drawings. The following embodiments are merely specific examples of the present invention, and do not limit the technical scope of the present invention.

< Structure of spread-type wearing article >

(integral structure)

Next, the structure of the spread-type wearing article will be described.

The unfolding type wearing article 1 according to the present embodiment includes: a waistline member 10 disposed at the waistline of the wearer; and an absorber 20 disposed from the back of the wearer to the front abdomen via the crotch.

The waistline member 10 has: a waist main body 16 (fig. 4) extending in the width direction, having elasticity capable of expanding and contracting in the width direction, and disposed at the waist of the wearer; and male buckles (1 st coupling parts) 12 provided on surfaces of both end portions 10c of the waist main body 16 in the width direction on the side facing the skin surface of the wearer.

Hereinafter, as shown in fig. 1 to 3, etc., in the developed-type wearing article 1, a direction in which the waistline body 16 (fig. 4) extends in the waistline member 10 is referred to as a waistline width direction (width direction), and a direction substantially orthogonal to the waistline width direction is referred to as a waistline orthogonal direction (orthogonal direction).

The waistline body 16 includes an inner sheet 14 (fig. 4), an outer sheet 15 (fig. 4), and a waistline elastic member 11 (fig. 4) joined to the inner sheet 14 and the outer sheet 15 in a state of being sandwiched between the inner sheet 14 and the outer sheet 15.

The absorber 20 is a member for absorbing body fluids such as urine and sweat. The absorber 20 is joined to the joining portion 10b of the waistline member 10 (fig. 3 and 4). In the present embodiment, the joint portion 10b is a portion that is offset downward from the edge on the waistline side, as well as the central portion in the waistline width direction of the waistline member 10. The absorber 20 extends from the joining portion 10b in the waist orthogonal direction so that the absorber 20 is arranged from the back of the wearer to the front abdomen via the crotch. The absorber 20 has a female fastener (2 nd coupling portion) 22 on an outer surface of a distal end portion in the waist orthogonal direction opposite to a skin-facing surface.

In the developed type wearing article 1 having such a structure, the absorber 20 is folded in half in the waist orthogonal direction and the coupling between the male fastener 12 and the female fastener 22 is released when the wearing article is in the final form (the stage in which the wearing article is used for the first time). In this state, the both side portions 10a are unfolded in the waistline width direction without being folded.

In addition, in the case of the developed wearing article 1 folded in the manner shown in the final step 13 in fig. 16 of the present embodiment, for example, in a state in which the both side portions 10a of the waistline member 10 are folded in the waistline width direction so as to face the skin surface of the absorber 20 in the developed wearing article shown in fig. 3, the absorber 20 is further folded in the waistline orthogonal direction so that the distal end portion of the absorber 20 faces the outer surface of the both side portions 10a of the waistline member 10. That is, in the present embodiment, the unfolding-type wearing article 1 is folded so that the both side portions 10a of the waistline member 10 are sandwiched between the joining portion 10b of the waistline member 10 and the absorber 20. In this state, the coupling of the male buckle 12 and the female buckle 22 is released. In addition, unlike the last step 13 in fig. 16, in the developed-type wearing article 1, the both side portions 10a may be folded in the waistline width direction so as to face the outer surface of the waistline member 10. The unfolding type wearing article 1 may be in an unfolded state shown in fig. 3, which is not folded.

In contrast to the unfolding-type wearing article 1, the wearing article of refastenable type is folded in a state where the male fastener 12 and the female fastener 22 are coupled when in the final configuration (the stage where the wearing article is used for the first time). Specifically, in the wearing article of the refastenable type, the absorber 20 in the wearing article of the developed form shown in fig. 3 is folded in half in the waistline orthogonal direction, and the male fastening device 12 and the female fastening device 22 are coupled in a state in which both side portions 10a, which are portions of the waistline member 10 adjacent to the joining portion 10b in the waistline width direction, are folded in the waistline width direction.

The wearer opens the waistline member 10 of the refastenable wearing article assembled in the pants-type form in a state where the male fastener 12 and the female fastener 22 are coupled, and inserts the legs to put on the wearing article like pants. In the refastenable wearing article, although the male fastener 12 and the female fastener 22 are previously joined, the joining of the two fasteners 12, 22 may be released to spread the wearing article into the form shown in fig. 3. The attachment and detachment of the two fasteners 12, 22 is repeated when the wearing article is fitted to the wearer or when the wearing article is replaced.

The following describes the respective parts of the unfolding-type wearing article 1.

(waist member)

The waistline member 10 has: a waist main body 16 (fig. 4) extending in the waist width direction, having elasticity capable of stretching in the waist width direction, and disposed at the waist of the wearer; and male buckles 12 provided on surfaces of both end portions 10c of the waist main body 16 in the waist width direction on the side facing the skin surface of the wearer. The waist main body 16 includes an inner sheet (fig. 4, etc.) 14, an outer sheet (fig. 4, etc.) 15, and a waist elastic member 11, which will be described later.

Here, the portion of the waist main body 16 to which the absorber 20 is joined is a joining portion 10b. In the present embodiment, as shown in fig. 2, a part of the waist elastic member 11 is present above the joining portion 10b in the waist orthogonal direction.

Further, the both side portions 10a in the waistline main body 16 are regions adjacent to the joining portions 10b in the waistline width direction. The both side portions 10a include both end portions 10c, and the both end portions 10c are both ends of the waistline body 16 in the waistline width direction. At least a part of the both end portions 10c is an engaging portion 15a2 (fig. 3 and 4) for engaging the male buckle 12.

The waist main body 16 has elasticity in the waist width direction as a whole. The joint 10b of the waist body 16 is a portion for disposing one end of the absorber 20. Further, the joint 10b includes a core arrangement portion 15a1 (fig. 2) for arranging the core 25, the core 25 constituting a part of the absorber 20. The engaging portion 15a2 of the waist main body 16 is a portion for disposing the male fastener 12.

The core arrangement portion 15a1 in the joint 10b has elasticity in the waist width direction smaller than that of the region other than the core arrangement portion 15a1, or has little elasticity. That is, in the waistline main body 16, the elasticity in the waistline width direction of the region other than the core arrangement portion 15a1 is greater than the elasticity of the core arrangement portion 15a 1. Further, in the joint 15a2, the elasticity thereof in the waist width direction is smaller than that of the region other than the joint 15a2, or little elasticity. That is, in the waistline main body 16, the elasticity in the waistline width direction of the region other than the core arrangement portion 15a1 and the joint portion 15a2 is greater than the elasticity of the joint portion 15a 2. In this way, the waist main body 16 has elasticity in the waist width direction as a whole based on the elasticity in the waist width direction of the region other than the core arrangement portion 15a1 and the joint portion 15a 2.

When the developed type wearing article 1 is put on a wearer, the absorber 20 is disposed in a range extending from the back of the wearer to the front abdomen via the crotch with the joint portion 10b of the waist main body 16 in contact with the back. In this state, both side portions 10a adjacent to the joint portion 10b of the waist main body 16 are extended to the outer surface of the distal end portion of the absorber 20 located in the front abdominal portion. Then, the unfolding type wearing article 1 is put on the wearer by coupling the male fastener 12 provided on the waist main body 16 and the female fastener 22 provided on the absorber 20.

Next, the planar shape of the waistline body 16 will be described: the upper edge of the waistline main body 16 in the waistline orthogonal direction is substantially linear in the waistline width direction. And a leg-surrounding curved portion 15b (fig. 3, 4, etc.) for forming a leg hole along the leg-surrounding shape is provided at the lower edge of the waistline member 10 in the waistline orthogonal direction, that is, the lower edge of the leg root side. The leg periphery curved portion 15b has a curved shape in which the length of the waistline main body 16 in the waistline orthogonal direction is increased from the both side portions 10a to the joint portion 10 b.

The specific structure of such a waist body 16 is further described. As shown in fig. 4, the waistline body 16 has: an inner sheet body 14 extending in the waist width direction; an outer sheet 15 extending in the waist width direction and covering an outer surface of the inner sheet 14 opposite to the skin-facing surface; and a waist elastic member 11 having elasticity that can stretch in the waist width direction.

As shown in fig. 3 and 4, the inner sheet 14 is, for example, a nonwoven fabric sheet, and is a belt-like member extending in the waistline width direction. An end portion of the absorber 20 is joined to a portion of the inner sheet 14 corresponding to the joining portion 10 b.

The male buckles 12 extend in the direction perpendicular to the waist on the skin-facing surface of the both end portions 10c of the inner sheet member 14 in the waist width direction. Specifically, the male buckle 12 is joined to the inner sheet 14. The length of the male fastener 12 in the direction perpendicular to the waist may be such that the connection between the male fastener 12 and the female fastener 22 is not easily released. For example, if the length of the male fastener 12 in the waist orthogonal direction is substantially the same as the length of the inner sheet 14 in the waist orthogonal direction, the waist main body 16 can be reliably coupled to the female fastener 22 of the absorber 20 over the entire length in the waist orthogonal direction.

The outer sheet 15 is made of, for example, nonwoven fabric, and is a belt-like member extending in the waistline width direction, similarly to the inner sheet 14. The outer sheet 15 is disposed on the outer surface side of the inner sheet 14 opposite to the skin surface side, and covers the outer surface of the inner sheet 14 opposite to the skin surface side.

The planar shape of the inner sheet 14 is the same as the planar shape of the waistline body 16 described above. As shown in fig. 4, the upper edge of the inner sheet 14 in the waistline orthogonal direction is formed in a straight line along the waistline width direction. The lower edge of the inner sheet 14 on the root side in the direction perpendicular to the waist has a curved leg periphery curve portion 15b along the leg periphery shape. Both ends of the inner sheet 14 in the waistline width direction are linear in the waistline orthogonal direction.

The lower edge of the outer sheet 15 has a curved leg-surrounding curved portion 15b along the leg-surrounding shape on the leg root side, as in the inner sheet 14, in a plan view. The outer sheet 15 has an extension 15c, and the extension 15c extends above the inner sheet 14 in the direction perpendicular to the waist in a state where the inner sheet 14 is overlapped to cover the waist elastic member 11.

As shown in fig. 3 and the like, the extension 15c is joined to the inner sheet 14 and the absorber 20 in a state where the extension 15c is folded back to cover the waist elastic member 11 and to cover an end portion of the absorber 20 in the waist orthogonal direction to the waist member 10. Accordingly, the uncomfortable feeling caused by the contact of the end portion of the absorber 20 with the skin can be suppressed. In addition, the end portion of the absorber 20 is not exposed, and the appearance can be improved.

The waist elastic member 11 is joined to at least one of the inner sheet 14 and the outer sheet 15 in a state where the waist elastic member 11 is linearly elongated in the waist width direction and sandwiched between the inner sheet 14 and the outer sheet 15. The waist elastic member 11 is disposed in a region from the upper edge of the inner sheet 14 to the leg periphery curved portion 15b on the leg root side, except for the extension portion 15 c. The waist elastic member 11 is subjected to weakening treatment at weakened portions 15a1, 15a2 described later.

The leg periphery curved portion 15b constitutes a part of a curved leg hole along the root shape of the leg. Further, the waist elastic member 11 adjacent to the leg periphery curved portion 15b elastically adheres a part of the peripheral edge portion of the leg hole to the upper portion of the leg root, thereby improving wearing comfort. Further, the waist elastic member 11 adjacent to the leg periphery curved portion 15b of the waist elastic member 11 may be curved along the curve of the leg periphery curved portion 15 b.

The waist elastic member 11 is formed of, for example, polyurethane, natural rubber, thermoplastic resin, or the like. The waist elastic member 11 is, for example, linear, stripe-like, sheet-like, or the like. The same materials and shapes are used for elastic members such as the elastic members constituting the leg gathers 31, the three-dimensional gather elastic members 41 and the absorber elastic members 21, which will be described later.

For the joining of the waist elastic member 11 to the inner sheet 14 and the outer sheet 15, bonding by a hot melt adhesive or welding by heat sealing may be used, but ultrasonic welding is more preferable. In the case of ultrasonic welding, the softness of the inner sheet 14 and the outer sheet 15 can be maintained, and the feeling of hard bonding is reduced, and the uncomfortable feeling is reduced, as compared with the case of using an adhesive.

The waist elastic member 11 has elasticity in the waist width direction. Accordingly, the waist elastic member 11 causes the waist main body 16 of the waist member 10 to be fitted to the waist in elastic contact. In the present embodiment, the waist elastic member 11 is constituted by a plurality of linear elastic members that extend in the waist width direction of the waist member 10 and are arranged at intervals in the waist orthogonal direction.

In the present embodiment, the waist elastic member 11 is weakened at the core arrangement portion 15a1 (also referred to as the weakened portion 15a 1) in the joining portion 10b of the waist member 10 for joining the absorber 20 (see fig. 2). In the present embodiment, the area of the joint 10b is larger than the area of the core arrangement portion 15a 1.

Specifically, in the absorbent body 20, the core 25 is disposed at the center in the waistline width direction, and is sandwiched between the front sheet 24 and the back sheet 26 in a state where the leg gathers 31 are disposed along both edges in the waistline width direction. The back sheet 26 is joined to the joining portion 10b of the waistline member 10. Further, at least the core arrangement portion 15a1 for arranging the core 25 in the joint portion 10b is subjected to the weakening treatment of the waist elastic member 11.

On the other hand, in the joint portion 10b, the waist elastic member 11 is not weakened at portions other than the core arrangement portion 15a1 (for example, at both edge portions of the front sheet 24 and the back sheet 26 at portions sandwiching the leg gathers 31).

Specifically, in the present embodiment, as described above, a part of the waist elastic member 11 is present above the joining portion 10b in the waist orthogonal direction. That is, a part of the waist elastic member 11 is disposed between the joining portion 10b and the upper end edge of the waist main body 16 in the waist orthogonal direction. Therefore, in the present embodiment, the weakening process is not applied to the waist elastic member 11 in the 3 directions in the joint portion 10b, that is, the both side portions adjacent to the core arrangement portion 15a1 in the waist width direction and the portion located on the upper side of the core arrangement portion 15a1 in the waist orthogonal direction.

As in the present embodiment, at least one of the waist elastic members 11 is provided in an extended state in a portion of the joint portion 10b on the upper side in the waist orthogonal direction than the core arrangement portion 15a 1. By joining the absorber 20 to such joining portion 10b, the distal end portion of the absorber 20 on the side of the waist member 10 overlaps with the waist elastic member 11 disposed at the upper portion. Accordingly, the free end (the end opposite to the waist member 10) of the absorber 20 in the direction perpendicular to the waist can be extended and contracted by the waist elastic member 21 described later, and the distal end of the absorber 20 on the waist member 10 side can be extended and contracted by the waist elastic member 11.

Further, in both end portions 10c in the waist width direction of the waist member 10, an engaging portion 15a2 (hereinafter, also referred to as a weakened portion 15a 2) for engaging the male buckle 12 is weakened to the waist elastic member 11.

In addition, based on the above-described manner, although the area of the joint 10b is larger than the area of the core arrangement portion 15a1, the area of the joint 10b and the area of the core arrangement portion 15a1 may coincide.

Further, the engaging portion 15a2 for engaging the male buckle 12 is at least a part of the both end portions 10c of the waistline member 10. However, the regions of both end portions 10c and the region of the joint portion 15a2 may be matched. In the present embodiment, the area of the joint 15a2 and the area of the weakened portion are identical, but the area of the weakened portion may be larger than the area of the joint 15a 2.

The weakening process is a process of weakening the elastic force of the elastic member to the waist main body 16. Further, the weakening process also includes a process for invalidating the elastic force of the elastic member. For example, the weakening process is performed by cutting the portions of the waist elastic member 11 located in the core arrangement portion 15a1 and the joint portion 15a 2. For example, the core arrangement portion 15a1 and the joint portion 15a2 may be weakened by cutting the waist elastic member 11 in a state of being joined to the core arrangement portion 15a1 and the joint portion 15a2, but not to the core arrangement portion 15a1 and the joint portion 15a2, in the inner sheet 14 and the outer sheet 15. The cutting is performed, for example, by: cutting the elastic member with a cutter; alternatively, the fusion cut is performed by heating the elastic member. By performing the weakening treatment, the elastic member is cut off, so that the elastic force of the core arrangement portion 15a1 and the joint portion 15a2 is weakened.

The weakening treatment includes, in addition to the treatment of removing elasticity by cutting off the elastic member as described above, a treatment of denaturing the elastic member so as to weaken the elasticity of the elastic member. In addition, the weakening may be performed by: the elastic member is intermittently bonded to the nonwoven fabric, and the elastic member is cut between the bonded portion and the bonded portion. Accordingly, the elastic force of the elastic member is reduced in a range in which the elastic member is cut off.

Based on the weakening process, in the weakened portion 15a1 for disposing the absorber 20 and the weakened portion 15a2 for disposing the male fastener 12, the elastic force of the waist elastic member 11 against the waist main body 16 is weakened. That is, the elastic force of the waist elastic member 11 against the waist main body 16 in the weakened portions 15a1 and 15a2 is weaker than the elastic force of the waist main body 16 in the portions adjacent to the weakened portions 15a1 and 15a2 in the waist width direction.

In this way, in the weakened portion 15a1 for disposing the absorber 20, the elastic force of the waist elastic member 11 against the waist main body 16 is weakened. Accordingly, shrinkage of the core 25 joined to the weakened portion 15a1 of the waistline body 16 can be suppressed, and the back and the like can be reliably covered by the core 25.

Further, in the weakened portion 15a2 where the male buckle 12 is arranged, the elastic force of the waist elastic member 11 against the waist main body 16 is weakened. Accordingly, contraction of the male fastener 12 can be suppressed, thereby suppressing a decrease in the coupling force between the male fastener 12 and the female fastener 22.

(absorber)

The absorber 20 is a belt-like member that can absorb body fluids such as urine, is joined to the joint portion 10b of the waist main body 16, and extends from the joint portion 10b in the waist orthogonal direction. The absorber 20 is disposed from the back of the wearer to the front abdomen via the crotch.

The absorber 20 has: a core 25 for absorbing body fluid; a surface sheet 24 provided on the skin surface side of the core 25 facing the wearer; a back sheet 26 provided on an outer surface side of the core 25 opposite to the skin surface side so that the core 25 is interposed between the back sheet 26 and the front sheet 24; and a female buckle 22 provided on an outer surface of the back sheet 26 opposite to the surface facing the skin surface and detachably coupled to the male buckle 12. Further, the absorber 20 further includes an absorber elastic member 21, leg gathers 31, three-dimensional gathers 40, and indicators (indicators) 50.

The front sheet 24 is a belt-like sheet extending in the direction perpendicular to the waist, and is provided on the skin surface side of the core 25 facing the wearer. The surface sheet 24 is formed by laminating two nonwoven fabrics, i.e., a surface 1 st nonwoven fabric 24a and a surface 2 nd nonwoven fabric 24b (fig. 11, 12, etc.), which have liquid permeability, of substantially the same size, and joining the surface 1 st nonwoven fabric 24a and the surface 2 nd nonwoven fabric 24 b.

The front side 1 st nonwoven fabric 24a has a front surface facing the skin surface of the wearer when worn, and a plurality of uneven shapes 20a are provided on the front surface facing the skin surface. The back surface of the front-side 1 st nonwoven fabric 24a has an uneven shape opposite to the uneven shape 20a on the front surface. The shape of the concave portion and the convex portion for forming the concave-convex shape 20a is not particularly limited, but is, for example, a circular shape, an elliptical shape, a polygonal shape, or the like in a plan view. The size of the concave portion and the convex portion is not limited as long as the concave portion and the convex portion can impart comfort to the skin surface, and for example, the concave portion and the convex portion can be suppressed from adhering to the skin surface when in contact with each other, and are, for example, circular, about 3mm to 5mm in plan view.

Thus, the 1 st nonwoven fabric 24a on the skin surface side of the top sheet 24 is provided with the uneven shape 20a. Therefore, the convex portions of the concave-convex shape 20a are in contact with the elastic sites of the skin surface of the wearer, and air can pass through the concave portions, so that the air permeability is good. Therefore, the surface sheet 24 can improve the feel of the skin as compared with the case where the surface sheet 24 is in surface-to-surface contact with the skin. Further, even after the absorber 20 absorbs body fluid such as urine and sweat, the convex portions of the top sheet 24 are in point contact with the wet skin surface by urine or the like, and the concave portions have air permeability, so that discomfort in touch feeling of the skin surface can be reduced.

The surface side 2 nd nonwoven fabric 24b is joined to the outer surface of the surface side 1 st nonwoven fabric 24a opposite to the skin-facing surface. The surface-side 2 nd nonwoven fabric 24b has a shape having a smoother undulation than the irregularities 20a of the surface-side 1 st nonwoven fabric 24 a. The surface of the surface-side 2 nd nonwoven fabric 24b facing the skin surface is, for example, flat. Thus, the undulations of the surface side 2 nd nonwoven fabric 24b are smaller than those of the surface side 1 st nonwoven fabric 24 a. Therefore, the ease of extension of the surface side 2 nd nonwoven fabric 24b in the surface direction is smaller than that of the surface side 1 st nonwoven fabric 24 a. Accordingly, the elongation of the surface 1 st nonwoven fabric 24a is restricted by the surface 2 nd nonwoven fabric 24b, and the uneven shape 20a of the surface 1 st nonwoven fabric 24a is maintained. At this time, the concave portions in the concave-convex shape 20a of the surface side 1 st nonwoven fabric 24a are joined to the flat surface of the surface side 2 nd nonwoven fabric 24b, and the shape of the convex portions in the concave-convex shape 20a is maintained based on the joining of the concave portions. For example, even when the wearer presses the concave-convex shape 20a by contact, the convex portion is less likely to deform, and a good skin feel can be maintained by point contact with the convex portion.

The surface sheet 24 is formed of two nonwoven fabrics (the surface 1 st nonwoven fabric 24a and the surface 2 nd nonwoven fabric 24 b), but the number of nonwoven fabrics may be 3 or more.

In the case where the uneven shape 20a is provided on the surface sheet 24, the uneven shape 20a may be provided on the surface of at least 1 nonwoven fabric facing the skin surface side among the plurality of nonwoven fabrics or the two nonwoven fabrics. Accordingly, the uneven shape 20a may be provided on all the nonwoven fabrics constituting the surface sheet 24.

The surface sheet 24 may be formed of 1 nonwoven fabric. In this case, the surface of the 1 nonwoven fabric facing the skin surface is provided with the uneven shape 20a.

In addition, for the joining of the surface side 1 st nonwoven fabric 24a and the surface side 2 nd nonwoven fabric 24b, bonding by a hot melt adhesive or welding by heat sealing may be used, but ultrasonic welding is more preferable. In the case of ultrasonic welding for this joining, the softness of the surface sheet 24 can be maintained, and the feeling of hard bonding is reduced, and the uncomfortable feeling is reduced, compared with the case of using an adhesive.

In the above manner, the surface of the first nonwoven fabric 24a on the surface side facing the skin surface is provided with the plurality of concave-convex shapes 20a. However, the surface sheet 24 also includes a flat surface-like surface of the surface-side 1 st nonwoven fabric 24a facing the skin surface. In this case, the surface sheet 24 may be formed of only 1 nonwoven fabric having a flat surface shape. That is, the surface sheet 24 may be formed of only the planar surface 1 st nonwoven fabric 24a, except for the surface 2 nd nonwoven fabric 24 b.

As shown in fig. 4 and the like, the core 25 is a strip-shaped sheet body having a rectangular shape extending in the direction perpendicular to the waist in a plan view. In addition, the constricted portion may be formed at the center position of both edge portions in the waistline width direction of the core 25 in the waistline orthogonal direction. In order to dispose the core 25 around the legs of the wearer without any gap, the two edge portions are recessed in the waist width direction to form the contracted portion. The constricted portion has a curved shape for extending the curve of the leg periphery curved portion 15 b.

The core 25 is manufactured by continuously joining the cores 25 in the waistline-orthogonal direction as shown in fig. 5A, while the manufacturing method described later will be described in detail. Between the successive cores 25 cutting zones Cut are provided. The continuous cores 25 are Cut along the cutting line N in the cutting area Cut, thereby being divided into 1 core 25 having a specified length 25L. In addition, the distribution density of the SAP in the Cut region Cut is lower than that in a holding region R2 described later. Specifically, in the present embodiment, the Cut regions Cut of the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2 hardly hold SAP. In addition, SAP may not be carried at all in the cutting area Cut.

The core 25 is formed of two nonwoven fabrics, i.e., a core-side 1 st nonwoven fabric S1 and a core-side 2 nd nonwoven fabric S2, and a super absorbent polymer (SAP: super Absorbent Polymer) supported by the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2. In the core 25, two nonwoven fabrics, i.e., the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2, are laminated in the manner shown in fig. 5B and the like. The SAP is a water-absorbent substance having water absorbency, and sodium polyacrylate or the like can be used, for example.

More specifically, the core 25 further includes a core-side 2 nd nonwoven fabric S2, and the core-side 2 nd nonwoven fabric S2 is laminated on the core-side 1 st nonwoven fabric S1 so as to face the core-side 1 st nonwoven fabric S1 via the SAP. On the facing surfaces of the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2, fiber layers are formed that are napped to form gaps for supporting SAP. By disposing SAP in the gaps between the fiber layers, a large amount of SAP can be supported by the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2. Examples of the nonwoven fabric having such a fibrous layer include air-laid nonwoven fabrics (air-laid nonwoven fabrics).

Further, by making the two nonwoven fabrics of the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2 support the SAP, the SAP can be supported more than when the 1 st nonwoven fabric is provided on the core side 1 st nonwoven fabric, and the absorption amount of the SAP for urine and the like can be increased.

Further, as shown in fig. 5A to 5C, the core-side 1 st nonwoven fabric S1 carries SAP in such a manner as to form a 1 st low-density region R11 and a holding region R2. The 1 st low-density region R11 is disposed adjacent to both ends of the holding region R2 in the waistline orthogonal direction. Further, the 1 st low density region R11 is a region from the end of the holding region R2 in the waist orthogonal direction to the dicing line N in the dicing region Cut of fig. 5A. The SAP has a lower distribution density in the 1 st low-density region R11 than in the retention region R2. In addition, the 1 st low-density region R11 may not carry SAP. The holding region R2 is a region that carries SAP to have a specified water absorbing property for urine or the like. The 1 st nonwoven fabric S1 on the core side exhibits a predetermined water absorption performance in the entire 1 st low-density region R11 and the holding region R2.

On the other hand, as shown in fig. 5B and 5C, the holding region R3 of the core-side 2 nd nonwoven fabric S2 is arranged at a position overlapping with the holding region R2 of the core-side 1 st nonwoven fabric S1 in a plan view. In addition, the 3 rd low-density region R13 of the core-side 2 nd nonwoven fabric S2 is arranged at a position overlapping the 1 st low-density region R11 of the core-side 1 st nonwoven fabric S1 in plan view. The distribution density of SAP in the 3 rd low-density region R13 is lower than the distribution density of SAP in the holding regions R2 and R3. In addition, the 3 rd low-density region R13 may not carry SAP. The distribution density of the SAP in the holding region R3 is set to have a prescribed water absorbing performance for urine or the like. The SAP distribution density in the 3 rd low-density region R13 and the holding region R3 of the core-side 2 nd nonwoven fabric S2 is set so as to be capable of exhibiting a predetermined water absorption performance.

Further, the density of the SAP in the holding region R3 may be substantially the same as or different from that of the holding region R2. The density of the SAP in the 3 rd low-density region R13 may be substantially the same as or different from that in the 1 st low-density region R11.

The core-side 1 st nonwoven fabric S1 is disposed on the skin side of the wearing article 1 facing the wearer, and the core-side 2 nd nonwoven fabric S2 is laminated on the back side of the core-side 1 st nonwoven fabric S1.

The two nonwoven fabrics, i.e., the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2, are laminated so that the fiber layers that are fluffed and support the SAP face each other. This can suppress the SAP from falling off. That is, the high-density fibers are entangled with each other at the outer surface side of the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2, which are free from fuzzing. By this outer portion, the SAP is supported in the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2.

The core-side 1 st nonwoven fabric S1 is formed so as to hold SAP. Since the absorbent performance per unit volume of the SAP is higher than that of fluff pulp (fluff pulp), the amount of fluff pulp used when fluff pulp is used can be reduced. Accordingly, the thickness of the core 25 can be reduced as compared with a nonwoven fabric formed of only fluff pulp in an amount required for a specified absorption performance. Since the thickness of the wearing article 1 including the core-side 1 st nonwoven fabric S1 is also small, the wearing article 1 is easily deformed in accordance with the body shape of the waistline portion of the wearer, and the fit of the wearing article 1 can be improved.

Moreover, the thickness of the core 25 can be reduced as compared with a nonwoven fabric formed of only fluff pulp in an amount required for a specified absorption performance. By thinning the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2, the thickness of the wearing article 1 can be thinned, so that the wearing article 1 can be easily deformed in accordance with the body shape of the waistline portion of the wearer, and the fit of the wearing article 1 can be improved.

Further, the retention region R2 lacks flexibility because the SAP has a distribution density higher than that of the 1 st low-density region R11. And the 1 st low-density region R11 has higher flexibility than the holding region R2 because the distribution density of SAP is lower than that of the holding region R2. Therefore, the core 25 having the 1 st low density region R11 is easily deformed in shape. Here, when the wearer wears the wearing article 1, both ends of the holding region R2 in the waist orthogonal direction are disposed so as to face the front abdomen and the back of the wearer, respectively. The 1 st low-density region R11 having a distribution density of SAP lower than that of the holding region R2 is disposed in a portion adjacent to both end portions of the holding region R2 in the waistline orthogonal direction. Therefore, the portion of the core 25 where the 1 st low density region R11 is disposed flexibly deforms along the body shape of the front abdominal portion and the back portion, and the portion contacts the front abdominal portion and the back portion with a soft touch, whereby the wearing comfort of the wearing article 1 can be improved.

The core 25 shown in fig. 5A to 5C and the surface sheet 24 having the concave-convex shape 20a may be combined to manufacture the wearing article 1. In this case, the air permeability and the skin feel can be improved by the concave-convex shape 20a of the surface sheet 24. Further, after absorbing body fluid, good breathability and skin feel can be maintained by the concave-convex shape 20a of the surface sheet 24.

Further, the arrangement of the low density regions in the core 25 is not limited to the above manner, and an arrangement such as shown in fig. 6A to 6D may be employed.

As shown in fig. 6A and 6B, in the core-side 1 st nonwoven fabric S1, the 1 st low-density region R11 is disposed adjacent to both ends of the holding region R2 in the waistline orthogonal direction, and the 2 nd low-density region R12 is disposed so as to be sandwiched in the holding region R2 in the waistline width direction. The holding region R2 is a region that carries SAP to have a specified water absorbing property for urine or the like. The SAP has a lower distribution density in the 2 nd low density region R12 than in the retention region R2. In addition, the 2 nd low density region R12 may not carry SAP. The distribution density of the SAP in the 2 nd low density region R12 may be substantially the same as or different from the distribution density of the SAP in the 1 st low density region R11. The 1 st nonwoven fabric S1 on the core side exhibits a predetermined water absorption performance in the entirety of the 1 st low density region R11, the 2 nd low density region R12, and the holding region R2.

Further, the formation position of the 2 nd low-density region R12 of the present embodiment will be described: as shown in fig. 6A, the 2 nd low density region R12 is provided so as to be continuous in the waistline orthogonal direction at the central portion in the waistline width direction of the core 25. The holding region R2 is provided so as to be adjacent to both sides in the waistline width direction of the 2 nd low density region R12.

The amount of SAP held in the 2 nd low-density region R12 is smaller than the amount of SAP held in the holding region R2. Therefore, the softness of the core 25 in the 2 nd low density region R12 is higher than the softness of the core 25 in the holding region R2. Accordingly, the core 25 is easily deformed along the body shape, and the stiff feel of the core 25 can be suppressed, so that the fit of the wearing article 1 can be improved.

For example, in fig. 6A to 6D, the 2 nd low density region R12 extends continuously in the waistline orthogonal direction at the central portion in the waistline width direction of the core 25. Accordingly, by bending the core 25 with reference to the 2 nd low-density region R12 having a smaller SAP amount and greater flexibility than the holding region R2, the core 25 can be deformed along the body shape of the wearer within the formation range of the 2 nd low-density region R12 in the waist orthogonal direction, and the fit of the wearing article can be improved.

Specifically, since the 2 nd low-density region R12 is arranged at the central portion in the waist width direction, the core 25 is easily deformed to be bent approximately symmetrically in an inverted V shape with the 2 nd low-density region R12 at the central portion as the center, as shown in fig. 6C. Accordingly, as shown in fig. 6C, when the wearer wears the article, the core 25 extending from the back portion to the front abdomen portion via the crotch portion deforms in accordance with the shape of the wearer's crotch portion. Therefore, the wearing comfort of the wearing article 1 can be further improved. As shown in fig. 6D, the core 25 may be deformed to be bent substantially symmetrically in a V-shape around the 2 nd low density region R12. In this case, too, the core 25 is less likely to become thicker between the crotch portions, and the wearing comfort of the wearing article 1 can be improved.

Further, since the amount of urine or the like absorbed by the 2 nd low density region R12 is smaller than that of the holding region R2, urine or the like can be diffused in the direction perpendicular to the waist along the 2 nd low density region R12. Accordingly, the core 25 can efficiently absorb urine or the like by the holding regions R2 adjacent to both sides in the waist width direction of the 2 nd low density region R12.

More specifically, based on the arrangement of the 2 nd low density region R12 and the holding region R2 shown in fig. 6A, the 2 nd low density region R12 is located at the central portion in the waist width direction of the core 25, that is, at a position in the crotch where the amount of urine or the like received is large. Therefore, urine or the like is highly likely to be guided to the 2 nd low density region R12 and the holding region R2 adjacent thereto in the waistline width direction. After the urine or the like is introduced into the 2 nd low density region R12 and the holding region R2, the urine or the like can be diffused along the 2 nd low density region R12 extending in the direction perpendicular to the waist while allowing the 2 nd low density region R12 and the holding region R2 around the same to absorb the urine or the like. At this time, urine or the like diffused along the 2 nd low density region R12 is also absorbed by the 2 nd low density region R12 and the holding region R2 adjacent thereto in the waistline width direction. Accordingly, by diffusing urine or the like, urine or the like can be quickly absorbed by a larger range of the holding region R2, as compared with when the 2 nd low density region R12 is not present (when the density of the SAP is constant throughout the holding range). Therefore, the sticky feeling of the skin surface caused by urine and the like can be quickly solved, and the uncomfortable feeling can be alleviated.

Further, since the 2 nd low-density region R12 can be used as a region for expanding the SAP in the holding region R2, excessive adhesion of the absorbent body 20 to the skin surface can be suppressed. Thus, the sticky feeling of the skin surface caused by urine and the like can be rapidly solved, and the uncomfortable feeling can be alleviated.

Further, the wearing article 1 having the core 25 shown in fig. 6A to 6D described above is put on the waist by coupling the male fastener 12 and the female fastener 22. In addition, in a state where the absorbent body 20 is attached to the crotch portion, the sense of attachment to the crotch portion can be improved based on the softness of the 2 nd low density region R12 of the core 25 before absorbing body fluid. Further, after the body fluid is absorbed, the expansion space of the SAP can be ensured by the 2 nd low density region R12 of the core 25, and thus the core 25 can be prevented from being excessively expanded to the skin surface side, and a good skin feel can be maintained.

The core 25 shown in fig. 6A to 6D and the surface sheet 24 having the concave-convex shape 20a may be combined to manufacture the wearing article 1. In this case, in a state where the absorbent body 20 is attached to the crotch, before absorbing body fluid, the wearing article 1 can be improved in the sense of attachment to the crotch and also in the breathability and the skin feel by the concave-convex shape 20a of the front sheet 24 and the 2 nd low density region R12 of the core 25. Further, since the expansion space of the SAP can be ensured by the 2 nd low density region R12 of the core 25 after absorbing the body fluid, unnecessary excessive expansion of the core 25 to the skin surface side can be suppressed, and good air permeability and skin touch can be maintained by the concave-convex shape 20a of the surface sheet 24.

The 2 nd low-density region R12 and the holding region R2 are not limited to be formed by adjusting the amount of SAP carried in the core-side nonwoven fabric. For example, a space formed by dividing the core-side nonwoven fabric in which the holding regions R2 are formed and separating the divided portions from each other in the width direction may be used as the 2 nd low-density region R12. Alternatively, a portion in which the surface of the core-side nonwoven fabric (the surface subjected to the napping treatment) of the holding region R2 is pressed to collapse the fibers in the napped state and thereby reduce the gap for holding the SAP may be used as the 2 nd low-density region R12.

In the above embodiment, the core-side 2 nd nonwoven fabric S2 has only the 3 rd low-density region R13 as the low-density region. However, both the core-side nonwoven fabrics S1 and S2 may have the 1 st low-density region R11, the 2 nd low-density region R12, and the holding region R2. For example, the core-side 1 st nonwoven fabric S1 has 1 st low-density regions R11 provided at both ends of the core-side 1 st nonwoven fabric S1 and 2 nd low-density regions R12 located between the two 1 st low-density regions R11. Similarly, the core-side 2 nd nonwoven fabric S2 has 3 rd low-density regions R13 provided at both ends of the core-side 2 nd nonwoven fabric S2 and 2 nd low-density regions R12 located between the two 3 rd low-density regions R13. In this case, the 2 nd low-density region R12 of the 1 st core-side nonwoven fabric S1 and the 2 nd low-density region R12 of the core-side 2 nd nonwoven fabric S2 may be disposed at different positions in a plan view or may be disposed at positions overlapping each other in a plan view.

In addition, for the 2 nd low-density region R12 of fig. 6A to 6D, for example, the method shown in fig. 7A to 7C may be adopted. Regarding the 2 nd low-density region R12 of fig. 7A to 7C, only the differences from fig. 6A to 6D will be described with emphasis.

As shown in fig. 7A, in the example, the 1 st low-density region R11 is disposed adjacent to both end portions of the holding region R2 in the waistline orthogonal direction, and a plurality of 2 nd low-density regions R12 are intermittently provided along the waistline orthogonal direction in the central portion in the waistline width direction of the core-side 1 st nonwoven fabric S1. Accordingly, by using the holding region R2 between the plurality of 2 nd low density regions R12 as a bank, the diffusion range of urine or the like in the core 25 and the absorption range of the holding region R2 can be divided into approximately 3.

Further, in the central portion in the waistline width direction of the core-side 1 st nonwoven fabric S1, the holding regions R2 are provided adjacent to the 2 nd low-density regions R12 in the waistline orthogonal direction at both end portions in the waistline orthogonal direction. That is, in the core-side 1 st nonwoven fabric S1, both ends in the waist orthogonal direction of the 2 nd low-density region R12 are closed by the holding region R2. Accordingly, the holding region R2 can be used as a bank for the 2 nd low density region R12. Therefore, based on the structure shown in fig. 7A, urine or the like can be prevented from being guided to the outside of the core 25 by the 2 nd low density region R12 in the waist orthogonal direction.

In the example shown in fig. 7B, in the core-side 1 st nonwoven fabric S1, the 1 st low-density region R11 is disposed adjacent to both ends of the holding region R2 in the waistline orthogonal direction, and in addition to the 2 nd low-density region R12 similar to fig. 6A provided at the central position in the waistline width direction, the 2 nd low-density region R12 is also provided on both sides of the 2 nd low-density region R12 in the waistline width direction. The 3 2 nd low density regions R12 extend parallel to each other along the waistline orthogonal direction. By adding the two 2 nd low density regions R12, urine or the like scattered on the surface of the core 25 is easily spread over the entire core 25, and flexibility in the direction perpendicular to the waist of the core 25 is also improved.

For the example shown in fig. 7C, the 1 st low-density region R11 is disposed adjacently to both end portions in the waistline orthogonal direction of the holding region R2 in the waistline orthogonal direction, whereas the 2 nd low-density region R12 shown in fig. 7B, which is disposed at the central position in the waistline width direction of the core-side 1 st nonwoven fabric S1, is not disposed. That is, the holding region R2 is provided at the center position in the waistline width direction of the core-side 1 st nonwoven fabric S1, and the 2 nd low-density regions R12 are provided at both sides of the center position in the waistline width direction. The two 2 nd low density regions R12 extend parallel to each other along the waistline orthogonal direction. Based on the two 2 nd low density regions R12, urine and the like are more likely to spread over the entire core 25, and flexibility in the waist orthogonal direction of the core 25 is also improved, as compared with the 1 st 2 nd low density region R12 shown in fig. 6A.

In the example shown in fig. 7A and 7B, the core 25 is easily deformed to be bent substantially symmetrically in a V-shape or an inverted V-shape with the central portion in the waist width direction in which the 2 nd low density region R12 is arranged as the center, similarly to the example shown in fig. 6A. In the example shown in fig. 7C, since two 2 nd low-density regions R12 are provided apart from the central portion in the waist width direction, the core 25 is easily deformed to be bent substantially symmetrically in a U-shape or an inverted U-shape.

The extending direction of the 2 nd low density region R12 is not limited to the waistline orthogonal direction. For example, the 2 nd low density region R12 may extend in the waist width direction in the core 25 and be sandwiched in the holding region R2 in the waist width direction. For example, when the 2 nd low density region R12 is arranged in the crotch along the waist width direction, urine or the like may be spread along the 2 nd low density region R12 in the waist width direction, and the holding region R2 adjacent to the 2 nd low density region R12 may be absorbed. Further, since the end portion in the waistline width direction of the 2 nd low density region R12 is adjacent to the holding region R2, the holding region R2 can be used as a dam. Accordingly, urine or the like can be prevented from being guided from the 2 nd low density region R12 to the outside in the waist width direction of the core 25.

Further, the 2 nd low density region R12 may have a portion extending in the waistline orthogonal direction and a portion extending in the waistline width direction. For example, the 2 nd low density region R12 may have a portion extending in the waistline orthogonal direction at the central portion in the waistline width direction of the core 25, and a portion diverging from the portion extending in the waistline orthogonal direction toward the waistline width direction. Accordingly, along the 2 nd low density region R12, urine and the like can be diffused in both the waist orthogonal direction and the waist width direction, and the holding region R2 can quickly absorb urine and the like.

The regions in which the SAP distribution densities are different from each other are not limited to the low density regions R11, R12, R13 and the holding regions R2, R3. For example, a plurality of regions having different distribution densities selected from the distribution region between the distribution density of SAP of 0 and the distribution density of SAP of the holding region R2 may be provided in the core 25 based on the holding region R2.

In addition, in the above-described embodiment, although the SAP is supported by both the core-side nonwoven fabrics, only one of the core-side nonwoven fabrics may support the SAP, and the remaining core-side nonwoven fabrics may not support the SAP. Moreover, fluff pulp may also be included.

For example, in the core 25 of fig. 5A to 5C, the core-side nonwoven fabric including fluff pulp may be disposed on the skin surface side of the core 25 facing the wearer, and the core-side 1 st nonwoven fabric S1 shown in fig. 5A to 5C may be disposed on the opposite side to the skin surface side. In this case, the fluff pulp of the core-side nonwoven fabric on the skin-side absorbs body fluid earlier than the SAP, and the SAP of the core-side 1 st nonwoven fabric S1 on the opposite side further absorbs body fluid absorbed by the fluff pulp. The core 25 of fig. 6A to 6D and fig. 7A to 7C may be configured such that the core-side nonwoven fabric including fluff pulp is disposed on the upper layer, and the core-side 1 st nonwoven fabric S1 shown in fig. 6A to 6D and fig. 7A to 7C is disposed on the lower layer, as in the above.

The method of supporting the SAP by the core-side nonwoven fabric is not limited to a method of supporting the SAP by the fiber layer of the core-side nonwoven fabric that is napped to form a gap for supporting the SAP. For example, the SAP may be disposed on the surface of the core-side nonwoven fabric by applying an adhesive to the surface of the core-side nonwoven fabric and dispersing the SAP on the applied adhesive. In this case, the amount of the adhesive applied to the low density regions R11, R12, R13 per unit area is smaller than the amount of the adhesive applied to the holding regions R2, R3 per unit area. Further, the SAP may be dispersed in the fiber layer of the fluffed core-side nonwoven fabric, and the SAP may be carried in the fiber layer of the core-side nonwoven fabric by being sucked from the surface opposite to the surface on which the SAP is dispersed.

The number of core-side nonwoven fabrics used to form the core 25 is not limited to two, and may be 1 core-side nonwoven fabric.

As shown in fig. 4 and the like, the back sheet 26 is a strip-shaped sheet having a rectangular shape extending in the direction perpendicular to the waist. The back sheet 26 is provided on the outer surface of the core 25 opposite to the surface facing the skin surface, and the core 25 is interposed between the back sheet 26 and the front sheet 24. The back sheet 26 includes: a liquid-impermeable sheet body 26a facing the core 25; and an outer sheet 26b for covering an outer surface of the liquid-impermeable sheet 26a opposite to the surface facing the core 25.

The liquid-impermeable sheet 26a is a belt-shaped sheet having water repellency and being impermeable to urine and the like. The liquid-impermeable sheet body 26a is formed of, for example, a nonwoven fabric made of polypropylene, polyethylene, or the like. Desirably, the liquid-impermeable sheet body 26a has air permeability.

The core 25 is joined to the liquid-impermeable sheet 26a in a state where the core 25 is disposed in a range of the waist width direction and the waist orthogonal direction of the liquid-impermeable sheet 26a. In this way, since the liquid-impermeable sheet body 26a is provided on the outer surface of the core 25 opposite to the surface facing the skin surface, even if the core 25 cannot completely absorb urine or the like, the outflow of urine or the like to the outside of the liquid-impermeable sheet body 26a can be suppressed.

In the example shown in fig. 4, the liquid-impermeable sheet 26a has a rectangular shape. However, in a plan view, the leg periphery curved portions may be formed in the liquid-impermeable sheet body 26a at the center positions of both edge portions in the waist width direction of the liquid-impermeable sheet body 26a in the waist orthogonal direction. In order to dispose the liquid-impermeable sheet body 26a around the legs of the wearer without gaps, the leg-surrounding curved portions are formed by recessing the both edge portions in the waist width direction.

The leg gathers 31 are elastic members corresponding to the leg roots when the wearer wears the article 1. The leg gathers 31 are provided along both edges of the liquid-impermeable sheet body 26a in the waistline width direction, and are provided over substantially the entire range of the liquid-impermeable sheet body 26a in the waistline orthogonal direction. The leg gathers 31 are disposed in an elongated state along the waistline orthogonal direction between the liquid-impermeable sheet body 26a and the top sheet body 24, and are joined to at least one of the liquid-impermeable sheet body 26a and the top sheet body 24. For the joining, bonding with a hot melt adhesive or welding based on heat sealing may be employed, but ultrasonic welding is more desirable. By providing such leg gathers 31, a soft touch can be imparted to the leg roots as compared with when both edge portions of the absorber 20 are directly abutted against the leg roots, and the wearing comfort of the wearing article 1 can be further improved.

The leg gathers 31 may be disposed between the liquid-impermeable sheet body 26a and the outer sheet body 26b and joined to at least one of them.

The absorber elastic member 21 is provided at a free end (an end on the opposite side to the waistline member 10) of the liquid-impermeable sheet body 26a in the waistline orthogonal direction, and has elasticity that can expand and contract in the waistline width direction. Therefore, the distal end portion of the absorber 20 having the liquid-impermeable sheet body 26a on the opposite side to the side joined to the waistline member 10 can be stretched in the waistline width direction. Further, as described above, the waistline member 10 may be stretched and contracted in the waistline width direction based on the waistline elastic member 11. Accordingly, since the distal end portions of the waist member 10 and the absorber 20 can be extended and contracted in the waist width direction according to the waist length of the wearer, the degree of freedom in selecting the coupling position between the male fastener 12 of the waist member 10 and the female fastener 22 of the absorber 20 is large. Accordingly, the fit of the wearing article 1 can be improved.

In addition, the absorber elastic member 21 is not an essential member. Even if the absorber elastic member 21 is omitted, the waistline member 10 has elasticity in the waistline width direction, so that the fit of the wearing article 1 can be improved.

The outer sheet 26b is a sheet extending in the direction perpendicular to the waist and made of nonwoven fabric, and is attached to the outer surface of the liquid-impermeable sheet 26a opposite to the surface facing the skin surface in a state where the liquid-impermeable sheet 26a is covered from the outer surface side. Therefore, the beauty of the outer side of the wearing article 1 and the skin feel of the wearing article 1 can be improved. In the example shown in fig. 4, the outer sheet 26b has a rectangular shape. However, in a plan view, leg-surrounding curved portions may be formed in the outer sheet 26b at a central position of both edge portions in the waistline width direction of the outer sheet 26b in the waistline orthogonal direction. In this case, in order to dispose the outer sheet 26b around the legs of the wearer without any gap, the leg-surrounding curved portions are formed by recessing the both edge portions in the waistline width direction.

As described above, leg periphery curves may be provided in the liquid-impermeable sheet body 26a and the outer sheet body 26b. Further, as described above, the lower edge of the leg root side of the waistline member 10 is provided with the leg periphery curve portion 15b. In this case, as shown in fig. 1 and 2, by assembling the wearing article 1 by connecting the male fastener 12 of the waistline member 10 and the female fastener 22 of the absorber 20, a curved leg hole disposed along the entire circumference of the leg root can be formed based on the leg-surrounding curved portions of the liquid-impermeable sheet body 26a and the outer sheet body 26b and the leg-surrounding curved portion 15b of the waistline member 10.

The peripheral edge of the leg hole is elastically fitted to the entire periphery of the leg root by the leg gathers 31 and the waist elastic member 11 disposed near the leg periphery curved portion 15 b. Accordingly, wearing comfort can be improved.

The female fastener 22 is provided on the outer surface of the distal end portion of the outer sheet 26b on the opposite side of the waistline member 10 in the waistline orthogonal direction. The female fastener 22 is provided over substantially the entire range in the waist width direction of the distal end portion of the outer sheet 26 b. The length of the female fastener 22 in the waist-orthogonal direction may be substantially the same as the length of the male fastener 12 in the waist-orthogonal direction, or may be longer than the length of the male fastener 12 in the waist-orthogonal direction.

In this way, the female fastener 22 is provided over substantially the entire range in the waist width direction of the distal end portion of the outer sheet 26 b. Therefore, by expanding and contracting the waist member 10 in the waist width direction, the male fastener 12 can be coupled to an arbitrary position in the waist width direction of the female fastener 22, and the degree of freedom in selecting the coupling position is large. Accordingly, the coupling position between the waistline member 10 and the absorber 20 can be easily adjusted according to the waistline length of each wearer, and the fit can be improved.

The indicator 50 changes color according to the amount of urine or the like absorbed by the core 25 and indicates that the wearer discharges urine. The indicator 50 extends in the waistline-orthogonal direction at the center portion in the waistline width direction of the outer sheet 26b on the skin-facing side surface of the outer sheet 26 b. As the indicator 50, for example, an adhesive that changes color according to the absorption amount of urine or the like is used.

As shown in fig. 4, the three-dimensional wrinkles 40 are provided on the skin-facing surface of the front sheet 24. The three-dimensional wrinkles 40 have: a pair of lift flaps 42; and three-dimensional creased elastic members 41 respectively provided on the standing flaps 42. The standing flaps 42 extend in the waistline-orthogonal direction and are joined to both edge portions of the top sheet 24 in the waistline width direction. Specifically, one side edge portion (for example, the right side edge portion) of each standing flap 42 in the waist width direction is joined to one side edge portion (for example, the right side edge portion) of the surface sheet 24. Each three-dimensional creased elastic member 41 is joined in an elongated state to the other side edge portion (for example, the left side edge portion) of the standing flap 42 in the waist width direction. In a state where the absorber 20 is bent in the waist orthogonal direction along the crotch of the wearer, the other side edge portion (for example, the left side edge portion) in the waist width direction of each standing flap 42 contracts based on the urging force of the three-dimensional creased elastic member 41, and thus each standing flap 42 stands up with respect to the surface sheet 24. When worn, the standing flaps 42 are elastically fitted to the back, crotch, front belly, etc. Accordingly, urine and the like can be prevented from flowing out of the wearing article 1.

In order that the waist member 10 and the absorber 20 are not unfolded when worn, the length of the female fastener 22 in the waist width direction and the waist orthogonal direction may be set to a length that can obtain a coupling force with the male fastener 12. For example, the female fastener 22 may be provided only at the center in the waist width direction at the distal end portion of the outer sheet 26b, or may be divided into two and provided at both side portions in the waist width direction.

The waist member 10 and the absorber 20 may be connected by providing the female fastener 22 on the waist member 10 and providing the male fastener 12 on the absorber 20.

The back sheet 26 may be formed of only the liquid-impermeable sheet 26 a.

A transfer sheet (not shown) may be provided between the surface sheet 24 and the core 25. The transfer sheet serves to rapidly spread urine or the like along the surface of the core 25 and prevent leakage of urine or the like absorbed by the core 25 from the surface sheet 24.

Since the coupling between the male fastener 12 and the female fastener 22 is released in the initial state of the developed wearing article 1, the wearing article can be developed into a predetermined form without releasing the coupling. In the wearing article of the developed form, both side portions 10a of the waistline member 10 protrude from the absorber 20 arranged on the joining portion 10b of the waistline member 10. The side portions 10a can be made to face the distal end portion of the absorber 20 along the waist of the wearer and to abut against the back sheet 26 of the absorber 20 disposed along the crotch of the wearer. Then, the male hook and loop fasteners 12 at both ends 10c in the waist width direction of the waist member 10 are connected to the female hook and loop fasteners 22 of the back sheet 26, whereby the spread-out wearing article 1 is supported at the waist, and the absorber 20 is pulled up, and the absorber 20 is attached to the crotch of the wearer.

By coupling the male fastener 12 and the female fastener 22 of the wearing article 1 in the developed form to each other in this way, the wearing article 1 can be put on like pants, and the wearer can put on the wearing article 1. In addition, when in the pants-type form, the male fastener 12 and the female fastener 22 are released from the connection, so that the pants-type diaper can be re-unfolded to a predetermined unfolded form.

Further, the wearing article 1 is compact by folding, and the plurality of wearing articles 1 can be brought into a form suitable for packaging, storage, and the like.

< method for producing developed wearing article >

Next, a method for manufacturing the spread-type wearing article 1 will be described.

In each step below, the direction MD (Machine Direction) a is a conveying direction of a sheet or the like, and the direction CD (Cross Direction) W is a direction substantially orthogonal to the MD direction a.

(1) Step 1 to step 2

As shown in fig. 8, 9, and 17, steps 1 to 2 are examples of steps for producing a waistline continuous body in which a plurality of waistline main bodies 16 are continuous in the lateral flow state shown in fig. 9. In the lateral flow state shown in fig. 9, the MD direction a coincides with the waistline width direction, and the CD direction W coincides with the waistline orthogonal direction.

(Process 1)

In step 1, the continuous body of the outer sheet 15 formed by connecting the plurality of outer sheets 15 is conveyed in the MD direction a (see fig. 17A), and the waist elastic members 11 are arranged in a straight line in the MD direction a on the continuous body of the outer sheet 15 (see fig. 17B). The waist elastic members 11 are disposed at intervals in the waist orthogonal direction from each other on the lower side of the upper end edge of the outer sheet 15.

Next, as shown in fig. 9 and 17C, the continuous body of the inner sheet 14, in which the plurality of inner sheets 14 are continuous, is conveyed in the MD direction a, and the continuous body of the inner sheet 14 is disposed on the continuous body of the outer sheet 15 so as to cover the waist elastic member 11 from above. As shown in fig. 9, the continuous body of the inner sheet 14 is positioned in a state where the upper side of the outer sheet 15 is exposed, and is covered and joined to the continuous body of the outer sheet 15. Accordingly, the protruding portion 15c is formed by the exposed portion of the outer sheet 15.

In this way, the waist elastic member 11 is arranged in a straight line in the MD direction a on the continuous body of the outer sheet body 15. However, the waist elastic member 11 disposed at the lower end edge of the inner sheet 14 of the waist elastic member 11 may be disposed in a curved shape along the curve of the leg periphery curve portion 15b formed in step 8 described later. For example, the waist elastic member 11 disposed at the lower end edge of the inner sheet 14 may be disposed on the outer sheet 15 along a substantially sinusoidal trajectory that meanders with respect to the MD direction a.

The waist elastic member 11 is sandwiched between the continuous body of the outer sheet 15 and the continuous body of the inner sheet 14 in an extended state, and is joined to at least one of the continuous body of the outer sheet 15 and the continuous body of the inner sheet 14. In addition, for the joining method, adhesion by a hot melt adhesive or welding by heat sealing may be used, but ultrasonic welding is more preferable.

(Process 2)

In step 2, the weakened portions 15a1 for disposing the absorbent body 20 and the waist elastic members 11 disposed on the weakened portions 15a2 of the male fastener tab 12 are weakened in the continuous body of the outer sheet 15 and the continuous body of the inner sheet 14. As described later, the weakening process is a process in which: the elastic member of the designated portion is cut by a cutter, melted by heating, or the like, so that the elasticity of the designated portion is weaker than the portion adjacent to the designated portion, or the elasticity of the designated portion is invalidated. Specifically, by the weakening process, the elastic force of the weakened portions 15a1, 15a2 becomes weaker than the elastic force of the portions adjacent to the weakened portions 15a1, 15a2 in the waist width direction (MD direction a of fig. 9).

As the weakening treatment, for example, a method of melting the waist elastic member 11 by an embossing roller (refer to japanese laid-open patent publication No. 2002-113042) or a method of cutting the waist elastic member 11 by a creasing cutter 60 (refer to fig. 8) may be employed.

The weakening process may be performed only in a period before the step 8 for attaching the absorbent body 20, which will be described later.

(2) Procedure 3 to procedure 7

Steps 3 to 7 are examples of the steps for producing the absorbent body 20 in the longitudinally flowing state shown in fig. 10. In the longitudinal flow state shown in fig. 10, the MD direction a coincides with the waistline orthogonal direction, and the CD direction W coincides with the waistline width direction.

(step 3)

In step 3, a surface sheet semi-product is formed in which a continuous body of the surface sheet 24 formed by connecting a plurality of surface sheets 24 and a continuous body of the three-dimensional wrinkles 40 formed by connecting a plurality of three-dimensional wrinkles 40 are combined.

In fig. 8, 10, and 18, a nonwoven sheet body for forming a continuous body of standing flaps 42 formed by connecting a plurality of standing flaps 42 is continuously conveyed in the MD direction a, and the nonwoven sheet body is cut in the MD direction a by a slitter (slit) 62 (see fig. 18A). The continuous bodies of the pair of cut belt-like standing flaps 42 are separated from each other at a predetermined interval W2 in the CD direction W (see fig. 18B). Next, the three-dimensional creased elastic members 41 are arranged in an elongated state in the MD direction a at the inner edge portions of the continuous bodies of the pair of standing flaps 42 (the edge portions of the continuous body of one standing flap 42 being close to the continuous body of the other standing flap 42 in the CD direction W) (see fig. 18C).

As shown in fig. 18D, the inner edge portion of the continuous body of the standing flap 42, on which the three-dimensional fold elastic member 41 is arranged, is folded back by a folding back machine (sailor) 63 so that the three-dimensional fold elastic member 41 is sandwiched inside the standing flap 42. Thereby forming the inward bend 40a. At this time, the three-dimensional creased elastic member 41 is joined to the continuous body of the standing flap 42 by means of adhesion by hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like in a state of being sandwiched in the inside bent portion 40a in the MD direction a in an elongated state. Thereby, a continuous body of the three-dimensional wrinkles 40 is produced.

Thereafter, the outer edge portions 40b of the continuous body of the three-dimensional gather 40 (the edge portions of the continuous body of one standing flap 42 apart from the continuous body of the other standing flap 42 in the CD direction W) are joined to the two outer edge portions of the continuous body of the surface sheet 24 continuously conveyed in the MD direction a by means of adhesion with a hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like, thereby producing a surface sheet semifinished product (see fig. 18E).

Next, a method for producing the continuous body of the surface sheet 24 will be described. First, the structure of the apparatus 85 for manufacturing a continuous body of the surface sheet 24 will be described.

Fig. 11 is a schematic diagram of the manufacturing apparatus 85. As shown in fig. 11, the manufacturing apparatus 85 includes: the 1 st and 2 nd rollers 92, 94 disposed adjacent to each other; and a joining device 100 disposed adjacent to the 1 st roller 92.

The 1 st roller 92 has a plurality of concave portions 92a on a cylindrical outer peripheral surface 92s, and the plurality of concave portions 92a are recessed radially inward from the outer peripheral surface 92s and engaged with a plurality of convex portions 94a described later. The 2 nd roller 94 has a plurality of protruding portions 94a protruding radially outward from the outer peripheral surface 94s on the cylindrical outer peripheral surface 94 s. The protruding portion 94a may have a hemispherical shape, for example, a hemispherical protruding tip thereof, or may have a rectangular parallelepiped shape, a cylindrical shape, a prismatic table shape, or the like. The 1 st and 2 nd rollers 92, 94 rotate in opposite directions to each other as indicated by arrows 92r, 94 r. The concave portion 92a of the 1 st roller 92 and the convex portion 94a of the 2 nd roller 94 are engaged with each other at the engagement region 93. More specifically, the 1 st and 2 nd rollers 92 and 94 are rotated so that the concave portion 92a and the convex portion 94a are engaged with each other in a state where a gap is formed between the concave portion 92a and the convex portion 94a in the engagement region 93, that is, in a state where the concave portion 92a and the convex portion 94a are not in contact with each other.

The joining device 100 is an ultrasonic sealing device for joining two continuous bodies, i.e., a continuous body of the surface-side 1 st nonwoven fabric 24a formed by joining a plurality of surface-side 1 st nonwoven fabrics 24a and a continuous body of the surface-side 2 nd nonwoven fabric 24b formed by joining a plurality of surface-side 2 nd nonwoven fabrics 24b, to each other to manufacture a continuous body of the surface sheet 24. For the joining method, bonding by a hot melt adhesive or welding by heat sealing may be used, but ultrasonic welding is more desirable. The surface sheet 24 is preferably prevented from hardening when being ultrasonically welded, as compared with when using an adhesive or heat sealing.

By using the manufacturing apparatus 85, the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b can be overlapped to form the uneven shape 20a. Further, by using the manufacturing apparatus 85, the continuous body of the surface side 1 st nonwoven fabric 24a and the continuous body of the surface side 2 nd nonwoven fabric 24b can be joined to each other in a state where tension is applied to the continuous body of the surface side 2 nd nonwoven fabric 24b so that the undulation of the continuous body of the surface side 2 nd nonwoven fabric 24b is made smoother than the undulation of the continuous body of the surface side 1 st nonwoven fabric 24a while maintaining the undulation of the continuous body of the surface side 1 st nonwoven fabric 24a 20a. A method for producing such a continuous body of the surface sheet 24 will be further described below.

As shown in fig. 11 and 12A, the continuous body of the surface 1 st nonwoven fabric 24a is wound around the outer peripheral surface 92s of the 1 st roll 92 earlier than the continuous body of the surface 2 nd nonwoven fabric 24 b. Since the concave portion 92a of the 1 st roll 92 is connected to a negative pressure source, the continuous body of the 1 st nonwoven fabric 24a on the surface side is adsorbed and held along the outer peripheral surface 92s of the 1 st roll 92. Next, the continuous body of the surface side 2 nd nonwoven fabric 24b is wound around the outer peripheral surface 92s of the 1 st roll 92 via the continuous body of the surface side 1 st nonwoven fabric 24a at the engagement region 93 or at a position slightly upstream of the engagement region 93. That is, the continuous body of the front side 2 nd nonwoven fabric 24b overlaps the outer side of the continuous body of the front side 1 st nonwoven fabric 24a at the meshing region 93 or at a position slightly upstream of the meshing region 93. In order to wind the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b around the outer peripheral surface 92s of the 1 st roll 92 as described above, the 1 st roll 92 guides the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b in the direction indicated by the arrow B, C (fig. 11).

The portions 24a1 and 24b1 covering the recess 92a in the continuous body of the surface side 1 st nonwoven fabric 24a and the continuous body of the surface side 2 nd nonwoven fabric 24b are pressed into the recess 92a by the protruding portions 94a in a state of overlapping each other in the engagement region 93. Thus, the portions 24a2 and 24B2 pressed into the concave portion 92A are formed on the continuous body of the surface side 1 st nonwoven fabric 24a and the continuous body of the surface side 2 nd nonwoven fabric 24B (see fig. 12A and 12B). That is, the uneven pattern 20a is formed by forming the plurality of portions 24a2 and 24b2 on the continuous body of the surface side 1 st nonwoven fabric 24a and the continuous body of the surface side 2 nd nonwoven fabric 24b that overlap each other.

As described above, the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b overlap in the engagement region 93, and are joined by the joining device 100 on the downstream side (right side in fig. 12A to 12C) than the engagement region 93. In this way, the relative movement of the two continuous bodies is suppressed based on the frictional resistance generated between the two continuous bodies due to the overlapping of the continuous bodies of the surface side 1 st nonwoven fabric 24a and the surface side 2 nd nonwoven fabric 24 b. By the above-described joining, the relative movement between the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b is restricted. On the other hand, as shown in fig. 11, on the upstream side (left side in fig. 12A to 12C) of the meshing area 93, the continuous body of the front side 1 st nonwoven fabric 24a and the continuous body of the front side 2 nd nonwoven fabric 24b are conveyed in a non-contact and non-bonded state. Therefore, on the upstream side of the meshing area 93, the relative movement of the continuous body of the surface side 1 st nonwoven fabric 24a and the continuous body of the surface side 2 nd nonwoven fabric 24b is allowed. Therefore, the relative movement of the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b is more likely to occur on the upstream side than on the downstream side of the meshing area 93.

As shown in fig. 12B, the convex portion 94a engaged with the concave portion 92a gradually comes out of the concave portion 92a with the rotation of the 1 st roller 92. As described above, the air in the concave portion 92a is sucked. Accordingly, the convex portion 94a is inserted into the concave portion 92a, whereby the plurality of portions 24a2 of the continuous body of the front side 1 st nonwoven fabric 24a are formed while staying in the concave portion 92 a. On the other hand, as shown in fig. 12C, as the convex portion 94a gradually comes out of the concave portion 92a, the portion 24b2 on the continuous body of the surface side 2 nd nonwoven fabric 24b is pulled by the tension applied to the continuous body of the surface side 2 nd nonwoven fabric 24b, and thereby is pulled out of the concave portion 92 a. Accordingly, the undulation formed in the continuous body of the surface side 2 nd nonwoven fabric 24b is smoother than the undulation formed in the continuous body of the surface side 1 st nonwoven fabric 24 a.

After the protruding portion 94a is completely removed from the recessed portion 92a, the portion 24b2 of the continuous body of the surface side 2 nd nonwoven fabric 24b pressed into the recessed portion 92a is completely pulled out from the recessed portion 92a based on the tension applied to the continuous body of the surface side 2 nd nonwoven fabric 24 b. Accordingly, the undulation formed in the continuous body of the surface side 2 nd nonwoven fabric 24b is smoother than the undulation 20a formed in the continuous body of the surface side 1 st nonwoven fabric 24 a. On the other hand, as described above, the portion 24a2 pressed into the concave portion 92a in the continuous body of the surface side 1 st nonwoven fabric 24a remains in the concave portion 92a, and therefore, the concave-convex shape 20a is formed only on the continuous body of the surface side 1 st nonwoven fabric 24 a.

In order to form the uneven pattern 20a only on the continuous body of the surface side 1 st nonwoven fabric 24a as described above, the tension T2 applied to the continuous body of the surface side 2 nd nonwoven fabric 24b is set to be larger than the tension T1 applied to the continuous body of the surface side 1 st nonwoven fabric 24a (T1 < T2). Accordingly, the portion 24b2 of the continuous body of the front side 2 nd nonwoven fabric 24b is pulled out of the concave portion 92a while being relatively moved with respect to the continuous body of the front side 1 st nonwoven fabric 24a in response to the protrusion 94a being pulled out of the concave portion 92 a. Accordingly, the uneven pattern 20a is formed on the continuous body of the surface side 1 st nonwoven fabric 24a, and the uneven pattern 20a on the continuous body of the surface side 2 nd nonwoven fabric 24b is formed to have a more gentle undulation than the uneven pattern 20a on the continuous body of the surface side 1 st nonwoven fabric 24a (in the present embodiment, the continuous body of the substantially flat surface side 2 nd nonwoven fabric 24b is formed).

As shown in fig. 11, the continuous body of the 1 st nonwoven fabric 24a on the surface side is conveyed in a state of being sucked into the concave portion 92a while contacting the outer peripheral surface 92s of the 1 st roll 92 at a position upstream of the meshing area 93. Accordingly, friction is generated between the 1 st roll 92 and the portion of the continuous body of the surface 1 st nonwoven fabric 24a extending from the upstream side portion of the engagement region 93 to the joining device 100. Therefore, even if the convex portion 94a is separated from the concave portion 92a, the portion 24a2 of the continuous body of the front side 1 st nonwoven fabric 24a pressed into the concave portion 92a is likely to stay in the concave portion 92a based on the friction force. Therefore, the uneven pattern 20a can be effectively formed on the continuous body of the 1 st nonwoven fabric 24a on the front surface side.

On the other hand, as described above, the continuous body of the surface side 2 nd nonwoven fabric 24b is wound around the outer peripheral surface 92s of the 1 st roll 92 via the continuous body of the surface side 1 st nonwoven fabric 24a at the engagement region 93 or at a position slightly upstream of the engagement region 93. That is, at the upstream side of the meshing area 93, the continuous body of the surface side 2 nd nonwoven fabric 24b is conveyed in a state of being in non-contact with the continuous body of the surface side 1 st nonwoven fabric 24a, the 1 st roll 92, and the 2 nd roll 94. Therefore, the portion of the continuous body of the surface side 2 nd nonwoven fabric 24b located upstream of the meshing area 93 does not generate friction with respect to the continuous body of the surface side 1 st nonwoven fabric 24a, the 1 st roll 92, and the 2 nd roll 94. Therefore, the portion of the continuous body of the front side 2 nd nonwoven fabric 24b located upstream of the meshing area 93 can be easily moved relative to the continuous body of the front side 1 st nonwoven fabric 24a and the 1 st roll 92. Accordingly, in order to draw out the portion 24b2 on the continuous body of the surface side 2 nd nonwoven fabric 24b from the recess 92a, the continuous body of the surface side 2 nd nonwoven fabric 24b may be urged to move to the upstream side of the meshing area 93 based on the tension T2.

Further, as shown in fig. 12B, since the continuous body of the surface side 2 nd nonwoven fabric 24B exists between the continuous body of the surface side 1 st nonwoven fabric 24a and the convex portion 94a, the continuous body of the surface side 1 st nonwoven fabric 24a does not contact the convex portion 94a. Accordingly, no frictional force is generated between the continuous body of the surface 1 st nonwoven fabric 24a and the convex portion 94a, and when the convex portion 94a is separated from the concave portion 92a, the continuous body of the surface 1 st nonwoven fabric 24a can be restrained from following the convex portion 94a. Therefore, even if the tension T1 applied to the continuous body of the front side 1 st nonwoven fabric 24a is set to be extremely small, the portion 24a2 of the continuous body of the front side 1 st nonwoven fabric 24a pressed into the concave portion 92a can be caused to stay in the concave portion 92 a. On the other hand, the portion 24b2 of the continuous body of the surface-side 2 nd nonwoven fabric 24b pressed into the concave portion 92a is in contact with the convex portion 94a, so that the continuous body of the surface-side 2 nd nonwoven fabric 24b easily follows the convex portion 94a when the convex portion 94a is separated from the concave portion 92 a. Accordingly, the portion 24b2 of the continuous body of the 2 nd nonwoven fabric 24b on the front surface side can be effectively pulled out from the recess 92a by the bonding tension T2.

As described above, the 1 st and 2 nd rolls 92 and 94 are rotated while sandwiching the continuous body of the 1 st nonwoven fabric 24a on the surface side and the continuous body of the 2 nd nonwoven fabric 24b on the surface side between the 1 st and 2 nd rolls 92 and 94. With this rotation, the plurality of convex portions 94a and the plurality of concave portions 92a are engaged in this manner, so that a plurality of convex portions 24a2 are intermittently formed on the continuous body of the non-woven fabric 24a on the surface side 1. Accordingly, the uneven pattern 20a is formed on the continuous body of the non-woven fabric 24a on the front side 1. On the other hand, as described above, the continuous body of the surface-side 2 nd nonwoven fabric 24b is pulled out of the concave portion 92a by the tension T2, and is formed in a substantially flat surface shape.

Next, the continuous body having the substantially flat surface-shaped surface-side 2 nd nonwoven fabric 24b is joined to the outer surface of the continuous body having the surface-side 1 st nonwoven fabric 24a having the uneven shape 20a opposite to the surface facing the skin surface. Specifically, the recess in the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b are joined. The continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b are joined by passing the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b between the 1 st roller 92 and the ultrasonic horn of the joining device 100. Thereby, a continuous body of the surface sheet 24 is formed. As indicated by arrow D (fig. 11), the continuous body of the surface sheet 24 is separated from the 1 st roller 92 and conveyed to the subsequent process.

According to the above-described manufacturing method, the uneven pattern 20a is formed simultaneously on the two nonwoven fabrics in a state where the surface 1 st nonwoven fabric 24a and the surface 2 nd nonwoven fabric 24b joined to each other are overlapped. Then, the surface side 2 nd nonwoven fabric 24b is joined to the surface side 1 st nonwoven fabric 24a while maintaining the uneven shape 20a on the surface side 1 st nonwoven fabric 24a in a state where tension is applied to the surface side 2 nd nonwoven fabric 24b so that the undulations of the surface side 2 nd nonwoven fabric 24b of the two nonwoven fabrics on which the uneven shape 20a is formed are made gentle. Accordingly, when the step for forming the uneven pattern 20a on the surface side 1 st nonwoven fabric 24a and the step for forming the surface side 2 nd nonwoven fabric 24b having gentle undulations are further performed after the step for overlapping the surface side 1 st nonwoven fabric 24a and the surface side 2 nd nonwoven fabric 24b having undergone these steps, the steps and the manufacturing apparatus can be simplified and facilitated. That is, according to the above-described manufacturing method, for example, the surface 1 st nonwoven fabric 24a and the surface 2 nd nonwoven fabric 24b can be formed into different relief shapes on the same production line, and the number of production lines can be reduced as compared with the case where the production line for manufacturing the surface 1 st nonwoven fabric 24a and the production line for manufacturing the surface 2 nd nonwoven fabric 24b are provided separately, and a configuration for joining different production lines can be omitted.

In this manner, the continuous body of the surface sheet 24 having the concave-convex shape 20a on the continuous body of the non-woven fabric 24a on the surface side 1 st can be formed. In contrast, the following manufacturing process can form a continuous body of the surface sheet 24 having the uneven shape in both the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24 b. Specifically, the tension of the continuous body of the surface side 2 nd nonwoven fabric 24b may be adjusted so that, after passing through the engagement region 93, a part or all of the portion 24b2 of the continuous body of the surface side 2 nd nonwoven fabric 24b pressed into the recess 92a remains in the recess 92 a. Accordingly, part or all of the portion 24b2 of the continuous body of the surface-side 2 nd nonwoven fabric 24b pressed into the concave portion 92a can be made to stay in the concave portion 92 a. Thus, a continuous body of the surface sheet 24 having the uneven shape and formed by the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b can be formed. At this time, it is not necessary to prepare a roll for molding the continuous body of the surface side 2 nd nonwoven fabric 24b, except for a roll for molding the continuous body of the surface side 1 st nonwoven fabric 24 a.

As still another alternative, a member that is plastically deformed when the convex portion 94a and the concave portion 92a are engaged may be used in place of the continuous body of the surface side 2 nd nonwoven fabric 24b, or a member that is plastically deformed when the convex portion 94a and the concave portion 92a are engaged may be used. In this way, the continuous body of the surface side 2 nd nonwoven fabric 24b or the member that is subject to plastic deformation is subjected to plastic deformation when passing through the engagement region 93, and the continuous body of the surface side 1 st nonwoven fabric 24a can be caused to stay in the recess 92a by the portion that is subject to plastic deformation. Accordingly, the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b are molded, and the continuous body of the surface 1 st nonwoven fabric 24a and the continuous body of the surface 2 nd nonwoven fabric 24b can be formed into the uneven shape.

In the above step, at least the inside of the recess 92a of the 1 st roll 92 may be heated at a temperature lower than the melting point of the continuous body of the 1 st nonwoven fabric 24a on the surface side. Accordingly, the continuous body of the surface side 1 st nonwoven fabric 24a can be molded more reliably. For example, by providing a heater inside the 1 st drum 92, the periphery of the recess 92a can be heated. In addition to heating the 1 st roll 92, the 2 nd roll 94 (in particular, the periphery of the convex portion 94 a) may be heated at a temperature lower than the melting point of the continuous body of the 1 st nonwoven fabric 24a on the surface side, or the 2 nd roll 94 (in particular, the periphery of the convex portion 94 a) may be heated at a temperature lower than the melting point of the continuous body of the 1 st nonwoven fabric 24a on the surface side, instead of heating the 1 st roll 92.

Unlike the above, the flat-surface-side 1 st nonwoven fabric 24a may be used as a continuous body of the surface sheet 24.

(Process 4)

In step 4, a continuous body of cores 25 is formed by connecting a plurality of cores 25, and cores 25 are manufactured from the continuous body of cores 25. A continuous body of the core 25 and a method of manufacturing the core 25 will be described with reference to fig. 13 to 15.

In the wearing article 1 described above, the continuous body of the core 25 is formed by stacking two continuous bodies, that is, the continuous body of the core-side 1 st nonwoven fabric S1 formed by connecting the plurality of core-side 1 st nonwoven fabrics S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 formed by connecting the plurality of core-side 2 nd nonwoven fabrics S2. Further, as in the example of fig. 5A to 5C, the SAP is held so as to form a holding region R2 for holding the SAP and a 1 st low density region R11 for holding the SAP having a lower density than the holding region R2, thereby manufacturing a continuous body of the core-side 1 st nonwoven fabric S1. In the example shown in fig. 6A to 7C, SAP is held so as to form a holding region R2, a 1 st low-density region R11, and a 2 nd low-density region R12, whereby a continuous body of the core-side 1 st nonwoven fabric S1 is produced. Next, a method for producing such a continuous body of the core 25 will be described. As described above, the continuous body of the core 25 may be formed of a continuous body of 1 nonwoven fabric on the core side.

As shown in fig. 13, the apparatus for producing the continuous body of the core 25 includes 1 st and 2 nd units U1, U2, a laminating roller R, a control device C, a laminating conveyor C3, a 3 rd applicator 96, a 4 th applicator 97, a folder 98, and a pair of press rollers 99. The 1 st and 2 nd units U1, U2 have the same structure as each other and are arranged substantially in plane symmetry with respect to the surface including the central axis of the laminating roller R.

The 1 st unit U1 includes a 1 st conveyor C1, a fuzzing roller 90, a 1 st applicator 91, a 1 st dispersing device 71, and a negative pressure box 79 provided at the 1 st conveyor C1. The 2 nd unit U2 includes a 2 nd conveyor C2, a fuzzing roller 90, a 1 st applicator 91, a 2 nd applicator 95, a 2 nd dispersing device 72, and a negative pressure box 79 provided at the 2 nd conveyor C2. The control device C performs drive control of the 1 st and 2 nd units U1 and U2 to laminate the continuous bodies of the two core-side nonwoven fabrics S1 and S2, thereby producing a continuous body of the core 25. When the continuous body of the core 25 is formed of a continuous body of 1 core-side nonwoven fabric, the control device C may control the driving of either one of the two units U1 and U2.

In the present embodiment, the continuous body of the core 25 includes a continuous body of the core-side 1 st nonwoven fabric S1 and a continuous body of the core-side 2 nd nonwoven fabric S2. The continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 include: a diffusion layer 81 as a substrate; and a short fiber layer 82 (see fig. 14 and 15) laminated on the diffusion layer 81. The staple fiber layer 82 is a layer of nonwoven fabric made of staple fibers, and is, for example, a layer of nonwoven fabric subjected to ventilation (air through) processing. The nonwoven fabric layer, which is also called an airlaid nonwoven fabric, may be formed by arranging short fibers and spraying them with hot air. On the other hand, the diffusion layer 81 has a smaller thickness than the short fiber layer 82, and has a higher fiber density than the short fiber layer 82. The diffusion layer 81 has high diffusion performance in the surface direction, and can allow liquid to permeate over a wide range.

The continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 are supplied to the raising roller 90. The raising roller 90 is a roller having an outer surface on which a large number of teeth are formed, and rotates at a circumferential speed slower than the conveyance speeds of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2. By setting the speed difference between the transport speed and the peripheral speed in this way, as shown in fig. 15B, the fluff roll 90 can fluff the staple fiber layer 82 of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 shown in fig. 15A. The speed difference between the conveying speed and the peripheral speed is not limited to the speed difference in the same direction, but includes a speed difference when the conveying direction and the rotating direction are opposite directions. By the fuzzing, the staple fiber layer 82 of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 is changed from the laid state shown in fig. 15A to the fuzzed state shown in fig. 15B. Thus, the bulk density of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 becomes small, and the thickness of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 becomes large. That is, the napping forms a gap for supporting SAP80 in the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2.

As shown in fig. 13, a 1 st applicator 91 for applying an adhesive for supporting the SAP80 on the continuous body of the 1 st nonwoven fabric S1 on the core side and the continuous body of the 2 nd nonwoven fabric S2 on the core side is provided between the raising roller 90 in the conveying direction and the 1 st and 2 nd conveyors C1, C2 described later, respectively. The adhesive is applied to the surface of the spun staple fiber layer 82 after the napping of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 by the 1 st applicator 91.

After the adhesive is applied, the continuous body of the core-side 1 st nonwoven fabric S1 is conveyed along the flat 1 st inclined surface F1 of the 1 st conveyor C1 while being sucked by the negative pressure provided by the negative pressure box 79. Along the flat 2 nd inclined surface F2 of the 2 nd conveyor C2 inclined in the direction opposite to the 1 st inclined surface F1, the continuous body of the core-side 2 nd nonwoven fabric S2 is conveyed while being sucked by the negative pressure provided by the negative pressure cassette 79.

The 1 st and 2 nd dispersing devices 71 and 72 in fig. 13 disperse SAP80 (see fig. 14) on the upper surfaces of the continuous body of the 1 st nonwoven fabric S1 on the core side conveyed along the 1 st inclined surface F1 and the continuous body of the 2 nd nonwoven fabric S2 on the core side conveyed along the 2 nd inclined surface F2, respectively, and SAP80 is an absorbent powder or granule. In this spreading, the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 are sucked by the negative pressure cassette 79, so that the spread SAP80 enters the gaps of the staple fiber layer 82 formed by the fluffing, as shown in fig. 14 and 15C. Further, SAP80 is bonded to the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 by the adhesive applied by 1 st applicator 91.

The 1 st absorbent layer L1 is formed by the short fiber layer 82 supporting SAP80 in the continuous body of the 1 st nonwoven fabric S1 on the core side, and the 2 nd absorbent layer L2 is formed by the short fiber layer 82 supporting SAP80 in the continuous body of the 2 nd nonwoven fabric S2 on the core side.

Further explanation is given to each of the dispersing devices 71, 72: each of the dispersing devices 71, 72 includes a hopper 73 for storing SAP80, a metering portion 74, a guide 75, and a dispersing cassette 76. The metering section 74 is used to regulate the amount of SAP80 falling from the hopper 73. The guide 75 guides the SAP80 guided out by the metering section 74 to the distribution box 76. The spreading box 76 spreads the SAP80 supplied from the guide 75 to a specified area in the surface of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2, and prevents splashing to an area other than the specified area. Specifically, the distribution box 76 includes: a cartridge body formed with a scattering opening (not shown in the figure) for letting SAP80 guided by guide 75 fall down, and preventing SAP80 falling down from the scattering opening from splashing to the surroundings; and a shutter (not shown in the drawings) housed in the cartridge body and for intermittently opening and closing the opening. By this spreading box 76, SAP80 is spread to a predetermined region in the staple fiber layer 82 of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 (fig. 5A to 7C).

A method of forming the 1 st and 2 nd low-density regions R11 and R12 and the holding region R2 in the continuous body of the core-side 1 st nonwoven fabric S1 shown in fig. 5A to 7C will be further described.

First, a 1 st method for forming the 1 st low-density region R11, the 2 nd low-density region R12, and the holding region R2 will be described. In the method 1, the 2 nd low-density region R12 and the holding region R2 of the continuous body of the core-side 1 st nonwoven fabric S1 are formed as follows. The 1 st applicator 91 applies the adhesive in a state where the amount of the adhesive applied to the region corresponding to the 2 nd low density region R12 (the 2 nd low density region R12 in fig. 6A to 7C) in the continuous body of the 1 st nonwoven fabric S1 on the core side is adjusted to be smaller than the amount of the adhesive applied to the region corresponding to the holding region R2. Therefore, the amount of SAP80 dispersed in the region corresponding to the 2 nd low density region R12 is smaller than the amount of SAP80 dispersed in the region corresponding to the holding region R2, which is carried by the continuous body of the core-side 1 st nonwoven fabric S1. For example, the application area of the 1 st applicator 91 may be set as follows: the adhesive is applied to the region corresponding to the holding region R2 in the continuous body of the core-side 1 st nonwoven fabric S1, but the adhesive is not applied to the region corresponding to the 2 nd low-density region R12.

On the other hand, the application amount of the adhesive applied by the 1 st applicator 91 to the continuous body of the core-side 2 nd nonwoven fabric S2 may be adjusted in accordance with the amount of SAP carried by the holding region R3 (fig. 5B).

In the method 1, the 1 st low-density region R11 of the continuous body of the 1 st nonwoven fabric S1 on the core side is formed by stopping or almost stopping the supply of the SAP80 to the region corresponding to the Cut region Cut (refer to fig. 5A), which is the region between the cores 25 adjacent to each other in the continuous body of the 1 st nonwoven fabric S1 on the core side. Specifically, the supply of SAP80 to the cutting area Cut is stopped or suppressed by closing or almost closing the dispensing opening by the shutter of the dispensing cartridge 76. Accordingly, the 1 st low-density region R11 is formed in the Cut region Cut of the 1 st nonwoven fabric S1 on the core side. In the cutting area Cut, the application of the adhesive by the 1 st applicator 91 is stopped or inhibited.

Similarly, the 3 rd low-density region R13 is formed in the core-side 2 nd nonwoven fabric S2 by stopping or suppressing the supply of SAP80 and the adhesive to the region corresponding to the Cut region Cut, which is the region between the cores 25 adjacent to each other in the continuous body of the core-side 2 nd nonwoven fabric S2.

As the 2 nd method for forming the 1 st low-density region R11, the 2 nd low-density region R12, and the holding region R2, the following method may be adopted, namely: the amount adjusting portion 74 adjusts the amount of SAP80 supplied in the direction orthogonal to the conveyance direction of the continuous body of the core-side 1 st nonwoven fabric S1, so that the 1 st low density region R11, the 2 nd low density region R12, and the holding region R2 can be formed as shown in fig. 5A to 7C. Specifically, the amount adjustment unit 74 adjusts the amount of SAP80 provided per unit area in the 1 st low-density region R11 and the 2 nd low-density region R12 to be smaller than the amount of SAP80 provided per unit area in the holding region R2. The dispensing box 76 dispenses the SAP80 in the amount adjusted by the adjusting portion 74 to the continuous body of the 1 st nonwoven fabric S1 on the core side. Accordingly, the amount of SAP80 carried by the 1 st low-density region R11 and the 2 nd low-density region R12 can be made smaller than the amount of SAP80 carried by the holding region R2.

In the method 2, the gate in the method 1 may be used to close or almost close the scattering openings to form the 1 st low-density region R11 of the continuous body of the core-side 1 st nonwoven fabric S1.

As the 3 rd method for forming the 1 st low-density region R11, the 2 nd low-density region R12, and the holding region R2, the 1 st low-density region R11, the 2 nd low-density region R12, and the holding region R2 shown in fig. 5A to 7C may be formed by a transfer body capable of holding the SAP80 in a predetermined pattern and capable of transferring the SAP80 to the continuous body of the core-side 1 st nonwoven fabric S1. Specifically, the transfer body has: an area corresponding to holding area R2, which holds SAP80 at a specified distribution density; and regions corresponding to the 1 st low-density region R11 and the 2 nd low-density region R12, which maintain the SAP80 at a lower density than the region corresponding to the retention region R2. The transfer body is arranged on the outer surface of the transfer roller. The continuous body of the core-side 1 st nonwoven fabric S1 is sandwiched between a transfer roller and a conveying roller around which the continuous body of the core-side 1 st nonwoven fabric S1 is wound. Accordingly, SAP80 held by the transfer body of the transfer roller is transferred onto the continuous body of the 1 st nonwoven fabric S1 on the core side, thereby forming 1 st low-density region R11, 2 nd low-density region R12, and holding region R2.

On the other hand, a continuous body of the core-side 2 nd nonwoven fabric S2 having the holding region R3 is formed by using a transfer body having a region corresponding to the holding region R3, which holds the SAP80 at a specified distribution density.

As still another method, the holding region R2 (unresectable region) and the low-density region R1 (resected region) may be formed by resecting the target portion for forming the low-density region R1 (1 st low-density region R11 in the example of fig. 5A to 5C, 1 st low-density region R11 and 2 nd low-density region R12 in the example of fig. 6A to 7C) in the continuous body of the core-side 1 st nonwoven fabric S1 after spreading the SAP80.

In addition, as still another method, after SAP80 is dispersed over the entire target region for forming the low-density region R1 (1 st low-density region R11 in the example of fig. 5A to 5C, 1 st low-density region R11 and 2 nd low-density region R12 in the example of fig. 6A to 7C) and the holding region R2 in the continuous body of the core-side 1 st nonwoven fabric S1, SAP80 is additionally dispersed only over the target region for forming the holding region R2, whereby the low-density region R1 and the holding region R2 may be formed.

The conveyance of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 and the distribution of the SAP80 to them are disclosed in, for example, international publication No. WO2017/131014, and all the descriptions thereof are incorporated herein.

Next, as shown in fig. 13, after SAP80 is spread, the 2 nd applicator 95 applies an adhesive to the surface of the continuous body of the one core-side 2 nd nonwoven fabric S2. Accordingly, the adhesive layer 83 shown in fig. 15D is formed on the continuous body of the core-side 2 nd nonwoven fabric S2. The continuous body of the core-side 2 nd nonwoven fabric S2 on which the adhesive layer 83 is formed is conveyed to the laminating roller R by the 2 nd conveyor C2, and the continuous body of the core-side 1 st nonwoven fabric S1 is conveyed to the laminating roller R by the 1 st conveyor C1.

As shown in fig. 13 and 14, the 1 st conveyor C1, the 2 nd conveyor C2, and the laminating roller R are configured such that the continuous body of the conveyed core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 are arranged in a V-shape when seen from the side. In a state where the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 are laminated, the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 are sandwiched between the laminating roller R and the conveyor C3. At this time, the 1 st absorbent layer L1 of the continuous body of the 1 st nonwoven fabric S1 on the core side conveyed by the 1 st conveyor C1 and the 2 nd absorbent layer L2 of the continuous body of the 2 nd nonwoven fabric S2 on the core side conveyed by the 2 nd conveyor C2 face each other. Accordingly, as shown in fig. 14 and 15D, the continuous body of the 1 st nonwoven fabric S1 on the core side and the continuous body of the 2 nd nonwoven fabric S2 on the core side are laminated and bonded via the adhesive layer 83 in a state where the 1 st absorbent layer L1 and the 2 nd absorbent layer L2 are opposed to each other. Thus, 1 thick laminate S was formed. In the laminate S, the 1 st absorbent layer L1 and the 2 nd absorbent layer L2 face each other via the adhesive layer 83, and the two layers L1, L2 are sandwiched between the diffusion layers 81, 81 of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2.

As described above, since the 1 st absorbent layer L1 and the 2 nd absorbent layer L2 of the two-layer nonwoven fabrics of the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2 are made to face each other and the core-side 1 st nonwoven fabric S1 and the core-side 2 nd nonwoven fabric S2 are laminated, the SAP80 can be suppressed from falling off from the 1 st absorbent layer L1 and the 2 nd absorbent layer L2. In addition, when the core 25 formed by stacking the 1 st absorbent layer L1 and the 2 nd absorbent layer L2 so as to face each other is used in the subsequent step, the SAP80 can be suppressed from falling off the core 25.

As shown in fig. 13, a tissue (towel) T is supplied to the stacking conveyor C3. A 3 rd applicator 96 (fig. 13) disposed upstream of the laminating conveyor C3 applies an adhesive to the upper surface of the tissue T.

Then, as shown in fig. 13 and 14, the lamination conveyor C3 supplies the thin paper T to which the adhesive has been applied to the lower side of the laminate S, and sandwiches the laminate S between the lamination conveyor C3 and the lamination roller R. Accordingly, as shown in fig. 15E, the laminate S is bonded to the surface of the thin paper T. Further, the lamination conveyor C3 conveys the joined body of the laminated body S and the thin paper T downstream.

As shown in fig. 13, a 4 th applicator 97, a folder 98, and a pair of press rollers 99 are provided downstream of the lamination conveyor C3. The lamination conveyor C3 is provided with a negative pressure cassette 78 for sucking the thin paper T.

The 4 th applicator 97 applies an adhesive to at least one side edge portion of both side edge portions in a direction orthogonal to the conveying direction among the upper surface of the thin paper T. In this example, the width of the thin paper T in the direction orthogonal to the conveyance direction is greater than 2 times the width of the laminate S.

The folding machine 35 folds the side portions of the sheet T extending from the laminate S to both sides in the width direction as shown in fig. 15F, thereby wrapping the laminate S with the sheet T. The press roller 99 presses the laminate S and the thin paper T in the thickness direction, thereby joining the thin paper T to the laminate S. Thereby producing a continuous body of cores 25 formed by connecting the cores 25. The continuous body of cores 25 is cut into individual cores 25 by a cutter, not shown in the figures.

The continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 may not have the diffusion layer 81. In this case, the step for stacking the diffusion layers 81 may be omitted. The continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2 may not be covered with the tissue T. In this case, the step for laminating the thin paper T and coating the laminate S may be omitted. The core 25 may be produced from only the continuous body of the core-side 1 st nonwoven fabric S1, instead of the laminated body S of the continuous body of the core-side 1 st nonwoven fabric S1 and the continuous body of the core-side 2 nd nonwoven fabric S2.

(Process 5)

In step 5, as shown in fig. 10, a rear sheet semi-product is formed by joining a continuous body of the rear sheet 26 and a continuous body of the leg gathers 31. Specifically, the continuous body of the liquid-impermeable sheet body 26a and the continuous body of the outer sheet body 26b are conveyed in the MD direction a. The continuous bodies of the two sheets 26a and 26b are joined by adhesion by a hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like, by applying an adhesive to at least one of the sheets and sandwiching the continuous bodies of the two sheets 26a and 26b by a pair of nip rolls (reference numerals are omitted) shown in fig. 8. Thereby, a continuous body of the back sheet 26 is formed.

Further, the continuous body of leg gathers 31 as elastic members is bonded in an elongated state in the MD direction a to both side portions of the liquid-impermeable sheet body 26a in the CD direction W orthogonal to the MD direction a by bonding with a hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like. Accordingly, the continuous body of the leg gathers 31 is provided on the continuous body of the back sheet 26, thereby manufacturing a back sheet semifinished product.

(step 6)

In step 6, an absorber semi-finished product is formed that combines the top sheet semi-finished product formed in step 3, the core 25 formed in step 4, and the back sheet semi-finished product formed in step 5.

At a nip roller (reference numeral omitted) provided at the junction point between the step 4 and the step 5, the core 25 manufactured in the step 4 is placed on the liquid-impermeable sheet 26a of the rear sheet semifinished product manufactured in the step 5 and bonded. Further, a plurality of absorber elastic members 21 of a prescribed length are held on the drum surface (outer surface) of the rotating drum P (fig. 8) provided on the downstream side of the nip roller. In response to the rotation of the rotating drum P, the absorber elastic member 21 is joined in an elongated state in a direction orthogonal to the conveying direction between adjacent cores 25 on the rear sheet semifinished product.

The surface sheet semi-finished product is supplied to the back sheet semi-finished product so as to sandwich the continuous body of the core 25 and the leg gathers 31 and the absorber elastic member 21, and the surface sheet semi-finished product is joined to the back sheet semi-finished product (see fig. 18F).

Further, the female fastener 22 (fig. 1 and 2) is provided on the outer surface of the back sheet body semi-finished product on the opposite side of the core 25 from the end portion for providing the absorber elastic member 21, over the entire width direction (corresponding to the waistline width direction).

Further, an indicator 50 (fig. 1 and 2) is provided on the surface of the back sheet semifinished product facing the skin surface side, the indicator 50 extending in the conveyance direction (MD direction a) of the back sheet semifinished product at the center portion of the outer sheet 26b in the CD direction W. Thereby, a semifinished product (absorbent semifinished product) of the absorbent body 20 continuous in the MD direction a is produced.

The step for providing the female snap 22 may be performed only during the period between the steps 5 and 12. The process for setting the indicator 50 may be performed only during the period between the process 5 and the process 13.

(Process 7)

In step 7, the semi-finished absorbent body formed in step 6 is cut into individual absorbent bodies 20. Specifically, the semi-finished absorbent article including the absorbent body 20 and the three-dimensional gathers 40 extending in the MD direction a is cut by the built-in cutter 64 for each predetermined length in the MD direction a, and each absorbent body 20 is manufactured. Thereafter, the direction of the absorber 20 is reversed by 90 degrees by the built-in drum 65, so that the absorber 20 is brought into a posture suitable for the subsequent assembly process in the lateral flow state. At this time, the absorber elastic member 21 is disposed so as to be located at a distal end portion of the absorber 20 on the opposite side of the waist main body 16 in the MD direction a (refer to fig. 3).

(3) Procedure 8 to procedure 13

The steps 8 to 13 are steps for assembling the developed type wearing article 1 in the lateral flow state shown in fig. 16. In these steps, first, the absorbent body 20 manufactured in step 7 is joined to the waistline continuous body manufactured in steps 1 to 2. Next, the waistline continuous body is cut into individual waistline members 10, and thereafter, the two side portions 10a located on both sides of the joined portion 10b in the waistline width direction (MD direction a of fig. 16) in the waistline members 10 are folded in the waistline width direction (MD direction a of fig. 16), and the absorber 20 is folded in half in the waistline orthogonal direction (CD direction W of fig. 16). In this state, the coupling of the male buckle 12 and the female buckle 22 is released.

In the lateral flow state shown in fig. 16, the MD direction a coincides with the waistline width direction, and the CD direction W coincides with the waistline orthogonal direction.

(step 8)

In step 8, in fig. 8, 16 and 19, one end portion (the end portion opposite to the female fastener 22) of the absorber 20 which is turned 90 degrees is disposed on the joint portion 10b of each waistline body 16 of the waistline continuous body manufactured in step 2 (see fig. 19A). The absorber 20 is joined to the joining portion 10b of the skin-facing surface of the inner sheet 14 of each waist body 16. The bonding method is not limited to bonding by a hot melt adhesive, and heat sealing welding or ultrasonic welding may be used.

In the present embodiment, in steps 1 to 2, a waistline continuous body in which the waistline main body 16 of the plurality of wearing articles 1 is continuous in the waistline width direction (MD direction a in fig. 9 and 16) is manufactured. That is, the waistline continuous body is formed by connecting the both end portions 10c of the waistline main body 16 to each other so that the waistline main bodies 16 of the plurality of wearing articles 1 are connected in the waistline width direction. The absorbent body 20 of each wearing article 1 extending in the direction perpendicular to the waist (CD direction W in fig. 9 and 16) is joined to the joining portion 10b of the waist continuous body corresponding to the portion of each waist main body 16.

(step 9)

In step 9, the waist continuous body (continuous body of the plurality of waist main bodies 16) is cut by a die cutter (die cutter) 66 having an elliptical shape, thereby providing the leg hole SP in fig. 16. Thereby forming a leg periphery curve portion 15b.

In addition, the steps 8 and 9 may be exchanged. That is, first, the leg holes SP are provided by cutting the portion between the joining portions 10b of the waistline continuous body with the die-cutting machine 66. Then, one end of the absorber 20, which is turned 90 degrees, is disposed on the joint 10b of each waistline main body 16 in the waistline continuous body.

(Process 10)

In step 10, the protruding portion 15c of the waist elastic member 11 is folded back and engaged with the male buckle 12 so as to cover a part of the waist elastic member (see fig. 19B). Specifically, the extension 15c is joined to each absorber 20 in a state of covering the end portion of each absorber 20 joined to the waistline continuous body. The bonding method is not limited to bonding by a hot melt adhesive, and heat sealing welding or ultrasonic welding may be used.

Further, the male fastener tab 12 is joined to the weakened portion 15a2 in the skin-surface side surface of the waistline continuous body. The weakened portion 15a2 is provided in a range from the folded-back portion of the protruding portion 15c to its lower side position. The bonding method is not limited to bonding by a hot melt adhesive, and heat sealing welding or ultrasonic welding may be used. In the waistline continuous body, the weakened portions 15a2 are located at the middle between the absorbent bodies 20 adjacent in the MD direction a. In which the male buckle 12 is engaged.

(step 11)

In step 11, the waist continuous body is cut in the CD direction W by the cutter 67 at an intermediate position between adjacent absorbent bodies 20 and at an intermediate position of the male fastener 12 in the MD direction a. Thus, the waist continuous body and the plurality of absorbent bodies 20 are separated into the respective waist main bodies 16 and the respective absorbent bodies 20 joined thereto. Further, between the adjacent absorbent bodies 20, the male fastener 12 is divided into two along the CD direction W and in the MD direction a, and remains on the respective both end portions 10c of the adjacent waist main body 16. In this state, each of the waist main bodies 16 is in a state of being unfolded in the MD direction a, and the absorber 20 is in a state of being unfolded in the CD direction W.

(step 12)

In step 12, both side portions 10a of the waistline member 10 are folded back in the MD direction a toward the joining portion 10b of the waistline member 10 by the end folding device 68 so that the two male fasteners 12 of both side portions 10c face the skin surface side of the absorbent body 20. In step 12, both end portions of each of the waistline bodies 16 cut out from the waistline continuum in step 11 are folded back directly.

(step 13)

In step 13, the direction of the absorber 20 is reversed by 90 degrees by a drum not shown in the figure, and the absorber 20 is folded in the MD direction a. Specifically, in a state in which the waist width direction of the absorbent body 20 is set in the MD direction a, the absorbent body 20 is folded in the MD direction a by the folding device 69 so as to cover both side portions 10a while the absorbent body 20 is conveyed in the MD direction a (see fig. 19C). At this time, the male fastener 12 of the waistline member 10 and the female fastener 22 of the absorber 20 are not coupled. Specifically, in step 12, both side portions 10a are folded in the MD direction a so that both end portions 10c of the waist member 10 face the skin-surface side surface of the absorbent body 20. Here, since the male fastener 12 is provided on the skin-surface-side surface of the both end portions 10c of the waistline member 10, the both end portions 10c are folded back as described above, and the male fastener 12 faces the skin-surface-side surface of the absorber 20. In step 13, the absorbent body 20 is folded in the MD direction a so as to cover both side portions 10a. The female fastener 22 is disposed on the outer surface of the back sheet 26 of the absorber 20, that is, on the surface of the absorber 20 opposite to the surface facing the both side portions 10a. Therefore, the wearing article 1 can be folded in a state where the male fastener 12 and the female fastener 22 are released.

The folding device 69 has: a pair of conveyors facing each other with a gap; and a pusher (pusher) insertable between the two conveyors. The folding device 69 is configured such that the pusher is inserted between the two conveyors, whereby the intermediate portion in the MD direction a of the absorber 20 of the wearing article 1 in which the both side portions 10a have been folded and inverted by 90 degrees is pressed between the folding device 69. Accordingly, the absorbent body 20 is folded in the MD direction a with the middle portion in the MD direction a as a reference so that the joined portion 10b of the waistline member 10 and the absorbent body 20 overlap. The folded wearing article 1 is then conveyed along two conveyors to a packing device not shown in the drawings.

The folding device 69 is not limited to folding the absorbent body 20 in the MD direction a. For example, the absorber 20 can be folded in the MD direction a by pressing the waistline member 10 by the pressing means and folding the end portion of the absorber 20 on the free end side toward the waistline member 10 side.

In addition, the step 12 may be omitted, and the absorbent body 20 may be folded in the MD direction a in the step 13 after the waistline continuous body is cut in the step 11.

The method for producing the stretched-out wearing article 1 is a method for producing a wearing article having a member comprising: a waistline member 10 disposed at the waistline of the wearer; and an absorber 20 that is joined to a joining portion 10b in the waistline width direction of the waistline member 10, and that extends from the joining portion 10b in a waistline orthogonal direction orthogonal to the waistline width direction, such that the absorber 20 is disposed from the back portion of the wearer to the front abdomen portion via the crotch portion, the manufacturing method including the steps of: a step of manufacturing the waistline member 10; a step of manufacturing the absorber 20; a step of joining the absorber 20 to the joining portion 10b of the waist main body 16; and a step of folding the absorber 20 in half in the direction perpendicular to the waist.

(step of producing the waist Member 10)

The above-described process for manufacturing the waistline member 10 includes: steps 1 to 2 for producing a waistline continuous body; a step (part of step 10) of joining the male fastener 12 to each waist main body 16 constituting the waist continuous body; and a step 12 of cutting the waistline continuous body.

(step of producing absorbent body 20)

The above-described process for producing the absorbent body 20 includes: a step 3 of manufacturing a surface sheet semi-finished product; a step 4 of manufacturing a core 25; a step 5 of manufacturing a rear sheet body semi-finished product; a step 6 of manufacturing an absorber semi-finished product; and a step 7 of cutting the semi-finished absorbent body into individual absorbent bodies 20.

(step of joining the absorbent body 20 to the joined portion 10b of the waist body 16)

Step 8 corresponds to a step of joining the absorber 20 to the joining portion 10b of the waist body 16.

(step of folding the absorber 20 in half in the waist orthogonal direction)

Step 13 corresponds to a step of folding the absorber 20 in half in the orthogonal direction.

The present invention is not limited to the above embodiment, and for example, the following embodiments may be adopted.

In the above-described developed wearing article 1, the joint portion 10b of the waistline member 10 is disposed in the back portion. Further, the absorber 20 extends from the joint portion 10b arranged at the back portion toward the front abdomen via the crotch portion, and the distal end portion thereof is arranged at the front abdomen. Further, both side portions 10a of the waistline member 10 are elongated from the back portion toward the front abdomen portion, and are coupled with the distal end portion of the absorber 20. However, the joint portion 10b of the waistline member 10 may be disposed in the front abdominal portion. The absorbent body 20 may extend from the joint portion 10b disposed in the front abdominal portion to the back portion via the crotch portion, and the distal end portion thereof may be disposed in the back portion. Further, both side portions 10a of the waistline member 10 extend from the front abdominal portion toward the back portion, and are coupled to the distal end portion of the absorber 20.

In the above-described developed wearing article 1, the female fastening device 22 is disposed on the outer surface of the back sheet 26 of the absorber 20. However, the female buckle 22 may be omitted, and the outer surface of the back sheet 26 may be treated so as to be coupled to the male buckle 12. Further, a back sheet 26 having a property of being able to be coupled to the male fastener 12 may be used. In addition, the following structure may be adopted: the outer surface of the back sheet 26 of the absorber 20 is provided with a male buckle 12, and the skin-side surface of the waistline member 10 may be coupled to the male buckle 12.

The above-described embodiments mainly include inventions having the following structures.

According to the above manufacturing method, a wearing article with improved wearing comfort can be manufactured. Specifically, according to the wearing article, the 1 st nonwoven fabric on the core side holds the water-absorbent polymer. Since the absorption performance per unit volume of the water-absorbent polymer is higher than that of fluff pulp, the amount of fluff pulp used when fluff pulp is used can be reduced. Accordingly, the thickness of the core can be reduced as compared with a nonwoven fabric formed of only fluff pulp in an amount required for a specified absorption property. The thickness of the wearing article including the core-side 1 st nonwoven fabric is also small, so that the wearing article is easily deformed in accordance with the body shape of the waist portion of the wearer, and the fit of the wearing article can be improved.

Further, the retention region lacks flexibility because the distribution density of the water-absorbent polymer is higher than that of the 1 st low density region. And the 1 st low-density region has higher flexibility than the holding region because the distribution density of the water-absorbent polymer is lower than that of the holding region. Therefore, the core having the 1 st low density region is easily deformed in shape. Here, when the wearer wears the wearing article, both ends in the orthogonal direction of the holding area are disposed so as to face the front abdomen and the back of the wearer, respectively. A1 st low-density region having a distribution density of the water-absorbent polymer lower than that of the holding region is disposed at a portion adjacent to both end portions in the orthogonal direction of the holding region in the orthogonal direction. Therefore, the portion of the core body in which the 1 st low density region is disposed flexibly deforms along the body shape of the front abdominal portion and the back portion, and the portion contacts the front abdominal portion and the back portion with a soft touch, whereby the wearing comfort of the wearing article can be improved.

In addition, since the wearing article is released from the coupling between the 1 st coupling portion and the 2 nd coupling portion in the initial state, the wearing article can be unfolded into a predetermined form without releasing the coupling. In the wearing article in the developed form, both side portions of the waistline member protrude from the absorber disposed at the joining portion of the waistline member. The side portions can be made to face the distal end portion of the absorber along the waist of the wearer and to abut against the back sheet of the absorber disposed along the crotch of the wearer. Then, by coupling the 1 st coupling portion of the both ends in the width direction of the waistline member with the 2 nd coupling portion of the back sheet, the wearing article is supported at the waistline so that the absorber is pulled up, which is fitted to the crotch of the wearer. By connecting the 1 st connecting portion and the 2 nd connecting portion of the wearing article in the developed form to each other in this way, the wearing article can be in the pants-like form, and the wearer can put on the wearing article like pants. In addition, when the underpants type structure is in the underpants type structure, the 1 st joint and the 2 nd joint are released from each other, so that the underpants type structure can be re-unfolded into a predetermined unfolded structure.

In the above method for producing a wearing article, it is preferable that the core-side 1 st nonwoven fabric holds the water-absorbent polymer so as to form a 2 nd low density region in the step of producing the core, and the 2 nd low density region holds the water-absorbent polymer having a lower density than the holding region and is sandwiched between the holding regions in the width direction.

According to the above manufacturing method, the core of the absorbent body having the 2 nd low density region is formed, and the distribution density of the water-absorbent polymer in the 2 nd low density region is lower than that in the holding region. The holding region lacks flexibility because of the high distribution density of the water-absorbent polymer, and the 2 nd low density region has higher flexibility than the holding region because of the low distribution density of the water-absorbent polymer. Therefore, the core having the 2 nd low density region is easily deformed in shape. Specifically, the 2 nd low density region is formed to be sandwiched in the width direction in the holding region. Therefore, by bending the core body with the 2 nd low density region as a reference, the absorber is easily deformed along the body shape, and the fit feeling can be improved.

Further, along the 2 nd low density region where the amount of absorption of urine or the like is small, urine or the like can be diffused in the orthogonal direction, and urine or the like can be efficiently absorbed by the holding region. Further, since the 2 nd low-density region can be used as a region for swelling the water-absorbent polymer in the holding region, excessive adhesion of the absorbent body to the skin surface can be suppressed. Thus, the sticky feeling of the skin surface caused by urine and the like can be rapidly solved, and the uncomfortable feeling can be alleviated.

In a state where the 1 st attachment portion and the 2 nd attachment portion are attached to support the wearing article at the waist and the absorbent body is attached to the crotch, before absorbing body fluid, the sense of attachment to the crotch can be improved based on the 2 nd low density region of the core. Further, after absorbing body fluid, the expansion space of the water-absorbent polymer can be ensured by the 2 nd low density region of the core, and thus unnecessary excessive expansion of the core to the skin surface side can be suppressed, and a good skin feel can be maintained.

In the above method for manufacturing a wearing article, it is preferable that the 2 nd low-density region is formed so as to extend in the orthogonal direction in the step of manufacturing the core.

According to the above manufacturing method, a wearing article having a core body formed with the 2 nd low density region extending in the orthogonal direction can be manufactured. In this wearing article, the core is curved with respect to the 2 nd low-density region extending in the orthogonal direction, so that the absorber can be deformed along the body shape of the wearer within the range of formation of the 2 nd low-density region in the orthogonal direction, and the fit of the wearing article can be further improved.

In the above method for producing a wearing article, the step of producing the absorbent body preferably includes the steps of: and a step of producing the surface sheet body, wherein a surface-side 1 st nonwoven fabric is formed with a concave-convex shape, and a surface-side 2 nd nonwoven fabric is bonded to an outer surface of the surface-side 1 st nonwoven fabric opposite to a surface facing the skin surface while maintaining the concave-convex shape.

According to the wearing article manufactured by the above manufacturing method, the 1 st nonwoven fabric on the front side of the front sheet body is provided with the concave-convex shape. Therefore, the convex portions of the concave-convex shape are in contact with the elastic points of the skin surface of the wearer, and the air can pass through the concave portions, so that the air permeability is good, and the skin touch can be improved as compared with the case where the surface sheet body is in surface-to-surface contact with the skin surface. The surface side 1 st nonwoven fabric having the uneven shape is bonded to the surface side 2 nd nonwoven fabric so as to maintain the uneven shape. Therefore, for example, even when the wearer presses the concave-convex shape by contact, the convex portion is less likely to deform, and a good skin feel due to point contact with the convex portion can be maintained.

In a state where the 1 st connecting portion and the 2 nd connecting portion are connected to support the wearing article at the waist and the absorber is attached to the crotch, the breathability and the skin feel can be improved by the uneven shape of the surface sheet before absorbing body fluid. Further, after absorbing body fluid, good breathability and skin feel can be maintained by the uneven shape of the surface sheet.

Further, when the surface side 1 st nonwoven fabric of the surface sheet has a concave-convex shape, and the 2 nd low density region is sandwiched in the width direction in the holding region in the core, there is the following effect. That is, in a state in which the 1 st connecting portion and the 2 nd connecting portion are connected to support the wearing article at the waist and the absorbent body is attached to the crotch, the concave-convex shape of the front sheet body and the 2 nd low density region of the core body can be used before absorbing body fluid, and the feeling of attachment to the crotch can be improved and the breathability and the skin touch can be improved. Further, since the expansion space of the water-absorbent polymer can be ensured by the 2 nd low density region of the core after absorbing the body fluid, the core can be prevented from unnecessarily excessively expanding to the skin surface side, and excellent air permeability and skin touch can be maintained by the uneven shape of the surface sheet.

In the method for producing a wearing article, it is preferable that in the step of producing the surface sheet, the surface side 1 st nonwoven fabric and the surface side 2 nd nonwoven fabric are overlapped to form the uneven shape at the same time, and the surface side 2 nd nonwoven fabric is bonded to the surface side 1 st nonwoven fabric in a state where tension is applied to the surface side 2 nd nonwoven fabric so that the undulation of the surface side 2 nd nonwoven fabric is gentle.

According to the above manufacturing method, the uneven shape is formed simultaneously on the two nonwoven fabrics in a state where the surface side 1 st nonwoven fabric and the surface side 2 nd nonwoven fabric joined to each other are overlapped. Then, the surface side 2 nd nonwoven fabric was joined to the surface side 1 st nonwoven fabric while maintaining the uneven shape on the surface side 1 st nonwoven fabric in a state where tension was applied to the surface side 2 nd nonwoven fabric so that the undulations of the surface side 2 nd nonwoven fabric of the two nonwoven fabrics formed with the uneven shape were smoothed. Accordingly, the process and the manufacturing apparatus can be simplified as compared with the case where the process for forming the uneven shape on the surface side 1 st nonwoven fabric and the process for forming the surface side 2 nd nonwoven fabric having gentle undulations are performed separately and then the process for overlapping the surface side 1 st nonwoven fabric and the surface side 2 nd nonwoven fabric having undergone these steps is further performed. That is, according to the above-described manufacturing method, for example, the surface 1 st nonwoven fabric and the surface 2 nd nonwoven fabric can be formed into different relief shapes on the same production line, and the number of production lines can be reduced as compared with the case where the production line for manufacturing the surface 1 st nonwoven fabric and the production line for manufacturing the surface 2 nd nonwoven fabric are separately provided, and a configuration for joining different production lines can be omitted.

In the above method for producing a wearing article, it is preferable that in the step of producing the core, the 1 st nonwoven fabric on the core side is napped, and the water-absorbent polymer is dispersed so that the water-absorbent polymer enters gaps between fiber layers formed by the napping.

According to the above production method, the 1 st nonwoven fabric on the core side is fluffed, so that the fiber layer having gaps is formed on the 1 st nonwoven fabric on the core side, and the water-absorbent polymer is dispersed in the fiber layer. Accordingly, a large amount of water-absorbent polymer can be supported in the gaps between the fiber layers of the core-side 1 st nonwoven fabric.

In the above method for producing a wearing article, the step of producing the core preferably further comprises the steps of: a spreading step of raising the core-side 2 nd nonwoven fabric and spreading the water-absorbent polymer so that the water-absorbent polymer enters gaps between fiber layers formed by the raising; and a lamination step of laminating the core-side 1 st nonwoven fabric and the core-side 2 nd nonwoven fabric so that the fiber layers of the core-side 1 st nonwoven fabric and the fiber layers of the core-side 2 nd nonwoven fabric face each other.

According to the above-described production method, since the water-absorbent polymer is dispersed in the fiber layers of the two nonwoven fabrics, i.e., the core-side 1 st nonwoven fabric and the core-side 2 nd nonwoven fabric, and the fiber layers are laminated so as to face each other, it is possible to produce a wearing article in which the water-absorbent polymer is prevented from falling off the fiber layers. In addition, when a core body formed by laminating fiber layers in such a way as to face each other is used in the subsequent step, the water-absorbent polymer can be prevented from falling off from the core body.

In the above method for producing a wearing article, the step of producing the absorbent body preferably further comprises the steps of: and a step of providing an absorber elastic member that is provided so as to be stretchable in the width direction at a distal end portion of the absorber on the opposite side of an end portion joined to the waist body in the orthogonal direction.

According to the above-described manufacturing method, it is possible to manufacture a wearing article having the absorber elastic member at the distal end portion of the absorber on the opposite side of the end portion joined to the waistline main body in the orthogonal direction. The distal end portion of the absorber of the wearing article on the opposite side to the end portion joined to the waist body is stretchable in the width direction by the absorber elastic member. In addition, the waistline body may also be stretched in the width direction. Accordingly, since the waist body and the absorber can be stretched and contracted in the width direction according to the waist length of the wearer, the degree of freedom in selecting the coupling position between the 1 st coupling portion of the waist body and the 2 nd coupling portion of the absorber is large. Therefore, the fit of the wearing article can be improved.

In the above method for producing a wearing article, the step of producing the absorbent body preferably further comprises the steps of: and a step of providing the 2 nd coupling portion, wherein the 2 nd coupling portion is provided on an outer surface of a distal end portion of the rear sheet body on a side opposite to the waistline member in the orthogonal direction, over substantially the entire range in the width direction of the distal end portion of the rear sheet body.

According to the above-described manufacturing method, it is possible to manufacture a wearing article having the 2 nd coupling portion on the outer surface of the distal end portion of the back sheet over the entire range in the width direction of the distal end portion. Therefore, by expanding and contracting the waistline member in the width direction, the 1 st coupling portion can be coupled to an arbitrary position in the width direction of the 2 nd coupling portion, and the degree of freedom in selecting the coupling position is large. Accordingly, the coupling position between the waist member and the absorber can be easily adjusted according to the waist length of each wearer, and the fit can be improved.

In the above method for manufacturing a wearing article, the step of manufacturing the waistline member preferably includes the steps of: a step of joining a waist elastic member, wherein the waist elastic member is joined to at least one of an inner sheet extending in the width direction and an outer sheet extending in the width direction and covering an outer surface of the inner sheet opposite to a surface facing the skin surface, the outer sheet being elastically joined to the waist elastic member in a state of being sandwiched between the inner sheet and the outer sheet, the inner sheet being elastically joined to at least one of the inner sheet and the outer sheet in the width direction; and a step of weakening the joint portion so that the elastic force of a core placement portion of the waist body, at which the absorbent body is joined, is weaker than the elastic force of a portion adjacent to the core placement portion in the width direction.

According to the above-described manufacturing method, it is possible to manufacture a wearing article in which the elastic force of the core arrangement portion for arranging the core in the waistline body is weaker than the elastic force of the portion adjacent to the core arrangement portion in the width direction. By joining the core to the core arrangement portion in the waistline main body of the wearing article, the core shrinkage can be suppressed. Accordingly, the rear portion and the like can be covered with the core body reliably. Further, since the portion adjacent to the core arrangement portion stretches, the degree of freedom in selecting the connection position between the 2 nd connection portion on the distal end portion of the absorbent body arranged along the crotch portion of the wearer and the 1 st connection portion provided in the waist body can be increased.

In the above method for manufacturing a wearing article, the step of manufacturing the waistline member preferably further includes the steps of: disposing the inner sheet so as to form a protruding portion that protrudes beyond an edge portion of the inner sheet in the orthogonal direction and in a direction away from the inner sheet; and a step of covering an end portion of the absorber by folding back the protruding portion in the orthogonal direction.

According to the above manufacturing method, a wearing article having improved wearing comfort and good appearance can be manufactured. Specifically, in the wearing article manufactured by the above-described manufacturing method, the protruding portion formed on the outer sheet body so as to protrude beyond the edge portion of the inner sheet body in a direction away from the inner sheet body is folded back, so that the end portion of the absorber that is joined to the waistline member is covered by the protruding portion of the outer sheet body. Accordingly, the uncomfortable feeling caused by the contact of the end portion of the absorber with the skin can be suppressed. In addition, the end of the absorber is not exposed, and the appearance can be improved.

In the above method for manufacturing a wearing article, the step of manufacturing the waistline member preferably further includes the steps of: and a weakening step of weakening a portion of the waist main body where the 1 st joint is disposed so that the portion of the waist main body where the 1 st joint is disposed has a weaker elastic force than a portion adjacent to the portion in the width direction.

According to the above manufacturing method, by weakening the elastic force of the portion of the waist body where the 1 st coupling portion is disposed, shrinkage of the 1 st coupling portion provided later can be suppressed. Accordingly, the decrease in the coupling force between the 1 st coupling portion and the 2 nd coupling portion can be suppressed.

In the above-described method for producing a wearing article, it is preferable that the method further includes a step of folding the absorber in the orthogonal direction, wherein in the step of producing the waistline member, a waistline continuous body is prepared in which waistline main bodies of a plurality of wearing articles are connected in the width direction, the waistline continuous body is cut so as to correspond to regions of the waistline main bodies, the waistline main body is produced, and in the step of joining the absorber to the joining portion of the waistline main body, the absorber is joined to the joining portion of the waistline continuous body so as to extend in the orthogonal direction from the joining portion, and the step of folding the absorber in the orthogonal direction includes the steps of: a step of folding back both side portions of the waist body, wherein both side portions of the waist body are folded back in the width direction so that both end portions of the waist body in the width direction face skin surfaces of the absorber at a stage after the waist continuous body is cut into the waist body; and folding the absorber in half, wherein the absorber is folded in half in the orthogonal direction so as to cover the two side portions folded in the width direction.

According to the above manufacturing method, the absorbent body is joined to the waist continuous body in which the waist main bodies are joined to each other so as to extend in the orthogonal direction in the region corresponding to each of the waist main bodies. Then, it is cut into individual wearing articles having the absorbent body joined to the waistline main body. Then, both side portions are folded in the width direction so that both end portions of the waist body face the skin-surface side surface of the absorbent body. Here, since the 1 st coupling portion is provided on the skin-facing surface of the both end portions of the waist main body, the 1 st coupling portion faces the skin-facing surface of the absorber by folding back the both end portions as described above. In this state, the absorber is folded in the orthogonal direction so as to cover both side portions. The 2 nd coupling portion is disposed on the outer surface of the back sheet of the absorber, that is, on the surface of the absorber opposite to the surface facing the both side portions. Therefore, the wearing article can be folded in a state where the 1 st and 2 nd coupling portions are released. Further, by directly folding back the end portions of the respective waistline bodies cut from the waistline continuous body, a folded wearing article can be manufactured.

Claims

1. A method for manufacturing a wearing article, comprising: a waistline member disposed at a waistline of a wearer; an absorber that is joined to the waist member and extends from a joining portion with the waist member in an orthogonal direction orthogonal to a width direction so as to be arranged from a back portion of a wearer to a front abdomen portion via a crotch portion, the manufacturing method comprising:

a process for producing the waistline member, the waistline member comprising: a waist body extending in the width direction, having elasticity capable of expanding and contracting in the width direction, and disposed at a waist of a wearer; a 1 st coupling portion provided on a surface of both end portions in the width direction of the waist body on a skin surface side facing a wearer;

a step of manufacturing the absorber, the absorber comprising: a core for absorbing body fluids; a surface sheet body provided on a skin surface side of the core body facing a wearer; a back sheet body provided on an outer surface side of the core opposite to the skin side so as to sandwich the core between the back sheet body and the front sheet body; a 2 nd coupling portion provided on an outer surface of the back sheet opposite to a surface facing the skin surface, and detachable from the 1 st coupling portion; the method comprises the steps of,

A joining step of joining the absorber to the joining portion of the waist body so as to extend in the orthogonal direction from the waist body, wherein,

the step of manufacturing the absorbent body includes a step of manufacturing the core body by holding the water-absorbent polymer in the 1 st nonwoven fabric on the core body side so as to form a holding region and a 1 st low-density region, the 1 st low-density region holding the water-absorbent polymer having a lower density than the holding region and being adjacent to both end portions in the orthogonal direction of the holding region in the orthogonal direction,

the coupling of the 1 st coupling portion and the 2 nd coupling portion is released.

2. The method of manufacturing an article of wear according to claim 1, wherein:

in the step of manufacturing the core, the 1 st nonwoven fabric on the core side is held with the water-absorbent polymer so as to form a 2 nd low density region, the 2 nd low density region holding the water-absorbent polymer having a lower density than the holding region and being sandwiched in the width direction in the holding region.

3. The method of manufacturing an article of wear according to claim 2, wherein:

In the step of manufacturing the core body, the 2 nd low-density region is formed so that the 2 nd low-density region extends in the orthogonal direction.

4. A method of producing a wearing article according to any one of claims 1 to 3, wherein:

the process for producing the absorbent body comprises the following steps:

and a step of producing the surface sheet body, wherein a surface-side 1 st nonwoven fabric is formed with a concave-convex shape, and a surface-side 2 nd nonwoven fabric is bonded to an outer surface of the surface-side 1 st nonwoven fabric opposite to a surface facing the skin surface while maintaining the concave-convex shape.

5. The method of manufacturing a wearing article according to claim 4, wherein:

in the step of manufacturing the surface sheet, the surface side 1 st nonwoven fabric and the surface side 2 nd nonwoven fabric are overlapped to form the concave-convex shape at the same time, and the surface side 2 nd nonwoven fabric is bonded to the surface side 1 st nonwoven fabric in a state where tension is applied to the surface side 2 nd nonwoven fabric so that the undulation of the surface side 2 nd nonwoven fabric is gentle.

6. The method of manufacturing a wearing article according to any one of claims 1 to 5, wherein:

In the step of manufacturing the core, the 1 st nonwoven fabric on the core side is fluffed, and the water-absorbent polymer is dispersed so that the water-absorbent polymer enters the gaps between the fiber layers formed by the fluffing.

7. The method of manufacturing an article of wear according to claim 6, wherein:

the process of manufacturing the core further comprises the steps of:

a spreading step of raising the core-side 2 nd nonwoven fabric and spreading the water-absorbent polymer so that the water-absorbent polymer enters gaps between fiber layers formed by the raising; the method comprises the steps of,

and a lamination step of laminating the core-side 1 st nonwoven fabric and the core-side 2 nd nonwoven fabric so that the fiber layers of the core-side 1 st nonwoven fabric and the fiber layers of the core-side 2 nd nonwoven fabric face each other.

8. The method of manufacturing a wearing article according to any one of claims 1 to 7, wherein:

the process for manufacturing the absorbent body further comprises the following steps:

and a step of providing an absorber elastic member that is provided so as to be stretchable in the width direction at a distal end portion of the absorber on the opposite side of an end portion joined to the waist body in the orthogonal direction.

9. The method of manufacturing a wearing article according to any one of claims 1 to 8, wherein:

and a step of providing the 2 nd coupling portion, wherein the 2 nd coupling portion is provided on an outer surface of a distal end portion of the rear sheet body on a side opposite to the waistline member in the orthogonal direction, over substantially the entire range in the width direction of the distal end portion of the rear sheet body.

10. The method of manufacturing a wearing article according to any one of claims 1 to 9, characterized in that:

the process for manufacturing the waistline member includes the steps of:

a step of joining a waist elastic member, wherein the waist elastic member is joined to at least one of an inner sheet extending in the width direction and an outer sheet extending in the width direction and covering an outer surface of the inner sheet opposite to a surface facing the skin surface, the outer sheet being elastically joined to the waist elastic member in a state of being sandwiched between the inner sheet and the outer sheet, the inner sheet being elastically joined to at least one of the inner sheet and the outer sheet in the width direction; the method comprises the steps of,

and a step of weakening the joining portion so that an elastic force of a core placement portion of the waist body, at which the absorbent body is joined, is weaker than an elastic force of a portion adjacent to the core placement portion in the width direction.

11. The method of manufacturing an article of wear according to claim 10, wherein:

the process of manufacturing the waistline member further includes the steps of:

disposing the inner sheet so as to form a protruding portion that protrudes beyond an edge portion of the inner sheet in the orthogonal direction and in a direction away from the inner sheet; the method comprises the steps of,

and a step of covering an end portion of the absorber by folding back the protruding portion in the orthogonal direction.

12. The method of manufacturing an article of wear according to claim 10 or 11, characterized in that:

and a weakening step of weakening a portion of the waist main body where the 1 st joint is disposed so that the portion of the waist main body where the 1 st joint is disposed has a weaker elastic force than a portion adjacent to the portion in the width direction.

13. The method of manufacturing a wearing article according to any one of claims 1 to 12, wherein:

Further comprising a step of folding the absorber in half in the orthogonal direction,

in the step of manufacturing the waistline member, a waistline continuous body is prepared in which waistline bodies of a plurality of wearing articles are continuous in the width direction, and the waistline continuous body is cut in a region corresponding to each waistline body to manufacture the waistline body,

in the joining step of joining the absorber to the joining portion of the waistline body, the absorber is joined to the joining portion of the waistline continuous body corresponding to the region of each waistline body in such a manner as to extend in the orthogonal direction from the joining portion,

the step of folding the absorber in half in the orthogonal direction includes the steps of:

a step of folding back both side portions of the waist body, wherein both side portions of the waist body are folded back in the width direction so that both end portions of the waist body in the width direction face skin surfaces of the absorber at a stage after the waist continuous body is cut into the waist body; the method comprises the steps of,

and folding the absorber in half so as to cover the two side portions folded in the width direction, the absorber being folded in half in the orthogonal direction.