JP2003102777A - Method of manufacturing diaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a diaper capable of reducing the part to be disposed of in a web as much as possible. SOLUTION: The invention is related to the method of manufacturing the diaper with a vertical oblong part 2 for covering the crotch part of a user and a wing-shaped horizontal oblong part 3 with wing parts 3a projecting left and right from the vertical oblong part 2. The method of manufacturing the diaper comprises a process of disposing a plurality of absorbent materials Ci separately from each other on the web W with a first side edge part 11 and a second side edge part 21 in the longitudinal direction Y of the web W, and a process of cutting to divide the web W in the width direction X into a first group G1 where the first side edge part is the horizontal oblong part 3 and a second group G2 where the second side edge part 21 is the horizontal oblong part 3, and cutting the web W so that the absorbent materials Ci are included in the first and second groups G1 and G2 respectively.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a disposable diaper.

[0002]

2. Description of the Related Art Generally, in this type of diaper, a portion covering a wearer's crotch is constricted as compared with a portion wound around the wearer's torso. In order to form the waist, the original web needs to be greatly trimmed.

[0003]

Since the trimmed portion is discarded, the material is wasted, which causes a cost increase and is not preferable from the viewpoint of environmental protection.

Therefore, an object of the present invention is to provide a method for manufacturing a diaper in which the waste portion of the web can be made as small as possible.

[0005]

In order to achieve the above object, the present invention comprises a vertically elongated portion that covers a wearer's crotch, and a horizontally elongated portion that has a wing portion protruding left and right from the vertically elongated portion. A method of manufacturing a diaper, comprising: disposing a plurality of absorbers on a web having a first side edge portion and a second side edge portion in a state of being separated from each other in a longitudinal direction of the web;
While dividing the web into the first group in which the side edge portion is the laterally long portion and the second group in which the second side edge portion is the laterally long portion so as to be divided in the width direction, the first and the second Each of the two groups includes a step of cutting the web so as to include the absorber.

In the present invention, generally, a cutting line for cutting the web in the step of cutting the web is expressed by a function having a predetermined waveform and a wavelength, and adjacent absorbers are alternately arranged in the first group or the first group. The webs are cut so that they belong to two groups.

Further, in the present invention, the first and second side edge portions are respectively cut along the width direction of the web to cut the web in the longitudinal direction so as to form the laterally long portion. Since the web is formed into a substantially T-shape by this cutting, the diaper to be manufactured also has a substantially T-shape. However, after cutting the web, another blade may be joined to the tip of the vertically long portion so that the final product has a substantially H shape.

In the present invention, the step of arranging the absorber is more excellent in productivity before it is cut into two groups, but after cutting into two groups or after separating each diaper. Good.

In the present invention, the unitized absorber may be placed on the web in the step of arranging (stacking) the absorber, but in the step, a highly absorbent material is placed on the web a plurality of times. It may be done by placing.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. First, before describing the present manufacturing method, an example of a T-shaped diaper that can be manufactured by the present manufacturing method will be described.

In FIG. 1, a T-shaped diaper 1 is formed into a generally T-shape by integrating a vertically elongated portion 2 having a predetermined width and a horizontally elongated portion 3 having a width wider than the vertically elongated portion 2. There is.
Here, the width W1 of the vertically long portion 2 is generally 450 for adults.
~ 1000mm, for children, 250 ~ 40
Set to about 0 mm. The length L of the horizontally long portion 3 is generally set to about 900 to 2000 mm for adults and about 500 to 800 mm for children.

The vertically long portion 2 is a base portion 2 which is continuous with the horizontally long portion 3.
a, a crotch portion 2b applied to the crotch of the wearer, and a tip portion 2c joined to the laterally long portion 3 when worn are integrated. On the other hand, at both ends of the horizontally long portion 3, wing portions 3a, 3a protruding to the left and right of the vertically long portion 2 are integrally provided, and the horizontally long portion 3 is wound around the wearer's torso and the wing portion is The T-shaped diaper 1 is attached to the wearer by joining 3a, 3a to the tip portion 2c of the vertically long portion 2.

A first surface fastener F1 is attached to a tip portion 2c of the vertically long portion 2, while both wing portions 3a of the horizontally long portion 3 are attached.
A second surface fastener F2 capable of being surface-bonded to the first surface fastener F1 is attached to 3a. Note that one of the surface fasteners F1 and F2 may be omitted.
In that case, the outermost sheet of the longitudinal portion 2 or the innermost sheet of the wing portion serves as a female fastener. Further, instead of the hook-and-loop fastener, an adhesive tape and a portion bonded to the adhesive tape may be provided.

The vertically long portion 2 is provided with an absorber C capable of absorbing body fluid discharged from the body. The absorber C may be provided long enough to extend to a part of the region of the horizontally long portion 3. In the horizontally long portion 3, the absorber C may be pressed by a sheet.

The absorbent body C may be provided with a plurality of leak preventive walls (so-called "cuffs") 2d which prevent feces and / or urine from coming out of the absorbent body C or the diaper. The leak preventive wall 2d may be bent at least once.
For example, the leak prevention wall 2d may have a three-dimensional portion and a folded portion, and the folded portion may be bent inward of the diaper while the wearer wears the diaper. Since such a folded portion is easily brought into close contact with the wearer's leg, the effect of preventing leakage is further enhanced. It is preferable that the elastic member passes through the three-dimensional portion to stand up the three-dimensional portion, but the elastic member may not pass through the three-dimensional portion for cost reduction. In the vertical portion 2,
A plurality of leg gathers 2e may be provided to prevent stool and / or urine from leaking from the T-shaped diaper. The T-shaped diaper 1 is preferably provided with a leak preventive wall 2d and a leg gather 2e from the viewpoint of leakage prevention, but from the viewpoint of reducing the air permeability and the price, the leak preventive wall 2d or the leg gather 2e is provided. Either one of them may be provided.

The laterally elongated portion 3 has an elastic member 4 serving as waist gathers for suppressing the displacement between the wearer and the T-shaped diaper 1.
Has been introduced. Further, the laterally long portion 3 may be provided with an elastic member 4 serving as a fit gather for improving the fitting property of the T-shaped diaper 1. Elastic member 4
May be thread rubber or flat rubber. Further, the elastic member 4 may be made of urethane, or a web having elasticity may be used for the horizontally long portion 3.

Next, an example of a method for manufacturing a T-shaped diaper will be described. Each step described below is performed while the web is being transported in the longitudinal direction (flow direction) of the web. As shown in FIG. 2, the first and / or the second side edge portions 11 and 21 of the web W are folded back, and the folded portion 11a,
21a and the portions 11b and 21b of the web W overlapping with the elastic member 4 are introduced and folded back.
21a and the portions 11b and 21b of the web W that overlap with 21a and the elastic member 4 are bonded to each other with an adhesive. Thus, as shown in FIG. 3 (a), the first and / or second side edge portions 11 and 21 are folded, respectively, and a plurality of web edges are formed along the longitudinal direction (flow direction) Y of the web W. The elastic member 4 is arranged. Hot melt may be used as the adhesive. First side edge 11 and second side edge 2
1 may be simultaneously folded and formed, or may be folded and formed in different steps.

Thereafter, as shown in FIG. 3 (b), a large number of absorbers C _i are arranged (stacked) on the surface of the web W, which is the inner side when worn, in the longitudinal direction Y of the web W. ) Do. The absorber C _i is arranged so as to be elongated along the width direction X of the web W. At this time, a large number of absorbers C _{1 to} C _n may be arranged so as to be alternately displaced in the width direction X of the web W with respect to the center line CL along the longitudinal direction Y of the web W. . The absorber C _i may be covered with a tissue and / or a non-woven fabric, and may be further provided with a leak preventive wall. The pitch at which the absorbers C _i are provided may be constant or may be changed regularly. In addition,
In FIGS. 3 to 5, the absorber C _i is drawn by a chain double-dashed line so as to be easily distinguished from other members.

[0019] When arranging the absorbent body C _i, the absorbent body C _i
May be laminated on the web W without changing the posture, or by using the turn drum 50 shown in FIG.
It may be rotated and laminated on the web W. In FIG. 6, after the pad 51 sucks and receives the absorber C _i on the front roll 48, the turn drum 50 turns the pad 51 by 90 ° and changes the posture of the absorber C _i. ,
The absorber C _i is passed over the rear roll 49. Incidentally, by changing the timing at which the pads 51 of the turn drum 50 adsorbs the absorber C _i, can be arranged by shifting the absorber C _i in the width direction X of the web W in FIG. 3 (b). Further, the pitch at which the absorbent bodies C _i are arranged can be reduced by closing the pitch of the adjacent pads 51, 51 before the absorber C _i is passed to the rear roll 49 in FIG.

On the other hand, as shown in FIG. 4, the first and second surface fasteners F1 and F2 are arranged (bonded) at predetermined positions on the web W. These surface fasteners F1 and F2 are shown in FIG.
Before the folding step of (1), it may be adhered to the lower surface of the web W in advance. In addition, the second surface fastener F2 may be arranged on the upper surface of the web W (the surface on which the absorber C is laminated) after the folding step. As shown in FIG. 5, the second surface fastener F2 may be cut into two pieces when the adjacent T-shaped diapers 1 are cut into two pieces. The manufacturing becomes easier as compared with the case where two second surface fasteners F2 that are cut in advance are bonded.

As shown in FIG. 4 (b), the web W is cut along the cutting line 5 so as to be divided into two in the width direction X of the web W, and is divided into a first group G1 and a second group G2. Can be divided. This grouping is preferably performed after the folding step and after the absorber C and the double-sided fasteners F1 and F2 are arranged. As shown in FIG. 5A, in the first group G1, the first side edge portion 11 is the horizontally long portion 3. On the other hand, in the second group G2, the second side edge portion 2
1 is the horizontally long portion 3.

As shown in FIG. 4B, in many cases, the adjacent absorbers C _i and C _{i + 1} are alternately arranged in the first group G1.
Alternatively, it belongs to the second group G2. Cutting line 5 for separating the above-mentioned first group G1 and second group G2
May be represented as a comb, a sawtooth or a sine, or a complex periodic function thereof. That is, the cutting line 5 may be represented by a function having a predetermined waveform, amplitude Af, and wavelength λ.

As shown in FIG. 5A, the first and second groups are cut before the grouping is cut, at the same time as the grouping is cut, or after the grouping is cut.
The side edges 11 and 21 are cutting lines 10 and 20 along the width direction X.
In this way, the adjacent T-shaped diaper 1 is cut. In this way, the vertically long portions 2 of the adjacent T-shaped diapers 1 belonging to the first group G1 sandwich the vertically long portions 2 of the T-shaped diapers 1 belonging to the second group G2. The tip portion 2c of the vertically long portion 2 belonging to the sandwiched second group G2 is adjacent to the blade portion 3a of the horizontally long portion 3 of the first group G1. The wing 3a is adjacent to the wing 3a of the same group.

Before the absorber C _i is placed, the absorber C _i
The elastic member 4 located below may be cut in advance. This is because the contraction of the elastic member 4 prevents the absorber C _{i from} contracting. The elastic member 4 may not be introduced into the portion where the absorber C _i is arranged.

Further, before the surface fasteners F1 and F2 are attached, if the elastic member 4 is provided in the portion where the surface fasteners F1 and F2 are attached, the elastic member 4 may be cut in advance. Due to the contraction of the elastic member 4, the surface fastener F
This is to prevent easy removal of 1 and F2.

In order to improve the fit of the T-shaped diaper 1 at the crotch portion, the vertically elongated portion 2 may be provided with a constricted portion as shown in FIG. 5 (b). The constricted portion is formed by extracting a predetermined portion (hatched portion) 2h from the web W. This cutting step may be performed at the same time as any of the steps described in this embodiment, or may be performed before or after each step.

The web W cut in this way is shown in FIG.
Regarding the width L of one diaper (the length L of the horizontally long portion) shown in (a), two diapers can be shaped in the width direction of the web W. Therefore, productivity is also high.

Instead of the hook-and-loop fasteners F1 and F2, an adhesive tape and a tape for fixing it may be joined. The female side of the hook-and-loop fasteners F1 and F2 may be replaced with a non-woven fabric.

FIG. 7 is a diagram showing another example of development of the T-shaped diaper 1. Differences from the T-shaped diaper 1 of FIG. 5A will be described below. In FIG. 7, in the T-shaped diaper 1, the absorbent body C is not displaced in the direction traversing the web W. Further, basically, the elastic member 4 may not be arranged below the absorber C. The elastic member 4 may be sandwiched between the folded webs W as in the T-shaped diaper 1 of FIG. 5A.
It may be sandwiched between the first web and the second or third web. For example, it is possible to arrange the elastic member 4 by applying an adhesive to one or the other web, inserting the elastic member 4 between the one web and the other web, and nipping the elastic member 4 with a nip roll or the like. is there.

FIG. 8 is a development view of the web W showing another cut state. As shown in FIG. 8A, the widths W0 and W2 of the vertically long portions 2 of the first group G1 and the width W1 of the vertically long portions 2 of the second group G2 may be different from each other. Further, the width of the vertically long portion 2 formed in the first group G1 is W.
They may be different from each other, such as 0 and W2. further,
The lengths Ll and Ls of the horizontally long portion 3 of the first group G1 and the length Lm of the horizontally long portion 3 of the second group G2 may be different from each other. The lengths of the horizontally long portions 3 formed in the first group G1 may be different from each other, such as Ll and Ls.

With such a shaping method, it becomes possible to simultaneously manufacture diapers of different sizes. Also,
In these cases, four diapers 1 are shaped at one wavelength λ of the cutting line 5.

Further, as shown in FIG. 8B, the cutting line 5
The waveform drawn by is the amplitude Afs, Af above and below the center line CL.
l may be different from each other. In this case, the height H1 of the horizontally long portion 3 of the first group G1 and the height H2 of the horizontally long portion 3 of the second group G2 are different from each other. In the T-shaped diaper of the present invention, as shown by the alternate long and short dash line in Fig. 7, the elastic member may be arranged in a wave shape from the wing portion 3a to below the absorber C. This is to improve the adhesion between the absorber C and the wearer. The elastic member located below the absorber C may be cut in advance as described above.

[0033]

As described above, according to the present invention,
Since the web is divided into a first group in which the first side edge portion is a horizontally long portion and a second group in which the second side edge portion is a horizontally long portion, the web can be divided into T-shapes so that the trimming area is zero or It can be made as small as possible. Therefore, the discarded portion of the web can be made as small as possible. Further, since it is possible to mold a pair of products in the width direction of the web with respect to the length of one laterally long portion, it is possible to improve the production speed. Furthermore, the width direction of the obtained diaper corresponds to the longitudinal direction of the web. Therefore, when a caregiver wears a diaper on an adult wearer lying sideways, a large external force is easily applied in the width direction of the diaper, but the diaper is less likely to be broken in this width direction.

If the cutting line that divides the web into two groups is expressed by a function having a predetermined amplitude and wavelength, the automatic control of the apparatus becomes easy and the web can be continuously cut.

Further, if the absorbers are arranged so as to be displaced in the width direction of the web alternately with respect to the center line of the web,
The absorber can be provided in a suitable position.

The productivity is improved by disposing the absorber before the grouping process.

[Brief description of drawings]

FIG. 1 is a perspective view showing a T-shaped diaper according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a step of disposing an elastic member on a web according to the embodiment of the manufacturing method of the present invention.

FIG. 3A is a plan view showing a web whose side edges are folded, and FIG. 3B is a plan view showing a web in which absorbent bodies are laminated.

FIG. 4A is a plan view of the web showing a state in which the hook-and-loop fasteners are joined, and FIG. 4B is a plan view of the web showing a state in which the fasteners are divided into a first group and a second group.

FIG. 5A is a development view of the web showing a state of being cut into a T-shaped diaper, and FIG. 5B is a development view of the web showing a state after trimming.

FIG. 6 is a conceptual diagram showing an apparatus for changing the posture and pitch of an absorber.

FIG. 7 is an exploded view of a web including a T-shaped diaper having another shape and structure.

FIG. 8 is a development view of the web showing another state of division.

[Explanation of symbols]

1: T-shaped diaper 2: Vertical part 3: Horizontal part 3a: Wing 11: First side edge 21: Second side edge C: absorber G1: First group G2: Second group W: Web X: Width direction Y: longitudinal direction

Continued front page    F-term (reference) 3B029 BF02                 4C098 AA09 CC02 CC03 CC05 CC07                       CC11 CC14 CE07 DD03 DD05                       DD06 DD10 DD12 DD22

Claims (8)

[Claims] 1. A method of manufacturing a diaper, comprising: a vertically elongated portion that covers a wearer's crotch; and a horizontally elongated portion that has a wing portion that protrudes to the left and right of the vertically elongated portion. A step of arranging a plurality of absorbers in a web having side edge portions in a state of being separated from each other in the longitudinal direction of the web; a first group in which the first side edge portions are the laterally long portions; and the second side The web is divided into a second group having an edge portion that is the laterally long portion so as to divide the web in the width direction, and the first and second groups each include the web so that the absorbent body is included therein. A method for manufacturing a diaper, which comprises a step of cutting. 2. The cutting line for cutting the web in the step of cutting the web is represented by a function having a predetermined waveform and a wavelength according to claim 1.
A method for manufacturing a diaper, wherein the web is cut so that adjacent absorbent bodies alternately belong to the first group or the second group. 3. The diaper according to claim 1, wherein the first and second side edge portions are cut along the width direction of the web to cut the web into the laterally long portions. Production method. 4. The method for manufacturing a diaper according to claim 1, 2, or 3, wherein in the step of cutting into the two groups, the vertically long portion of one group is cut so as to sandwich the vertically long portion of the other group. 5. The method for manufacturing a diaper according to claim 1, 2, 3 or 4, wherein in the step of cutting into the two groups, the blade portion is cut so as to face the tip of the vertically long portion. 6. The method according to claim 1, wherein the first and second side edge portions are respectively cut before cutting the side edge portions along a width direction of the web. The method for manufacturing a diaper further comprising the step of disposing a plurality of elastic members along the longitudinal direction of the web. 7. The absorbent body according to claim 1, wherein, in the step of disposing the absorbent body, the absorbent body is alternately arranged in a width direction of the web with respect to a center line along a longitudinal direction of the web. A method for manufacturing diapers that are arranged in a misaligned state. 8. The method of manufacturing a diaper according to claim 1, wherein at least the vertically long portion has a leak preventive wall.