JP2009153754A - Apparatus for producing composite sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus for producing a composite sheet, capable of suppressing the damage of projections in a shaping roll, and suitably producing a composite sheet having uniform projected parts. <P>SOLUTION: The apparatus for producing the composite sheet includes: the shaping roll 11 where the plurality of projections 111 are arranged in the peripheral surface part; and an anvil roll 13 for joining the sheets 2, 3 between the shaping roll 11 and it, while rotating together with the shaping roll 11. The projections 111 are arranged to have a space in the rotary axial direction of the shaping roll 11 and to be deviated in the peripheral direction of the shaping roll 11, so that any subsequent projection 111 starts joining the both sheets 2, 3 in a linear joint part before any one of the projections 111, coming to the linear joint part of the both sheets 2, 3 by the shaping roll 11 and the anvil roll 13, terminates joining the both sheets 2, 3. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a composite sheet manufacturing apparatus, and more particularly to a composite sheet manufacturing apparatus suitable for a sheet for absorbent articles such as sanitary napkins and disposable diapers.

  As a technique related to a composite sheet manufacturing apparatus in which two sheets are partially joined to form a large number of joined portions, and one sheet has a convex portion formed in a portion other than the joined portions, The applicant has proposed the technique described in Patent Document 1 below.

  In the manufacturing apparatus of the above technique, after supplying one sheet to the meshing portion between two rolls having concave and convex shapes that mesh with each other and shaping the concave and convex shapes, the sheet is placed on the peripheral surface of one shaping roll. While being held, the sheet is transferred to a bonding position with another sheet, while both sheets are supplied between the shaping roll and the anvil roll, and both sheets are bonded between these rolls.

JP 2005-111908 A

  By the way, when the composite sheet is continuously manufactured by the above-described manufacturing apparatus, damage to the convex portion tends to be accelerated by an impact repeatedly applied to the convex portion of the shaping roll at the time of joining both sheets.

  This invention is made | formed in view of the said subject, The manufacture of the composite sheet which can suppress the damage of the convex part of a shaping roll, and can manufacture suitably the composite sheet which has a uniform convex part. An object is to provide an apparatus.

  In the present invention, the first sheet and the second sheet are partially joined to form a large number of concave portions, and the first sheet has convex portions formed between the concave portions. An apparatus for producing a composite sheet, wherein the first and second sheets are formed between a shaping roll having a plurality of convex portions arranged on a peripheral surface portion and the shaping roll while rotating together with the shaping roll. An anvil roll that joins the two sheets before the projecting part finishes joining the two sheets. The convex portions are spaced in the direction of the rotation axis of the shaping roll so that any of the convex portions that come around starts joining the two sheets at the line joining portion, and the shaping roll Composite sheet manufacturing equipment that is offset in the circumferential direction By subjecting, in which to achieve the above object.

  In addition, the present invention is a composite sheet manufactured by the composite sheet manufacturing apparatus of the present invention, wherein the first sheet and the second sheet are partially joined to form a large number of concave portions. In addition, a convex portion is formed between the concave portions in the first sheet, and the convex portions adjacent in the width direction of the first sheet correspond to the convex portion of the shaping roll. The present invention provides a composite sheet formed by shifting the length of the first sheet in the circumferential direction.

  In the composite sheet manufacturing apparatus of the present invention, any one of the convex portions that come to the line joining portion of the two sheets by the shaping roll and the anvil roll comes next before finishing the joining of both sheets. Since the convex part of the sheet starts joining of the two sheets at the line joint part, the impact applied to the convex part at the time of joining the two sheets can be kept low, and the durability of the apparatus is improved. In addition, since the composite sheet manufactured by the composite sheet manufacturing apparatus of the present invention has a convex portion so as not to be seen when the sheet is viewed from the width direction (direction orthogonal to the sheet conveyance direction), When the sheet is used as a surface sheet of an absorbent article, the liquid diffusibility can be easily controlled.

The present invention will be described below based on preferred embodiments with reference to the drawings.
First, the composite sheet manufacturing apparatus of the present invention (hereinafter also referred to as a manufacturing apparatus) will be described based on a preferred embodiment.

  As shown in FIG. 1, the manufacturing apparatus 10 according to the present embodiment includes a sheet 2 and a sheet 3 that are partially joined to form a large number of concave portions 1 </ b> B. It is an apparatus for manufacturing the composite sheet 1 in which the convex portion 1A is formed. The composite sheet 1 is formed with a joint 1C in which the sheets 2 and 3 are joined.

The manufacturing apparatus 10 includes a first roll (shaping roll, hereinafter also referred to as a roll) 11 and a second roll (hereinafter, also referred to as a roll) that have irregularities on the peripheral surface portion and rotate so that the concave portions and the convex portions are engaged with each other. 12) and an anvil roll 13 that joins the sheets 2 and 3 together with the roll 11.
Hereinafter, the manufacturing apparatus 10 will be described in more detail.

  As shown in FIG. 2, the roll 11 is formed by combining a plurality of spur gears 111 and gear-like spacers 112 and concentrically attaching the gears 111 and the spacers 112 to the rotating shaft 113. It is what was collected in. The gear 111 and the spacer 112 have the same width or different widths. The center of the gear 111 and the spacer 112 is open, and the rotating shaft 113 is inserted into the opening. The gear 111, the spacer 112, and the rotating shaft 113 are each formed with a notch (not shown), and a key (not shown) is inserted into the notch. As a result, idle rotation of the gear 111 and the spacer 112 is prevented.

  The spacer 112 includes a substantially annular center portion 1120 and beam teeth 1121 that are a number of protrusions extending radially from the periphery of the center portion 1120. Each beam tooth 1121 in the spacer 112 has the same length. If the diameter of a circle virtually formed by connecting the tips of the beam teeth 1121 is defined as the tip circle diameter for convenience, the tip circle diameter of the beam teeth 1121 is greater than the tip circle diameter of the gear 111. Is also getting smaller. Preferably, the diameter of the tip circle of the spacer 112 is equal to or smaller than the diameter of the root circle of the gear 111. One beam tooth is preferably present for every 10 to 15 teeth of adjacent gears from the two viewpoints of securing suction force and roll rigidity.

  As shown in FIG. 3, the roll 11 is provided with a plurality of sets of gear groups 110 each including a single gear 111 and a single spacer 112. In each gear group 110, the gear 111 and the spacer 112 are arranged so that the teeth of the gear 111 and the spacer 112 are aligned in the axial direction of the roll. In the roll 11, three or more sets of gear groups 110 are used. Therefore, the gear 111 and the spacer 112 are alternately attached to the rotating shaft 113.

  In the roll 11, the gear 111 has the same circular diameter of the tooth tip. In addition, the tooth width of the gear 111 (the width of the convex portion 11A of the roll 11) has the same tooth width. In addition, the tooth | gear width of each gearwheel 111 may differ for the objective of changing the shape of the convex part formed in a sheet | seat in a sheet | seat width direction.

  In each gear group 110, a plurality of gap portions 114 are formed between the two gears 111 at regular intervals along the rotation direction of the roll 11. Each gap 114 is formed by two gears 111 and a spacer 112 positioned between them. More specifically, each gap 114 is defined by opposing sides of the two gears 111 and two adjacent teeth on the spacer 112. Accordingly, the number of gaps 114 is the same as the number of teeth of the beam teeth 1121 of the spacer 112. The gap 114 opens outward in the recess 11B described above.

  In the present embodiment, the gear group 110 is incorporated so that the gap 114 is also arranged outside the both sides of the sheet 2. Thereby, as will be described later, suction force acts on both side portions of the sheet 2 to prevent the side portions of the sheet 2 from being bent.

  A plurality of openings 115 are formed in the gear 111 so as to surround a central opening into which the rotating shaft 113 is inserted. Each opening 115 has the same diameter, and is formed at a position equidistant from the center of the gear. The angles formed by the adjacent openings 115 in one gear 111 and the center of the gear are all equal. The number of openings 115 in each gear 111 is the same as the number of beam teeth 1121 of the spacer 112. When the gear groups 110 are assembled, the gears 111 and the spacers 112 are arranged so that the openings 115 are positioned between adjacent beam teeth 1121 in one spacer 112. In this state where the gear groups 110 are assembled and the gear groups 110 are arranged so that the pitches of the concavo-convex portions are different from each other, the openings 115 of the gears 111 are connected to the rotation axis direction of the roll 11. A plurality of suction paths 116 extending in the rotation axis direction are formed inside the roll 11. Each suction path 116 communicates with the gap 114 described above.

  At least one end of the suction path 116 communicates with an intake source (not shown) such as a blower or a vacuum pump. Therefore, when a suction operation is performed by operating the intake source, intake is performed from the gap portion 114 through the suction path 116.

  The roll 11 of the present embodiment is particularly effective when a large number of small convex portions are formed with a small pitch, and even if a low module spur gear that is a gear with a small pitch and a small tooth size is used, The gap 114 can be enlarged by increasing the tooth width or decreasing the number of teeth. As a result, the area of the suction hole can be sufficiently secured. Furthermore, there is also an advantage that the pitch and size of the convex portions can be freely changed by a simple operation by simply changing the combination and width of the gears and the spacer 112.

As shown in FIG. 4, the roll 11 includes a plurality of rows in which convex portions 11 </ b> A are arranged at an equal pitch in the circumferential direction X of the roll 11 at predetermined intervals in the width direction of the roll 11. The pitch interval of the convex portions 11A in the circumferential direction X of the roll 11 in one row is P, the circumferential length of the convex portion 11A is A, and the number of rows in which the convex portions 11A in the width direction of the roll 11 are arranged is N. Sometimes P <A × N.
Here, the pitch P of the convex portions 11 </ b> A refers to the pitch interval in the circumferential direction between the convex portions 11 </ b> A when the peripheral surface of the roll 11 is developed, and the peripheral length A of the convex portions 11 </ b> A refers to the peripheral surface of the roll 11. Is the length in the circumferential direction of the convex portion 11A. In the present embodiment, N is the number of gears 111 and does not include the number of spacers 112.

  In the manufacturing apparatus 10, a plurality of rows in which convex portions 11 </ b> A are arranged at an equal pitch in the circumferential direction X of the roll 11 are arranged at predetermined intervals in the width direction of the roll 11. The deviation D in the circumferential direction of the roll 11 between the protrusions 11A in adjacent rows is that the two sheets are continuously joined at the line joining portion, and the protrusions in the row are formed independently. It is preferable that it is in a range of (1/2) P over (3/4) P or less with respect to the pitch P of the part. Here, the circumferential shift D of the convex portions 11 </ b> A between the rolls 11 refers to the distance between the circumferential ends of the convex portions 11 </ b> A in adjacent rows on the circumferential surface of the roll 11.

  In FIG. 2, among the many convex portions 11 </ b> A formed on the peripheral surface of the roll 11, a region surrounded by the four convex portions 11 </ b> A serving as the four corners of the rhombus is a concave portion 11 </ b> B. The recesses 11 </ b> B are arranged in a row along the rotation direction of the roll 11. This row is arranged in multiple rows in the axial direction Y of the roll 11.

  As shown in FIG. 1, the roll 12 is formed by combining a plurality of gears in a similar manner so that a concavo-convex portion corresponding to the concavo-convex portion of the peripheral surface portion of the roll 11 is formed. The circle diameter of the tooth tip is smaller than that of the roll 11, and the number of convex portions 12A is reduced accordingly. Further, the suction path as in the roll 11 is not formed in the roll 12.

  The leading end of the convex portion 12A of the roll 12 is arranged with a gap so as not to contact the concave portion 11B of the roll 11 at the position where the sheet 2 is pushed into the concave portion 112 of the roll 11 by the convex portion 12 of the roll 12. . Moreover, the roll 11 and the roll 12 are arrange | positioned so that it may rotate in a non-contact state also in a part other than this.

  The anvil roll 13 includes heating means (not shown). And when the sheet | seats 2 and 3 are clamped between the surrounding surface of the anvil roll 13 of the state heated with this heating means, and the convex part 11A of the roll 11, both sheets 2 and 3 are heat-fused and joined. As a result, the joint 1B is formed.

  In the manufacturing apparatus 10, any one of the convex portions 11 </ b> A that wrap around the line joining portions of the two sheets 2 and 3 by the roll 11 and the anvil roll 13 comes next before finishing the joining of the two sheets 2 and 3. 11 A of convex parts have a space | interval in the rotating shaft direction of the roll 11, and it has shifted | deviated to the circumferential direction of the roll 11 so that any convex part 11A may start joining of both the sheets 2 and 3 in the said line joint part. It is arranged.

  Although not shown in the drawing, the manufacturing apparatus 10 includes a drive source that rotationally drives the rolls 11 and 12 and the anvil roll 13 at a predetermined rotational speed.

  Next, a preferred embodiment of the composite sheet of the present invention will be described together with an embodiment of a production method using the production apparatus 10.

  As shown in FIG. 5, in the composite sheet of this embodiment, the sheet 2 and the sheet 3 are partially joined to form a large number of concave portions 1B, and the sheet 2 protrudes between the concave portions 1B. A shaped portion 1A is formed. In the composite sheet of the present embodiment, one joint 1C is formed with respect to one concave portion 1B.

The convex portion 1A is a flat rectangular parallelepiped or truncated quadrangular pyramid with rounded ridgelines as a whole. The convex portion 1A preferably has a height H of 1 to 10 mm, particularly 1 to 6 mm. The bottom dimension (L in FIG. 5A) of the convex portion 1A in the sheet length direction (X direction) is preferably 2 to 30 mm, particularly preferably 2 to 5 mm, and the sheet width direction (Y direction). The bottom dimension (W in FIG. 5 (b)) is preferably 2 to 30 mm, particularly preferably 2 to 5 mm. The bottom area of the convex portion 1A is preferably 4 to 900 mm ² , particularly 4 to 25 mm ² . The height H is the height from the joint 1C.

  The form of the joining portion 1C corresponds to the tip surface of the convex portion 11A of the roll 11, and is substantially rectangular in plan view.

  In the composite sheet 1, the convex portions 1 </ b> A and the concave portions 1 </ b> B appear alternately in a row in the sheet length direction (circumferential direction X of the roll 11), and the convex portions 1 </ b> A correspond to the convex portions 11 </ b> A of the roll 11. The staggered arrangement is shifted in the length direction of the sheet according to the shift. Similarly, the concave portion 1B has a staggered arrangement shifted in the length direction of the sheet. The length direction of the sheet coincides with the flow direction in the manufacturing process of the composite sheet 1 by the manufacturing apparatus 10.

  There is no restriction | limiting in particular in the material used for the sheet | seat 2 and the sheet | seat 3 which comprise the composite sheet 1, Typically, various nonwoven fabrics and films are used as an absorbent article. As a nonwoven fabric, the nonwoven fabric manufactured by the card | curd method, the spun bond nonwoven fabric, the melt blown nonwoven fabric, the spunlace nonwoven fabric, the needle punch nonwoven fabric etc. are mentioned, for example. When a film is used as the surface sheet of the absorbent article to form a composite sheet, the composite sheet is perforated to provide a large number of apertures so that the liquid can be permeated. As the sheets 2 and 3, the sheet described in [0010] of JP-A-2005-111908 according to the previous application of the present applicant can be used.

  In manufacturing the composite sheet 1 using the sheets 2 and 3, first, in the manufacturing apparatus 10, the roll 2 and the roll 12 are rotated at a predetermined rotation speed while the sheet 2 is supplied to the meshed portion, and the uneven shape is obtained. Then, the sheet 2 is transferred to the peripheral surface of the anvil roll 13 in a state where the sheet 2 is sucked and held on the peripheral surface of the roll 11 by the suction force through the suction path. The sheet 3 is supplied so as to be overlapped with the sheet 2, and these sheets are thermally bonded between the roll 11 and the anvil roll 13 to be partially joined.

  And as shown in FIG. 5, while the sheet | seat 2 and the sheet | seat 3 are partially joined by the junction part 1C, many concave streak parts 1B are formed, and the inside is convex shape with a hollow between concave part 1B. A composite sheet 1 having a large number of portions 1A is manufactured.

  As described above, in the manufacturing apparatus 10 according to the present embodiment, any one of the convex portions 11 </ b> A that come around the line joining portion of the two sheets 2 and 3 by the roll 11 and the anvil roll 13 joins the two sheets 2 and 3. Before finishing, since any one of the convex portions 11A that come next starts joining the two sheets 2 and 3 at the line joint portion, the impact applied to the convex portions 11A when the two sheets 2 and 3 are joined is kept low. And the durability of the apparatus is improved. Moreover, since the pressurizing force between the roll 11 and the anvil roll 13 can be lowered, the pressurizing means can be reduced in size. Moreover, the composite sheet 1 manufactured by the manufacturing apparatus 10 has a good shape and arrangement of the convex portions 1A.

The present invention is not limited to the embodiment.
In the production apparatus of the present invention, side rings that are always in contact with the anvil roll can be attached to both sides of the shaping roll as needed to stabilize the joining of both sheets by the shaping roll and the anvil roll.

  In the manufacturing apparatus of the present invention, the shaping roll is preferably constituted by a combination of a plurality of gears as in the above embodiment, but can also be constituted by a single roll having an uneven portion on the peripheral surface. Moreover, you may comprise a roll only with a gearwheel without using a spacer.

  In the above-described embodiment, the shaping roll provided with the concave portion 11B in such a manner that the gear 111 and the spacer 112 are combined and surrounded by four teeth (convex portions) 11A is used. However, as shown in FIG. A plurality of gears 111 ′ are combined symmetrically in the circumferential direction via a gap 114 (spacer), and these gears 111 ′ are attached concentrically to the rotating shaft to form a roll, and are surrounded by six convex portions 11 A. It is also possible to use one provided with a concave portion 11B. Further, as shown in FIG. 6B, in the embodiment of FIG. 6A, the convex portion 11A in the gear 111 'can be shifted in the circumferential direction. In the case of Fig.6 (a) and FIG.6 (b), two junction parts 1C are formed with respect to one concave-shaped part 1B in the obtained composite sheet.

  The spacer diameter may be the same as that of the shaping roll gear. In this case, the beam teeth of the spacer are also considered as convex portions of the present invention, and the shaping roll is formed.

  Further, the composite sheet of the present invention joins these sheets by adhesive bonding or ultrasonic bonding instead of joining the sheet 2 and the sheet 3 by heat fusion as in the above embodiment. Thus, a joint portion may be formed.

  The composite sheet of the present invention is suitably used as a surface sheet of an absorbent article, another constituent member such as an exterior material of the absorbent article, or a disposable clothing sheet.

Hereinafter, the present invention will be described more specifically with reference to examples.
[Example 1]
Using the shaping roll and anvil roll having the following forms of irregularities, rotate the shaping roll and the anvil roll at a certain distance so as to contact each other, calculate the linear pressure at that time, the convex part of the shaping roll The linear pressure fluctuation due to contact between the slab and the anvil roll was evaluated. The results are shown in Table 1. In addition, the linear pressure was calculated | required by the value which remove | divided the sum total of the thrust obtained with the two pressurization cylinders which pressurize a shaping roll and an anvil roll by the contact line length. However, the length of the contact line is the width of the gear having a convex portion on the roll peripheral surface when a line parallel to the shaping roll rotation axis is drawn on the roll peripheral surface (the convex portion of the gear comprising a spur gear (for example, FIG. 2). It is defined as a value calculated by adding the width of the side ring to the total value when side rings are attached to both sides of the roll.

Tooth pitch P of shaping roll: 3.18mm
Tooth width / Tooth circumferential length: 1.0 mm / 0.8 mm
Deviation of adjacent rows of shaping rolls: 1.79 mm (D in FIG. 4)
Number of gears: 64 (64 gears + 64 spacers = 128 total)

[Comparative Example 1]
The linear pressure was measured and the impact was evaluated in the same manner as in Example 1 except that the shift of the teeth in the adjacent rows of the shaping roll was set to a half pitch.

[Comparative Example 2]
The linear pressure was measured and the impact was evaluated in the same manner as in Comparative Example 1 except that side rings with a width of 4 mm were attached to both sides of the shaping roll.

  As shown in Table 1, since the results of Example 1 are smaller in line length variation than Comparative Examples 1 and 2, the impact during bonding is small. Further, since the side ring need not be provided, the apparatus can be made compact and the thrust force can be reduced. On the other hand, since the comparative example 1 has a part with a wire length of 0 mm, the shaping roll moves up and down, and the load applied to the convex part increases. In Comparative Example 2, the load applied to the convex portion of the shaping roll is smaller than that in Comparative Example 1, but since the linear pressure fluctuation is larger than that in Example 1, the impact is increased.

It is a schematic diagram which shows the principal part in one Embodiment of the manufacturing apparatus of the composite sheet of this invention with the manufacturing method of a composite sheet. It is a perspective view which shows the form of the 1st roll which comprises a shaping roll. It is a disassembled perspective view of the gear of a 1st roll. It is a top view which shows the one part expansion | deployment form of the surrounding surface of the 1st roll in the manufacturing apparatus of the composite sheet shown in FIG. It is a schematic diagram which shows one Embodiment of the composite sheet of this invention, (a) is a side view of a composite sheet, (b) is the front view seen from the flow direction of the composite sheet. (A) And (b) is a top view which shows the one part expansion | deployment form of the 1st roll surrounding surface in other embodiment of the composite sheet of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Composite sheet 1A Convex part 1B Concave part 1C Joint part 2, 3 Sheet 10 Composite sheet manufacturing apparatus 11 1st roll 11A Convex part 11B Concave part 12 2nd roll 121 Convex part 13 Anvil roll

Claims (5)

The first sheet and the second sheet are partially joined to form a plurality of concave portions, and the first sheet is manufactured as a composite sheet in which convex portions are formed between the concave portions. A device that performs
A shaping roll in which a plurality of convex portions are arranged on the peripheral surface portion, and an anvil roll that joins the first and second sheets with the shaping roll while rotating together with the shaping roll. ,
Before any of the convex portions that come to the line joint portion of the two sheets by the shaping roll and the anvil roll finishes joining the two sheets, any of the convex portions that go around next is the A composite sheet in which the projections are spaced apart in the rotation axis direction of the shaping roll and shifted in the circumferential direction of the shaping roll so that the joining of the two sheets is started at the wire joining portion Manufacturing equipment. A plurality of rows in which the convex portions are arranged in the circumferential direction of the shaping roll are arranged in the width direction of the shaping roll,
In the shaping roll, the pitch of the convex portion in the circumferential direction of the shaping roll in one row is P, the circumferential length of the convex portion is A, and the number of the rows in the width direction of the shaping roll is N. And when
P <A × N
The apparatus for producing a composite sheet according to claim 1.   The composite sheet according to claim 2, wherein a deviation D in a circumferential direction between the protrusions in adjacent rows is in a range of (1/2) P over (3/4) P or less with respect to the pitch P of the protrusions. Manufacturing equipment.   The said shaping roll is assembled by concentrically mounting a plurality of gears having teeth that become the convex portions on the peripheral surface thereof, and the teeth are shifted in the circumferential direction. The composite sheet manufacturing apparatus according to any one of the above. A composite sheet manufactured by the composite sheet manufacturing apparatus according to claim 1,
The first sheet and the second sheet are partially joined to form a large number of concave portions, and the first sheet has convex portions formed between the concave portions,
The composite sheet in which the convex portions adjacent in the width direction of the first sheet are formed so as to be shifted in the circumferential direction of the length of the first sheet corresponding to the convex portions of the shaping roll.

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