JP2022069291A - Manufacturing method and manufacturing apparatus for composite sheet - Google Patents

Abstract

To provide a manufacturing method and a manufacturing apparatus for a composite sheet capable of performing a formation of a welded portion and a formation of a through hole in one step in manufacturing of the composite sheet formed with a through hole at the welded portion.SOLUTION: A manufacturing method for a composite sheet has: a superposition step for superposing a first sheet 1 and a second sheet 2 while carrying them in the same direction to form a lamination sheet 10A; and an ultrasonic processing step for forming a welded portion 4 by carrying the lamination sheet 10A into a clearance 46 between a circumferential surface portion of an anvil roll 31 and an oscillation-applied surface 421 at a tip portion of an ultrasonic horn 42, bringing the oscillation-applied surface 421 into contact with one surface of the lamination sheet 10A, and applying ultrasonic oscillation. Immediately before carrying the lamination sheet 10A into the clearance 46, a surface in contact with the oscillation-applied surface 421 at the clearance 46 in the lamination sheet 10A is brought into contact with an edge portion 47 of a carrying-in port of the clearance 46 in the ultrasonic horn 42.SELECTED DRAWING: Figure 7

Description

The present invention relates to a technique for manufacturing a composite sheet in which two sheets are fused and a through hole is formed in the fused portion.

As a surface sheet for absorbent articles such as disposable diapers and menstrual napkins, those having irregularities on the surface that comes into contact with the wearer's skin are known, and for example, the first and second sheets are fused. A composite sheet is known which has a large number of fused portions, and a portion of the first sheet other than the fused portions forms a convex portion protruding on the side opposite to the second sheet side. Since the surface of such a composite sheet is uneven, it is excellent in touch and anti-diffusion property. It is also known that through holes are formed in the fused portion of such a composite sheet to improve the liquid drawability and the like (see Patent Documents 1 and 2).
Further, although it is not the above-mentioned method for manufacturing a composite sheet, it is known that an ultrasonic fusion machine is used for joining the sheets (see Patent Documents 3 and 4).

In the case of producing a composite sheet in which a through hole is formed in a fused portion as described in Patent Documents 1 and 2, if the fused portion and the through hole are formed in different steps, the fused portion is formed. There may be a misalignment between the position of and the position of the through hole. On the other hand, if the formation of the fused portion and the formation of the through hole can be completed in one step, such a positional deviation can be effectively suppressed. However, with the method using a conventional ultrasonic fusion machine, it is difficult to form the fusion zone and the through hole in one step, and the through hole may not be stably formed in the fusion zone. rice field. In view of such drawbacks of the prior art, the applicant has previously proposed a technique capable of forming a fused portion and forming a through hole in one step by using an ultrasonic fusion machine. (See Patent Documents 5 and 6).

Japanese Unexamined Patent Publication No. 2006-175688 Japanese Unexamined Patent Publication No. 2006-175689 Japanese Unexamined Patent Publication No. 2008-260131 Japanese Patent Publication No. 2011-591319 Japanese Unexamined Patent Publication No. 2019-93467 Japanese Unexamined Patent Publication No. 2019-188802

The techniques described in Patent Documents 5 and 6 can complete the formation of a fused portion and the formation of a through hole in one step, and efficiently manufacture a composite sheet having a through hole formed in the fused portion. However, there is room for improvement in terms of the ease of forming through holes. For example, when the sheet material which is the material for forming the composite sheet contains a resin having a relatively high melting point (for example, polyethylene terephthalate), the sheet material is simultaneously subjected to a fusion portion forming treatment and a through hole forming treatment. As a result, the through hole is not formed as designed in the portion to be treated, and the resin remains in the planned portion of the through hole in a state where the fiber morphology is maintained, resulting in a through hole smaller than the design dimension. It may end up. There is a demand for a technique capable of forming a fused portion and forming a through hole as designed in one step without selecting a material for forming the composite sheet. Further, it is desirable that such a technique does not cause the manufacturing equipment to become large and complicated, and can achieve the purpose with a relatively simple equipment configuration.

An object of the present invention is to provide a technique capable of forming a fused portion and forming a through hole in one step in the production of a composite sheet having a through hole formed in the fused portion.

The present invention is a method for manufacturing a composite sheet having a plurality of fused portions in which the first sheet and the second sheet are fused, and through holes are formed in the fused portions.
One embodiment of the method for manufacturing a composite sheet of the present invention includes a superposition step of forming a laminated sheet by superimposing the first sheet and the second sheet while transporting them in the same direction.
In one embodiment of the method for manufacturing a composite sheet of the present invention, the laminated sheet is provided with a vibration application surface of a peripheral surface portion of an anvil roll and a vibration application surface of a tip portion of an ultrasonic horn of an ultrasonic fusion machine arranged to face the peripheral surface portion. It has an ultrasonic treatment step of forming the fused portion by bringing it into the clearance of the above and bringing the vibration application surface into contact with one surface of the laminated sheet and applying ultrasonic vibration.
In one embodiment of the method for manufacturing a composite sheet of the present invention, immediately before the laminated sheet is carried into the clearance, the surface of the laminated sheet that comes into contact with the vibration application surface in the clearance is the clearance in the ultrasonic horn. Contact the edge of the carry-in entrance.

Further, the present invention is an apparatus for manufacturing a composite sheet having a plurality of fused portions in which the first sheet and the second sheet are fused, and through holes are formed in the fused portions.
One embodiment of the composite sheet manufacturing apparatus of the present invention includes an anvil roll and an ultrasonic fusion machine, the ultrasonic fusion machine including an ultrasonic horn arranged to face the peripheral surface of the anvil roll. Further, the ultrasonic processing unit is provided with a clearance for carrying the object to be processed between the peripheral surface of the anvil roll and the vibration application surface of the tip of the ultrasonic horn.
In one embodiment of the composite sheet manufacturing apparatus of the present invention, the first sheet and the second sheet are conveyed in the same direction and laminated to form a laminated sheet, and the laminated sheet which is the object to be treated is formed. It is provided with a material transporting unit to be carried into the clearance.
In one embodiment of the composite sheet manufacturing apparatus of the present invention, the ultrasonic processing unit applies ultrasonic vibration by bringing the vibration application surface into contact with one surface of the laminated sheet carried into the clearance. The fused portion is formed in the above.
In one embodiment of the composite sheet manufacturing apparatus of the present invention, immediately before the laminated sheet is carried into the clearance, the surface of the laminated sheet that comes into contact with the vibration application surface in the clearance is the clearance in the ultrasonic horn. It is designed to be in contact with the edge of the carry-in entrance.
Other features, effects and embodiments of the invention are described below.

According to the present invention, in the production of a composite sheet in which a through hole is formed in a fused portion, a method and an apparatus for producing a composite sheet capable of forming a fused portion and forming a through hole in one step are provided. Provided.

FIG. 1 is a perspective view of a main part showing an embodiment of a composite sheet manufactured by the present invention. FIG. 2 is an enlarged plan view of the composite sheet shown in FIG. 1 as viewed from the first sheet side. FIG. 3 is a schematic view showing an embodiment of the composite sheet manufacturing apparatus of the present invention. FIG. 4 is an enlarged perspective view showing a main part of the anvil roll (concave and convex roll) shown in FIG. FIG. 5 is a front view showing a state in which the ultrasonic welding machine shown in FIG. 3 is viewed from the upstream side in the transport direction of the object to be processed. FIG. 6 is a diagram showing the tip of the ultrasonic horn and its vicinity in the manufacturing apparatus shown in FIG. FIG. 7A schematically shows a state in which the object to be processed is carried into the clearance between the peripheral surface of the anvil roll and the vibration application surface of the ultrasonic horn in the manufacturing apparatus shown in FIG. It is a cross-sectional view along the direction, and FIG. 7 (b) is an enlarged view of a portion surrounded by a dotted line in FIG. 7 (a). FIG. 8 is a diagram corresponding to FIG. 7 in a form outside the scope of the present invention. FIG. 9 is a cross-sectional view schematically showing a cross section of the tip of an embodiment of the ultrasonic horn according to the present invention along the transport direction of the object to be processed. FIG. 10 is a diagram corresponding to FIG. 6 of an embodiment of the superposition step according to the present invention. FIG. 11 is a view corresponding to FIG. 9 of another embodiment of the ultrasonic horn according to the present invention.

Hereinafter, the present invention will be described based on the preferred embodiment thereof with reference to the drawings. In the description of the drawings below, the same or similar parts are designated by the same or similar reference numerals. The drawings are basically schematic, and the ratio of each dimension may differ from the actual one.

First, the composite sheet manufactured by the method for manufacturing the composite sheet or the manufacturing apparatus of the present invention will be described. 1 and 2 show a composite sheet 10 which is an embodiment of the composite sheet. The composite sheet 10 has a plurality of fused portions 4 to which the first sheet 1 and the second sheet 2 are fused, and a through hole 6 is formed in the fused portion 4.

In the present embodiment, the composite sheet 10 has a convex portion 5 in which at least a part of the portion other than the fused portion 4 in the first sheet 1 projects to the side opposite to the second sheet 2 side. The convex portions 5 and the fused portions 4 are arranged alternately and in a row in the X direction, which is one direction parallel to the surface of the composite sheet 10, and such rows are arranged in a row. It is formed in multiple rows in the Y direction, which is parallel to and orthogonal to the one direction. The convex portions 5 and the fused portions 4 in the rows adjacent to each other are arranged so as to be offset in the X direction, and more specifically, they are arranged so as to be offset by a half pitch.

In the composite sheet 10, the Y direction coincides with the flow direction of the object to be processed at the time of manufacturing (mechanical direction, hereinafter also referred to as “MD”), and the X direction is a direction orthogonal to the MD at the time of manufacturing (hereinafter, “M)”. Also referred to as "CD"). Further, the rotation axes of the first roll (anvil roll) 31 and the second roll 32, which will be described later, are parallel to the CD and orthogonal to the MD.

In the present embodiment, the composite sheet 10 has a large number of recesses 3 sandwiched between the convex portions 5 in both the X direction and the Y direction on the surface on the first sheet 1 side, and the bottom of each recess 3 is formed. A fused portion 4 having a through hole 6 is formed therein. When viewed as a whole, the composite sheet 10 has large undulating irregularities on the surface on the first sheet 1 side, which is composed of the concave portion 3 and the convex portion 5, and the surface on the second sheet 2 side is flat. Or, it is a substantially flat surface with relatively small undulations with respect to the surface on the first sheet 1 side.

Each of the fused portions 4 in the composite sheet 10 has a substantially rectangular plan view shape that is long in the Y direction, and a through hole 6 having a substantially rectangular plan view shape is formed inside each of the fused portions 4. There is. In other words, each fused portion 4 is formed in an annular shape surrounding the through hole 6.
It is preferable that only one through hole 6 is formed in one fused portion 4, and it is preferable that the through hole 6 is formed at a specific position predetermined in relation to the position of the fused portion 4.
Further, the through hole 6 may or may not have a plan view shape similar to the plan view shape of the outer peripheral edge of the fused portion 4, but is preferably a similar shape.

In the fused portion 4, the first sheet 1 and the second sheet 2 are bonded to each other by melting and solidifying the resin constituting at least one of the first sheet 1 and the second sheet 2.
When the first sheet 1 and the second sheet 2 are made of a fiber sheet such as a non-woven fabric, in the fused portion 4, the constituent fibers of the first sheet 1 and the second sheet 2 are melted or melted resin. It is preferable that the fibrous morphology cannot be visually observed by being buried in the cloth, that is, it is in a filmed state in appearance. That is, the fused portion 4 is preferably in the form of a film.

The first sheet 1 and the second sheet 2 are each made of a sheet material. As the sheet material, for example, a fiber sheet such as a non-woven fabric, a woven fabric, or a knitted fabric; a resin film or the like can be used, and two or more of these may be laminated. The type of sheet material may be the same or different between the first sheet 1 and the second sheet 2.

From the viewpoint of improving the feel to the touch, it is preferable that at least one of the first sheet 1 and the second sheet 2, preferably both of them, contains a non-woven fabric. The term "consisting of a non-woven fabric" as used herein includes a form in which only a part of the sheet is a non-woven fabric (for example, a laminate of a non-woven fabric and a resin film) and the entire sheet is a non-woven fabric. The form is included.
As the non-woven fabric constituting both sheets 1 and 2, non-woven fabrics produced by various manufacturing methods can be used without particular limitation. A laminated non-woven fabric in which two or more of these non-woven fabrics are laminated can be used.

The first sheet 1 and the second sheet 2 are typically configured to contain a resin. The sheet material such as the non-woven fabric constituting both the sheets 1 and 2 is typically mainly composed of various resins including a thermoplastic resin. The constituent fibers of both sheets 1 and 2 may be a single fiber made of one kind of resin or a blended polymer in which two or more kinds of resins are mixed, or may be a composite fiber. The composite fiber referred to here is a synthetic fiber (for example, a thermoplastic fiber) obtained by combining two or more types of resins having different components with a spinneret and spinning them at the same time, and the plurality of components are continuous in the length direction of the fiber. A structure that is mutually bonded within a single fiber. The form of the composite fiber includes a core sheath type, a side-by-side type, and the like, and is not particularly limited.
Examples of the thermoplastic resin constituting both sheets 1 and 2 include polyolefins such as polyethylene, polypropylene and polybuden; polyesters such as polyethylene terephthalate and polybutylene terephthalate; polyamides such as nylon 6 and nylon 66; polyacrylic acid and polymethacrylics. Examples thereof include acid alkyl esters, polyvinyl chloride, and polyvinylidene chloride. One of these resins can be used alone or as a blend of two or more.

By the way, when at least one of the first sheet 1 and the second sheet 2 contains a refractory resin having a relatively high melting point, both sheets 1 and 2 are melted and penetrated as compared with the case where this is not contained. Since the amount of energy required to form the hole 6 increases, it may be difficult to form the through hole 6 by only one step of ultrasonic treatment. Examples of such a high melting point resin include resins having a melting point of more than 200 ° C., and specific examples thereof include polyethylene terephthalate (PET). For example, in the present invention, one or both of the sheets 1 and 2 are configured to include a nonwoven fabric, and the constituent fibers of the nonwoven fabric include a core-sheath type composite fiber having a core made of PET and a sheath made of polyethylene. However, when at least one of both sheets 1 and 2 is configured to contain PET in this way, it may be difficult to form the through hole 6 by only one step of ultrasonic treatment. However, according to the present invention, even when the material for forming the composite sheet 10 contains a refractory resin such as PET, the fused portion 4 and the through hole 6 are formed due to the characteristic configuration of the present invention described later. It is possible to carry out with one step of ultrasonic treatment.

The basis weight of each of the first sheet 1 and the second sheet 2 is not particularly limited, and may be appropriately set according to the intended use of the composite sheet and the like. For example, when the composite sheet is used as a constituent member (surface sheet or the like) of an absorbent article, the basis weights of both sheets 1 and 2 are preferably 10 g / m ² or more, more preferably 15 g / m ² or more, respectively. , And more preferably 40 g / m ² or less, more preferably 35 g / m ² or less.

Next, the manufacturing method and the manufacturing apparatus of the composite sheet of the present invention will be described. FIG. 3 shows the overall configuration of the manufacturing apparatus 20 which is an embodiment of the composite sheet manufacturing apparatus of the present invention, and FIGS. 4 to 7 show the main parts of the manufacturing apparatus 20.
The manufacturing apparatus 20 is the above-mentioned manufacturing apparatus for the composite sheet 10, and includes at least an ultrasonic processing unit 40 and an object transporting unit 30.
The ultrasonic processing unit 40 includes an anvil roll 31 and an ultrasonic fusion machine 41, and the ultrasonic fusion machine 41 includes an ultrasonic horn 42 arranged to face the peripheral surface of the anvil roll 31, and the anvil roll 31 is included. A clearance 46 is provided between the peripheral surface portion (specifically, the tip surface 35c of the convex portion 35 described later) and the vibration application surface 421 of the tip portion of the ultrasonic horn 42 to carry the object to be processed. That is.
Further, the object transporting unit 30 superimposes the first sheet 1 and the second sheet 2 while transporting them in the same direction (MD) to form a laminated sheet 10A, and clears the laminated sheet 10A which is the object to be processed. It is to be carried into 46.
The laminated sheet 10A is simply a stack of the first sheet 1 and the second sheet 2, and the laminated sheets 1 and 2 are not fused to each other in the laminated sheet 10A.

In the present embodiment, the composite sheet 10 which is a manufacturing object has "a convex portion 5 in which at least a part of a portion other than the fused portion 4 in the first sheet 1 protrudes to the side opposite to the second sheet 2 side. Correspondingly, the anvil roll 31 is a concavo-convex roll having irregularities on the peripheral surface portion. Further, the object transporting portion 30 makes the first sheet 1 follow the peripheral surface portion of the anvil roll 31 which is the uneven roll, so that the first sheet 1 has an uneven shape along the uneven shape of the peripheral surface portion. The laminated sheet 10A is formed by deforming and superimposing the second sheet 2 on the deformed first sheet 1, and due to the function of forming the unevenness, the object to be conveyed 30 is uneven. It can be said to be a shaping part.

In the present embodiment, the manufacturing apparatus 20 further includes, in addition to the anvil roll 31 which is an uneven roll, another uneven roll 32 having an uneven surface portion that meshes with the unevenness of the peripheral surface portion of the anvil roll 31.
Hereinafter, the anvil roll 31 which is an uneven roll is also referred to as a “first roll 31”, and the other uneven roll 32 is also referred to as a “second roll 32”.
In the present embodiment, the object to be conveyed 30 uses both rolls 31 and 32, and rotates both rolls 31 and 32 so that the meshing portion 33 between the irregularities of both rolls 31 and 32 is formed to engage with each other. By introducing the first sheet 1 into the portion 33, the first sheet 1 is deformed into an uneven shape along the uneven shape of the peripheral surface portion of the first roll 31.

FIG. 4 shows a part of the peripheral surface portion of the first roll 31. The first roll 31 is formed by combining a plurality of spur gears 31a, 31b, ... With a predetermined tooth width into a roll shape. The teeth of each gear form a convex portion 35 having an uneven shape on the peripheral surface portion of the first roll 31, and the tip surface 35c of the convex portion 35 is the ultrasonic horn 42 of the ultrasonic fusion machine 41 described later. It is a pressure surface that pressurizes the first and second sheets 1 and 2 (laminated sheet 10A) to be fused with the vibration application surface 421 that is the tip surface.

The tooth width (length in the axial direction of the gear) of each gear constituting the first roll 31 determines the dimension in the X direction of the convex portion 5 of the composite sheet 10, and the length of the tooth of each gear (rotation of the gear). The length in the direction) determines the dimension in the Y direction of the convex portion 5 of the composite sheet 10.
Adjacent gears are combined so that the pitch of their teeth is offset by half a pitch. As a result, the peripheral surface of the first roll 31 has an uneven shape.
In the illustrated embodiment, the tip surface 35c of each convex portion 35 has a long side along the rotation direction of the first roll 31 (the gear) and a short side along the rotation axis direction of the first roll 31 (the gear). , Has a rectangular shape.
When the tip surface 35c has a shape longer in the rotation direction, it is easy to raise the temperature by lengthening the contact time of the tip portion of the ultrasonic horn 42 with the vibration application surface 421 of the convex portion 35 of the first roll 31. It is preferable because it can be used.

The recesses of the gears in the first roll 31 form uneven recesses in the peripheral surface portion of the first roll 31.
A suction hole 34 is formed in the tooth bottom portion (bottom portion of the recess) of each gear. The suction hole 34 is connected to a suction source (not shown) such as a blower or a vacuum pump, and is a junction portion between the first sheet 1 and the second sheet 2 from the meshing portion 33 between the first roll 31 and the second roll 32. It is controlled so that suction is performed until.
Therefore, the first sheet 1 deformed into an uneven shape by the engagement between the first roll 31 and the second roll 32 is deformed into a shape along the uneven shape of the peripheral surface portion of the first roll 31 by the suction force of the suction hole 34. It is conveyed to the confluence portion of the first sheet 1 and the second sheet 2 and the application portion 36 of the ultrasonic vibration by the ultrasonic fusion machine 41 in the state maintained in the above-mentioned state.
In the first roll 31 shown in FIG. 4, a predetermined gap G is provided between the adjacent gears, so that an unreasonable stretching force is applied to the first sheet 1 or the meshing portions 33 of both rolls 31 and 32 are engaged. Since the inconvenience of cutting the first sheet 1 is suppressed, the first sheet 1 is likely to be deformed into an uneven shape along the shape of the peripheral surface portion of the first roll 31.

The second roll 32, which is an uneven roll, has an uneven shape on its peripheral surface portion that meshes with the unevenness of the peripheral surface portion of the first roll 31. The second roll 32 has the same configuration as the first roll 31 except that it does not have a suction hole 34.
The diameter of the first roll 31 and the diameter of the second roll 32 may be different on the premise that the uneven portions of both rolls 31 and 32 mesh with each other. Then, the first sheet 1 can be deformed into an uneven shape by introducing the first sheet 1 into the meshing portion 33 of both rolls 31 and 32 while rotating both rolls 31 and 32 having irregularities that mesh with each other. can.
In the meshing portion 33, a plurality of portions of the first sheet 1 are pushed into the concave portions of the peripheral surface portion of the first roll 31 by the convex portions of the second roll 32, and the pushed portions are the recessed portions of the composite sheet 10 to be manufactured. It becomes a convex portion 5.
A plurality of convex portions to be inserted into the concave portions of the first roll 31 are formed on the peripheral surface portion of the second roll 32, and the convex portions corresponding to all the concave portions of the first roll 31 are formed on the second roll 32. Is not required to be formed.

As described above, the object transporting portion 30 shown in FIG. 3 is provided with two uneven rolls having irregularities on the peripheral surface portion, and the meshing portions 33 between the irregularities of the two uneven rolls 31 and 32 are formed. By rotating both rolls 31 and 32 in such a manner and introducing the first sheet 1 into the meshing portion 33, the first sheet 1 is deformed into an uneven shape. The uneven roll included in the 30 may be only the first roll 31 capable of sucking the first sheet 1 introduced into the peripheral surface portion, that is, the second roll 32 may not be present. In that case, simply by introducing the first sheet 1 into the peripheral surface portion of the first roll 31, the first sheet 1 becomes the peripheral surface portion due to the suction force of the suction holes 34 (see FIG. 4) arranged in the peripheral surface portion. It deforms to follow the shape of the unevenness. Such follow-up / deformation of the first sheet 1 by suction on the peripheral surface portion of the first roll 31 can be realized by appropriately adjusting the suction force, the arrangement of the suction holes 34, and the like.

The ultrasonic processing unit 40 includes an ultrasonic fusion machine 41 provided with an ultrasonic horn 42, and the laminated sheet 10A is obtained by superimposing the second sheet 2 on the first sheet 1 in a state of being deformed into an uneven shape. The laminated sheet 10A was carried into the clearance 46 between the peripheral surface portion of the first roll 31 and the vibration application surface 421 of the tip portion of the ultrasonic horn 42, and the laminated sheet 10A was carried into the peripheral surface portion (specifically, the convex portion 35). By sandwiching it with the vibration application surface 421 and applying ultrasonic vibration, a through hole 6 is formed and a fused portion 4 having the through hole 6 is formed.

As shown in FIGS. 3 and 5, the ultrasonic fusion splicer 41 includes an ultrasonic oscillator (not shown), a converter 43, a booster 44, and an ultrasonic horn 42.
The ultrasonic oscillator (not shown) is electrically connected to the converter 43, and a high voltage electric signal having a wavelength of about 15 to 50 kHz generated by the ultrasonic oscillator is input to the converter 43.
The ultrasonic oscillator (not shown) is installed on the movable table 45 or outside the movable table 45.

The converter 43 has a built-in piezoelectric element such as a piezo piezoelectric element, and converts an electric signal input from an ultrasonic oscillator into mechanical vibration by the piezoelectric element. The booster 44 adjusts, preferably amplifies, and transmits the amplitude of the mechanical vibration generated from the converter 43 to the ultrasonic horn 42.
The ultrasonic horn 42 is made of a lump of metal such as an aluminum alloy or a titanium alloy, and is designed to resonate correctly at the frequency used.
The ultrasonic vibration transmitted from the booster 44 to the ultrasonic horn 42 is also amplified or attenuated inside the ultrasonic horn 42, and is applied to the first and second sheets 1 and 2 to be fused. As such an ultrasonic fusion machine 41, a commercially available ultrasonic horn, converter, booster, and ultrasonic oscillator can be used in combination.

The ultrasonic fusion splicer 41 is fixed on the movable table 45, and the position of the movable table 45 is advanced and retracted along the direction approaching the peripheral surface portion of the first roll 31, so that the height of the clearance 46 (the first). The separation distance between the peripheral surface portion of 1 roll 31 and the vibration application surface 421 of the ultrasonic horn 42) and the pressing force applied to the object to be processed carried into the clearance 46 can be adjusted. Then, the laminated sheet 10A to be fused is carried into the clearance 46, and the peripheral surface portion (tip surface 35c of the convex portion 35) of the first roll 31 defining the clearance 46 and the vibration application surface 421 of the ultrasonic horn 42 By applying ultrasonic vibration from the vibration application surface 421 while pressurizing with the above, the portion of the laminated sheet 10A located on the tip surface 35c of the convex portion 35 generates heat, and the first sheet 1 constituting the laminated sheet 10A is generated. And / or the second sheet 2 is melted and solidified again to form a fused portion 4, and a through hole 6 penetrating both sheets 1 and 2 is formed in a state of being surrounded by the melted portion. ..

The vibration application surface 421 at the tip of the ultrasonic horn 42 is formed of the tip surface of the main body 420 of the ultrasonic horn 42 made of a metal such as an aluminum alloy or a titanium alloy, and is an object to be treated, more specifically, a laminated sheet 10A. It abuts on the second sheet 2 constituting one surface (the surface opposite to the contact surface side with the peripheral surface portion of the first roll 31).
As shown in FIGS. 5 and 6, a plurality of main body portions 420 of the ultrasonic horn 42 are connected to the vibration application surface 421, which is the tip surface thereof, and intersect (orthogonal) with the vibration application surface 421. It has a surface of 422 to 424.
In the present embodiment, the vibration application surface 421 has a rectangular shape in which the length of the CD is longer than the length of the MD in the plan view, and the main body 420 has the CD of the vibration application surface 421 in the rectangular shape in the plan view. It has a pair of surfaces 422 and 423 connected to a pair of long sides along the axis, and a pair of side surfaces 424 and 424 connected to a pair of short sides along the MD of the vibration application surface 421. The front surface 422 of the main body 420 is located on the upstream side of the MD and is adjacent to the carry-in entrance of the clearance 46. The carry-in entrance of the clearance 46 is an opening on the upstream side of the MD in the clearance 46, and is an entrance / exit of the object to be processed (laminated sheet 10A). The back surface 423 of the main body 420 is located on the downstream side of the MD and is adjacent to the carry-out port of the clearance 46.

As shown in FIG. 6, the ultrasonic processing unit 40 brings the vibration application surface 421 into contact with one surface (second sheet 2 in this embodiment) of the laminated sheet 10A carried into the clearance 46 to generate ultrasonic vibration. As shown in FIG. 7, the manufacturing apparatus 20 vibrates in the clearance 46 of the laminated sheet 10A immediately before the laminated sheet 10A is carried into the clearance 46, where the fused portion 4 is formed by applying the application. It is characterized in that the surface in contact with the application surface 421 (second sheet 2 in the present embodiment) is made to be in contact with the carry-in inlet edge 47 of the clearance 46 in the ultrasonic horn 42. As shown in FIG. 5, the carry-in entrance edge portion 47 of the ultrasonic horn 42 is at or near the tip of the main body portion 420 on the front surface 422 of the main body portion 420 of the ultrasonic horn 42, and is along the carry-in entrance of the clearance 46. It is extended to the CD. Reference numeral 31S in FIG. 7 is a contour line of the peripheral surface of the first roll 31, and in the present embodiment, extends in the circumferential direction through the tips of a plurality of convex portions 35 on the peripheral surface portion of the first roll 31. It is a virtual line.

The above-mentioned "contact of the laminated sheet 10A with the carry-in inlet edge 47 of the ultrasonic horn 42 immediately before being carried into the clearance 46" is intentional. The term "intentional contact" as used herein means that the laminated sheet 10A comes into contact with the carry-in inlet edge 47 of the ultrasonic horn 42 immediately before being carried into the clearance 46 due to an unintended variation in the thickness of the laminated sheet 10A. It means to exclude.
In this way, by intentionally bringing the laminated sheet 10A into contact with the carry-in inlet edge 47 of the ultrasonic horn 42 immediately before carrying it into the clearance 46, a large shearing force acts on the laminated sheet 10A, and as a result, the clearance 46 Although the through hole 6 is formed in the laminated sheet 10A or the through hole 6 is not formed at the time before being carried into the laminated sheet 10A, the laminated sheet 10A is centered on the contact portion with the carry-in inlet edge portion 47. The strength is reduced, and the subsequent formation of the through hole 6 in the clearance 46 becomes easy. Therefore, according to the manufacturing apparatus 20, in the production of the composite sheet 10 in which the through hole 6 is formed in the fused portion 4, it is possible to carry out the formation of the fused portion 4 and the formation of the through hole 6 in one step. be.

In the present embodiment, as shown in FIG. 7, the separation distance L between the peripheral surface portion of the first roll 31 and the vibration application surface 421 at the carry-in port of the clearance 46, that is, the height L of the carry-in port of the clearance 46 is the carry-in. The thickness T of the object to be processed (laminated sheet 10A) to be carried into the mouth is shorter than that immediately before being carried into the mouth. The "thickness T" here refers to the maximum thickness when the thickness of the object to be treated is not constant, and is not the actual thickness (thickness of the portion where the forming material such as fiber is present) but the apparent thickness (coverage). Distance between one surface and the other surface of the processed material). In this way, the magnitude relationship of "height L of the carry-in port of the clearance 46 <thickness T immediately before the carry-in to the carry-in port of the object to be processed" is established, and the above-mentioned object to be processed (laminated sheet 10A) is established. The contact of the ultrasonic horn 42 with the carry-in inlet edge 47 immediately before being carried into the clearance 46 becomes easier, and it is further possible to form the fused portion 4 and the through hole 6 in one step. It will be easier.

According to the findings of the present inventors, the larger the difference between the height L and the thickness T, the greater the change in the thickness of the laminated sheet 10A before and after being carried into the clearance 46, and accordingly, the laminated sheet 10A. The frictional force acting on the through hole 6 is increased, and the formation of the through hole 6 becomes easy.
The ratio of the height L to the thickness T is preferably 0.0125 or more, more preferably 0.025 or more, and preferably 0.025 or more, as height L / thickness T on the premise of height L <thickness T. It is 0.5 or less, more preferably 0.125 or less.
The height L of the carry-in port of the clearance 46 is preferably 0.01 mm or more, more preferably 0, on the assumption that the height L of the object to be processed (laminated sheet 10A) is shorter than the thickness T immediately before being carried into the carry-in port. It is 0.02 mm or more, preferably 0.4 mm or less, and more preferably 0.1 mm or less.

In the present embodiment, the positional relationship between the ultrasonic horn 42 and the first roll 31 is adjusted in order to establish the magnitude relationship of the above-mentioned “height L <thickness T”. Specifically, as shown in FIG. 8, the center 421C of the MD of the vibration application surface 421 of the ultrasonic horn 42 is on a virtual straight line 31L extending in the radial direction of the first roll 31 through the rotation center of the first roll 31. When the position of the center 421C is set as the reference position RP in the case of being located at, in the present embodiment, as shown in FIG. 7, the ultrasonic horn so that the center 421C is located on the downstream side of the MD from the reference position RP. 42 are arranged.
In this type of fusion splicer, as shown in FIG. 8, the center 421C of the MD of the vibration application surface 421 is aligned with the reference position RP from the viewpoint of smoothly carrying the object to be processed into the clearance. Or, contrary to FIG. 7, it is common to position the center 421C on the upstream side of the MD with respect to the reference position RP, so that the object to be processed is as shown in FIG. 8 (b). The laminated sheet 10A is smoothly carried into the inside from the carry-in entrance of the clearance 46 without coming into contact with the carry-in inlet edge portion 47 of the ultrasonic horn 42.
On the other hand, in the present embodiment, priority is given to facilitating the formation of the through hole 6, and therefore, in order to surely establish the magnitude relationship of the above-mentioned "height L <thickness T", the above-mentioned general Contrary to the method, the center 421C of the MD of the vibration application surface 421 is shifted to the downstream side of the MD from the reference position RP. The distance G1 (see FIG. 7A) of the center 421C of the MD of the vibration application surface 421 from the reference position RP is the above-mentioned, in consideration of the total length of the MD of the vibration application surface 421, the radius of the first roll 31, and the like. It may be adjusted so that the magnitude relation (height L <thickness T) of is established.

As a method of establishing the magnitude relationship of the above-mentioned "height L <thickness T", in addition to the method of adjusting the position of the ultrasonic horn 42, for example, the shape of the vibration application surface 421 of the ultrasonic horn 42 is adjusted. There is a way to do it. Specifically, as in the ultrasonic horn 42A shown in FIG. 9, in the cross-sectional view along the MD (cross-sectional view along the direction orthogonal to the rotation axis of the first roll 31), the vibration application surface 421 is the first roll 31. If it has a shape along the contour line (virtual line extending in the circumferential direction through the tips of the plurality of convex portions 35 of the first roll 31) 31S, the magnitude relationship can be easily established. Therefore, it is preferable.

As shown in FIGS. 6 and 7, the vibration application surface 421 of the tip of the ultrasonic horn 42 faces the tip surface 35c of the convex portion 35 forming the unevenness of the peripheral surface of the first roll 31, which is an uneven roll. In a state where a clearance 46 is provided between the vibration application surface 421 and the tip surface 35c of the convex portion 35 (hereinafter, this state is also referred to as "state A"), the vibration application surface 421 and the vibration application surface 421. The separation distance (height of the clearance 46) of the convex portion 35 from the tip surface 35c changes due to the movement of the convex portion 35 with the rotation of the first roll 31.
In the state A, the convex portion 35 is first than a virtual perpendicular line (not shown) extending in the radial direction of the first roll 31 through the rotation center of the first roll 31 and orthogonal to the vibration application surface 421. When the roll 31 is located upstream in the rotation direction (MD), the separation distance (height of the clearance 46) between the vibration application surface 421 and the tip surface 35c of the convex portion 35 is the rotation direction (MD). It gradually decreases from the upstream side to the downstream side of.
Further, in the state A, when the convex portion 35 overlaps with the virtual vertical line, the separation distance (height of the clearance 46) between the vibration application surface 421 and the tip surface 35c of the convex portion 35 is the carry-in entrance of the clearance 46. It gradually decreases from the virtual vertical line toward the virtual vertical line, becomes minimum at the position of the virtual vertical line, and gradually increases from the virtual vertical line toward the carry-out port of the clearance 46.
Further, in the state A, when the convex portion 35 is located on the downstream side of the rotation direction (MD) of the first roll 31 from the virtual vertical line, the vibration application surface 421 and the tip surface 35c of the convex portion 35. The separation distance (height of the clearance 46) gradually increases from the upstream side to the downstream side in the rotation direction (MD).

In the ultrasonic horn 42A shown in FIG. 9, the vibration application surface 421 is the first in the cross-sectional view corresponding to the arcuate contour line 31S of the peripheral surface of the first roll 31 in the cross-sectional view along the MD. It has an arc shape that is recessed toward the direction away from the rotation axis of the roll 31, and the vibration application surface 421 and the contour line 31S are parallel to each other. When the cross-sectional shape of the vibration application surface 421 along the MD is arcuate in this way, the shearing force applied to the laminated sheet 10A, which is the object to be treated, is improved in the ultrasonic treatment step described later, so that the fused portion 4 and the penetration portion 4 and the penetration portion are penetrated. Simultaneous formation of the holes 6 can be performed more reliably.
When the vibration application surface 421 has an arc shape in a cross-sectional view along the MD as shown in FIG. 9, the tip surface 35c of each of the plurality of convex portions 35 of the first roll 31 corresponding to the arc shape is the same cross-sectional view. It is preferable that the first roll 31 has a convex shape in a direction away from the rotation axis and the direction of the curve coincides with the vibration application surface 421.
The radius of curvature of the vibration application surface 421 of the ultrasonic horn 42A is preferably 100% or more with respect to the radius of curvature of the tip surface 35c of the convex portion 35 of the first roll 31.
The radius of curvature of the vibration application surface 421 is preferably 500% or less, more preferably 200% or less.

As a method of establishing the magnitude relationship of the above-mentioned "height L <thickness T", in addition to the method of adjusting the position of the ultrasonic horn 42 and the shape of the vibration applying surface 421, for example, the MD of the vibration applying surface 421. A method of making the length L1 (see FIG. 6) relatively short, and a method of making the diameter 31R (see FIG. 3) of the first roll 31 relatively long can be mentioned.
The length L1 of the MD of the vibration application surface 421 is preferably 2.5 mm or more, more preferably 3.5 mm or more, and preferably 16 mm or less, more preferably 8 mm or less.
The diameter 31R of the first roll 31 is preferably 40 mm or more, more preferably 160 mm or more, and preferably 1600 mm or less, more preferably 800 mm or less.

In the present embodiment, the manufacturing apparatus 20 includes a preheating means 51 for preheating at least one of the first sheet 1 and the second sheet 2 before applying ultrasonic vibration.
The preheating means 51 is arranged inside the first roll 31 and extends parallel to the rotation axis (CD) of the first roll 31.
Further, a plurality of preheating means 51 are arranged in the vicinity of the outer peripheral portion around the rotation axis of the first roll 31 with an interval in the circumferential direction.
As the preheating means 51, one that can heat the object to be heated (first sheet 1, second sheet 2) by applying heat energy from the outside can be used, and examples thereof include a cartridge heater using a heating wire. However, the present invention is not limited to this, and various known heating means can be used without particular limitation.

The preheating means 51 is a part of the preheating mechanism 50. In addition to the preheating means 51, the preheating mechanism 50 includes a temperature measuring means (not shown) capable of measuring the temperature of the object to be processed before applying ultrasonic vibration, and a preheating means based on the measured values of the temperature measuring means. A temperature control unit (not shown) for controlling the temperature of 51 is provided. The heating temperature of the peripheral surface portion of the first roll 31 by the preheating means 51 is controlled by the temperature control unit. The preheating mechanism 50 can maintain the temperature of the first sheet 1 carried into the ultrasonic vibration application unit 36 within a predetermined range during the operation of the manufacturing apparatus 20.

In the present embodiment, as shown in FIG. 6, the manufacturing apparatus 20 includes a horn heating means 61 for heating the ultrasonic horn 42 including the vibration application surface 421. As the horn heating means 61, various known heating means such as a heater can be used without particular limitation.
The position of the horn heating means 61 may be any position as long as it can heat the vibration application surface 421, and is not particularly limited. It is arranged on any one or more of a plurality of surfaces 422 to 424 of the main body portion 420 of the sound wave horn 42. In the present embodiment, the horn heating means 61 is arranged on the back surface 423 of the main body portion 420.

The horn heating means 61 is a part of the horn heating mechanism 60. In addition to the horn heating means 61, the horn heating mechanism 60 measures the temperature of the horn heating means 61 based on the temperature measuring means (not shown) capable of measuring the temperature of the vibration application surface 421 and the measured values of the temperature measuring means. It is equipped with a temperature control unit (not shown) to control. The heating temperature of the vibration application surface 421 by the horn heating means 61 is controlled by the temperature control unit. The horn heating mechanism 60 can maintain the temperature of the vibration application surface 421 within a predetermined range during the operation of the manufacturing apparatus 20.

The ultrasonic fusion machine 41 applies ultrasonic vibration to the object to be processed to generate heat and melt the object to be processed to fuse it, and is the same as the preheating means 51 and the horn heating means 61 described above. Is clearly distinguished.

In the method of manufacturing the composite sheet 10 using the manufacturing apparatus 20 having the above-described configuration, as shown in FIG. 3, the first sheet 1 and the second sheet 2 are conveyed in the same direction and superposed to form a laminated sheet 10A. It has a superposition step to form. Further, in such a manufacturing method, the laminated sheet 10A is provided with a peripheral surface portion of the first roll 31 and a vibration application surface 421 at the tip of the ultrasonic horn 42 of the ultrasonic fusion machine 41 arranged to face the peripheral surface portion. It has an ultrasonic treatment step of carrying it into the clearance 46, bringing the vibration application surface 421 into contact with one surface (second sheet 2) of the laminated sheet 10A, and applying ultrasonic vibration to form the fused portion 4.

In the present embodiment, as described above, as the first roll 31, a concavo-convex roll having irregularities on the peripheral surface portion is used, and in the superposition step, the first roll 31 is rotated while the concavo-convex roll 31 is rotated. The first sheet 1 is made to follow the peripheral surface portion of 31 and deformed into an uneven shape, and the deformed first sheet 1 is conveyed while being held on the peripheral surface portion of the first roll 31, and the first sheet being conveyed is being conveyed. The second sheet 2 is superposed on the 1 to form the laminated sheet 10A.
Further, in the present embodiment, as described above, in addition to the first roll 31 which is an uneven roll, the second roll which is another uneven roll having unevenness meshing with the unevenness of the peripheral surface portion of the first roll 31. 32 is used, and in the superposition step, both rolls 31 and 32 are rotated so that the meshing portion 33 between the irregularities of the rolls 31 and 32 is formed, and the first sheet 1 is introduced into the meshing portion 33. As a result, the first sheet 1 is deformed into an uneven shape.

Then, in the method of manufacturing the composite sheet 10, immediately before the laminated sheet 10A, which is the object to be treated, is carried into the clearance 46 between the peripheral surface portion of the first roll 31 and the vibration application surface 421 of the ultrasonic horn 42, the laminated sheet 10A The surface of the clearance 46 in contact with the vibration application surface 421 (second sheet 2 in the present embodiment) is characterized in that the surface (second sheet 2 in the present embodiment) is brought into contact with the carry-in inlet edge portion 47 of the clearance 46 in the ultrasonic horn 42. Due to this feature, according to such a manufacturing method, it is possible to carry out the formation of the fused portion 4 and the formation of the through hole 6 in one step.

According to the method for manufacturing the composite sheet 10, the laminated sheet 10A is brought into the laminated sheet 10A by contact with the carry-in inlet edge 47 of the clearance 46 in the ultrasonic horn 42 of the laminated sheet 10A immediately before the laminated sheet 10A is carried into the clearance 46. Through holes 6 can be formed. In this case, in the laminated sheet 10A, the through hole 6 is first formed before being carried into the clearance 46, and then the fused portion 4 is formed by applying ultrasonic vibration after being carried into the clearance 46. , The composite sheet 10. In order to ensure the formation of the through hole 6 before being carried into the clearance 46, the size relationship "height L of the carry-in port of the clearance 46 <immediately before the carry-in of the object to be processed into the carry-in port" It is effective to establish the "thickness T", and the device for that is as described above.

Further, from the viewpoint of ensuring that the formation of the fused portion 4 and the formation of the through hole 6 can be carried out in one step by fully utilizing the characteristic configuration of the present invention described above, in the superposition step, the superposition step is performed. As shown in FIG. 10, the first sheet 1 is conveyed while being held on the peripheral surface portion of the first roll 31, and the second sheet 2 is superposed on the first sheet 1 being conveyed to form the laminated sheet 10A. It is preferable to carry the laminated sheet 10A while holding it on the peripheral surface portion of the first roll 31 and carry it into the clearance 46. That is, in the form shown in FIG. 6, the laminated sheet 10A is formed by superimposing the first sheet 1 and the second sheet 2 at substantially the same position as the carry-in port of the clearance 46, and reaches the carry-in port of the laminated sheet 10A. However, instead of this, as shown in FIG. 10, both sheets 1 and 2 are overlapped with each other at a position separated from the carry-in entrance of the clearance 46 to the upstream side of the MD to some extent, and the laminated sheet 10A is formed. It is preferable to form the laminated sheet 10A, transport the formed laminated sheet 10A to a certain distance, and then carry the formed laminated sheet 10A into the clearance 46.
The distance from the clearance 46 at the position where the first sheet 1 and the second sheet 2 are overlapped is preferably 3 mm or more, more preferably 10 mm or more, and preferably 50 mm or less, more preferably 30 mm or less. If the separation distance is within the above range, as described above, immediately before the laminated sheet 10A is carried into the clearance 46, the surface of the laminated sheet 10A that comes into contact with the vibration application surface 421 at the clearance 46 is formed on the ultrasonic horn 42. It is fully possible to bring it into contact with the carry-in entrance edge 47 of the clearance 46. The "separation distance" here means the separation distance along the transport path of the object to be transported (laminated sheet 10A), and as shown in FIG. 10, for example, the transport path of the laminated sheet 10A is a circle of the first roll 31. When it is along the arcuate peripheral surface, it means the distance along the peripheral surface.

In the ultrasonic processing step, the pressing force applied to the first and second sheets 1 and 2 sandwiched between the tip surface 35c of the convex portion 35 of the first roll 31 and the vibration application surface 421 of the ultrasonic horn 42 is determined. From the viewpoint of ease of forming the fused portion 4 and the through hole 6, 10 N / mm or more is preferable, and 15 N / mm or more is more preferable.
The pressing force is preferably 30 N / mm or less, more preferably 25 N / mm or less.
The "pressurizing pressure" here is a so-called linear pressure, which is the tooth width of the convex portion 35 (the length of the convex portion 35 along the CD) that contacts the pressing force (N) of the ultrasonic horn 42 with the ultrasonic horn 42. It is shown by the value (pressurization per unit length) divided by the total length (excluding the concave portion of the first roll 31).

From the same viewpoint, the frequency of the applied ultrasonic vibration is preferably 15 kHz or higher, more preferably 20 kHz or higher.
The frequency is preferably 50 kHz or less, more preferably 40 kHz or less.
From the same viewpoint, the amplitude of the applied ultrasonic vibration is preferably 20 μm or more, more preferably 25 μm or more.
The amplitude is preferably 50 μm or less, more preferably 40 μm or less.
When measuring the frequency and amplitude of ultrasonic vibration, the displacement of the tip of the ultrasonic horn is measured with a laser displacement meter or the like, and the frequency and amplitude are measured by setting the sampling rate to 200 kHz or more and the accuracy to 1 μm or more.

In the present embodiment, as described above, the manufacturing apparatus 20 includes the preheating means 51 (preheating mechanism 50), and in the method for manufacturing the composite sheet 10 using the manufacturing apparatus 20, before being subjected to the ultrasonic treatment step. In order to preheat at least one of the first sheet 1 and the second sheet 2 by the preheating means 51, the characteristic configuration of the present invention described above (the object to be processed is brought into the ultrasonic horn 42 immediately before being carried into the clearance 46). In combination with the action and effect of (intentionally contacting the edge portion 47), the simultaneous formation of the fused portion 4 and the through hole 6 can be performed more reliably. However, the manufacturing apparatus 20 does not have to be provided with the preheating means 51 (preheating mechanism 50).

The conditions for preheating the object to be treated by the preheating means 51 are not particularly limited and may be appropriately adjusted according to the type of the object to be processed, etc., but at least one of the first sheet 1 and the second sheet 2 may be used on the sheet. It is preferable to heat the product to a temperature lower than the melting point and 50 ° C. lower than the melting point. That is, it is preferable to perform either or both of the following (1) and (2) prior to the application of ultrasonic vibration.
(1) The first sheet 1 is heated to a temperature lower than the melting point of the first sheet and 50 ° C. lower than the melting point.
(2) The second sheet 2 is heated to a temperature lower than the melting point of the second sheet and 50 ° C. lower than the melting point.
Preferably, the first sheet 1 is heated to a temperature lower than the melting point of the first sheet and 50 ° C. lower than the melting point, and the second sheet 2 is heated below the melting point of the second sheet and 50 from the melting point. ℃ Heat above a low temperature.

As a method of the method (1), that is, a method of setting the first sheet 1 to a temperature lower than the melting point of the first sheet 1 and 50 ° C. lower than the melting point, for example, the first sheet 1 on the first roll 31. The temperature was measured between the meshing portion 33 between the first roll 31 and the second roll 32 and the ultrasonic vibration applying portion 36 by the ultrasonic fusion machine 41, and the measured value was within the above-mentioned specific range. The temperature of the preheating means 51 is controlled so as to be inside.
As a method of preheating the first sheet 1 to a temperature in a specific range, the temperature of the peripheral surface portion of the first roll 31 is set in the first roll 31 so that the first sheet 1 has a temperature in the specific range. A variety of methods can be used in place of the method controlled by the heater arranged in the above.
For example, a heater, a hot air outlet, and a far-infrared irradiation device are provided in the vicinity of the peripheral surface portion of the first roll 31, and the temperature of the peripheral surface portion of the first roll 31 before or after the first sheet 1 is placed. A method of controlling the temperature of the first sheet 1 by heating the second roll 32 in contact with the first sheet 1 in the meshing portion 33 and controlling the temperature of the peripheral surface portion thereof can be mentioned.
Further, a method of contacting the first sheet 1 before being placed along the first roll 31 with a heated roller, passing through a space maintained at a high temperature, blowing hot air, and the like can be mentioned.

As a method of the method (2), that is, a method of setting the second sheet 2 to a temperature lower than the melting point of the second sheet 2 and 50 ° C. lower than the melting point, the second sheet 2 before merging with the first sheet 1 is used. Was measured by a temperature measuring means arranged in the transport path of the second sheet 2, and the measured value was arranged in the transport path of the second sheet 2 so as to be within the above-mentioned specific range. 2 It is preferable to control the temperature of the heating means (not shown) of the sheet 2.
The heating means of the second sheet 2 may be a contact method such as contacting a heated roller or the like, or a non-contact method such as passing through a space maintained at a high temperature, blowing or penetrating hot air, or irradiating infrared rays. It may be an expression.

The melting points of the first sheet 1 and the second sheet 2 can be measured using, for example, a differential scanning calorimetry device (DSC) PYRIS Diamond DSC manufactured by Perkin-Elmer. In such a measurement method, the melting point of the measurement target (first sheet 1, second sheet 2) is determined from the peak value of the measurement data.
When the first sheet 1 or the second sheet 2 is a fiber sheet such as a non-woven fabric and the constituent fibers are composite fibers composed of a plurality of components such as a core sheath type and a side-by-side type, the melting point of the sheet. Is the melting point of the lowest temperature among the plurality of melting points measured by DSC as the melting point of the composite fiber sheet.

Further, in the present embodiment, as described above, the manufacturing apparatus 20 includes the horn heating means 61 (horn heating mechanism 60), and in the ultrasonic processing step, the vibration application surface 421 heated by the horn heating means 61 is used. Since ultrasonic vibration is applied to the object to be processed (laminated sheet 10A) by using the peripheral surface portion of the first roll 31, the object to be processed is subjected to the above-mentioned characteristic configuration of the present invention (immediately before being carried into the clearance 46). Combined with the action and effect of (intentionally contacting the carry-in inlet edge portion 47 of the ultrasonic horn 42), the simultaneous formation of the fused portion 4 and the through hole 6 can be performed more reliably. However, the manufacturing apparatus 20 does not have to be provided with the horn heating means 61 (horn heating mechanism 60).

The heating conditions by the horn heating means 61 are not particularly limited, and may be appropriately adjusted according to the type of the object to be treated and the like.
For example, the method (2) may be carried out by using the horn heating means 61 instead of the preheating means 51. That is, by controlling the temperature of the ultrasonic horn 42 (vibration application surface 421) heated by the horn heating means 61, the temperature of the second sheet 2 immediately before the ultrasonic vibration is applied is set to the second sheet 2. The first and second sheets 1 and 2 sandwiched between the convex portion 35 of the concave-convex roll 331 and the vibration application surface 421 are heated to a temperature lower than the melting point of the above and 50 ° C. lower than the melting point. Ultrasonic vibration may be applied to.
Further, only one of the preheating means 51 and the horn heating means 61 may be used, or both may be used in combination.

FIG. 11 shows another embodiment of the present invention. Regarding other embodiments described later, components different from those of the above-described embodiments will be mainly described, and similar components will be designated by the same reference numerals and description thereof will be omitted. The description of the embodiment is appropriately applied to the components not particularly described.

In the ultrasonic horn 42B shown in FIG. 11, the tip portion thereof is configured to include a heat storage portion 425 fixed to the metal main body portion 420 of the ultrasonic horn 42B, and the vibration application surface 421 is formed from the heat storage portion 425. It is formed. The heat storage unit 425 is made of a heat storage material, which is a material having a lower thermal conductivity than the metal constituting the main body portion 420.
When the vibration application surface 421 is formed from the heat storage unit 425, the heat of the first and second sheets 1 and 2 generated by the ultrasonic vibration is stored in the heat storage unit 425, and as a result, the temperature of the heat storage unit 425 rises. Since the first sheet 1 and the second sheet 2 can be heated, the above-mentioned characteristic configuration of the present invention (immediately before carrying into the clearance 46, the object to be processed is intended at the carry-in inlet edge 47 of the ultrasonic horn 42. In combination with the action and effect of (contacting with each other), the simultaneous formation of the fused portion 4 and the through hole 6 can be performed more reliably. Further, if the vibration application surface 421 is formed from the heat storage portion 425, there are inconveniences such as adhesion of the molten resin generated by melting of the first and second sheets 1 and 2 to the transport means, winding of the sheet around the transport roll, and the like. There is an advantage that the occurrence is suppressed and the maintenance burden of the manufacturing equipment is reduced.
The vibration application surface 421 including the heat storage portion 425 shown in FIG. 11 has an arc shape in a cross-sectional view along the MD, similarly to the vibration application surface 421 of the ultrasonic horn 42A shown in FIG. 9, but has the same cross section. It may be a straight line (for example, a straight line extending in the tangential direction of the first roll 31) without forming an arc shape in view.

The thermal conductivity of the heat storage material constituting the heat storage unit 425 is preferably 2.0 W / mK or less, and more preferably 1.0 W / mK or less, from the viewpoint of making it difficult to dissipate heat to the ultrasonic horn 42 or the atmosphere.
Further, the thermal conductivity of the heat storage material is preferably 0.1 W / mK or more, more preferably 0.5 W / mK or more, from the viewpoint of efficiently heating the sheet. The thermal conductivity of the heat storage material can be measured according to a conventional method using a thermal conductivity measuring device.
The thickness Th (see FIG. 11) of the heat storage unit 425 is not particularly limited, but is preferably 5 μm or more, and more preferably 10 μm or more, from the viewpoint of more reliably achieving the action and effect of the heat storage unit 425. The thickness Th is preferably 100 μm or less, more preferably 50 μm or less.

As the heat storage material constituting the heat storage unit 425, it is preferable to use a synthetic resin having excellent wear resistance and heat resistance on the premise that the thermal conductivity is lower than that of the metal constituting the main body portion 420. As the resin, for example, polyimide, polybenzoimidazole, polyetherethyl ketone, polyetheretherketone (PEEK), polyphenylene sulfide, polyetherimide, polyamideimide, etc., have a rockwell hardness of R120 or more and R140 or less, and a heat resistant temperature of 150. Examples thereof include synthetic resins having a temperature of ° C. or higher and 500 ° C. or lower.
As the heat storage material, a synthetic resin such as polyimide or polybenzimidazole having a rockwell hardness of R125 or more and R140 or less and a heat resistant temperature of 280 ° C. or more and 400 ° C. or less is particularly preferable.
Here, the rockwell hardness is a value measured according to ASTM D-785, and the heat resistant temperature is a value measured according to ASTM D-648.

The means for fixing the heat storage portion 425 made of synthetic resin to the metal main body portion 420 is not particularly limited, and known fixing means can be adopted. The heat storage unit 425 made of synthetic resin can be formed, for example, by thermal spraying on a metal main body 420 and fixed to the main body 420. The term "thermal spraying" as used herein means that particles of a thermal spraying material such as metal or ceramics, which have been melted or brought into a state close to it by heating, are accelerated and collided with the substrate surface at high speed to form a coating film on the substrate surface. It is a known surface treatment method for forming. As the spraying material, a material that can be sprayed and can contribute to the improvement of the fixing strength of the heat storage portion 425 made of synthetic resin can be used without particular limitation, but the bonding force to the main body portion 420 made of a metal such as a titanium alloy can be used. From the viewpoint of excellent wear resistance and heat resistance, ceramics such as tungsten carbide, zirconia, and chrome carbide, alloys such as aluminum magnesium and zinc aluminum, metals such as aluminum, stainless steel, titanium, and molybdenum, and composites of metal and ceramics. A material such as thermite is preferably used.

The composite sheet 10 produced by the present invention preferably has the following constitution.
The height H of the convex portion 5 (see FIG. 1) is preferably 1 mm or more, more preferably 3 mm or more.
The height H of the convex portion 5 is preferably 10 mm or less, more preferably 6 mm or less.
The number of convex portions 5 per unit area (1 cm ² ) of the composite sheet 10 is preferably 1 or more, and more preferably 6 or more.
The number of convex portions 5 per unit area (1 cm ² ) of the composite sheet 10 is preferably 20 or less, more preferably 15 or less.
The bottom dimension A (see FIG. 1) of the convex portion 5 in the X direction is preferably 0.5 mm or more, more preferably 1.0 mm or more.
The bottom dimension A is preferably 5.0 mm, more preferably 4.0 mm or less.
The bottom dimension B (see FIG. 1) of the convex portion 5 in the Y direction is preferably 1.0 mm or more, more preferably 2.0 mm or more.
The bottom dimension B is preferably 10.0 mm or less, more preferably 7.0 mm or less.
The ratio of the bottom dimension A in the X direction to the bottom dimension B in the Y direction (bottom dimension A: bottom dimension B) is preferably 1: 1 or more, and more preferably 1: 2 or more.
The ratio (bottom dimension A: bottom dimension B) is preferably 1:10 or less, more preferably 2: 5 or less.
The bottom area (bottom dimension A × bottom dimension B) of the convex portion 5 is preferably 0.5 mm ² or more, and more preferably 2 mm ² or more.
The bottom area of the convex portion 5 is preferably 50 mm ² or less, more preferably 20 mm ² or less.

The dimension C (see FIG. 1) of the fused portion 4 in the X direction is preferably 0.5 mm or more, more preferably 0.8 mm or more.
The dimension C is preferably 2 mm or less, more preferably 1.5 mm or less.
The dimension D (see FIG. 1) of the fused portion 4 in the Y direction is preferably 1.0 mm or more, more preferably 1.2 mm or more.
The dimension D is preferably 5.0 mm or less, more preferably 3.0 mm or less.
The ratio of the dimension C in the X direction to the dimension D in the Y direction (dimension C: dimension D) is preferably 1: 1 or more, and more preferably 2: 3 or more.
The ratio (dimension C: dimension D) is preferably 1: 3 or less, more preferably 2: 5 or less.

The area inside the outer peripheral edge of the fused portion 4 is preferably 0.5 mm ² or more, and more preferably 1.0 mm ² or more.
The area inside the outer peripheral edge of the fused portion 4 is preferably 5.0 mm ² or less, more preferably 4.0 mm ² or less.
The "area inside the outer peripheral edge of the fused portion 4" as used herein includes the area of the through hole 6.
The opening area of the through hole 6 is preferably 50% or more, more preferably 80% or more, based on the area inside the outer peripheral edge of the fused portion 4.
The opening area of the through hole 6 is preferably less than 100%, more preferably 95% or less, based on the area inside the outer peripheral edge of the fused portion 4.
The opening area of the through hole 6 is preferably 1 mm ² or more, and more preferably 3 mm ² or more.
The opening area of the through hole 6 is preferably 10 mm ² or less, more preferably 7 mm ² or less.

Since the composite sheet 10 has unevenness and has a fused portion 4 having a through hole 6 at the bottom of the concave portion 3 constituting the unevenness, it is excellent in touch and diffusion prevention property in the plane direction. It also has excellent breathability and liquid drawability.
Taking advantage of these characteristics, the composite sheet 10 is preferably used as a constituent member of an absorbent article such as a disposable diaper, a menstrual napkin, a panty liner, and an incontinence pad, and is particularly suitable for a surface sheet of an absorbent article.
When the composite sheet 10 is used as a surface sheet for an absorbent article, typically the first sheet 1 forms a surface facing the wearer's skin side (skin facing surface) and the second sheet 2 is a surface sheet. It forms a surface facing the absorber side (non-skin facing surface) when worn.

The composite sheet 10 can also be used for applications other than the surface sheet of the absorbent article.
As an absorbent article application other than the surface sheet of the composite sheet 10, for example, a sheet arranged between the surface sheet and the absorber and also called a second sheet, a sublayer, etc .; a three-dimensional gather, a leak-proof cuff, etc. A sheet for forming a wall (particularly a sheet forming an inner wall of a leak-proof wall) can be exemplified.
As an application other than the absorbent article of the composite sheet 10, for example, a cleaning sheet, particularly a cleaning sheet mainly for liquid absorption; a decorative sheet for interpersonal use can be exemplified.
When the composite sheet 10 is used as a cleaning sheet, it is preferable to use the first sheet 1 side toward the surface to be cleaned because the convex portion 5 has good followability to the surface to be cleaned which is not smooth.
When the composite sheet 10 is used as a decorative sheet, the convex portion 5 can follow the skin of the subject, exert a massage effect, and absorb excess cosmetic agent (separately used) and sweat. It is preferable to use one sheet with the one side facing the skin side.

Although the present invention has been described above based on the preferred embodiment thereof, the present invention is not limited to the above embodiment and can be appropriately modified without departing from the spirit of the present invention. The configuration provided in one of the above embodiments can be applied to other embodiments.

Further, the following additional notes will be disclosed with respect to the above-described embodiment of the present invention.
<1>
A method for manufacturing a composite sheet in which a first sheet and a second sheet have a plurality of fused portions and through holes are formed in the fused portions.
A superposition step of forming a laminated sheet by superimposing the first sheet and the second sheet while transporting them in the same direction.
The laminated sheet is carried into the clearance between the peripheral surface portion of the anvil roll and the vibration application surface of the tip portion of the ultrasonic horn of the ultrasonic fusion machine arranged opposite to the peripheral surface portion, and is carried onto one surface of the laminated sheet. It has an ultrasonic treatment step of forming the fused portion by bringing the vibration application surface into contact and applying ultrasonic vibration.
Immediately before carrying the laminated sheet into the clearance, a method for manufacturing a composite sheet in which the surface of the laminated sheet that contacts the vibration application surface in the clearance is brought into contact with the carry-in inlet edge of the clearance in the ultrasonic horn. ..
<2>
In the superposition step, the first sheet is conveyed while being held on the peripheral surface of the anvil roll, and the second sheet is superposed on the first sheet being conveyed to form the laminated sheet.
The method for manufacturing a composite sheet according to <1>, wherein the laminated sheet is conveyed while being held on the peripheral surface of the anvil roll and carried into the clearance.
<3>
Immediately before the laminated sheet is carried into the clearance, the through hole is formed in the laminated sheet by the contact of the laminated sheet with the carry-in inlet edge of the clearance in the ultrasonic horn. The method for manufacturing a composite sheet according to <2>.
<4>
The method for producing a composite sheet according to any one of <1> to <3>, wherein at least one of the first sheet and the second sheet before applying ultrasonic vibration is preheated.
<5>
Any of the above <1> to <4>, wherein the vibration application surface is heated, and in the ultrasonic treatment step, ultrasonic vibration is applied using the heated vibration application surface and the peripheral surface portion of the anvil roll. The method for manufacturing a composite sheet according to item 1.
<6>
As the anvil roll, an uneven roll having an uneven surface is used.
In the stacking step, while rotating the uneven roll, the first sheet is made to follow the peripheral surface portion of the concave-convex roll to be deformed into an uneven shape, and the deformed first sheet is used as the peripheral surface portion of the concave-convex roll. The laminated sheet is formed by superimposing the second sheet on the first sheet being transported while holding it on top.
Claims <1> to <the composite sheet have a convex portion in which at least a part of the first sheet other than the fused portion has a convex portion protruding on the side opposite to the second sheet side. 5. The method for manufacturing a composite sheet according to any one of 5>.
<7>
In the superimposing step, in addition to the uneven roll, another uneven roll having an uneven surface portion that meshes with the unevenness of the peripheral surface portion of the concave-convex roll is used so that the meshing portion between the unevennesses of both rolls is formed. The method for manufacturing a composite sheet according to <6>, wherein both rolls are rotated and the first sheet is introduced into the meshing portion to deform the first sheet into an uneven shape.
<8>
The method for producing a composite sheet according to any one of <1> to <7>, wherein at least one of the first sheet and the second sheet contains a non-woven fabric.
<9>
The method for producing a composite sheet according to any one of <1> to <8>, wherein at least one of the first sheet and the second sheet contains polyethylene terephthalate.

<10>
Each of the plurality of fused portions has a shape (rectangular shape) long in one direction in a plan view, and inside each of the plurality of fused portions, a shape (rectangular shape) long in the one direction in a plan view. The method for manufacturing a composite sheet according to any one of <1> to <9>, wherein the through hole of (shape) is formed.
<11>
The method for producing a composite sheet according to any one of <1> to <10>, wherein the plurality of fused portions are each formed in an annular shape surrounding the through hole.
<12>
The method for producing a composite sheet according to any one of <1> to <11>, wherein the fused portion is in the form of a film.
<13>
Immediately before the laminated sheet is carried into the clearance, the contact of the laminated sheet with the carry-in inlet edge of the clearance in the ultrasonic horn is intentional, any of the above <1> to <12>. The method for manufacturing a composite sheet according to item 1.

<14>
A composite sheet manufacturing apparatus in which a first sheet and a second sheet have a plurality of fused portions and through holes are formed in the fused portions.
It has an anvil roll and an ultrasonic fusion machine, the ultrasonic fusion machine includes an ultrasonic horn arranged to face the peripheral surface portion of the anvil roll, and the peripheral surface portion of the anvil roll and the tip of the ultrasonic horn. An ultrasonic processing unit and an ultrasonic processing unit that are provided with a clearance for carrying the object to be processed between the vibration application surface and the unit.
The first sheet and the second sheet are conveyed in the same direction and stacked to form a laminated sheet, and the laminated sheet to be processed is carried into the clearance. ,
The ultrasonic processing unit is configured to form the fused portion by bringing the vibration application surface into contact with one surface of the laminated sheet carried into the clearance and applying ultrasonic vibration.
Immediately before the laminated sheet is carried into the clearance, the surface of the laminated sheet that contacts the vibration application surface in the clearance is brought into contact with the carry-in inlet edge of the clearance in the ultrasonic horn. Composite sheet manufacturing equipment.
<15>
The above <14>, wherein the separation distance between the peripheral surface portion of the anvil roll and the vibration application surface at the carry-in entrance of the clearance is shorter than the thickness immediately before the carry-in of the object to be carried into the carry-in entrance. Composite sheet manufacturing equipment.
<16>
When the center of the object to be transported on the vibration-applied surface is located on a virtual straight line extending in the radial direction of the anvil roll through the rotation center of the anvil roll, the object to be processed on the vibration-applied surface. The composite sheet manufacturing apparatus according to <14> or <15>, wherein the center is located downstream of the reference position in the transport direction when the position of the center in the transport direction is set as the reference position. ..
<17>
The vibration application surface has a shape along the contour line of the peripheral surface of the anvil roll in a cross-sectional view along the transport direction of the object to be processed, and is any one of <14> to <16>. The equipment for manufacturing the composite sheet according to the section.
<18>
Item 3. The apparatus for manufacturing a composite sheet according to any one of <14> to <17>, which comprises a preheating means for preheating at least one of the first sheet and the second sheet before applying ultrasonic vibration. ..
<19>
The apparatus for manufacturing a composite sheet according to any one of <14> to <18>, comprising a horn heating means for heating the vibration application surface.
<20>
The tip portion of the ultrasonic horn is configured to include a heat storage portion fixed to a metal main body portion of the ultrasonic horn, and the vibration application surface is formed from the heat storage portion. The apparatus for manufacturing a composite sheet according to any one of <19>.
<21>
The ultrasonic fusion machine is fixed on a movable table and is fixed.
By advancing and retreating the position of the movable table along the direction approaching the peripheral surface of the anvil roll, the height of the clearance and the pressing force applied to the object to be carried into the clearance can be adjusted respectively. , The apparatus for manufacturing a composite sheet according to any one of <14> to <20>.
<22>
The vibration application surface has an arc shape recessed in a direction away from the rotation axis of the anvil roll in a cross-sectional view along the transport direction of the object to be processed. The composite sheet manufacturing apparatus according to any one of the following items.

<23>
The anvil roll is an uneven roll having irregularities on the peripheral surface portion, and is an uneven roll.
In the object transporting portion to be processed, the first sheet is made to follow the peripheral surface portion of the uneven roll to be deformed into an uneven shape, and the second sheet is superposed on the deformed first sheet to form the laminated sheet. The apparatus for producing a composite sheet according to any one of <14> to <22> to be formed.
<24>
The tip surface of the convex portion constituting the unevenness of the peripheral surface portion of the concave-convex roll has a rectangular shape having a long side along the rotation direction of the uneven roll and a short side along the rotation axis direction of the uneven roll. 23> The composite sheet manufacturing apparatus.
<25>
The composite sheet manufacturing apparatus according to <23> or <24>, wherein the uneven roll is formed by combining a plurality of gears having a predetermined tooth width into a roll shape.
<26>
The recess of the gear in the concave-convex roll forms an uneven recess on the peripheral surface of the concave-convex roll, and a suction hole is formed at the bottom of the recess of the gear.
The composite sheet according to <25>, wherein the first sheet is maintained in a state of being deformed into an uneven shape by following the peripheral surface portion of the uneven roll by the suction force of the suction holes. Device.
<27>
The composite sheet manufacturing apparatus according to <25> or <26>, wherein a predetermined gap is provided between the adjacent gears in the concave-convex roll.
<28>
In a state where the vibration application surface faces the tip surface of the convex portion constituting the unevenness of the peripheral surface portion of the concave-convex roll, and the clearance is provided between the vibration application surface and the tip surface of the convex portion.
The convex portion extends in the radial direction of the concave-convex roll through the rotation center of the concave-convex roll and is orthogonal to the vibration application surface. When located on the upstream side of the MD), the separation distance (height of the clearance) between the vibration application surface and the tip surface of the convex portion is from the upstream side to the downstream side in the rotation direction (MD). Gradually decrease,
When the convex portion overlaps with the virtual vertical line, the separation distance (height of the clearance) between the vibration application surface and the tip surface of the convex portion gradually decreases from the carry-in port of the clearance toward the virtual vertical line. , It becomes the minimum at the position of the virtual vertical line, and gradually increases from the virtual vertical line toward the carry-out port of the clearance.
When the convex portion is located downstream of the virtual vertical line in the rotation direction (MD), the separation distance (height of the clearance) between the vibration application surface and the tip surface of the convex portion is the rotation. The composite sheet manufacturing apparatus according to any one of <23> to <27>, which gradually increases from the upstream side to the downstream side in the direction (MD).
<29>
In addition to the uneven roll, another uneven roll having an uneven surface portion that meshes with the unevenness of the peripheral surface portion of the concave-convex roll is provided, and both rolls are rotated so that the meshing portion between the unevennesses of both rolls is formed. The composite sheet according to any one of <23> to <27>, wherein the first sheet is introduced into the meshing portion to deform the first sheet into an uneven shape. manufacturing device.

10A Laminated sheet 10 Composite sheet 1 1st sheet 2 2nd sheet 3 Concave part 4 Fused part 5 Convex part 6 Through hole 20 Composite sheet manufacturing equipment 30 Processed object transport part (concave and convex forming part)
31 First roll (anvil roll, uneven roll)
32 Second roll (concave and convex roll)
33 Engagement part 34 Suction hole 35 Convex part 35c Tip surface of convex part 36 Ultrasonic vibration application part 40 Ultrasonic processing part 41 Ultrasonic fusion machine 42, 42A, 42B Ultrasonic horn 420 Ultrasonic horn body 421 Vibration Application surface (tip surface of ultrasonic horn)
425 Heat storage unit 43 Converter 44 Booster 45 Movable table 46 Clearance 47 Clearance inlet edge in ultrasonic horn 50 Preheating mechanism 51 Preheating means 60 Horn heating mechanism 61 Horn heating means

Claims (18)

A method for manufacturing a composite sheet in which a first sheet and a second sheet have a plurality of fused portions and through holes are formed in the fused portions.
A superposition step of forming a laminated sheet by superimposing the first sheet and the second sheet while transporting them in the same direction.
The laminated sheet is carried into the clearance between the peripheral surface portion of the anvil roll and the vibration application surface of the tip portion of the ultrasonic horn of the ultrasonic fusion machine arranged opposite to the peripheral surface portion, and is carried onto one surface of the laminated sheet. It has an ultrasonic treatment step of forming the fused portion by bringing the vibration application surface into contact and applying ultrasonic vibration.
Immediately before carrying the laminated sheet into the clearance, a method for manufacturing a composite sheet in which the surface of the laminated sheet that contacts the vibration application surface in the clearance is brought into contact with the carry-in inlet edge of the clearance in the ultrasonic horn. .. In the superposition step, the first sheet is conveyed while being held on the peripheral surface of the anvil roll, and the second sheet is superposed on the first sheet being conveyed to form the laminated sheet.
The method for manufacturing a composite sheet according to claim 1, wherein the laminated sheet is conveyed while being held on the peripheral surface portion of the anvil roll and carried into the clearance. Claim 1 or 2 in which the through hole is formed in the laminated sheet by the contact of the laminated sheet with the carry-in inlet edge of the clearance in the ultrasonic horn immediately before the laminated sheet is carried into the clearance. The method for manufacturing a composite sheet according to the above. The method for producing a composite sheet according to any one of claims 1 to 3, wherein at least one of the first sheet and the second sheet before applying ultrasonic vibration is preheated. The method according to any one of claims 1 to 4, wherein the vibration application surface is heated, and in the ultrasonic treatment step, ultrasonic vibration is applied using the heated vibration application surface and the peripheral surface portion of the anvil roll. The method for manufacturing a composite sheet according to the description. As the anvil roll, an uneven roll having an uneven surface is used.
In the stacking step, while rotating the uneven roll, the first sheet is made to follow the peripheral surface portion of the concave-convex roll to be deformed into an uneven shape, and the deformed first sheet is used as the peripheral surface portion of the concave-convex roll. The laminated sheet is formed by superimposing the second sheet on the first sheet being transported while holding it on top.
The composite sheet is any of claims 1 to 5, wherein at least a part of the first sheet other than the fused portion has a convex portion protruding on the side opposite to the second sheet side. The method for manufacturing a composite sheet according to claim 1. In the superposition step, in addition to the uneven roll, another uneven roll having an uneven surface portion that meshes with the unevenness of the peripheral surface portion of the uneven surface roll is used so that the meshing portion between the unevennesses of both rolls is formed. The method for manufacturing a composite sheet according to claim 6, wherein both rolls are rotated and the first sheet is introduced into the meshing portion to deform the first sheet into an uneven shape. The method for producing a composite sheet according to any one of claims 1 to 7, wherein at least one of the first sheet and the second sheet includes a non-woven fabric. The method for producing a composite sheet according to any one of claims 1 to 8, wherein at least one of the first sheet and the second sheet contains polyethylene terephthalate. A composite sheet manufacturing apparatus in which a first sheet and a second sheet have a plurality of fused portions and through holes are formed in the fused portions.
It has an anvil roll and an ultrasonic fusion machine, the ultrasonic fusion machine includes an ultrasonic horn arranged to face the peripheral surface portion of the anvil roll, and the peripheral surface portion of the anvil roll and the tip of the ultrasonic horn. An ultrasonic processing unit and an ultrasonic processing unit that are provided with a clearance for carrying the object to be processed between the vibration application surface and the unit.
The first sheet and the second sheet are conveyed in the same direction and stacked to form a laminated sheet, and the laminated sheet to be processed is carried into the clearance. ,
The ultrasonic processing unit is configured to form the fused portion by bringing the vibration application surface into contact with one surface of the laminated sheet carried into the clearance and applying ultrasonic vibration.
Immediately before the laminated sheet is carried into the clearance, the surface of the laminated sheet that contacts the vibration application surface in the clearance is brought into contact with the carry-in inlet edge of the clearance in the ultrasonic horn. Composite sheet manufacturing equipment. The tenth aspect of the present invention, wherein the separation distance between the peripheral surface portion of the anvil roll and the vibration application surface at the carry-in entrance of the clearance is shorter than the thickness immediately before the carry-in of the object to be carried into the carry-in entrance. Composite sheet manufacturing equipment. When the center of the object to be transported on the vibration-applied surface is located on a virtual straight line extending in the radial direction of the anvil roll through the rotation center of the anvil roll, the object to be processed on the vibration-applied surface. The composite sheet manufacturing apparatus according to claim 10 or 11, wherein the center is located on the downstream side in the transport direction from the reference position when the position of the center in the transport direction is set as the reference position. The method according to any one of claims 10 to 12, wherein the vibration application surface has a shape along the contour line of the peripheral surface of the anvil roll in a cross-sectional view along the transport direction of the object to be processed. Composite sheet manufacturing equipment. The composite sheet manufacturing apparatus according to any one of claims 10 to 13, further comprising a preheating means for preheating at least one of the first sheet and the second sheet before applying ultrasonic vibration. The composite sheet manufacturing apparatus according to any one of claims 10 to 14, further comprising a horn heating means for heating the vibration application surface. The anvil roll is an uneven roll having irregularities on the peripheral surface portion, and is an uneven roll.
In the object transporting portion to be processed, the first sheet is made to follow the peripheral surface portion of the uneven roll to be deformed into an uneven shape, and the second sheet is superposed on the deformed first sheet to form the laminated sheet. The apparatus for producing a composite sheet according to any one of claims 10 to 15, which is formed. In addition to the uneven roll, another uneven roll having unevenness that meshes with the unevenness of the peripheral surface portion of the concave-convex roll is provided, and both rolls are rotated so that the meshing portion between the unevennesses of both rolls is formed. The composite sheet manufacturing apparatus according to claim 16, wherein the first sheet is introduced into the meshing portion to deform the first sheet into an uneven shape. Claims 10 to 17 wherein the tip portion of the ultrasonic horn includes a heat storage portion fixed to a metal main body portion of the ultrasonic horn, and the vibration application surface is formed from the heat storage portion. The apparatus for manufacturing a composite sheet according to any one of the above items.

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