JP3088874B2 - Method and apparatus for manufacturing perforated sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a three-dimensionally perforated sheet and an apparatus therefor.
The present invention relates to a method and an apparatus for producing a three-dimensionally perforated sheet used for a surface material that directly contacts the skin such as a sanitary napkin or a diaper.

[0002]

2. Description of the Related Art Conventionally, perforated films or nonwoven fabrics have been generally used as surface sheets for absorbent articles such as sanitary napkins and diapers. In the case of using a perforated film as a surface material, Japanese Patent Publication No. 57-17081
Although the film itself is disclosed in Japanese Patent Application Laid-Open Publication No. Sho 62-68928 and the like, the film itself has a bad sensation of contact with the skin and gives a discomfort to the user. On the other hand, as a nonwoven fabric type surface material, a sheet recently provided with holes is known. As a technique for producing such an apertured nonwoven fabric, Japanese Patent Application Laid-Open No. 63-182460 discloses a nonwoven fabric in which apertures are mixed irregularly by performing a fiber rearrangement treatment on a fiber material layer with a jet of water. A method of obtaining is disclosed.

In Japanese Patent Application Laid-Open No. 55-6536, a heat-fusible binder is sprayed on a sheet, the sheet is spot-bonded at regular intervals, and then passed through a high-pressure water jet end. A method for obtaining a nonwoven fabric having an excellent aperture is disclosed. In addition, 4-48
In Japanese Patent Publication No. 99, a process of using a hot-melt hydrophobic fiber sheet and injecting the fiber sheet with a high-speed water stream to entangle the fibers and distribute the fibers to give apertures, and flame the fiber sheet with a flame By broiling,
There is a step of melting or burning out the fibers remaining in the open area, and these are improvements of a known technique generally called a spunlace method.

As a method for mechanically opening holes, Japanese Patent Laid-Open No.
As disclosed in Japanese Unexamined Patent Publication No. 2-27876 and Japanese Patent Publication No. 62-125061, a method has been proposed in which a nonwoven fabric sheet is sandwiched and opened between a needle projecting outward and a pusher (socket).

[0005]

However, there are the following problems with an apertured nonwoven fabric sheet formed by the improved method of the spunlace method. Since the non-woven fabric sheet is opened in the non-woven fabric manufacturing process, the opening becomes almost full width, and as a surface material when actually used for sanitary products and diapers, the entire width becomes an opening sheet, It is difficult to open holes only at certain locations. Furthermore, since the opening method uses liquid energy to open the holes, the cost of supplying and processing the liquid is greatly increased. Further, the opening ratio and the opening diameter of the sheet cannot be easily changed. Once the opened nonwoven fabric is wound up, problems such as blockage of the holes also occur. Furthermore, a problem such as a fire occurs when the fiber remaining in the opening is roasted with a flame.

In a mechanical opening method, a sheet is sandwiched between a needle and a pushing body (socket) for receiving the needle, and the needle is pushed into the socket while rotating the needle and the socket. For this reason, the socket needs to be pushed into and pulled out of the socket, and the shape and pitch of the needle are limited, and the required aperture ratio and aperture diameter cannot be obtained. For this reason, when a conventional perforated nonwoven fabric is used as the surface material of the sanitary napkin and the surface material of the diaper, good results are not necessarily obtained in the evaluation of appearance, absorption rate, and the like. Accordingly, the present invention provides a three-dimensionally perforated sheet suitable for a surface material such as a sanitary napkin and a diaper having a high absorption performance and a good appearance and texture by easily forming an opening having an appropriate shape in an appropriate place and also in an appropriate shape. It is an object to provide a manufacturing method and an apparatus.

[0007]

According to the present invention, there is provided a method of manufacturing a three-dimensional perforated sheet having three-dimensional perforations, comprising a plurality of pyramidal or conical convex pins arranged in a row along a sheet conveying direction. And the sheet is interposed between a first pressing die in which the rows are arranged in multiple rows and a second pressing die having a ridge portion fitted between the multiple rows. The above object has been achieved by providing a method for producing a three-dimensionally perforated sheet, characterized by forming a large number of openings. The present invention also relates to a three-dimensionally perforated sheet manufacturing apparatus having a three-dimensionally perforated sheet, wherein the rotating roll is disposed in a sheet conveying area, and has a plurality of pyramidal or conical convex pins on its peripheral edge. A pin roll formed by laminating plates, and disposed for facing the pin roll with the sheet interposed therebetween, and a peripheral portion is fitted between multiple rows of the convex pins formed by laminating the pin disks. The object has been achieved by providing an apparatus for manufacturing a three-dimensionally perforated sheet comprising a ridge roll formed by laminating ridge disks at predetermined intervals.

[0008]

According to the method and the apparatus for manufacturing a three-dimensionally perforated sheet of the present invention, the sheet is provided with a first pressing die (pin roll) and a pin row and pins arranged in the circumferential direction of the first pressing die (pin roll). Second pressing die inserted between rows (Rolls)
In the course of passing through the sheet, a plurality of three-dimensional perforations can be made in the flow direction of the sheet, and as a result, a desired three-dimensional perforated sheet can be manufactured. In this case, the pin roll or the ridge roll can be formed of a pin disk or a ridge disk, and if the number of these disks is adjusted or the length and shape of the pin at the peripheral edge are changed, the three-dimensional The perforation of the perforated sheet can be easily formed at an appropriate place of the sheet, and an opening having an appropriate shape can be easily formed.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to FIGS. In each of the drawings, FIG. 1 is an explanatory diagram showing an outline of an embodiment of a three-dimensionally perforated sheet manufacturing apparatus suitably used when the method of manufacturing a three-dimensionally perforated sheet of the present invention is performed, and FIG. FIG. 3 is a perspective view of a main part of a roll unit portion for forming a hole in the manufacturing apparatus of FIG. 1, FIG. 3 is a partial cross-sectional view along an axis of a pin roll used in the roll unit portion, and FIG. FIG. 5 is a partial sectional view taken along the axis of a ridge roll used in the roll unit, and FIG. 4 is a partial sectional view taken along the axis of a ridge roll used in the roll unit. It is the figure seen from the axial direction of the strip | roll, and FIG.
FIG. 9 is a partial cross-sectional view showing a process of punching a sheet as viewed from a sheet flow direction, and FIG. 9 is a partial cross-sectional view of a process of punching a sheet as viewed from an axial direction of a pin roll. FIG. 10 is a partial cross-sectional view seen from the sheet flow direction when the sheet perforations are formed in a staggered pattern in another embodiment of the roll unit portion, and FIG. It is the arrangement figure of the pin disk seen from the direction.

First, an embodiment of the method for producing a three-dimensionally perforated sheet of the present invention, which is suitably used in the method for producing a three-dimensionally perforated sheet of the present invention, will be described with reference to FIGS. The present invention relates to a method of manufacturing a three-dimensionally perforated sheet having three-dimensionally perforated sheets, and includes a plurality of pyramid or conical shaped protruding pins 5 along a sheet 2 conveying direction (the direction of arrow A in FIGS. 4 and 9).
Are arranged in rows, and the rows are arranged in rows, and the pin rolls 5 (first pressing dies) are arranged in rows as shown in FIG. A large number of perforations are formed by interposing the sheet 2 between the ridge roll 6 (the second pressing die) having the strip disks 61, 61.

The method for producing a three-dimensionally perforated sheet of the present invention will be further described.
Are arranged in a row along the transport direction of the vehicle, and the rows are arranged side by side. As shown in FIG. 8, the ridge roll 6 has a ridge 61 inserted between rows of the pins 52 of the pin roll 5. The sheet 2 is pierced by passing the sheet 2 between the rolls having these relationships. In such a method of manufacturing a three-dimensional perforated sheet, the convex pin 52 of the pin roll 5 is used.
It is easy to appropriately change the design of the number of rows and the number of rows in the row, and it is possible to perforate the sheet 2 at a desired position. Further, since the length and shape of the convex pins 52 can be changed in units of rows, it is possible to perforate a size or a specific shape according to the purpose. For example, as in the embodiment shown in FIG. 3, the pin roll 5 as the first pressing die includes a pin disk 51 having a convex pin 52 formed on a peripheral edge thereof and a spacer 53.
When these are overlapped, it is possible to easily change the number of juxtaposed pins 52 and the design of the juxtaposed positions. Similarly, the shape of the perforations in the sheet 2 can be easily changed.

Next, an apparatus for manufacturing a three-dimensionally perforated sheet according to this embodiment will be described in detail. As shown in FIG. 8, the apparatus for manufacturing a three-dimensionally perforated sheet according to the present embodiment is a rotary roll disposed in the conveying area of the sheet 2, and has a plurality of pyramidal or conical convex pins 52 at the peripheral edge. A pin roll 5 formed by laminating the discs 51 and a pin roll 5 disposed opposite to each other with the sheet 2 interposed therebetween. And a ridge roll 6 formed by stacking ridge disks 61 for insertion to be inserted at predetermined intervals. The present embodiment will be described in more detail. As shown in FIG. 1, the sheet 2 is supplied from the supply roll 1 of the apparatus 9 for manufacturing a three-dimensionally perforated sheet. It is supplied to the roll unit 4 in a state where it is not present. After a large number of three-dimensional perforated portions, which will be described later, are formed by the pin roll 5 and the ridge roll 6 in the roll unit 4, the sheet 2 is transferred to the next process via the position regulating device 7 at the subsequent stage of the roll unit 4. It is configured to be supplied.
The roll unit 4 is connected to a pressurizing device 8 that applies a pressing force to the pin roll 5 and the ridge roll 6.

As shown in FIG. 2, the roll unit 4 comprises a pin roll 5 and a ridge roll 6, and the sheet 2 comes into contact with the pin roll 5 at the position of the sheet 2a and is conveyed in accordance with the rotation of the pin roll 5. The sheet 2 comes into contact with the ridge roll 6 at the position of the sheet 2b, and the convex pins 52 formed on the pin roll 5 are sufficiently inserted by the ridge roll 6. In the sheet 2, the convex pins 52 are pulled out at the position of the sheet 2c,
A three-dimensional perforation like the sheet 2d is formed on the sheet 2 surface. In addition, as the sheet 2, a nonwoven fabric made of a thermoplastic resin such as polyethylene, polypropylene, and polyester, a laminated film obtained by laminating a film on the nonwoven fabric, and the like are preferably used.

As shown in FIG. 3 and FIG.
Are the rotating shaft 54, the fastening members 55, 55, and the pin disk 5
, And spacers 56, 56,... The center portions of the pin disk 51 and the spacer 56 are pierced to form an insertion hole for the rotating shaft 54, and the pin disk 51 and the spacer 56 themselves are formed in an annular shape. A large number of convex pins 52 (height c of the perspective portion, depth d to the peripheral surface of the spacer 56) are arranged and arranged at equal intervals on the peripheral portion of the pin disk 51. Key grooves 57 are formed at two places of the insertion hole 51A as stoppers.
A large number of pin disks 51 are overlapped in the axial direction of the rotating shaft 54 with a spacer 56 interposed therebetween, and constitute the pin roll 5. Therefore, the pin disk 51 itself forms a row of pins 52, and when these are overlapped, the rows become multi-rows.
3 is the width of the spacer 56. The pin disk 51 and the spacer 56 can be attached to and detached from the rotating shaft 54, and are fixed by the fastening members 55, 55 when fixed by the rotating shaft 54. Here, the thickness (p ₁ ) of the pin disk 51
Is preferably 0.5 to 5 mm, and the width of the spacer 56 is substantially determined by the thickness of the ridge disk 61 of the ridge roll 6 described later and the thickness of the processing sheet 2. An insertion hole 58 for a cartridge heater is formed in the rotating shaft 54, and the pin disk 51 is appropriately heated by heating the cartridge heater.

As shown in FIG. 5 and FIG.
, A ridged disk 61, a rotating shaft 62, fastening members 63, 63, and spacers 64, 64,. The center portions of the ridge disk 61 and the spacer 64 are pierced to form an insertion hole for the rotating shaft 62, and the ridge disk 61 and the spacer 64 themselves are formed in an annular shape. A large number of ridged disks 61 are overlapped in the axial direction of the rotating shaft 62 with a spacer 64 interposed therebetween to form a ridged roll 6. The protruding disk 61 and the spacer 64 can be attached to and detached from the rotating shaft 62, and are fixed by the fastening members 63, 63 when fixed by the rotating shaft 62.

As shown in FIG. 7 and FIG.
The space between them is the width of the spacer 64.
It is formed corresponding to the thickness of 51. Also, ridged disk
61 thickness (p_Three) Are pins 52 against the processing sheet 2.
It is desirable to insert it thinly,
Considering the strength, the thickness is preferably 0.1 to 1 mm. Also
The clearance between the ridge disk 61 and the pin disk 51 (p_Two)as well as
(P_Four) Is preferably 0.1 to 2 mm.
The width of the spacer 56 between the discs 51 (p_Two+ P_Three+
p _Four) Is preferably 0.3 to 5 mm.
And the pitch (p₀= P₁+ P
_Two+ P_Three+ P_Four) Is preferably 0.8 to 10 mm
No. The rotary shaft 62 has a cartridge heater insertion hole 65.
Are formed, and the protrusions are appropriately formed by heating the cartridge heater.
The disk 61 is being heated. Addition of pin 52 of pin roll 5
The heat temperature depends on the type of sheet to be processed,
A range of 0 ° C. is desirable.

In the manufacturing apparatus 9 for a three-dimensionally perforated sheet configured as described above, the sheet 2 to be processed is unwound from the supply roll 1 and is sent to the roll unit 4 after the position control device 3 prevents the lateral runout and the like. Can be As shown in FIG. 7, the sheet 2 is located between the pin roll 5 and the ridge roll 6 which are appropriately heated, and is in a state where a part of the pin 52 of the pin disk 51 of the pin roll 5 is perforated. Sheet 2 is further transported,
As shown in FIG. 8, the ridge disk 61 of the ridge roll 6 is fitted between the pin disks 51, 51 with the sheet 2 sandwiched therebetween, and the sheet 2 is formed with a three-dimensional perforation. When the protruding disk 61 is inserted from the position h _{0 to} the position h ₁ with respect to the pin roll 5 in FIG. 7 (not shown), the sheet 2 is slightly larger than the time h _0. Is pierced. Furthermore, when fitted ridges disc 61 to the position of h ₂ is as shown in FIG. 8, it is fairly large diameter hole drilled in the sheet 2. Furthermore, sufficient opening is obtained when the projection disc 61 to the position of h ₃ of FIG. 7 is fitted. Therefore, while passing through the roll unit 4, the sheet 2
As shown in FIG. 9, the sheet 2 rests on the convex pins 52 of the pin disk 51, and
2, a large number of three-dimensional perforations are formed in the concave portions having a similar shape.

In this case, the pin disk 51 of the pin roll 5 and the convex disk 61 of the convex roll 6 are replaced, and as shown in FIG. 4, the pin dimensions c, d, e, f and the pin disk of the pin disk 51 are changed. The required aperture diameter and aperture ratio can be easily obtained by changing the thickness (p ₁ ) of 51. When the depth d-c of the gap f between the convex pins 52 of the pin disk 51 is sufficiently taken and the sheet 2 is inserted into the gap f, the sheet 2 is pierced through a hole formed by a normal pin or needle. Large pore size,
A three-dimensional perforated sheet having a three-dimensional appearance can be formed.
Further, by appropriately changing the number and the position of the pin disks 51 of the pin roll 5, perforations can be formed at desired positions of the processing sheet, and the design of the perforation positions of the processing sheet can be facilitated.

Therefore, since the three-dimensionally perforated sheet 2 formed as described above has an appropriate aperture diameter, aperture ratio, and three-dimensional shape, this sheet 2 can be used as a surface material for absorbent articles such as sanitary napkins and diapers. When used as, blood, urine, and the like are quickly absorbed through each of the holes. Further, by providing a three-dimensional opening, the opening is not deformed more than necessary due to pressurization at the time of mounting, and it is possible to suppress the leaching of absorbed blood, urine, and the like to the surface.

Next, another embodiment of the apparatus for manufacturing a three-dimensionally perforated sheet according to the present invention will be described with reference to FIGS. The pin roll 25 of the apparatus for manufacturing a three-dimensionally perforated sheet according to the present embodiment is configured substantially in the same manner as the embodiment shown in FIGS. 3 and 4, and the same members as those in the embodiment shown in FIGS. 10 and 11 are given the same reference numerals and their detailed description is omitted, but FIGS.
The difference from this embodiment is that when the pin disk 51 of the pin roll 25 is mounted on the rotating shaft 54 and overlapped, the positions of the key grooves 57, 57 of the pin disks 51 adjacent to each other are made different to form a convex shape. The positions of the pins 52 are provided with a half pitch phase. Even in such a configuration, the three-dimensional perforated sheet shown in FIGS. 3 and 4 can be easily formed in the sheet, and the staggered three-dimensional perforated sheet can be formed by shifting the pin disk 51 by a half pitch. Moldable (not shown).
In FIGS. 10 and 11, the pin disk 51 is accurately shifted by a half pitch. However, by slightly changing the positions of the key grooves, three-dimensional perforated sheets having various opening patterns are formed. I can do things.

According to the method and the apparatus for manufacturing a three-dimensionally perforated sheet of the present invention, the sheet is inserted into the first pressing die (pin roll) and the first pressing die (pin roll). ) Can produce a plurality of rows of three-dimensional perforated sheets in the sheet. Then, by adjusting the positional relationship between the ridge disk and the pin disk to be fitted and changing the shape of the pin disk such as the thickness, it is possible to freely set the aperture diameter, the aperture ratio, the three-dimensional shape, and the like. The three-dimensional perforated sheet can be arbitrarily manufactured according to the purpose of use. For example, in the case of sanitary napkins, if it is necessary to have a slightly larger opening in the center of the surface material, a smaller opening around the center, and a non-opening around the periphery, the thickness of the pin disk should be reduced. The aperture sheet can be easily obtained by changing at the center and its periphery. ADVANTAGE OF THE INVENTION According to this invention, the absorption performance is improved, and the three-dimensional perforated sheet which improved wet back, especially the three-dimensional perforated sheet suitable for surface materials, such as a sanitary napkin and a diaper, can be manufactured.

[0022]

According to the method and the apparatus for manufacturing a three-dimensionally perforated sheet according to the present invention, an opening having an appropriate shape and an appropriate shape can be easily formed to have high absorption performance, good appearance and good texture. A three-dimensional perforated sheet suitable as a surface material such as a sanitary napkin and a diaper can be provided.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an outline of an embodiment of a three-dimensionally perforated sheet manufacturing apparatus suitably used when the method of manufacturing a three-dimensionally perforated sheet of the present invention is carried out.

FIG. 2 is a perspective view of a main part of a roll unit for forming perforations in the manufacturing apparatus of FIG. 1;

FIG. 3 is a partial cross-sectional view along an axis of a pin roll used in a roll unit.

FIG. 4 is a diagram viewed from an axial direction of a pin roll used in a roll unit portion.

FIG. 5 is a partial cross-sectional view along the axis of a ridge roll used in the roll unit.

FIG. 6 is a diagram viewed from the axial direction of a ridge roll used in a roll unit portion.

FIG. 7 is a partial cross-sectional view showing a process of punching a sheet, viewed from a sheet flow direction.

FIG. 8 is a partial cross-sectional view illustrating a process of punching a sheet as viewed from a sheet flow direction.

FIG. 9 is a partial cross-sectional view of a process of punching a sheet as viewed from an axial direction of a pin roll.

FIG. 10 is a partial cross-sectional view seen from the sheet flow direction when a perforation of a sheet is formed in a staggered pattern in another embodiment of the roll unit portion.

11 is an arrangement diagram of a pin disk when the pin roll of FIG. 10 is viewed from an axial direction.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 supply roll 2 sheet 3, 7 position regulating device 4 roll unit 5 pin roll 6 convex roll 51 pin disc 52 convex pin 61 convex strip disc

────────────────────────────────────────────────── (5) Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI D06C 23/04 (56) References JP-A-5-228173 (JP, A) JP-A-6-126871 (JP, A) ( 58) Fields investigated (Int.Cl. ⁷ , DB name) D04H 1/00-18/00 A61F 13/15-13/84 D06C 3/00-29/00 B26F 1/00-3/16 B28B 11 / 00-19/00 B29C 53/00-53/84 B29C 59/00-59/18 B29C 63/00-73/34 B29D 1/00-31/02 B32B 1/00-35/00

Claims (3)

(57) [Claims] 1. A method of manufacturing a three-dimensional perforated sheet having three-dimensional perforations, comprising a plurality of pyramidal or conical convex pins arranged in a row along a sheet conveying direction, wherein the rows are multi-rows. A large number of three-dimensional perforations are formed by interposing the sheet between a first pressing die arranged side by side and a second pressing die having a ridge portion fitted between the multiple rows. A method for producing a three-dimensionally perforated sheet, comprising: 2. An apparatus for manufacturing a three-dimensional perforated sheet having three-dimensional perforations, comprising: a rotating roll arranged in a sheet conveying area, wherein a plurality of pyramid- or conical-shaped convex pins are provided on a peripheral portion of the rotating roll. A pin roll formed by stacking plates, and disposed opposite to the pin roll with the sheet interposed therebetween;
And a ridge roll formed by stacking ridged disks for insertion in which a peripheral edge is inserted between multiple rows of the convex pins formed by overlapping the pin disks at predetermined intervals. 3D perforated sheet manufacturing equipment. 3. A heating mechanism for partially softening or partially melting said sheet is provided on at least one of said pin roll and said ridge roll.
An apparatus for manufacturing a three-dimensional perforated sheet according to the above.