JP3107863B2 - Manufacturing method of disposable diapers - 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 disposable diapers.

[0002]

2. Description of the Related Art A diaper manufacturing method of this type includes a so-called vertical taking method of forming a diaper vertically from a continuous web as a material thereof, and a so-called horizontal taking method of forming a diaper horizontally. In the vertical take-up method, a continuous elastic member for surrounding the legs is supplied and attached in the length direction (moving direction) of the continuous web, and the absorber also has its front and rear ends directed in the length direction (moving direction) of the continuous web. Supply and arrange. On the other hand, in the horizontal take-up method, the direction of attachment of the continuous elastic member for surrounding the legs to the continuous web and the arrangement of the absorber are reversed from those in the vertical take-up method. By the way, as each continuous web that is the material of the diaper top and back sheet,
In the longitudinal method, those having the same width as those of the sheets are used.
Those having the same width dimension as the vertical dimension of those sheets are used.

[0003]

It is not clear which of the longitudinal method and the horizontal method is more advantageous, but it may be advantageous to use the horizontal method depending on the structure of the diaper. However, a problem arises in the case of manufacturing a diaper having a special structure provided with flaps or the like which rise elastically on both sides thereof. In other words, in order to mass-produce disposable diapers at a low cost, all the constituent materials of the diapers are stacked while being transported in the same direction as the diaper production line to form a plurality of connected diapers. It is indispensable to adopt a method of separating from the connected diaper, but when manufacturing a diaper provided with the flap or the like, transfer along the diaper production line while directing all the components of the diaper in the same direction. If they do, they will not be able to manufacture such diapers. This is because the flaps should be arranged in a direction perpendicular to the continuous web and the production line. This will be more clearly understood from the following description of the present invention.

In the present invention, a take-over method is employed.
Therefore, it is necessary to change a part of the direction of a certain constituent material of the diaper at right angles to the production line direction of the diaper and position the component material in the production line direction. An issue is whether diapers can be manufactured with high efficiency.

[0005]

SUMMARY OF THE INVENTION The method of the present invention for solving the above problems, in a very simple manner, continuously transfers all constituent materials of a diaper in a certain direction along a diaper production line. However, except for the continuous material for the diaper backsheet, other continuous materials (including absorbent panels that are formed in advance and spaced apart) are laminated to form a continuous laminated body including a flap, and then the continuous laminated body is formed. The body is cut into individual diaper width dimensions to form laminate pieces, and the laminate pieces are turned by 90 degrees with respect to the direction of movement of the continuous laminate and stacked on a continuous material for a backsheet. A final continuous laminate is formed, and predetermined portions of the final continuous laminate are joined to separate individual diapers.

[0006]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a manufacturing method according to the present invention.

1 to 3 show a disposable diaper manufactured by the method of the present invention. The diaper 1 has recessed notches 2 for surrounding the legs on both side edges. The diaper 1 is configured as follows. That is, the outer sheet 3 and the inner sheet 4 having a width dimension and a length dimension smaller than the width dimension and the length dimension of the outer sheet 3 and being superposed on the upper surface thereof.
The absorbent panel 7 is disposed in the center of the upper surface of the back sheet 6 to which the elastic member 5 for surrounding the legs is attached, and the width and length are smaller than the width and length of the back sheet 6, respectively. The absorbent panel 7 is covered with a first top sheet 8 having dimensions, and both sides of the first top sheet 8 are joined to both sides of the back sheet 6. The outer portions of the back sheet 6 and the first top sheet 8 are joined to the outer portions of a pair of flaps 10 each having an elastic member 9 attached to the inner edge. Further, the back sheet 6 has an opening 11 having substantially the same width dimension as the back sheet 6 and having a width dimension which is longer in the longitudinal direction in the central region and is larger than the interval dimension between the inner edges of both flaps 10. The outer periphery of the second top sheet 13 is formed, and the outer periphery of the second top sheet 13 to which the elastic member 12 for surrounding the body is attached at the opposite end in the length direction is joined. A known tape fastener 14 for fastening the waist is attached to both sides of one end in the length direction of the diaper 1.

An opposing surface of the outer sheet 3 and the inner sheet 4,
Although not shown, the opposing surfaces of the inner sheet 4 and the absorbing panel 7 and the opposing surfaces of the absorbing panel 7 and the first top sheet 8 are joined in a dot shape as necessary. The concave notch 2 is formed on the outer edge of the back sheet 6, each flap 10 and the second top sheet 13.

The elastic members 5 for surrounding the legs are composed of members 5A and 5B.
Consists of Each of these members 5A and 5B is made of a plurality of thread-like rubbers, and has a central portion 5a and both-side extending portions 5b along the concave notch portion 2. Both-side extending portions 5b
Under the required rate of elongation, it is adhered to the back sheet 6 with an adhesive (not shown), and has a contraction force necessary for giving a gather to the adhesive portion. As will be described later, the central portion 5a is not bonded to the back sheet 6 with an adhesive and does not have a contracting force like the extended portions 5b on both sides, but has a slight contracting force. By cutting to separate from each other and shrinking (snap back) itself,
It can be prevented from lying between the extension portions 5b on both sides. The waist surrounding elastic member 12 is also made of a plurality of thread-like rubbers, and is adhered to the second top sheet 13 with an adhesive (not shown) at a required rate of elongation. The elastic member 9 for the flap is made of a single thread-like rubber.
An adhesive (not shown) is attached near the inner edge of the flap 10 and covered with the inner edge.

The outer sheet 3 is made of a breathable nonwoven fabric,
A gas-permeable, liquid-impermeable plastic film or a gas-permeable, liquid-absorbing tissue paper is used for the inner sheet 4, a mixture of ground pulp and superabsorbent polymer particles is used for the absorption panel 7, The sheet 8 is made of a liquid-permeable fibrous nonwoven fabric, the flaps 10 are made of a water-repellent and breathable fibrous nonwoven fabric, the second top sheet 13 is made of a water-repellent and breathable fibrous nonwoven fabric, and the elastic members 5, 9,. 12 is made of rubber or a plastic material exhibiting rubber elasticity. However, depending on the case, a gas-permeable and liquid-impermeable plastic film may be used for the outer sheet 3, and a material having the same effect as the outer sheet 3 or a gas-permeable nonwoven fabric may be used for the inner sheet 4. When a gas-permeable and liquid-impermeable plastic film is used for the outer sheet 3 and a gas-permeable and liquid-absorbing tissue paper is used for the inner sheet 4, the back sheet 6 is composed of only the outer sheet. The inner sheet is used as a support or packaging sheet for the absorber 7 or as a carrier sheet for the absorber 7 during diaper production.

FIG. 4 to FIG. 12 show main steps for manufacturing a diaper according to the present invention. In the following description, it should be understood that all the components of the diaper have been moved on the diaper production line to the final step of its production.

In FIG. 4, the center area of the material of the above-mentioned outer sheet 3 at predetermined intervals in the length direction of the first continuous web 103 having a width dimension corresponding to the length of the above-mentioned diaper 1 is shown. A hot-melt type adhesive is applied to form an elliptical annular bonding area 115 slightly longer in the width direction.

The material of the elastic member 5 for surrounding the legs, which is described above, includes three first A and first B continuous elastic members 10 each.
5A and 105B are stretched to a required ratio along the substantially half circumference of each bonding area 115 of the first continuous web 103, and are supplied in a sine curve shape while crossing between adjacent bonding areas 115. Each part of the elastic members located in the area 115 is bonded. The portion of the elastic members thus bonded forms an annular elastic portion 105b,
The other portions 105a of the 1A and 1B continuous elastic members 105A and 105B are located between the annular elastic portions, but since they are not coated with an adhesive, they are almost relaxed close to each other. . However, a slight contraction force remains in the portion 105a. Although not shown, the portion 105a is cut into two adjacent elastic portions 105b so as to be separated from each other and contracts (snaps back) itself. It can be prevented from lying between the two annular elastic portions 105b.

1A and 1B continuous elastic members 111A,
In order to supply 111B in a sine curve, for example, as disclosed in Japanese Patent Laid-Open No. 33201/1991, traverse means for supporting each can be used.

An annular elastic portion 105 is provided on the first continuous web 103.
b and 1A and 1B continuous elastic members 10
5A and 105B are bonded without providing the bonding area 115 on the first continuous web 103 as described above, but only on the portion where the annular elastic portion 105b is formed by the continuous elastic members, that is, the continuous elastic members. The hot-melt adhesive can be directly applied at predetermined intervals in the length direction.

In FIG. 5, the distance S (see FIG. 4) between the center lines 116 of the adjacent annular elastic portions 105b in the width direction of the first continuous web 103, which is the material of the inner sheet 4 described above. Absorbing panels 7 are supplied and arranged at predetermined intervals in the length direction of the second continuous web 104 having a small width dimension W in the central region to form a first continuous laminated body 117.

In FIG. 6, the first top sheet 8 already described
Of the third continuous web 108 having a width smaller than the width of the second continuous web 104.
The absorbent panel 7 is covered on the upper surface of the continuous laminated body 117 so that at least both sides thereof are covered with the first continuous laminated body 117.
Are joined to each other with hot melt adhesives (not shown) to form a second continuous laminate 118.

In FIG. 7, the pair of flaps 10 described above are used.
The second continuous elastic member 109 is stretched to a required rate in the vicinity of the inner edges of a pair of fourth continuous webs 110 each having a width dimension not more than one half of the width dimension of the second continuous laminated body 118. While being supplied, they are bonded with a hot-melt adhesive (not shown), and their inner edges are turned over to cover the continuous elastic members.

In FIG. 8, a pair of fourth continuous webs 11
0 on both sides in the longitudinal direction of the upper surface of the second continuous laminate 118, the inner edges of the fourth continuous web are
18 are supplied so as to be separated from each other in the width direction, and the respective outer portions of the fourth continuous web are joined with a hot melt type adhesive (not shown) to form a third continuous laminate 119.

The third continuous web 108 may be joined to the upper surface of the second continuous laminate 118 after joining a pair of fourth continuous webs 110 on both sides.

Referring again to FIG. 8, the third continuous laminate 11
9 under tension by a suction device (not shown) arranged in the movement area of the first and second absorption layers 7 along the center line 120 between each of the absorption panels 7 adjacent to each other, that is, the first The lamination piece 121 is formed by cutting the continuous web 103 in the width direction to a length dimension smaller than the width dimension.

In FIG. 9, the third continuous laminated body 119
Piece 1 under tension with a swivel device arranged in the movement area of
21 is turned by 90 degrees with respect to the moving direction of the first continuous web 103 and the third continuous laminated body 119. Although not shown, this turning device may be, for example, a device having a suction holding portion that turns by a cam mechanism. With this suction holding portion, the laminated piece 1
21 can be maintained in a tensioned state so as not to contract by the contraction force of the elastic member 109.

In FIG. 10, as described above, the lower surface of the laminated piece 121 which is turned by 90 degrees and is in a tensioned state does not substantially protrude outward from the center line 116 of each of the annular elastic portions 105b adjacent to each other. So that the first continuous web 1
The fourth continuous laminated body 122 is formed by sequentially overlapping the upper surface of the third laminated body 03.

In FIG. 11, the material of the above-mentioned second top sheet 13, which is substantially the same as the width of the first continuous web 103, is located near the both longitudinal edges of the upper surface of the fifth continuous web 113. The material of the elastic member 12 for the girth of the body described above is supplied and adhered while extending the three third continuous elastic members 112 at a required ratio. However, the third continuous elastic member 112 is attached to the first continuous web 103 at the same time as or after the adhesion of the first A and first B continuous elastic members 105A and 105B to the first continuous web 103.
3 may be bonded in the vicinity of both longitudinal edges.

Referring again to FIG. 11, the fifth continuous web 11
3, the opening 11 having a width greater than the spacing between the inner edges of the pair of flaps 10 of each of the laminate pieces 121 at predetermined intervals in the length direction of the laminate piece 121, and extending in the width direction of the fifth continuous web 113. To form

In FIG. 12, the fifth flaps 10 are extended so that the inner edges of the pair of flaps 10 project from both inner edges of the opening 11.
The fifth continuous laminate (continuous diaper) 123 is formed by overlapping and joining the upper surface of the continuous web 113 to the upper surface of the fourth continuous laminate 122.

Referring again to FIG. 12, the annular elastic portion 105b
The part 124 of the fifth continuous laminated body 123 surrounded by is cut off to form the above-described recessed portion 2 for surrounding the leg.

Further, in FIG. 12, the fifth continuous laminated body 123 is cut on the center line 116 to obtain the individual diapers 1 shown in FIG.

As shown in FIG. 1, after the diapers are cut into individual diapers, tape fasteners 14 for fastening the waist are provided on both sides of one end in the longitudinal direction.

As the constituent materials of the diaper, the materials described above for the diaper in FIGS. 1 to 3 are used, and the same applies to the necessary joining of the respective materials.

In the present invention, the third continuous elastic member 1 as shown in FIG.
The fifth continuous web 113 having the opening 12 and the opening 12 may not be joined to the fourth continuous laminate 122. In this case, the width dimension of the third continuous web 108 is substantially equal to the interval S (see FIG. 4) between the center lines 116 of the adjacent annular elastic portions 105b in the width direction of the first continuous web 103. Then, after forming the fourth continuous laminated body 122, the concave notch 2 for surrounding the legs is formed and cut into individual diapers.
In the diaper in this case, the pair of flaps 10 are located on the uppermost surface of the diaper.

[0032]

As can be understood from the above description, the method of the present invention is, in short, to provide a continuous elastic member for surrounding the legs on the continuous web for the back sheet of the diaper so that the diaper can take over the so-called diaper. Laminating other continuous diaper materials, including the diaper flap continuous material (including absorbent panels that are pre-formed and spaced apart) while attaching, and dividing the continuous laminate into individual diapers Cut into pieces, the laminate pieces are stacked on the continuous web for the back sheet, and the top continuous web for the top sheet is stacked on the upper surface to form a final continuous laminate. Disconnect into diapers.

Therefore, according to the method of the present invention, the continuous elastic member for surrounding the legs is attached to the continuous web for the back sheet so that the diaper can be so-called taken over from the constituent material of the diaper to the diaper production line. Along with producing a diaper in which the flaps are arranged so that the direction is different from the moving direction of the continuous web by 90 degrees,
Diapers can be continuously mass-produced at low cost by a manufacturing apparatus.

[Brief description of the drawings]

FIG. 1 is a perspective view of a disposable diaper to be manufactured by the method of the present invention.

FIG. 2 is a cross-sectional view of the diaper along the center in the width direction.

FIG. 3 is an exploded perspective view of the diaper.

FIG. 4 is a partial plan view of a first continuous web with a first continuous elastic member attached thereto.

FIG. 5 is a partial plan view of the first continuous laminated body.

FIG. 6 is a partial plan view of a second continuous laminated body.

FIG. 7 is a partial plan view of a fourth continuous web.

FIG. 8 is a partial plan view of a third continuous laminated body.

FIG. 9 is a plan view of a laminate piece.

FIG. 10 is a partial plan view of a fourth continuous laminated body.

FIG. 11 is a partial plan view of a fifth continuous web in which a third continuous elastic member is attached and an opening is formed.

FIG. 12 is a partial plan view of a fifth continuous laminated body.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 diaper 2 concave notch for surrounding legs 7 absorption panel 103 first continuous web 104 second continuous web 105A, 105B first continuous elastic member 108 third continuous web 109 second continuous elastic member 110 fourth continuous web 113 5 continuous webs 117 first continuous laminate 118 second continuous laminate 119 third continuous laminate 121 laminated piece 122 fourth continuous laminate 123 fifth continuous laminate 124 part to be cut off

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) A61F 13/49-13/539

Claims (3)

(57) [Claims] 1. A method for producing a disposable diaper, comprising the following steps. a. 1A and 1B continuous elastic members are supplied in the length direction to the central region of the upper surface of the first continuous web moving in a constant direction under extension, and the first A continuous elastic members form a substantially half-circle of an annular shape; Further, the first B continuous elastic member is curved and bonded so as to form the remaining substantially half circumference of the annular shape to form an annular elastic portion, and the annular elastic portion is separated by a predetermined distance in the length direction of the central region of the upper surface. Be arranged in. b. In the width direction of the first continuous web, the first continuous web has a width dimension that is not larger than the distance between the center lines of the annular elastic portions adjacent to each other. A first continuous laminate is formed by arranging absorption panels at predetermined intervals in the length direction. c. A third continuous web having a width dimension not larger than the width dimension of the second continuous web and moving in the fixed direction is overlapped on the upper surface of the first continuous laminate, and the second continuous web is covered by covering the absorbing panel. Construct a laminate. d. Each of the pair of fourth movable members having a width dimension equal to or less than half of the width dimension of the second continuous laminate and moving in the fixed direction.
Feeding and bonding a second continuous elastic member along the inner edge of the continuous web under elongation. e. The pair of fourth continuous webs are supplied such that their inner edges are spaced apart from each other in the width direction of the second continuous laminate and their outer portions are located on the upper surface of the second continuous laminate, respectively. The third continuous web and the fourth
Joining the outer portion of the continuous web to form a third continuous laminate. f. The third continuous laminate is cut into a length dimension smaller than the width dimension of the first continuous web in the width direction under tension between each of the adjacent absorption panels, and the pair of fourth A laminated piece having a pair of flaps, which is a cut piece of the continuous web, is formed, and the laminated piece under the tension is shifted by 90 degrees with respect to the moving direction of the first continuous web and the third continuous laminate. The upper surface of the first continuous web is turned so that the lower surface of the turned laminated piece under the tensioned state does not protrude substantially outward from the center line of each of the annular elastic portions adjacent to each other. Layer 4
Construct a continuous laminate. g. Cutting the fourth continuous laminate on the center line of the annular elastic portion; 2. A method for producing a disposable diaper, comprising the following steps. a. 1A and 1B continuous elastic members are supplied in the length direction to the central region of the upper surface of the first continuous web moving in a constant direction under extension, and the first A continuous elastic members form a substantially half-circle of an annular shape; Further, the first B continuous elastic member is curved and bonded so as to form the remaining substantially half circumference of the annular shape to form an annular elastic portion, and the annular elastic portion is separated by a predetermined distance in the length direction of the central region of the upper surface. Be arranged in. b. In the width direction of the first continuous web, the first continuous web has a width dimension that is not larger than the distance between the center lines of the annular elastic portions adjacent to each other. A first continuous laminate is formed by arranging absorption panels at predetermined intervals in the length direction. c. A third continuous web having a width dimension not larger than the width dimension of the second continuous web and moving in the fixed direction is overlapped on the upper surface of the first continuous laminate, and the second continuous web is covered by covering the absorbing panel. Construct a laminate. d. Each of the pair of fourth movable members having a width dimension equal to or less than half of the width dimension of the second continuous laminate and moving in the fixed direction.
Feeding and bonding a second continuous elastic member along the inner edge of the continuous web under elongation. e. The pair of fourth continuous webs are supplied such that their inner edges are spaced apart from each other in the width direction of the second continuous laminate and their outer portions are located on the upper surface of the second continuous laminate, respectively. The third continuous web and the fourth
Joining the outer portion of the continuous web to form a third continuous laminate. f. The third continuous laminate is cut to a length smaller than the width of the first continuous web in the width direction under tension between each of the adjacent absorption panels, and the pair of fourth A laminated piece having a pair of flaps, which is a cut piece of the continuous web, is formed, and the laminated piece under the tension is shifted by 90 degrees with respect to the moving direction of the first continuous web and the third continuous laminate. The upper surface of the first continuous web is turned so that the lower surface of the turned laminated piece under the tensioned state does not protrude substantially outward from the center line of each of the annular elastic portions adjacent to each other. Layer 4
Construct a continuous laminate. g. The fifth continuous web having a width dimension substantially equal to the width dimension of the first continuous web, is disposed at predetermined intervals in a length direction of the fifth continuous web moving in the fixed direction, and the pair of each of the laminate pieces is Forming an opening having a width dimension greater than the spacing dimension of the inner edges of the flaps; h. The fifth continuous web is connected to the fourth web so that the inner edges of the pair of flaps project from both inner edges of the opening.
Forming a fifth continuous laminate by overlapping and joining the continuous laminate. i. Cutting the fifth continuous laminate on the center line of the annular elastic portion. 3. The first continuous web is made of a breathable fiber nonwoven fabric, the second continuous web is made of a breathable plastic film, and the absorbent panel is made of a crushed pulp and a superabsorbent polymer particle. The mixture, a liquid-permeable fibrous nonwoven fabric for the third continuous web, a water-repellent and breathable fibrous nonwoven fabric for the fourth continuous web, and a breathable fibrous nonwoven fabric for the fifth continuous web. The manufacturing method according to claim 1, wherein a material exhibiting rubber elasticity is used for each of the continuous elastic members.