JP3586256B2 - Method for producing disposable diaper having patterned sheet - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a disposable diaper, and more particularly to a method for manufacturing a disposable diaper having a pattern sheet in which a pattern such as multicolor printing can be viewed only on a part of the back or front of the diaper.
[0002]
[Prior art]
In a so-called open-type disposable diaper for babies and infants or a disposable diaper preformed in a pants-type, a pattern such as a figure of an animal or a character generally appears on the outer diaper.
[0003]
As a conventional method of applying the pattern, a continuous pattern or a repetitive pattern is printed in advance on a film serving as an outer sheet (back sheet) of a diaper, and the diaper is continuously manufactured by an automatic machine using the outer sheet. General.
[0004]
Japanese Unexamined Patent Publication (Kokai) No. 3-90602 discloses an exterior sheet (back sheet) that can be seen through, and the exterior sheet and a third member inside the exterior sheet are placed via a hot-melt adhesive having a color. Are joined. Then, while applying the hot-melt adhesive in the form of dots, a region having a high dot density is formed with the hot-melt adhesive, and a pattern or pattern is expressed in the region having a high dot density. Through the exterior sheet.
[0005]
[Problems to be solved by the invention]
In the method of manufacturing a diaper by using a film on which a pattern is printed in advance as an exterior sheet as described above, an absorbent layer and a liquid-permeable inner sheet (top sheet) are stacked on the strip-shaped exterior sheet, and thereafter, With the step of separating into individual diapers. Therefore, in a disposable diaper after completion, it is practically impossible to control which pattern or design is located at which position on the outer surface of the diaper. Therefore, printing of the exterior sheet is limited to the continuous pattern or the repetitive pattern as described above, and the degree of freedom in selecting the design of the pattern appearing on the exterior is limited. In addition, since it is necessary to perform printing on the entire film serving as the exterior sheet, the production cost of the exterior sheet (the film having a printed pattern) is increased. For example, if the pattern is to be expressed by multicolor printing, the cost is increased. Extremely high.
[0006]
Next, in the method described in JP-A-3-90602, a colored hot-melt adhesive is applied to an exterior sheet using a roll coater, and a pattern is expressed by dot application of the hot-melt adhesive. Therefore, a clear pattern cannot be obtained, and of course, a multicolor pattern cannot be expressed. Further, in FIG. 1 of the above publication, the pattern is made to appear only on a part of the diaper. However, the method of applying the pattern by the roll coater as described above is disadvantageous in that misalignment between the completed diaper and the pattern is likely to occur. There is.
[0007]
The present invention has been made to solve the above-mentioned conventional problems, and it is possible to apply a pattern to only a part of a diaper at a low cost. For example, even when a pattern of multicolor printing is used, a significant increase in cost can be prevented. It is an object of the present invention to provide a method for manufacturing a disposable diaper as described above.
[0008]
Further, the present invention provides a disposable diaper and a method of manufacturing the disposable diaper, which can minimize a positional shift between the pattern and the diaper when a pattern is applied to a part of the diaper, and can freely cope with a change in a location where the pattern is applied. It is intended to be.
[0009]
[Means for Solving the Problems]
The present invention has an exterior sheet directed to the outside, a liquid-permeable inner sheet directed to the liquid receiving side, and an absorbent layer located between the exterior sheet and the inner sheet, and comprises a belly of a wearer. In the method of manufacturing a disposable diaper in which a front portion applied to the side, an intermediate portion applied to the crotch portion, and a rear portion applied to the back side are formed.
(A) attaching a pattern sheet having an area smaller than that of the exterior sheet and having a pattern on the surface thereof at a predetermined position on the inner surface of the exterior sheet that can be seen through, with the surface facing the exterior sheet; ,
(B) stacking a liquid-impermeable sheet or a hydrophobic sheet inside the exterior sheet, and sandwiching the pattern sheet between the exterior sheet and the liquid-impermeable sheet or the hydrophobic sheet;
(C) installing an absorbing layer and the inner sheet inside the outer sheet;
Which is characterized by having
[0010]
Preferably, the pattern sheet is formed by printing a pattern on a resin film, and more preferably, the pattern sheet is moisture-permeable.
[0011]
In the step (a), it is preferable that the pattern sheet is adhered to the exterior sheet using an adhesive randomly applied to the inner surface of the exterior sheet.
[0012]
In the present invention, both sides of the front portion and both sides of the rear portion are joined to form a waist opening and a pair of leg openings, and a waist gather is formed by an elastic member provided in the waist opening. A method of manufacturing a pants-type disposable diaper in which leg gathers are respectively formed by elastic members provided in the leg openings, wherein in the step (a), the pattern sheet is formed by combining the waist gathers and the leg gathers. Can be configured to be attached to an area that does not cover both sides.
[0013]
Alternatively, both sides of the front part and both sides of the rear part are joined to form a waist opening and a pair of leg openings, and a gather continuous around the waist from the front part to the rear part is formed. A method of manufacturing a pants-type disposable diaper,
In the step (a), the pattern sheet may be configured to be adhered to an area not to be gathered.
[0015]
Further, it is preferable that the exterior sheet is a nonwoven fabric.
Furthermore, when looking at the disposable diaper in a state of bending the intermediate portion in contact and the rear and front portions face the back or the front, the pattern sheet is not more than, for example, 50% of the area of the diaper preferable.
[0016]
The disposable diaper of the present invention may be a so-called open type or may be formed in advance in a pants type.
[0017]
When the disposable diaper is viewed from the back, when viewed from the front, in a state where the diaper is not attached to the human body, the diaper is crushed into a flat shape so that the front part and the rear part are in close contact, and this is crushed. It means the state viewed from the back side or the front side. Alternatively, the disposable diaper has a three-dimensional shape in the same state as when the diaper is worn on a human body, and at this time, it means a projection shape when the diaper is viewed from the back side and when viewed from the front side. In other words, the condition that the area occupied by the pattern sheet is smaller than the area (projected area) of the diaper under any one of the crushed state and the three-dimensional state of the diaper is sufficient.
[0018]
The pattern sheet is, for example, polygonal, circular, or elliptical.
[0019]
As described above, when a breathable and moisture-permeable sheet is used as the pattern sheet, when the exterior sheet is breathable and moisture-permeable, by attaching the pattern sheet, the ventilation and moisture-permeable functions of the exterior sheet are improved. Does not inhibit. However, if the pattern sheet is as small as 50% or less than the area of the exterior sheet when viewed from the back or the front, even if the pattern sheet does not have air permeability or moisture permeability, In addition, the influence on prevention of stuffiness of the diaper as a whole can be reduced.
[0020]
For example, the exterior sheet is a nonwoven fabric, a liquid-impermeable sheet or a hydrophobic sheet is superimposed on the inside of the exterior sheet, and the pattern sheet is formed of the exterior sheet and the liquid-impermeable sheet or the hydrophobic sheet. It is affixed between them.
[0021]
Alternatively, the exterior sheet may be a film, and the pattern sheet may be attached to an inner surface of the film.
[0022]
In the manufacturing method of the present invention, if the accuracy when attaching the pattern sheet to the exterior sheet is ensured, it is possible to attach the pattern at a predetermined position of the diaper without displacing the pattern. Further, it is possible to easily cope with a change in the position where the pattern is attached and a change in the size of the pattern.
[0023]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is a perspective view showing a pants-type disposable diaper manufactured by one embodiment of the manufacturing method of the present invention, FIG. 2 is a sectional view taken along line II-II of the pants-type disposable diaper shown in FIG. And FIG. 6 are perspective views showing an example of a method for manufacturing the disposable diaper.
[0024]
The disposable diaper 1 shown in FIG. 1 is formed in a pants shape in advance, and has a so-called hourglass shape in a deployed state before the forming. The diaper 1 has a front surface 2A applied to the wearer's abdomen during use, a rear surface 2C applied to the buttocks and / or back during use, and an intermediate portion 2B applied to the crotch during use.
[0025]
The lateral side 4A of the front part 2A and the lateral side 4C of the rear part 2C are joined to each other. As a result, a waist opening 5 is formed by the waist end 3A of the front surface 2A and the waist end 3C of the rear surface 2C. Further, leg openings 6 are formed on the left and right sides of the front part 2A, the intermediate part 2B, and the rear part 2C.
[0026]
An elastic member (elastic band) 7 is attached to the waist ends 3A and 3C in the lateral direction, and a waist gather is formed along the waist opening 5 by the elastic contraction force of the elastic member 7 as shown in FIG. Is done. An elastic member (elastic band) 8 is attached around the leg opening 6. As shown in FIG. 1, a leg gather (around the leg side) is formed around the leg opening 9 by the elastic contraction force of the elastic member 8. Cuff) is formed.
[0027]
In the sectional view of FIG. 2, the lower side in the figure is the outer surface side of the diaper 1, and the inner side is the inner surface side of the diaper 1. The laminated structure of the diaper has a waterproof sheet 12 (a liquid-impermeable sheet) formed of a breathable and moisture-permeable film inside an exterior sheet 11 formed of a nonwoven fabric which is a breathable and moisture-permeable material. Are stacked. Further, an absorbent layer 13 is superposed on the inner side of the waterproof sheet 12, and a liquid-permeable inner sheet 14 is superposed on the innermost side. A rectangular piece-shaped pattern sheet 15 is sandwiched between the exterior sheet 11 and the waterproof sheet 12.
[0028]
A hot-melt adhesive 16a is applied to the inner surface of the exterior sheet 11 in a random shape such as a wavy shape, and the exterior sheet 11 and the waterproof sheet 12 are adhered by the hot-melt adhesive 16a. The pattern sheet 15 is adhered and fixed to the exterior sheet 11 by the hot melt adhesive 16a.
[0029]
Hot melt adhesives 16b and 16c are also randomly applied to the inner surface of the waterproof sheet 12 and the inner surface of the absorbent layer 13, so that the waterproof sheet 12 and the absorbent layer 13 are bonded to each other, and the absorbent layer 13 and the inner sheet 14 are adhered.
[0030]
The outer sheet 11, the inner sheet 14, and the waterproof sheet 12 have the same hourglass shape when the diaper 1 is deployed. However, only the waterproof sheet 12 may have a shape smaller than the outer sheet 11 and the inner sheet 14. The absorbing layer 13 has an hourglass shape smaller than the outer sheet 11 and the inner sheet 14. The outer sheet 11 and the inner sheet 14 (and the waterproof sheet 12) are located at positions off the periphery of the absorbent layer 13, that is, the lateral side 4A of the front part 2A, the lateral side 4C of the rear part 2C, At the waist ends 3A and 3C and around the waist opening 5, they are bonded to each other by the hot melt type adhesives 16a and 16b.
[0031]
On the other hand, the pattern sheet 15 occupies a sufficiently smaller area than the exterior sheet 11, and a pattern 17 such as a figure of an animal face, a character or a plant, or a pattern 17 such as a symbol or a character is printed on the outer surface thereof. Have been. In the illustrated embodiment, a one-point pattern 17 is printed on one pattern sheet 15. Further, any combination of the figures, symbols, and characters may be printed as the pattern 17. Since the pattern sheet 15 is in the shape of a small square piece, the area of the margin around the pattern 17 is small. Therefore, the pattern sheet 15 can be manufactured at low cost. In addition, since the pattern sheet 15 is small and the size of the pattern 17 is also small, even if the pattern 17 is printed in multiple colors, a significant increase in cost can be suppressed.
[0032]
The pattern sheet 15 is a resin film such as polyethylene or polypropylene, a paper material, a laminate material of a paper material and a resin film, or the like, and is preferably a material capable of printing the pattern 17 vividly. However, in the case where the pattern sheet 15 is formed of a resin film, if a gas permeable and moisture permeable film is used, the gas permeability and the gas permeability of the portion where the pattern sheet 15 is attached will not be impaired. The pattern sheet 15 may be made of a non-woven fabric such as a point bond, a spun bond, and a spun lace. The pattern sheet 15 formed of this nonwoven fabric is breathable and permeable.
[0033]
The exterior sheet 11 is a nonwoven fabric and has a light transmittance that can be visually confirmed by seeing through the pattern 17, and is, for example, a point bond, an air through, a spun bond, a spun lace nonwoven fabric, or the like.
[0034]
The waterproof sheet 12 is a breathable and moisture-permeable resin film such as polyethylene or polypropylene. The absorbent layer 13 is formed of an absorbent material, for example, ground pulp or a mixture of ground pulp and a superabsorbent polymer, and the ground pulp or a mixture of ground pulp and the superabsorbent polymer is wrapped in an absorbent sheet such as a tissue. It is a thing.
[0035]
The inner sheet 14 is liquid-permeable and is formed of hydrophobic fibers, hydrophilic fibers, or the like that have been subjected to hydrophilic treatment, and is, for example, a point bond, an air through, a spun bond, a spun lace nonwoven fabric, or the like. Alternatively, the inner sheet 14 may be formed by laminating a cushion layer made of a bulky nonwoven fabric on the nonwoven fabric.
[0036]
The pattern sheet 15 is attached to the rear surface 2C of the diaper 1, or attached from the rear surface 2C to the intermediate portion 2B. In this case, when the disposable diaper 1 is viewed from the back (direction (i)) in the same three-dimensional state as worn on a human body as shown in FIG. The area occupied by the pattern sheet 15 is smaller than the entire visual area of the diaper when crushed into a flat state so that the rear surface portion 2C is in close contact and viewed from the back (the direction (i)). Preferably, the area occupied by the pattern sheet 15 with respect to the entire visual area is preferably 50% or less.
[0037]
Further, the pattern sheet 15 may be attached to the front surface 2A of the diaper 1, or may be attached from the front surface 2A to the intermediate portion 2B. In this case, when the diaper 1 is viewed from the front ((ii) direction) in the three-dimensional state of the diaper 1 or in a state where the diaper 1 is crushed, an area 15 occupied by the pattern sheet 15 with respect to the entire visual area of the diaper 1 Is sufficiently small, and the area ratio is preferably 50% or less.
[0038]
The pattern sheet 15 can be attached to both the front surface 2A and the rear surface 2C.
[0039]
The pattern sheet 15 can be attached to an arbitrary position, but is formed around the waist opening 5 by a waist gather formed by the elastic member 7 and around the leg opening 6 by the elastic member 8. It is preferable to attach it to an area that does not hang on both of the formed leg gathers. Further, even in the case where a gather continuous from the front portion 2A to the rear surface portion 2C and around the waist is formed, it is preferable that the pattern sheet 15 be attached to a position where the gather is not applied to the gather.
[0040]
When the pattern sheet 15 is attached to a position where the pattern sheet 15 does not catch on the gathers, the pattern sheet 15 can be kept relatively flat, and the pattern 17 can be prevented from being distorted.
[0041]
Further, it is preferable that the pattern sheet 15 be attached to a position avoiding a joint between the lateral side 4A of the front surface 2A and the lateral side 4C of the rear surface 2C. The joining of the side portion 4A and the side portion 4C is realized by thermal welding. However, if the pattern sheet 15 is present at this joining portion, the joining by the thermal welding will be hindered.
[0042]
Next, a method of manufacturing the disposable diaper 1 shown in FIGS. 1 and 2 will be described.
[0043]
After applying the hot-melt adhesive 16a to the non-woven fabric which will become the exterior sheet 11, as shown in FIG. 5, the pattern sheet 15 on which the pattern 17 is printed in advance is positioned so as to have a constant interval, and is positioned on the non-woven fabric. Install. The pattern sheet 15 is cut into a predetermined size from a belt-shaped sheet (tape sheet) 15A. At this time, the pattern sheets 15 are cut at regular intervals so that the patterns 17 appear uniformly on the individual pattern sheets 15 cut out, and are sequentially placed on the nonwoven fabric.
[0044]
A film serving as a waterproof sheet 12 is superimposed on the exterior sheet 11, sandwiched by a heating roller 20 and given heat, and individual pattern sheets are placed between the nonwoven fabric serving as the exterior sheet 11 and the film serving as a waterproof sheet. 15 are sandwiched and adhered.
[0045]
Next, a hot-melt adhesive 16b is applied to the upper surface of the film of the joined body of the nonwoven fabric forming the exterior sheet 11 and the film forming the waterproof sheet 12. Then, as shown in FIG. 6, an absorbent layer 13 is provided on the joined body so as to be spaced apart from each other and so as to be aligned with the pattern sheet 15. A hot melt type adhesive 16c is applied to the surface of the absorption layer 13.
[0046]
Then, a non-woven fabric serving as a top sheet 14 is overlaid on the absorbent layer 13, and these laminates are sandwiched between heating rollers, and the respective layers are adhered to each other. Thereafter, the leg opening is cut along the cutting line L1 and divided into individual stacked bodies, that is, a stacked body having the front surface portion 2A, the rear surface portion 2C, and the intermediate portion 2B along the cutting line L2. Further, the lateral side 4A of the front surface 2A and the lateral side 4C of the rear surface 2C are joined to form the pants type shown in FIG.
[0047]
In the above steps, the description of the steps of attaching the elastic members 7 and 8 is omitted.
[0048]
FIG. 3 and FIG. 4 are cross-sectional views showing another embodiment of the structure of the laminated body forming the disposable diaper 1.
[0049]
In FIG. 3, a nonwoven fabric 21, which is a hydrophobic sheet having air permeability and moisture permeability, is overlaid inside the exterior sheet 11, and the pattern sheet 15 is provided between the nonwoven fabric 21 and the exterior sheet 11. It is sandwiched and adhered. The nonwoven fabric 21 is, for example, a spunbonded nonwoven fabric formed of polypropylene fibers, or a sheet in which a spunbonded nonwoven fabric, a meltblown nonwoven fabric, and a spunbonded nonwoven fabric are stacked.
[0050]
In FIG. 4, a waterproof film is used as the exterior sheet 22. This waterproof film is a resin film such as polyethylene or polypropylene, and has air permeability and moisture permeability. The waterproof film is transparent or translucent and has a light transmittance enough to allow the pattern 17 of the pattern sheet 15 to be seen through.
[0051]
A hot-melt adhesive 16a is applied to the inner surface of the outer sheet 22 of the waterproof film, and the pattern sheet 15 is overlaid and adhered.
[0052]
Next, FIGS. 7A and 7B are rear views showing modified examples of the attachment position of the pattern sheet 15.
[0053]
In FIG. 7A, the pattern sheet 15 is mounted on the rear surface 2C of the disposable diaper 1 at a position where the pattern sheet 15 is offset to the right side and in a well-balanced position as a whole. In the example shown in FIG. 7B, two pattern sheets 15 on which different patterns are printed are divided into right and left portions and mounted at well-balanced positions on the rear surface 2C.
[0054]
As described above, in the present invention, the pattern 17 can be provided at an arbitrary position of the diaper 1 and in an arbitrary number, so that the degree of freedom in design can be increased.
[0055]
The pattern sheet 15 is not limited to a square or a rectangle, and may be a circle or an ellipse in addition to a polygon such as a triangle or a pentagon.
[0056]
In addition, the disposable diaper of the present invention is not limited to the pants type shown in FIG. 1 and may be an hourglass type so-called open type.
[0057]
【The invention's effect】
As described above, in the present invention, a pattern can be attached to an arbitrary position. Further, since a pattern sheet having a relatively small area is used, there is little waste of sheet material such as a resin film forming the pattern sheet. In addition, since the pattern is printed on the small-area pattern sheet, the cost of printing the pattern can be reduced. Further, since the printing cost can be reduced as compared with the case where a continuous pattern or a repeated pattern is printed on the entire exterior sheet as in the related art, the pattern can be printed in multiple colors.
[0058]
In addition, a one-point or several-point pattern can be positioned and attached to the diaper with high accuracy, and pattern displacement hardly occurs.
[0059]
Further, it is possible to easily cope with a change in the pattern to be applied to the diaper and a change in the position to which the pattern is applied.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a pants-type diaper manufactured by a manufacturing method of the present invention;
2 is a sectional view taken along line II-II of the pants-type diaper shown in FIG.
FIG. 3 is a cross-sectional view showing another embodiment of the laminated structure;
FIG. 4 is a cross-sectional view showing another embodiment of the laminated structure;
FIG. 5 is a perspective view showing a method for manufacturing a disposable diaper according to the present invention;
FIG. 6 is a perspective view showing a method for manufacturing a disposable diaper according to the present invention;
FIGS. 7A and 7B are rear views showing a modification of a position where a pattern is applied to a diaper;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Disposable diaper 2A Front part 2B Intermediate part 2C Rear part 3A Front waist part 3C Rear waist part 5 Waist opening 6 Leg opening 7,8 Elastic member 11 Exterior sheet 12 Waterproof sheet 13 Absorbent layer 14 Inner sheet 15 Pattern sheet 17 Pattern 16a, 16b, 16c hot melt adhesive

Claims (6)

It has an exterior sheet directed to the outside, a liquid-permeable inner sheet directed to the liquid receiving side, and an absorbing layer located between the exterior sheet and the inner sheet, and is applied to the abdomen of the wearer. In the manufacturing method of the disposable diaper in which the front part, the middle part applied to the crotch part, and the rear part applied to the back side are formed,
(A) attaching a pattern sheet having an area smaller than that of the exterior sheet and having a pattern on a surface thereof to a predetermined position on the inner surface of the exterior sheet that can be seen through, with the surface facing the exterior sheet; ,
(B) stacking a liquid-impermeable sheet or a hydrophobic sheet inside the exterior sheet, and sandwiching the pattern sheet between the exterior sheet and the liquid-impermeable sheet or the hydrophobic sheet;
(C) installing an absorbing layer and the inner sheet inside the outer sheet;
A method for producing a disposable diaper, comprising: The method for manufacturing a disposable diaper according to claim 1, wherein the pattern sheet is obtained by printing a pattern on a resin film. The method for producing a disposable diaper according to claim 1, wherein the pattern sheet is moisture-permeable. The disposable diaper according to any one of claims 1 to 3, wherein in the step (a), the pattern sheet is attached to the exterior sheet using an adhesive randomly applied to an inner surface of the exterior sheet. Manufacturing method. The method for producing a disposable diaper according to any one of claims 1 to 4, wherein the liquid impermeable sheet or the hydrophobic sheet is air-permeable and moisture-permeable. The method for producing a disposable diaper according to any one of claims 1 to 5 , wherein the exterior sheet is a nonwoven fabric.

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