JP5978654B2 - Disposable diaper and method for manufacturing disposable diaper - Google Patents

Description

  The present invention relates to a disposable diaper and a method for producing a disposable diaper. More specifically, the present invention provides a cushioning sheet by attaching a cushion-forming sheet intermittently joined along the extending direction of the elastic member to the waist elastic member disposed at the waist end of the disposable diaper. It is related with the disposable diaper which can form a high waist gather, and its manufacturing method.

Conventionally, for example, disposable diapers for infants and the elderly are known. There are various types of disposable diapers. For example, pants-type disposable diapers and tape-type disposable diapers are known (for example, Patent Document 1, Patent Document 2, and Patent Document 3).
A pants-type disposable diaper is a disposable diaper of a type in which both sides of a front body and a back body are joined in advance. As a pants-type disposable diaper, the outer body on which the absorbent main body is placed is integrated from the front body to the back body (Patent Document 1), or the exterior body is the front body and the back body. A cross-linked type (Patent Document 2) in which an absorbent main body is cross-linked between a front body exterior body and a back body exterior body is known.
A tape-type disposable diaper is a type of disposable diaper in which an adhesive tape is attached to both sides of the front body or the back body, and the front body and the back body are bonded using the adhesive tape when worn (Patent Document 3). ).

  In the disposable diaper of the type described above, a plurality of waist elastic members are generally fixed in an expanded state around the periphery of the waist opening in the front body and the back body. By fixing a plurality of stretchable members in an extended state along the front and back ends of the disposable diaper, wrinkles are generated in the vicinity of the waist opening when the waist stretchable members contract. . By this wrinkle, a waist gather is formed in the vicinity of the waist opening. This waist gather improves the adhesion between the wearer's skin and the disposable diaper. For this reason, by forming a waist gather, the fit feeling of a diaper improved and it was supposed that the fall of a diaper and the leakage of excrement could be prevented.

Here, the waist elastic member which forms a waist gather is fixed to sheets, such as a nonwoven fabric, by adhesion means, such as hot melt.
For example, hot melt can be applied to the sheet forming the waist opening, and the waist elastic member can be fixed thereto. However, when the hot melt is directly applied to the sheet, the range in which the hot melt is applied becomes wide, so that the sheet becomes hard and the texture of the nonwoven fabric is deteriorated.
On the other hand, in order to reduce the range in which the hot melt is applied, the hot melt can be directly applied to the waist stretchable member and fixed to the sheet forming the waist opening. However, in general, a hot melt suitable for fixing an elastic elastic body tends to use a hard material having poor deformability at room temperature. Therefore, the hardness of the hot melt entangled with the elastic elastic body through the sheet is low. It is easily transmitted to the wearer and the texture of the nonwoven fabric is likely to be damaged.

  Therefore, in order to prevent the texture of the nonwoven fabric from being damaged by the fixation of the waist elastic member, a technique for forming a so-called “flute structure” by arranging a cushion forming sheet around the periphery of the waist opening has been proposed. (Patent Document 4). In the technique disclosed in Patent Document 4, a cushion forming sheet is disposed at a waist end portion to which a waist elastic member is fixed, and the cushion forming sheet is intermittently fixed to a sheet constituting a waist gather. Thereby, when a waist elastic member contracts, it will be in the state where the cushion formation sheet floated in the point which is not being fixed. Thus, by forming a space between the cushion forming sheet and the sheet constituting the waist gather, the hardness of the sheet sandwiching the waist elastic member is not directly transmitted to the skin, and the nonwoven fabric material itself is soft. Now you can touch your skin.

JP 2009-254662 A JP 2010-233733 A Japanese Patent Laid-Open No. 2005-323585 JP 2011-254996 A

By the way, when forming a “flute structure” using a cushion-forming sheet as in the prior art, for example, after the cushion-forming sheet is intermittently joined to an outer sheet or an inner sheet that forms an outer body of a diaper. It is necessary to fold back so that the waist elastic member is sandwiched between these sheets.
FIG. 12 is a cross-sectional view showing a structure example of a conventional waist gather having a “flute structure”. 12A shows an example of a “flute structure” folded at a normal position, and FIG. 12B shows an example of a “flute structure” folded at an unfavorable position.
First, as shown in FIG. 12A, an outer sheet 11 ′ and an inner sheet 12 ′ forming an exterior body are provided in the vicinity of the waist opening. A plurality of tammy expansion / contraction members 15 'are sandwiched and fixed between the outer sheet 11' and the inner sheet 12 '. Further, the outer sheet 11 ′ is longer than the inner sheet 12 ′ and extends in the direction of the waist opening, and a plurality of waist elastic members 13 ′ are formed in the extended outer sheet 11 ′. It is fixed. Further, a cushion-forming sheet 20 ′ is attached to a portion of the outer sheet 11 ′ that extends longer and is located in the distal direction than the plurality of waist elastic members 13. At this time, the front end portion of the outer sheet 11 ′ and the cushion forming sheet 20 ′ are intermittently joined along the extending direction of the waist elastic member 13 ′ so that the joined portion and the non-joined portion are continuous. Then, at the position of the folding line F1 shown in FIG. 12 (a), that is, at the position of the boundary between the plurality of waist elastic members 13 ′ fixed to the outer sheet 11 ′ and the cushion forming sheet 20 ′, the cushion forming sheet 20 ′ is The attached outer sheet 11 ′ is folded back to the skin contact surface side. Thereafter, the cushion forming sheet 20 ′ is bonded to the inner sheet 12 ′. Thus, according to the conventional technique, the “flute structure” is formed in the vicinity of the waist opening by the cushion forming sheet 20 ′.

  However, when a diaper is produced at a high speed, when the cushion-forming sheet 20 ′ having a short length is joined to the outer sheet 11 ′ having a long length in the longitudinal direction of the diaper, the overlapping portion of both sheets travels the sheet. Since there is a tendency that an extension force is partially applied when sandwiched between rolls to be unneeded, unnecessary wrinkles are likely to occur in the overlapping portion of both sheets. As described above, when unnecessary wrinkles are mixed in the waist gather having the “flute structure”, there is a problem that a portion having a poor touch is formed.

  In addition, it is difficult to accurately control the outer sheet 11 ′ to which the cushion forming sheet 20 ′ is attached at the preferred position (fold line F1) shown in FIG. there were. For this reason, the outer sheet 11 ′ may be folded not at the normal position (fold line F1) shown in FIG. 12 (a) but at an unfavorable position (fold line F2) shown in FIG. 12 (b), for example. was there. That is, as shown in FIG. 12B, when an error occurs in the folding position of the outer sheet 11 ′, for example, the cushion is formed at the position (fold line F2) where the cushion forming sheet 20 ′ is joined to the outer sheet 11 ′. There is a possibility that the forming sheet 20 ′ and the outer sheet 11 ′ are folded back toward the skin contact surface side. In such a case, in the folding region T, a situation where the sheet overlaps four times including the outer sheet 11 ′ and the cushion forming sheet 20 ′ is caused. Thus, when the outer sheet 11 ′ is folded back at the unfavorable position (F2) shown in FIG. 12B, the outer sheet 11 ′ is at the normal position (F1) shown in FIG. As compared with the case where the sheet can be folded back, the number of sheet materials overlapping in the folding area T increases, and as a result, the touch in the folding area T deteriorates. Therefore, in forming a waist gather having a “flute structure”, it is not preferable to attach the cushion forming sheet 20 ′ to the outer sheet 11 ′ and to fold the outer sheet 11 ′.

  Further, when the “flute structure” is formed using the cushion forming sheet as in the prior art, for example, the waist elastic member 13 ′ and the tammy elastic member 15 ′ are fixed to the outer sheet 11 ′ and the inner sheet 12 ′. After that, it is necessary to perform a process of intermittently joining the cushion forming sheet 20 ′ to the outer sheet 11 ′. That is, it is necessary to accurately dispose the cushion forming sheet 20 ′ at a proper position on the outer sheet 11 ′ and to accurately provide intermittent bonding to these sheets. However, when producing a large amount of diapers in a short time, high-precision control is required to accurately control the arrangement of the cushion-forming sheet 20 ′ and its joining position. For this reason, in manufacturing a diaper having a “flute structure”, if an error occurs when the cushion-forming sheet 20 ′ is disposed on the outer sheet 11 ′ and intermittent joining of both sheets is given, the joining position of both sheets There is a possibility that a deviation will occur, and there is a risk that the shipment rate of non-defective products will be reduced.

  Therefore, at present, when a “flute structure” is formed using a cushion-forming sheet, for example, the folding position of the overlapping portion of the cushion-forming sheet and the outer sheet or the seat where the cushion-forming sheet is attached "Flute structure" that can be formed with a simpler structure and process to prevent the texture of the waist opening from being damaged or the cushion forming sheet from being displaced at the joining position due to the error of There is a need for disposable diapers having the following and methods for producing the same.

Accordingly, as a result of intensive studies on the means for solving the problems of the conventional invention, the inventor of the present invention has provided a cushion-forming sheet separate from the outer sheet and the inner sheet. By providing an elastic member bonding layer to be bonded to the member and a cushion forming layer located on the skin contact surface side of the elastic member bonding layer, and intermittently bonding these elastic member bonding layer and cushion forming layer, The present inventors have found that a disposable diaper having a “flute structure” that can be formed by a simpler structure and process, and a method for producing the disposable diaper can be provided. Then, the inventor has conceived that the problems of the prior art can be solved based on the above knowledge, and completed the present invention.
Specifically, the present invention has the following configuration.

The 1st side of the present invention is related with a disposable diaper.
The disposable diaper of the present invention includes a front body 1, a back body 2, and a crotch part 3 positioned between the front body 1 and the back body 2.
The disposable diaper includes an outer sheet 11, an inner sheet 12, one or a plurality of waist elastic members 13, and a cushion forming sheet 20.
The outer sheet 11 is a sheet member that is located on both or either of the front body 1 and the back body 2.
The inner sheet 12 is a sheet member that is bonded to the skin contact surface side of the outer sheet 11 at a position that does not reach the waist end 4 of either or both of the front body 1 and the back body 2.
The waist stretchable member 13 is one or a plurality of elastic stretchable members that are fixed in a stretched state along the width direction of the diaper at the position of the waist end 4 with respect to the skin contact surface side of the outer sheet 11. For this reason, at least a part of the waist elastic member 13 is fixed at a position where it does not overlap the inner sheet 12. However, a part of the waist elastic member 13 may be sandwiched and fixed between the outer sheet 11 and the inner sheet 12.
The cushion forming sheet 20 is a separate sheet member that is joined to the skin contact surface of the waist elastic member 13 and separate from the outer sheet 11 and the inner sheet 12.
Here, the cushion forming sheet 20 includes an elastic member bonding layer 21 bonded to the waist elastic member 13 and a cushion forming layer 22 positioned on the skin contact surface side of the elastic member bonding layer 21. The elastic member bonding layer 21 and the cushion forming layer 22 may be integrated or separate.
And the elastic member joining layer 21 and the cushion formation layer 22 are joined intermittently so that a joining part and a non-joining part may continue along the extension direction of the waist elastic member 13.

As described above, in the present invention, the cushion-forming sheet 20 is relatively short in the longitudinal direction of the diaper with respect to the outer sheet 11, and the elastic member joining layer 21 and the cushion are formed when forming the “flute structure”. Since the formation layer 22 only needs to be superposed, a disposable diaper having a “flute structure” can be produced by a simpler process than before. Therefore, production troubles can be reduced in the production of disposable diapers.
Further, the present invention applies intermittent joining to form a “flute structure” on the cushion forming sheet 20 alone, for example, as shown in FIG. The outer sheet 11 to which is attached is not folded back. For this reason, this invention can exclude the possibility that a sheet | seat member will overlap more than necessary in the waist opening part of a diaper. Therefore, according to this invention, in the waist edge part of a diaper, the situation which gives a wearer an unnecessary discomfort and reduces the texture of a nonwoven fabric sheet can be prevented.
Further, in the present invention, since the cushion forming sheet 20 alone is intermittently joined to form the “flute structure”, the cushioning sheet 20 and the elastic member joining layer 21 and the cushion are formed. After the layer 22 is joined intermittently, the disposable diaper can be manufactured by joining the cushion forming sheet 20 to the waist elastic member 13 fixed on the outer sheet 11. For this reason, since it is not necessary to intermittently join the cushion forming sheet 20 having a short length to the outer sheet 11 that is long in the longitudinal direction of the diaper as in the prior art, the “flute structure” can be realized with a simpler configuration. Can be formed.

  In the disposable diaper of the present invention, the cushion forming sheet 20 is preferably formed by a sheet member in which the elastic member joining layer 21 and the cushion forming layer 22 are integrated. That is, it is preferable that the cushion forming sheet 20 is folded toward the skin contact surface side to form the elastic member bonding layer 21 and the cushion forming layer 22.

  As in the above-described configuration, the cushion-forming sheet 20 is softened by folding the single cushion-forming sheet 20 to form the stretchable member bonding layer 21 and the cushion-forming layer 22. That is, the upper edge of the cushion forming sheet 20 basically corresponds to the edge of the waist opening of the diaper. For this reason, since the cross section of the sheet | seat which forms both layers 21 and 22 contacts the wearer's abdomen as the elastic member joining layer 21 and the cushion formation layer 22 are separate bodies, the touch will fall. In this respect, as in the above-described configuration, the cushion forming sheet 20 formed integrally is folded so as to be in contact with the wearer's abdomen. In general, since the folded portion of the seat has a better feel than the cross section of the seat, by folding the cushion-formed sheet 20 formed integrally as in the above configuration, unnecessary stimulation is given to the wearer. It can prevent giving.

In the disposable diaper of the present invention, the cushion-forming sheet 20 is joined to the skin contact surface of the waist elastic member 13 such that the folded portion 23 is positioned beyond the waist opening edge of the outer sheet 11. It is preferable.

  As described above, generally, the folded portion of the sheet has a better touch than the cross section of the sheet. However, in the present invention, the waist opening edge of the outer sheet 11 may be a cross section of the sheet. Then, like the said structure, by making the folding | returning part 23 of the cushion formation sheet 20 into the position which protruded from the waist opening edge of the outer sheet | seat 11, a wearer's abdominal part is the folding | returning part 23 of the cushion formation sheet 20. It is possible to prevent contact with the edge of the waist opening of the outer sheet 11, so that the feel of the end of the waist opening is improved.

The 2nd side surface of this invention is related with the manufacturing method of a disposable diaper.
In the manufacturing method of the present invention, a disposable diaper constituted by a front body 1, a back body 2, and a crotch 3 positioned between the front body 1 and the back body 2 is manufactured.
In the manufacturing method of this invention, the process of obtaining an exterior body, the process of obtaining a cushion formation sheet, and the process of joining an exterior body and a cushion formation sheet are performed. The process of joining the exterior body and the cushion forming sheet is performed after the process of obtaining the exterior body and the process of obtaining the cushion formation sheet, and the process of obtaining the exterior body and the process of obtaining the cushion formation sheet are either The configuration may be performed first.
First, the process of obtaining the exterior body
For the skin contact surface side of the outer sheet 11 located in both or either the front body 1 and the back body 2,
A step of joining the inner sheet 12 to a position that does not reach the waist end 4 of either or both of the front body 1 and the back body 2;
A step of fixing one or a plurality of waist elastic members 13 in a stretched state along the width direction of the diaper at the position at the waist end 4 is performed.
By these steps, in the step of obtaining the exterior body, the exterior body 10 including the outer sheet 11, the inner sheet 12, and the waist elastic member 13 is obtained.
On the other hand, the step of obtaining a cushion-forming sheet includes:
A step of intermittently bonding the cushion forming layer 22 to the skin contact surface side of the elastic member bonding layer 21 so that the bonded portion and the non-bonded portion are continuous is performed.
By this step, in the step of obtaining the cushion forming sheet, the cushion forming sheet 20 including the elastic member joining layer 21 and the cushion forming layer 22 is obtained. Subsequently, in the step of joining the exterior body and the cushion forming sheet,
The stretchable member bonding layer 21 of the cushion forming sheet 20 is placed on the waist in the exterior body 10 so that the continuous direction of the joint portion and the non-joint portion in the cushion formation sheet 20 matches the extension direction of the waist stretchable member 13 in the exterior body 10. The elastic member 13 is joined to the skin contact surface side.

In the present invention, the cushion forming sheet 20 is attached to the outer sheet 11 after intermittently joining the cushion forming sheet 20 alone to form the “flute structure” in the present invention. Thus, since the manufacturing method of the present invention does not fold the outer sheet 11 with the cushion forming sheet 20 attached to the outer sheet 11 as in the prior art, the waist opening of the diaper is more than necessary. It is possible to eliminate the possibility that the sheet member is superposed on the sheet.
In the present invention, the cushion forming sheet 20 can be attached to the outer sheet 11 after intermittently joining the cushion forming sheet 20 alone to form the “flute structure”. That is, the manufacturing method of the present invention attaches the cushion forming sheet 20 to the outer sheet 11 and intermittently joins both the sheets 11 and 20 to form a “flute structure” as in the prior art. It is not a thing. Therefore, according to the manufacturing method of the present invention, when performing intermittent joining to the cushion forming sheet 20, control with such high accuracy is not required, and thus a disposable diaper having a “flute structure” is manufactured in a simpler process. become able to.

Further, in a general diaper processing machine, when the cushion forming sheet 20 of the outer sheet 11 is joined, a continuum (original cushion) of the cushion forming sheet 20 is provided at both ends in the width direction of the continuum of the outer sheet 11 (original outer sheet). Forming sheet). At this time, generally, in order to join both end portions of the original outer sheet, embossing rolls engraved with a joining pattern are used at two locations on the surface of one shaft. Then, when the wide outer outer sheet is slightly meandered, one of the laminated parts with the original cushion forming sheet located at both ends thereof is wide and the other is narrow, and the joining position is also simultaneously on both sides of the original outer sheet. There was a risk of errors.
In this regard, in the present invention, when forming the joint portion on the original cushion forming sheet, the elastic member joining layer 21 and the cushion forming layer 22 that are relatively narrower than the original outer sheet may be joined. It is also possible to easily arrange the rolls separately on the rear body side and the front body side. In other words, in the conventional technology, the overlapping portion of the original outer sheet and the original cushion forming sheet tends to be pulled more strongly than the other positions, so if the total width of both sheets is wide, the force that pulls the sheet in the flow direction Unevenness was easy and wrinkles were easy to enter. In this regard, according to the present invention, as described above, the embossing roll can be made into a separate unit having separate rolls on the back body side and the front body side, and the width at the time of joining can be narrowed. Therefore, wrinkles can be made difficult to enter.

Further, in the conventional manufacturing method, after the cushion forming sheet 20 is joined to the outer sheet 11, the tammy stretchable material 15 is disposed, and is sandwiched between the outer sheet 11 and the inner sheet 12, and then the absorbent main body is placed on the inner sheet. The outer sheet 11 is folded immediately after being laminated and the waist stretchable material 13 is disposed, and is sandwiched and fixed between the stretchable member bonding layer 21 and the outer sheet 11 located in the folded portion. As described above, in the conventional manufacturing method, since there are many processing steps after the cushion forming layer is formed, floating portions other than the joint portion of the cushion forming layer are wrinkled, or shear force is applied to the joint portion. May take damage. Thereby, the touch after flute formation will worsen as a result.
In this regard, according to the manufacturing method of the present invention, the stretchable member bonding layer 21 and the cushion forming layer 22 are formed on the cushion forming sheet 20, the layers 21 and 22 are bonded intermittently, and the layers are bonded intermittently. By simply attaching the cushion forming sheet 20 to the outer sheet 11, a waist gather having a “flute structure” can be formed. Thus, in the manufacturing method of this invention, since the process after the cushion formation sheet 20 and the expansion-contraction member joining layer 21 were joined decreases, and a manufacturing process is simplified, an unnecessary wrinkle arises in a waist gather. In addition, it is possible to avoid a situation where the joint is damaged.

In the production method of the present invention, the step of obtaining a cushion-forming sheet includes:
After folding the cushion forming sheet 20 to the skin contact surface side and forming the elastic member bonding layer 21 and the cushion forming layer 22,
It is preferable that the elastic member bonding layer 21 and the cushion forming layer 22 are intermittently bonded so that the bonded portion and the non-bonded portion are continuous.
Moreover, the cushion forming sheet 20 can also be obtained by laminating both sheets using the elastic member joining layer 21 and the cushion forming layer 22 as separate sheets and then joining them intermittently.

  As in the above process, the cushion-forming sheet 20 is folded back to form the elastic member joining layer 21 and the cushion-forming layer 22, and then the layers 21 and 22 are joined intermittently, so that the portion corresponding to the abdomen of the folded-back portion is As it is looped, the diaper feels good. Moreover, the shape retention of the “flute structure” is improved by joining both sheets. Moreover, when the elastic member joining layer 21 and the cushion forming layer 22 are formed as separate sheets, the step of folding the sheet can be omitted, so that productivity is good.

  In the present invention, since the cushion forming sheet 20 can be intermittently joined to form a “flute structure”, for example, as shown in FIG. The attached outer sheet 11 is not folded back, and unnecessary wrinkles can be prevented from entering the cushion forming portion. Moreover, the possibility that the sheet member overlaps more than necessary at the waist opening of the diaper can be eliminated. Therefore, according to the present invention, it is possible to prevent a situation in which an uncomfortable feeling is given to the wearer and the texture of the nonwoven fabric sheet is lowered.

  Further, according to the present invention, since the cushion forming sheet 20 itself can be intermittently joined to form the “flute structure”, the elastic member joining layer 21 and the cushion forming layer 22 of the cushion forming sheet 20 are provided. After intermittently joining the disposable diapers, the cushion-forming sheet 20 can be joined to the waist elastic member 13 fixed on the outer sheet 11. For this reason, the present invention eliminates the need to fold the outer sheet, for example, by intermittently joining the cushion forming sheet 20 to the outer sheet 11 and disposing the expansion / contraction member at the planned folding portion of the outer sheet, as in the prior art. For this reason, according to the present invention, the step of forming the stretchable member joining layer 21 and the cushion forming layer 22 from the cushion forming sheet 20 (joining step), and the waist stretchable member 13 on the outer sheet 11 are placed on the stretchable member joined. The process of laminating the layers 21 can be made separate, and troubles during production can be greatly reduced.

FIG. 1 is an external perspective view showing an example of the disposable diaper of the present invention. FIG. 2 is a development view showing an example of the disposable diaper of the present invention. FIG. 3 is a cross-sectional view showing a cross-sectional shape taken along line YY shown in FIG. FIG. 4 is an enlarged cross-sectional view showing the cross-sectional view of FIG. 3 on the front body side, and shows a first embodiment of the disposable diaper of the present invention. FIG. 5 is a conceptual diagram for explaining the flute structure. FIG. 6 is an explanatory diagram illustrating an example of a process of forming a waist gather having a flute structure. FIG. 7: is an expanded sectional view which shows 2nd Embodiment of the disposable diaper of this invention. FIG. 8: is an expanded sectional view which shows 3rd Embodiment of the disposable diaper of this invention. FIG. 9 is a conceptual diagram showing a first embodiment of a method for manufacturing a disposable diaper according to the present invention. FIG. 10 is a perspective view conceptually extracted and shown in the first embodiment of the disposable diaper by processing the original cushion forming sheet and overlaying it on the original waist elastic member. FIG. 11: is the perspective view which extracted conceptually and showed the process of processing an original cushion formation sheet and superposing | stacking on an original waist elastic member in 2nd Embodiment of a disposable diaper. FIG. 12 is a cross-sectional view showing a structure example of a waist gather having a conventional flute structure. FIG. 12A shows an example of a flute structure folded at a normal position, and FIG. 12B shows an example of a flute structure folded at an unfavorable position.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below, and includes those appropriately modified by those skilled in the art from the following embodiments.

(1. Overall configuration of disposable diapers)
The present invention relates to a disposable diaper having a waist gather formed at a waist end. The present invention is widely applicable to, for example, known pants-type disposable diapers and tape-type disposable diapers. A pants-type disposable diaper is a disposable diaper of a type in which both sides of a front body and a back body are joined in advance. As the pants-type disposable diaper, the outer body on which the absorbent main body is placed may be an integrated body that is hung from the front body to the back body, and the exterior body is the front body and the back body. And a crosslinked type in which the absorbent main body is crosslinked between the front body exterior body and the back body exterior body. The tape-type disposable diaper is a type of disposable diaper in which an adhesive tape is attached to both sides of the front body or the back body, and the front body and the back body are bonded using the adhesive tape when worn.
In the following, among these various types of disposable diapers, the contents of the present invention will be specifically described by taking as an example an integrated pants-type disposable diaper in which the exterior body is integrated from the front body to the back body. Explained.

  FIG. 1 is a perspective view showing an example of a state in which the disposable diaper 100 is viewed from the front body 1 side. FIG. 2 is a development view showing an example of a disposable diaper, and shows a state in which the disposable diaper is viewed from the skin contact surface side. As shown in the developed view of FIG. 2, when the disposable diaper 100 is worn, the disposable diaper 100 is applied to the front body 1 that contacts the wearer's abdomen, the back body 2 that contacts the back of the wearer, and the inseam of the wearer. The crotch part 3 is separated. In the disposable diaper 100, the direction connecting the front body 1 and the back body 2 is the “longitudinal direction”, and the direction orthogonal to the longitudinal direction is the “width direction”.

  As shown in FIG. 1 and FIG. 2, the disposable diaper 100 is fixed to the outer body 10 formed from the front body 1 to the rear body 2 and to the skin contact surface side of the outer body 10 around the crotch 3. The absorbent main body 30 is provided. As shown in the development view of FIG. 2, the exterior body 10 has a shape in which a portion of the crotch part 3 where the legs of the wearer are located is cut out during wearing. Moreover, the absorptive main body 30 is formed in the substantially rectangular shape extended from the front body 1 side to the back body 2 side centering on the crotch 3. The absorptive main body 30 is comprised by various absorptive members for absorbing and holding excrement, such as a wearer's urine.

  2 is assembled to the state shown in FIG. 1 by joining the widthwise ends of the front body 1 and the back body 2 in the exterior body 10 from the deployed state shown in FIG. As shown in FIG. 1, in the pants-type disposable diaper 100, the waist opening 5 is formed by the edge of the front body 1 and the edge of the back body 2 in the longitudinal direction of the diaper. Moreover, the both ends of the front body 1 and the back body 2 are joined, and the leg periphery opening part 6 located around a wearer's leg part at the time of mounting | wearing is formed. For this reason, the wearer can put on the pants-type disposable diaper 100 by putting both legs from the waist opening 5 and taking out each leg from the opening 6 around the legs.

(2. Components of disposable diapers)
Next, each part structure of the disposable diaper 100 is demonstrated.
FIG. 3 is a cross-sectional view showing an example of a state in which the disposable diaper 100 is cut in the longitudinal direction along the line YY shown in the development view of FIG. 2. In FIG. 3, the vertical direction is the longitudinal direction of the disposable diaper. In FIG. 3, the right side is the skin contact surface side, and the left side is the non-contact surface side. Moreover, FIG. 4 is the expanded sectional view which expanded the front body of the disposable diaper among sectional drawings of FIG. Normally, various sheet members constituting a disposable diaper are extremely thin, but in the cross-sectional views of FIGS. 3 and 4, various sheet members are drawn with a conceptual thickness.

(2-1. Exterior body)
The exterior body 10 of the disposable diaper 100 is a member for holding the absorbent main body 30 in a state applied to the wearer's body. As shown in FIGS. 2 and 3, the exterior body 10 basically includes an outer sheet 11, an inner sheet 12, a plurality of waist elastic members 13, a plurality of tammy elastic members 15, and a plurality of leg elastic members. The member 17 and the cushion forming sheet 20 are provided.

  In the outer sheet 11, a plurality of waist elastic members 13 are fixed in an extended state along the width direction of the diaper at the waist end portions 4 in the vicinity of both end edges forming the waist opening 5. The cushion forming sheet 20 is joined to the outer sheet 11 so as to be superimposed on the skin contact surface side of the plurality of waist elastic members 13 at the position where the plurality of waist elastic members 13 are disposed. For this reason, the plurality of waist elastic members 13 are sandwiched and fixed between the outer sheet 11 and the cushion forming sheet 20. And the waist gathers 14 are formed in the waist end part 4 near a waist opening part by shrink | contracting in the state in which the some waist elastic member 13 was fixed between the outer sheet | seat 11 and the cushion formation sheet 20. FIG.

  In addition, an inner sheet 12 having a length that does not reach the waist end 4 in the vicinity of both end edges forming the waist opening 5 is bonded to the skin contact surface side of the outer sheet 11. Between the outer sheet 11 and the inner sheet 12, a plurality of tammy expansion / contraction members 15 are fixed in an extended state at a position closer to the crotch part 3 of the diaper than the plurality of waist expansion / contraction members 13. The plurality of tammy expansion / contraction members 15 are fixed in an extended state along the width direction of the diaper. When the plurality of tammy expansion / contraction members 15 contract, a tammyaza 16 is provided around the abdomen of the front body 1 and the back body 2. It is formed.

  Moreover, between the outer sheet | seat 11 and the inner sheet | seat 12, the some leg expansion-contraction member 17 is being fixed in the expansion | extension state along the hollowed part in which a wearer's both leg part is located at the time of mounting | wearing. When the leg elastic member 17 contracts, a leg gather 18 is formed at a position around both legs of the wearer at the time of wearing.

(2-1-1. Configuration of West Gather: First Embodiment)
The waist gathers 14 are gathers formed on the waist end 4 near the waist opening 5 of the disposable diaper by the contraction action of the plurality of waist elastic members 13. In the present embodiment, the waist gathers 14 are formed on each of the front body 1 side and the back body 2 side. However, the waist gathers 14 should just be formed in any one of the front body 1 side and the back body 2 side at least.

  As shown in FIG. 3 and FIG. 4, in the present embodiment, the exterior body 10 includes an outer sheet 11 in the outermost layer on the skin non-contact surface side. As the material constituting the outer sheet 11, a woven fabric or a non-woven fabric can be used, and it is particularly preferable to use a non-woven fabric or a wet non-woven fabric made of a thermoplastic resin such as polyethylene, polypropylene, or polyester. In the present specification, “outer sheet” means a sheet material to which the waist elastic member 13 is fixed. For this reason, the outer sheet | seat 11 is not necessarily restricted to what is located in the outermost layer of a disposable diaper. For example, another sheet material may be bonded to the outer sheet 11 so as to cover the skin non-contact surface side of the outer sheet 11.

  An inner sheet 12 is disposed on the skin contact surface side of the outer sheet 11. The inner sheet 12 sandwiches the plurality of tammy elastic members 15 and the plurality of leg elastic members 17 between the outer sheet 11. The inner sheet 12 is bonded to the outer sheet 11 with a length that does not reach the position of the waist end 4 in the vicinity of both end edges that form the waist opening 5. For this reason, not all of the plurality of waist elastic members 13 are sandwiched between the outer sheet 11. However, some of the waist elastic members 13 may be located between the outer sheet 11 and the inner sheet 12. As with the outer sheet 11, for example, the inner sheet 12 is preferably made of a nonwoven fabric made of a thermoplastic resin such as polyethylene, polypropylene, or polyester.

  As shown in FIG. 3 and FIG. 4, a plurality of waist stretchable members 13 are arranged in the stretched state along the width direction of the diaper at the waist ends 4 of the front body 1 and the back body 2 of the outer sheet 11. ing. That is, the plurality of waist elastic members 13 are joined to a portion (waist end portion 4) in which the outer sheet 11 extends in the direction of the waist opening 5 rather than the inner sheet 12. However, some of the plurality of waist elastic members 13 may be sandwiched between the outer sheet 11 and the inner sheet 12. The number of waist elastic members 13 should just be at least one, for example, it is good also as being 2-15, 4-12, or 6-9. As shown in FIGS. 3 and 4, the waist elastic members 13 are arranged at predetermined intervals in the longitudinal direction of the disposable diaper. The plurality of waist elastic members 13 are preferably juxtaposed substantially in parallel as shown in the development view of FIG. As shown in FIG. 2, the plurality of waist stretchable members 13 are preferably arranged so as to extend in substantially the entire width direction of the front body exterior body 1a and the back body exterior body 2a in the extended state. The plurality of waist elastic members 13 may be arranged in an expanded state in an area of about 80% to 99% or 85% to 95 with respect to the length in the width direction of the front body 1 and the back body 2. preferable.

  The plurality of waist elastic members 13 are fixed to the outer sheet 11. The plurality of waist elastic members 13 are fixed to the outer sheet 11 in a stretched state that allows a sufficient elastic force to be applied without applying an excessive tightening force to the wearer. The stretch rate when the plurality of waist elastic members 13 are fixed is, for example, preferably 200 to 400%, and particularly preferably 250 to 350%. The “stretch ratio” indicates a percentage of the length of the stretchable member in the stretched state with respect to the length (original size) of the stretchable member in the non-stretched state. Moreover, as a method of fixing the plurality of waist elastic members 13 to the sheet material, a known method can be appropriately employed. The plurality of waist elastic members 13 are, for example. An adhesive having high fluidity such as a hot-melt adhesive may be applied or sprayed, or may be fixed by heat or ultrasonic welding such as an adhesive heat seal.

  And as FIG. 4 shows, the cushion formation sheet 20 is joined to the skin contact surface side of the some waist elastic member 13. As shown in FIG. The cushion forming sheet 20 is a sheet member that is disposed for the purpose of enhancing the cushioning properties and flexibility of the waist gathers 14 and is formed by a separate sheet member from the outer sheet 11 and the inner sheet 12. The cushion forming sheet 20 is preferably formed of, for example, a nonwoven fabric. The nonwoven fabric of the cushion forming sheet 20 may be a hydrophilic nonwoven fabric or a water-repellent nonwoven fabric.

  As shown in FIG. 4, the cushion forming sheet 20 is folded toward the skin contact surface side, and a folded portion 23 is formed at the folded position. At this time, the folded portion 23 of the cushion forming sheet 20 is preferably formed at a position protruding from the edge of the outer sheet 11 forming the waist opening 5. For example, the length of the folded portion 23 of the cushion forming sheet 20 protruding is preferably 0.5 mm to 5 mm, 1 mm to 4 mm, or 1.5 mm to 3 mm. By making the folding | returning part 23 of the cushion formation sheet 20 into the position which protruded from the waist opening edge of the outer sheet | seat 11, it can prevent that the cross section of the outer sheet | seat 11 touches a wearer's abdomen directly.

  Further, when the cushion forming sheet 20 is folded at the folded portion 23, the elastic member bonding layer 21 positioned on the skin non-contact surface side and the skin contacting surface side are positioned with the folded portion 23 serving as a boundary line. A cushion forming layer 22 is formed.

  The elastic member bonding layer 21 is bonded to the skin contact surface side of the outer sheet 11 and the skin contact surface side of the plurality of waist elastic members 13 fixed to the outer sheet 11. For this reason, the elastic member joining layer 21 sandwiches and fixes the plurality of waist elastic members 13 between the outer sheet 11. That is, the elastic member bonding layer 21 is bonded to the outer sheet 11 in the region between the plurality of waist elastic members 13 while being bonded to the plurality of waist elastic members 13. As shown in FIG. 4, the elastic member bonding layer 21 preferably extends from the bonding position with the waist elastic member 13 in the direction of the crotch part 3 of the diaper (downward in FIG. 4). In this case, the part of the elastic member joining layer 21 extending in the direction of the crotch part 3 is joined so as to cover both ends in the longitudinal direction of the absorbent main body 30 (particularly the top sheet 32) from the skin contact surface side. It is preferable. Further, as shown in FIG. 4, the portion of the elastic member bonding layer 21 extending in the direction of the crotch 3 may be partially bonded to the skin contact surface side of the inner sheet 12. . As described above, by joining the elastic member joining layer 21 of the cushion-forming sheet 20 to the skin contact surface side of the absorbent main body 30, the absorbent main body 30 is displaced or peeled off at both end portions in the longitudinal direction. Can be prevented.

  On the other hand, the cushion forming layer 22 is located on the skin contact surface side of the elastic member bonding layer 21. In the present embodiment, the elastic member bonding layer 21 is formed so that the length in the diaper longitudinal direction is shorter than the elastic member bonding layer 21. At this time, the overlapping portion of the elastic member joining layer 21 and the cushion forming layer 22 has a length that can cover at least a part or all of the plurality of waist elastic members 13. For example, in the example shown in FIG. 4, the overlapping portion of the elastic member joining layer 21 and the cushion forming layer 22 is formed with a length that can cover all of the plurality of waist elastic members 13 disposed on the waist end portion 4. Has been. In particular, the length of the overlapping portion of the bonding member bonding layer 21 and the cushion forming layer 22 is preferably longer than the waist end portion 4 of the outer sheet 11. In the present embodiment, the cushion forming layer 22 is formed integrally with the elastic member bonding layer 21, but the elastic member bonding layer 21 is formed of a separate sheet member from the cushion forming layer 22. It may be.

  In this way, in the waist gather 14, as shown in FIG. 4, the outer sheet 11, the waist elastic member 13, the elastic member bonding layer 21, and the cushion forming layer are sequentially arranged from the member located on the skin non-contact surface side. 22 is located. For this reason, the number of sheet members laminated to constitute the waist gathers 14 is three.

  Then, the stretchable member joining layer 21 and the cushion forming layer 22 of the cushion forming sheet 20 are joined intermittently along the extending direction of the waist stretchable member 13 so that joined portions and non-joined portions are alternately continued. As a result, a “flute structure” is formed in the waist gathers 14.

(2-1-2. Flute structure)
"Flute structure" means that when the elastic elastic member contracts by intermittently bonding the two layers of sheets bonded to the elastic elastic member in the stretched state along the extending direction of the elastic elastic member. This means a structure in which a space is generated between the two layers of sheets. FIG. 5 is a schematic diagram in which a part of the seat members constituting the waist gathers 14 is extracted and drawn in order to explain the “flute structure” formed by the cushion forming sheet 20 of the present invention. In FIG. 5, the upper side in the figure is the skin contact surface side, and the lower side in the figure is the skin non-contact surface side.

  FIG. 5A shows an example in which the waist elastic member 13 is in an extended state, and the elastic member joining layer 21 and the cushion forming layer 22 of the outer sheet 11 and the cushion forming sheet 20 are stretched. As shown in FIG. 5A, the cushion forming sheet 20 is folded back at the folded portion 23 corresponding to the waist opening edge to form the elastic member joining layer 21 and the cushion forming layer 22. As shown in FIG. 5A, the elastic member joining layer 21 and the cushion forming layer 22 are intermittently joined along the longitudinal direction of the waist elastic member 13. That is, between the stretchable member joining layer 21 and the cushion forming layer 22, joined portions 24 and non-joined portions 25 are alternately and continuously formed along the extending direction (diaper width direction) of the waist stretchable member 13. Yes. For example, the interval between the joint portions 24 in the extending direction of the waist elastic member 13 is preferably, for example, 2 to 50 mm, and particularly preferably 5 to 10 mm.

  Further, as shown in FIG. 5A, a plurality of each joint portion 24 may be formed in a dot shape. The joint portions 24 formed in a dot shape are formed in a row along a direction (longitudinal direction of the diaper) orthogonal to the extending direction of the waist elastic member 13, and each joint portion 24 is in the longitudinal direction of the diaper. Are arranged at predetermined intervals. For example, it is preferable that the space | interval of each junction part 24 in the longitudinal direction of a diaper shall be 0.5-5 mm, for example, and it is especially preferable that it is 1-3 mm. Moreover, it is preferable that each joining part 24 is provided in the cushion formation layer 22 from the one end to the other end in the longitudinal direction of a diaper. Thus, it is preferable that the elastic member joining layer 21 and the cushion forming layer 22 are joined together by the joining portion 24 while maintaining intermittency in the width direction of the diaper.

  5B, the waist elastic member 13 contracts from the state shown in FIG. 5A, and the elastic member joining layer 21 and the cushion forming layer 22 of the outer sheet 11 and the cushion forming sheet 20 are bent. An example of the state is shown. As shown in FIG. 5B, when the waist elastic member 13 contracts, the outer sheet 11, the elastic member bonding layer 21, and the cushion forming layer 22 are bent. Since the elastic member bonding layer 21 and the cushion forming layer 22 are intermittently bonded at the bonding portion 24, when the waist elastic member 13 contracts, the elastic member bonding layer 21 and the cushion forming layer 22 are not joined to the non-bonding portion 25. A space S is formed. Thus, the space S formed between the elastic member joining layer 21 and the cushion forming layer 22 functions as a cushion and makes the feel of the waist gather 14 flexible. In particular, the formation of the space S makes it difficult for the hardness of the bonding agent applied to the waist elastic member 13 and the hardness of the waist elastic member 13 itself to be directly transmitted to the wearer's skin. , Irritation to the wearer's skin is reduced. Therefore, the wearing feeling of a disposable diaper can be made favorable.

(2-1-3. Formation process of waist gathers)
Next, an example of a process of forming a waist gather having a “flute structure” will be described with reference to FIG.
As shown in FIG. 6A, a sheet laminate in which a plurality of tammy elastic members 15 are sandwiched and fixed between the outer sheet 11 and the inner sheet 12 is obtained. At this time, both ends in the longitudinal direction of the outer sheet 11 are extended beyond both ends in the longitudinal direction of the inner sheet 12. The extended portion of the outer sheet 11 becomes the waist end 4. And the absorptive main body 30 is attached to the skin contact surface side of the inner sheet 12 as shown in FIG. As will be described later, the absorbent main body 30 basically has a configuration in which an absorber is interposed between the top sheet and the back sheet.

  Thereafter, as shown in FIG. 6B, the plurality of waist elastic members 13 are fixed to the skin contact surface side of the outer sheet 11 at the waist end 4. At this time, the waist elastic member 13 is fixed to the outer sheet 11 in a state of extending along the width direction of the diaper. For example, a hot melt adhesive can be used to fix the waist elastic member 13.

  On the other hand, as shown in FIG. 6C, a cushion forming sheet 20 is prepared as a separate sheet member from the outer sheet 11 and the inner sheet 12. Then, the cushion forming sheet 20 is folded back toward the skin contact surface side at the position of the fold line F. Then, as shown in FIG. 6D, the cushion forming sheet 20 is formed with the stretchable member bonding layer 21 and the cushion forming layer 22 located on the skin non-contact surface side with the folded-back portion 23 as a boundary. . At this time, it is preferable that the joining member joining layer 21 extends longer toward the crotch part 3 than the cushion forming layer 22. Moreover, it is preferable that the cushion forming sheet 20 is folded back so that the overlapping portion of the bonding member bonding layer 21 and the cushion forming layer 22 is longer than the waist end 4 of the outer sheet 11. And before joining the cushion forming sheet 20 to the waist elastic member 13, the elastic member joining layer 21 and the cushion forming layer 22 of the cushion forming sheet 20 are joined to the joining portion along the extending direction of the waist elastic member 13. It joins intermittently so that a non-joining part may continue.

  Thereafter, as shown in FIG. 6 (e), the formed cushion forming sheet 20 in which the bonding member bonding layer 21 and the cushion forming layer 22 are intermittently bonded is centered on the waist end 4 of the outer sheet 11. These are joined to the contact surface side of the plurality of waist elastic members 13. At the same time, it is preferable that the joining member joining layer extends at a portion longer than the cushion forming layer and covers and fixes the lengthwise end of the absorbent main body. By doing so, it is possible to prevent troubles that the superabsorbent polymer spills out from the end of the absorbent main body or the urine oozes out. As a bonding agent for bonding the cushion forming sheet 20, a hot melt adhesive can be used. As the hot melt adhesive, a hot melt adhesive having fluidity such as rubber, polyolefin, and vinyl acetate is appropriately used. You can choose. At this time, it is preferable to join the cushion forming sheet 20 so that the folded portion 23 of the cushion forming sheet 20 protrudes toward the waist opening 5 from the upper end edge of the outer sheet 11. Thus, the folding | returning part 23 of the cushion formation sheet 20 is located in the position protruded to the waist opening part 5 side, Therefore The folding | returning part 23 of the cushion formation sheet 20 is rather than the waist opening edge of the outer sheet | seat 11. Protruding. As a result, the wearer's abdomen preferentially contacts the folded portion 23 of the cushion forming sheet 20 and does not contact the cross section of the waist opening edge of the outer sheet 11, so that the touch at the waist opening end is not touched. Become good.

  When the cushion forming sheet 20 is joined, a waist gather having a “flute structure” is formed as shown in FIG. As shown in FIG. 6 (f), the cushion-forming sheet 20 is such that the stretchable member bonding layer 21 extending in the direction of the crotch 3 has both end portions in the longitudinal direction of the absorbent main body 30 from the skin contact surface side. It is preferable that they are joined so as to cover them.

  Thus, in the example shown in FIG. 6, the cushion forming sheet 20 is subjected to intermittent joining for forming a “flute structure” on the cushion forming sheet 20 alone, and then the cushion forming sheet 20 is attached to the waist elastic member. 13 can be fixed. That is, the step of folding the cushion forming sheet 20 and the step of intermittently joining the folded cushion forming sheet 20 can be performed only on the cushion forming sheet 20. For example, when the cushion forming sheet 20 is fixed to the waist elastic member 13 and then the cushion forming sheet 20 is folded or intermittently joined, unnecessary wrinkles are formed at the folding position or joining position of the cushion forming sheet 20. Although it is likely to occur, in the example shown in FIG. 6, since these steps are performed on the cushion forming sheet 20 alone, a waist gather having a “flute structure” can be formed by a simpler process, A situation where unnecessary wrinkles occur in the waist gather can be prevented.

Further, in the example shown in FIG. 6, the stretchable member bonding layer 21 and the cushion forming layer 22 are formed on the cushion forming sheet 20, the layers 21 and 22 are intermittently bonded, and the cushion is bonded intermittently. By simply attaching the forming sheet 20 to the outer sheet 11, a waist gather having a “flute structure” can be formed. Thus, since the process after the cushion forming sheet 20 and the elastic member bonding layer 21 are bonded is reduced and the process is simplified, unnecessary wrinkles are generated in the waist gathers and the bonded part is damaged. The situation can be avoided.
Further, in the example shown in FIG. 6, the cushion forming layer 22 is shorter than the stretchable member bonding layer 21, so that the edge of the cushion forming sheet 20 forms a flute-like opening. Therefore, it can be expected that ventilation will be improved by increasing the number of paths for exhausting the air in the diaper.

(2-1-4. Configuration of West Gather: Second Embodiment)
FIG. 7 shows a disposable diaper according to the second embodiment. FIG. 7 is an enlarged cross-sectional view showing an enlarged cross-sectional shape of the front body 1 side of the disposable diaper, as in FIG. 4.
In the second embodiment shown in FIG. 7, the cushion forming layer 22 of the cushion forming sheet 20 extends longer than the elastic member bonding layer 21 in the direction in which the crotch part 3 of the diaper is present (downward in the drawing). Is formed. In other words, the elastic member bonding layer 21 is formed to have the same length as the waist end portion 4 on which the plurality of elastic elastic members 13 are disposed, while the cushion forming layer 22 is formed from the elastic member bonding layer 21. Also, the crotch part 3 of the diaper extends in the direction in which it exists. Thus, the cushion forming sheet 20 may be formed by forming the cushion forming layer 22 longer than the elastic member bonding layer 21. In addition, as shown in FIG. 7, when the cushion forming layer 22 is elongated, the portion of the cushion forming layer 22 extending in the direction of the crotch 3 is the length of the absorbent main body 30 (particularly the top sheet 32). It is preferable that both ends in the direction are joined so as to cover the skin contact surface side.

  As shown in FIG. 7, by extending the cushion forming layer 22 of the cushion forming sheet 20 longer than the elastic member bonding layer 21, the bonding state of the elastic member bonding layer 21 and the cushion forming layer 22 is increased. Dissociation can be prevented. That is, in the second embodiment, the cushion forming layer 22 can completely cover the elastic member bonding layer 21 from the skin contact surface side. It does not contact the elastic member bonding layer 21. For this reason, even when a wearer's skin is rubbed against the cushion formation sheet 20, the situation where the junction part between the elastic member joining layer 21 and the cushion forming layer 22 peels can be avoided.

(2-1-5. Configuration of West Gather: Third Embodiment)
FIG. 8 shows a disposable diaper according to the third embodiment. FIG. 8 is an enlarged cross-sectional view showing an enlarged cross-sectional shape of the front body 1 side of the disposable diaper, as in FIG. 4.
In the third embodiment shown in FIG. 8, the cushion-forming sheet 20 is constituted by a separate sheet member, with the elastic member joining layer 21 and the cushion-forming layer 22. As described above, the cushion forming sheet 20 may be formed by superposing two sheet members to form the elastic member bonding layer 21 and the cushion forming layer 22. The sheet member constituting the elastic member joining layer 21 and the sheet member constituting the cushion forming layer 22 may be formed of the same material or may be formed of different materials. .

  As in the third embodiment shown in FIG. 8, by forming the elastic member joining layer 21 and the cushion forming layer 22 with separate sheet members, a waist gather having a “flute structure” is formed. There is no need to perform the step of folding the cushion forming sheet 20, and instead, the step of superimposing the elastic member joining layer 21 and the cushion forming layer 22 may be performed. For this reason, the cushion formation sheet 20 which has the elastic member joining layer 21 and the cushion formation layer 22 can be formed comparatively easily. Further, when the elastic member bonding layer 21 and the cushion forming layer 22 are intermittently bonded, if the elastic member bonding layer 21 and the cushion forming layer 22 are connected, there is a possibility that unnecessary wrinkles may be generated at the connecting portion. However, by providing the stretchable member joining layer 21 and the cushion forming layer 22 as separate bodies, it is possible to avoid unnecessary wrinkling when the layers 21 and 22 are joined intermittently.

(2-2. Absorbent body)
The absorbent main body 30 is disposed over the front body 1 and the back body 2 with the crotch 3 of the outer body 10 as the center, and absorbs liquid such as urine by contacting the wearer's crotch when the disposable diaper 100 is worn. Hold. As shown in the development view of FIG. 2 and the cross-sectional view of FIG. 3, the absorbent main body 30 has an absorbent body 31, a top sheet 32, a back sheet 33, and a three-dimensional gather 34 as a basic configuration.

  The absorber 31 is a member for absorbing a liquid such as urine and holding the absorbed liquid. The absorber 31 is disposed between the liquid-permeable top sheet 32 and the liquid-impermeable back sheet 33. The absorber 31 has a function of absorbing the liquid that has passed through the top sheet 32 and is made of an absorbent material. A well-known material can be employ | adopted for the absorptive material which comprises the absorber 31. FIG. As an absorptive material, it is good also as using a fluff pulp, a superabsorbent polymer, or a hydrophilic sheet, for example. In addition, as the absorbent material, one type of fluff pulp, superabsorbent polymer, or hydrophilic sheet may be used alone, or two or more types may be used in combination. The absorbent material is usually formed and used in a single-layer or multi-layer mat shape. The absorbent material is preferably encapsulated by the upper core wrap sheet 35 and the lower core wrap sheet 36. The upper core wrap sheet 35 and the lower core wrap sheet 36 cover the absorbent material from the skin contact surface side and the skin non-contact surface side, and prevent the absorbent material from leaking outside. As the upper core wrap sheet 35 and the lower core wrap sheet 36, tissue paper, absorbent paper, a nonwoven fabric subjected to a hydrophilic treatment, or the like can be used as appropriate.

  The top sheet 32 is a member that is in direct contact with the skin of the wearer's crotch and allows liquid such as urine to pass through the absorbent body 31. For this reason, the top sheet 32 is made of a liquid-permeable material having high flexibility. Moreover, the top sheet 32 is arrange | positioned so that the skin contact surface side of the absorber 31 may be coat | covered. The example of the impermeable material which comprises the top sheet 32 is a woven fabric, a nonwoven fabric, or a porous film. Further, for example, a thermoplastic resin fiber such as polypropylene, polyethylene, polyester, or nylon may be hydrophilized and further made into a nonwoven fabric.

  The back sheet 33 is a member for preventing the liquid that has passed through the top sheet 32 and absorbed by the absorber 31 from leaking to the outside of the diaper. For this reason, the back sheet 33 is made of a liquid-impermeable material. The back sheet 33 covers the absorbent body 31 from the non-skin contact surface side in order to prevent liquid leakage from the bottom surface of the absorbent body 31. An example of the impermeable material constituting the back sheet 33 is a liquid impermeable film made of polyethylene resin. In particular, it is preferable to use a microporous polyethylene film in which a plurality of fine pores of 0.1 to 4 μm are formed.

  The three-dimensional gather 34 is a member that stands along both side edges of the absorber 31 and prevents side leakage of urine excreted by the wearer. Each of the pair of three-dimensional gathers 34 is provided with a plurality of three-dimensional gather expansion / contraction members 37 at the tip thereof, and rises toward the wearer's skin contact direction when the three-dimensional gather expansion / contraction members 37 contract. . For this reason, the pair of three-dimensional gathers 34 serves as a urine leak-proof wall, and urine that has not permeated through the top sheet 32 or urine that has not been absorbed by the absorber 31 can be obtained from the openings around the legs of the disposable diaper. Prevent leaking side leaks. The three-dimensional gather 34 can employ | adopt the well-known structure used for the conventional disposable diaper. The three-dimensional gather 34 can be formed, for example, by sandwiching and fixing a stretched three-dimensional gather elastic member 37 between the layers of the water-repellent sheet. As the water-repellent sheet, for example, a non-woven sheet obtained by a production method such as card embossing or spunbond can be used, and it is particularly preferable to use a non-woven sheet such as SMS or SMMS having high waterproofness.

(3. Manufacturing method of disposable diapers)
(3-1. Manufacturing method of disposable diaper: First embodiment)
Then, 1st Embodiment of the manufacturing method of a disposable diaper is described with reference to FIG.9 and FIG.10. In the following description, for example, the expression “original outer sheet” is used. However, the “original outer sheet” and the like are later cut into a disposable diaper production line to become an outer sheet of the disposable diaper later. Means a member.

FIG. 9 is a conceptual diagram showing a manufacturing process of the disposable diaper according to the present invention. In FIG. 9, the direction shown by the arrow A is the flow direction of the diaper manufacturing process.
In the manufacturing method of the present invention, first, a plurality of original tammy elastic members 115 and a plurality of leg elastic members 117 are arranged on an original outer sheet 111 (skin contact surface side) fed out from an unillustrated original fabric roll. For example, it is fixed by a hot melt adhesive or the like (step S1). At this time, the plurality of original tammy expansion and contraction members 115 have a portion corresponding to the waist end portion of the original outer sheet 111 and coincide with the flow of the original outer sheet 111 on the front body side and the rear body side of the original outer sheet 111. It is fixed in the extended state. Further, the original leg elastic member 117 is fixed in an extended state so as to meander on the front body side and the back body side of the original outer sheet 111. It is preferable that the hot-melt adhesive is directly applied to the original Tammy elastic member 115 and the leg elastic member 117 by a technique such as a comb gun, for example. In the subsequent step S3, the original tammy elastic member 115 and the plurality of original leg elastic members 117 are cut and partially discontinuous. For this reason, when joining the original Tammy stretchable member 115 and the original leg stretchable member 117, the joined portions and the non-joined portions are alternately continued so that these stretchable members can be partially discontinuous. Thus, it is preferable to apply an adhesive.

  Thereafter, the original inner sheet 112 is bonded onto the original tammy elastic member 115 and the original leg elastic member 117 fixed to the original outer sheet 111 (step S2). At this time, the original inner sheet 112 has a width that does not reach the waist end portion of the original outer sheet 111 from the front body side to the rear body side of the original outer sheet 111. The original inner sheet 112 is preferably bonded around the crotch portion of the original outer sheet 111 in a state where the hot melt adhesive is applied to the entire surface by a technique such as curtain spray.

  Thereafter, the original Tammy elastic member 115 and the original leg elastic member 117 are cut in a direction orthogonal to the sheet flow direction while being sandwiched between the original outer sheet 111 and the original inner sheet 112 (step S3). Since the original Tammy elastic member 115 and the original leg elastic member 117 are sandwiched and fixed between the original outer sheet 111 and the original inner sheet 112 so that the joined portions and the non-joined portions are alternately continued, the non-joined portions are By cutting, it becomes discontinuous in the non-joining part.

  Then, the absorptive main body 130 is bonded on the original inner sheet 112 (skin contact surface side) (step S4). The absorbent main body 130 is bonded to a region where the original Tammy elastic member 115 and the original leg elastic member 117 are discontinuous. Although illustration of the process of forming the absorptive main body 130 is omitted, it may be formed by a known process. The absorbent main body 130 may be bonded using, for example, a hot melt adhesive.

  Then, the leg outer opening 106 is formed by cutting and cutting the original outer sheet 111 and the original inner sheet 112 (step S5).

  Then, on the original outer sheet 111 (skin contact surface side), a plurality of original waist elastic members 113 are arranged along the sheet flow direction at positions corresponding to the waist ends of the front body side and the back body side. It is attached in an extended state (step S6). The raw waist elastic member 113 is preferably directly applied with a hot melt adhesive by a method such as a comb gun, for example. Here, the attachment of the original waist elastic member 113 means a state in which the original waist elastic member 113 is disposed on the original outer sheet 111 via a hot melt adhesive. Finally, the original waist elastic member 113 is fixed by being overlapped and bonded to the original elastic member bonding layer 121 of the original cushion forming sheet 120 in a subsequent process.

Subsequently, a process of superimposing the original cushion forming sheet 120 on the original waist elastic member 113 on the original outer sheet 111 is performed (step S7). Here, the process of overlapping the original cushion forming sheet 120 will be described in detail with reference to FIG.
FIG. 10 is a perspective view conceptually extracting and showing the process of processing the original cushion forming sheet 120 and superimposing it on the original waist elastic member 113.
As shown in FIG. 10, the original cushion forming sheet 120 is a step of obtaining a laminate of the original outer sheet 111, the original inner sheet 112, the original waist elastic member 113, the original tammy elastic member 115, and the original leg elastic member 117. Is processed in a separate process.
The original cushion forming sheet 120 is, for example, drawn out from a raw roll (not shown) and introduced into the production line in a flat state without a fold. A pair of sailors 210 for folding back both ends in the width direction of the original cushion forming sheet 120 toward the inner side in the width direction is located on the downstream side of the original fabric roll. The sailors 210 are provided at both ends in the width direction of the original cushion forming sheet 120, and the both end portions of the original cushion forming sheet 120 are inward in the width direction along the inner edges that contact the seat while sandwiching both end portions of the original cushion forming sheet 120. Guide and fold. The layer folded by the sailor 210 in this way corresponds to the original cushion forming layer 122 of the original cushion forming sheet 120, and the layer that is not folded corresponds to the original stretchable member bonding layer 121.

  In the processing line of the original cushion forming sheet 120, the embossing device 220 is located on the downstream side of the sailor 210. The embossing device 220 includes an embossing roll 221 and an anvil roll 222 at positions facing each other across the original cushion forming sheet 120. The embossing roll 221 and the anvil roll 222 have a rotation axis in a direction orthogonal to the flow direction of the original cushion forming sheet 120.

The embossing roll 221 includes a pattern block 223, and convex portions and concave portions are provided alternately and continuously along the rotation direction of the embossing roll 221. At the position of the pattern block 223 of the emboss roll 221, both ends in the width direction in which the elastic member bonding layer 121 and the cushion forming layer 122 of the original cushion forming sheet 120 overlap are processed. For this reason, the convex part of the pattern block 223 comes into contact with the overlapping part of the elastic member joining layer 121 and the cushion forming layer 122. For example, the pattern block 223 is preferably one that can be heated and pressurized, and is preferably one that thermally melts the stretchable member bonding layer 121 and the cushion forming layer 122 of the original cushion forming sheet 120 in contact with the convex portion. .
On the other hand, the anvil roll 222 has a flat surface and is disposed at a position facing the embossing roll 221. The anvil roll 222 sandwiches the original cushion forming sheet 120 between the convex portion of the pattern block 223 in the embossing roll 221.

  As shown in FIG. 10, the original cushion forming sheet 120 is introduced between the embossing roll 221 and the anvil roll 222. Then, the embossing roll 221 and the anvil roll 222 are rotated and sent out downstream while sandwiching the original cushion forming sheet 120. At this time, the pattern block 223 of the embossing roll 221 presses the portion where the elastic member bonding layer 121 and the cushion forming layer 122 of the original cushion forming sheet 120 overlap with each other between the flat surface of the anvil roll 222. And according to the continuous pattern of the recessed part and convex part which were provided in the pattern block 223, the expansion-contraction member joining layer 121 and the cushion forming layer 122 of the original cushion forming sheet 120 are joined intermittently. At this time, the intermittent direction of the stretchable member bonding layer 121 and the cushion forming layer 122 coincides with the flow direction of the original cushion forming sheet 120. In this way, intermittent bonding can be imparted to the elastic member bonding layer 121 and the cushion forming layer 122 of the original cushion forming sheet 120.

  In the processing line of the original cushion forming sheet 120, a slitter 230 is positioned on the downstream side of the embossing device 220. The slitter 230 rotates the circular blade to cut the original cushion forming sheet 120 at the center in the width direction. Thereby, the original cushion forming sheet 120 is divided into an original cushion forming sheet 120a on the front body side and an original cushion forming sheet 120b on the rear body side. Each of the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side is formed with the stretchable member bonding layer 121 and the cushion forming layer 122 in an overlapping state. The original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side cut by the slitter 230 are each of the original outer sheet 111 by a widening roll that moves the travel axis of the sheet (not shown) in the width direction. It is spaced apart to a position that overlaps both end portions (waist end portions).

  A guide roller 240 and a pasting roller 250 are positioned on the downstream side of the slitter 230. The conveyance roller 240 guides and guides the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side to join the flow of the laminate of the original inner sheet 112 and the original waist elastic member 113. Transport. A plurality of guide rollers 240 are preferably provided. The original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side conveyed by the guide roller 240 are overlapped by the original outer sheet 111, the original inner sheet 112, and the original waist elastic member by the overlapping roller 250. The laminated body 113 is superposed and pressure-bonded.

  More specifically, as shown in FIG. 10, each of the original cushion forming sheet 120 a on the front body side and the original cushion forming sheet 120 b on the rear body side is an intermittent of the elastic member bonding layer 121 and the cushion forming layer 122. The direction is superimposed on the original waist elastic member 113 so that the direction coincides with the extension direction of the original waist elastic member 113. At this time, for example, on the skin contact surface side of the original waist elastic member 113 fixed on the original outer sheet 111 or the original cushion forming sheet 120a on the front body side and the back body side by a hot melt application device (not shown). A hot melt adhesive is applied or sprayed on the non-skin contact surface side of the original cushion forming sheet 120b. For this reason, the original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side are joined to the original waist elastic member 113 by, for example, a hot melt adhesive.

Thereby, the original waist elastic member 113 is fixed to both ends of the original outer sheet 111 in the width direction, and the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side are respectively joined to the original waist elastic member 113. Is done. The front body side original cushion forming sheet 120a and the back body side original cushion forming sheet 120b are formed by intermittently joining the elastic member joining layer 121 and the cushion forming layer 122, respectively.
At this time, it is preferable that the original stretchable member bonding layer 121 of the original cushion forming sheet 120 is partially bonded onto the absorbent main body 130 disposed on the original inner sheet 121.
In this way, the original exterior body sheet 110 for holding the absorbent main body 130 can be obtained.

The subsequent steps for manufacturing the disposable diaper are shown in FIG.
9, after performing the process (step S7) of superimposing the original cushion forming sheet 120 on the original waist elastic member 113, the front body of the original exterior body sheet 110 is folded back at the crotch part, Overlay the body (step S8).

  Thereafter, side seals are formed along the direction perpendicular to the sheet flow direction at positions corresponding to the side flaps of the front and rear bodies of the original exterior body sheet 110 (step S9). At this time, the side seals are formed in two rows along a direction orthogonal to the sheet flow direction. The side seal may be applied using, for example, a known heat embossing device or ultrasonic embossing device.

Thereafter, between the sides formed in two rows, the original exterior body sheet 110 is cut in a direction orthogonal to the sheet flow direction (step S10). Thereby, the continuous body of the disposable diaper which adjoined along the flow direction of a sheet | seat can be cut | disconnected to the individual disposable diaper 100. FIG.
Through the above steps, a pants-type disposable diaper of the type in which the exterior body 10 is integrated from the front body to the back body can be manufactured.

  According to the above process, in the stage before joining the original cushion forming sheet 120 to the original waist elastic member 113, the step of folding the original cushion forming sheet 120 by the sailor 210, the elastic member joining layer 121 of the original cushion forming sheet 120, A step of intermittently joining the cushion forming layer 122 with the embossing device 220 can be performed. For this reason, by joining the original cushion forming sheet 120 subjected to these processing treatments to the original waist elastic member body 113, a waist gather having a “flute structure” can be easily formed. Therefore, according to the manufacturing method of the present embodiment, for example, in a state where the original cushion forming sheet 120 is joined to the original outer sheet 111, it is not necessary to perform a complicated process of folding the original outer sheet 111. Disposable diapers with a “flute structure” can be manufactured in a simpler process. Therefore, it is possible to suppress errors that occur in the process of manufacturing disposable diapers, and the non-defective product shipment rate of disposable diapers is improved.

(3-2. Manufacturing method of disposable diaper: second embodiment)
Then, 2nd Embodiment of the manufacturing method of a disposable diaper is described with reference to FIG. FIG. 11 is a perspective view conceptually extracting and showing the process of processing the original cushion forming sheet 120 and superimposing it on the original waist elastic member 113, as in FIG.

  In the manufacturing method according to the second embodiment, as in the manufacturing method according to the first embodiment, first, the original outer sheet 111, the original inner sheet 112, the original waist elastic member 113, the original Tammy elastic member 115, and the original A laminated body of the leg elastic members 117 is obtained. That is, in the manufacturing method according to the second embodiment, the same steps (steps S1 to S5) as in the first embodiment may be performed.

  On the other hand, in the manufacturing method according to the second embodiment, the original cushion forming sheet 120 is processed in a step different from the step of obtaining the laminate. The original cushion forming sheet 120 is, for example, drawn out from a raw roll (not shown) and introduced into the production line in a flat state without a fold. And the slitter 230 for dividing the original cushion formation sheet 120 into the width direction is located in the downstream of the original fabric roll. The slitter 230, for example, rotates a circular blade to form a cutting line in the central portion in the width direction of the original cushion forming sheet 120, and the original cushion forming sheet 120 is separated from the original cushion forming sheet 120a on the front body side and the back body side. The original cushion forming sheet 120b is divided. The original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side cut by the slitter 230 are each of the original outer sheet 111 by a widening roll that moves the travel axis of the sheet (not shown) in the width direction. It is spaced apart to a position that overlaps both end portions (waist end portions).

  Further, on the downstream side of the slitter 230, the sailor 210 is located at a position corresponding to each of the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side. The sailor 210 is provided one by one on the conveyance line of the original cushion forming sheet 120a on the front body side and on the conveyance line of the original cushion forming sheet 120b on the back body side, and the original cushion forming sheet 120a on the front body side, While sandwiching the end portion of the original cushion-forming sheet 120b on the back body side, the sheet is guided and folded inward in the width direction of the sheet along the inner edge contacting the sheet. The layer folded back by the sailor 210 corresponds to the cushion forming layer 122 of the original cushion forming sheet 120, and the layer not folded back corresponds to the elastic member joining layer 121. The elastic member joining layer 121 and the cushion forming layer 122 are formed on each of the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side.

  On the downstream side of the sailor 210, the embossing device 220 is located at a position corresponding to each of the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side. The embossing device 220 is provided one by one on the transport line of the front cushion side original cushion forming sheet 120a and on the transport line of the back body side original cushion forming sheet 120b. The embossing roll 221 and the sonic horn 224 are provided at positions facing each other across the original cushion forming sheet 120b on the back body side. The embossing roll 221 has a rotation axis in a direction perpendicular to the flow direction of the sheet 120, and the sonic horn 224 is fixed at a position where the sheet is sandwiched between the embossing roll 221.

  The embossing roll 221 includes a pattern block 223, and convex portions and concave portions are provided alternately and continuously along the rotation direction of the embossing roll 221. In the original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side, the pattern block 223 of the embossing roll 221 is introduced at the position where the stretchable member bonding layer 121 and the cushion forming layer 122 overlap. Embossed. For this reason, the convex part of the pattern block 223 comes into contact with the overlapping part of the elastic member joining layer 121 and the cushion forming layer 122.

  On the other hand, the sonic horn 224 sandwiches the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side between the convex portions formed on the pattern block 223 of the embossing roll 221. Friction heat by ultrasonic vibration is applied to both sheets 120a and 120b to weld the elastic member bonding layer 121 and the cushion forming layer 122. More specifically, the sonic horn 224 includes a horn portion that contacts the friction target sheet, a booster portion connected to the horn portion, and a converter portion connected to the booster portion. The converter unit converts the high-frequency electric signal into mechanical vibration and conducts it to the booster unit. The booster unit increases or decreases the vibration generated by the converter unit and causes the horn unit to ultrasonically vibrate. The horn unit vibrates in resonance with the ultrasonic vibration of the converter unit and the booster unit, and applies vibration energy to the friction target sheet to generate frictional heat.

  As shown in FIG. 11, between the embossing roll 221 and the sonic horn 224, the front body side original cushion forming sheet 120a and the back body side original cushion forming sheet 120b are respectively introduced. Then, the embossing roll 221 rotates and is fed downstream from the sonic horn 224 while sandwiching the original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side. At this time, between the embossing roll 221 and the sonic horn 224, the portions where the elastic member joining layers 121 and the cushion forming layers 122 of the two sheets 120a and 120b overlap are in contact. Then, frictional heat is applied to both sheets 120a and 120b by ultrasonic vibration of the sonic horn 224, and the expansion and contraction of both sheets 120a and 120b according to the continuous pattern of the concave and convex portions provided in the pattern block 223. The member bonding layer 121 and the cushion forming layer 122 are intermittently ultrasonically welded. At this time, the intermittent direction of the elastic member joining layer 121 and the cushion forming layer 122 coincides with the flow direction of both sheets 120a and 120b. In this manner, the stretchable member bonding layer 121 and the cushion forming layer 122 can be intermittently bonded to each of the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side.

  The guide roller 240 and the bonding roller 250 are located on the downstream side of the embossing device 220 as in the first embodiment. The guide roller 240 conveys the original body-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the back body side so as to merge with the flow of the laminated body of the original inner sheet 112 and the original waist elastic member 113. . The original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side conveyed by the guide roller 240 are overlapped by the original outer sheet 111, the original inner sheet 112, and the original waist elastic member by the overlapping roller 250. It is superposed on the laminated body 113. That is, as shown in FIG. 11, each of the original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side has an intermittent direction between the stretchable member bonding layer 121 and the cushion forming layer 122. It overlaps on the original waist elastic member 113 so as to coincide with the extending direction of the waist elastic member 113. At this time, for example, on the skin contact surface side of the original waist elastic member 113 fixed on the original outer sheet 111 or the original cushion forming sheet 120a on the front body side and the back body side by a hot melt application device (not shown). A hot melt adhesive is applied or sprayed on the non-skin contact surface side of the original cushion forming sheet 120b. For this reason, the original cushion-forming sheet 120a on the front body side and the original cushion-forming sheet 120b on the rear body side are joined to the original waist elastic member 113 by, for example, a hot melt adhesive. In this way, the original exterior body sheet 110 for holding the absorbent main body 130 can be obtained.

  In the subsequent manufacturing process, as in the first embodiment, after the step of superimposing the original cushion forming sheet 120 (step S7), the front body of the original exterior body sheet 110 is overlaid on the back body (step S8), A side seal is formed (step S9), and the continuous body of the disposable diaper is cut into individual disposable diapers 100 (step S10). Thereby, the pants-type disposable diaper of the type which the exterior body 10 hung from the front body to the back body and united can be manufactured.

According to the process according to the second embodiment, the original cushion forming sheet 120 is divided into the original cushion forming sheet 120a on the front body side and the original cushion forming sheet 120b on the rear body side, and then divided. For each of the sheets 120a and 120b, it is possible to perform a step of folding back by the sailor 210 and a step of performing intermittent joining by the embossing device 220. In this manner, by individually joining the front body side original cushion forming sheet 120a and the back body side original cushion forming sheet 120b, it is possible to prevent the joint portion from being twisted or wrinkled during joining.
That is, in a general diaper processing machine, when trying to join the original elastic member joining layer 121 and the original cushion forming layer 122 intermittently to the original cushion forming sheet 120 in which the front body side and the back body side are integrated, For example, when the original cushion forming sheet 120 is meandered a little, the laminated portion of the original elastic member joining layer 121 and the original cushion forming layer 122 located at both ends in the width direction is wide on one side and narrowed on the other, There is a risk of errors in the width.
In this regard, in the second embodiment, the original cushion-forming sheet 120 is divided into the front-body-side original cushion-forming sheet 120a and the back-body-side original cushion-forming sheet 120b, and then the divided sheets. Since each of 120a and 120b is to be folded by the sailor 210 and bonded by the embossing device 220, as described above, the original stretchable member bonding layers 121 located at both ends in the width direction of the original cushion forming sheet 120 and A situation in which an error occurs in the width of the laminated portion of the original cushion forming layer 122 can be reduced. For this reason, according to the second embodiment, even if the elastic member bonding layer 121 and the cushion forming layer 122 are intermittently bonded by the embossing device 220, unnecessary wrinkles are hardly generated in the laminated portion. The feel of a waist gather having a “flute structure” can be improved.

In the above, the manufacturing method of the disposable diaper which concerns on this invention was demonstrated taking the preferable form as an example. However, the manufacturing method of the present invention is not limited to the above-described embodiment, and can be appropriately changed by those skilled in the art from the above-described embodiments within the obvious range.
For example, the above manufacturing method is not only a type of pants-type disposable diaper in which the exterior body is integrated from the front body to the back body, but also a type of pants-type disposable diaper in which the exterior body is separated in the front body and the back body, etc. The present invention can also be applied to a method for manufacturing a tape-type disposable diaper of the type in which an adhesive tape is attached to both sides of the front body or the back body.
Moreover, in 1st Embodiment of the manufacturing method of a disposable diaper, the embossing apparatus by the combination of an embossing roll and an anvil roll is taken as an example as the original cushion formation layer 122 in the original cushion formation sheet 120, and the original elastic member joining layer 121 joining means. As described above, for example, an ultrasonic fusing type embossing apparatus using an embossing roll and a sonic horn may be employed. Moreover, in 2nd Embodiment of the manufacturing method of a disposable diaper, the embossing apparatus by the combination of an embossing roll and a sonic horn is taken as an example as an original cushion formation layer 122 in the original cushion formation sheet 120, and an original expansion-contraction member joining layer 121 joining means. As described above, it is also possible to employ a heat-sealing embossing device using a combination of an embossing roll and an anvil roll.

  The disposable diaper according to the present invention can be applied to diapers for infants and the elderly. Therefore, the present invention can be suitably used in industries related to child care and nursing care.

DESCRIPTION OF SYMBOLS 1 Front body 2 Back body 3 Crotch part 4 Waist edge part 5 Waist opening part 6 Leg circumference opening part 10 Exterior body 11 Outer sheet 12 Inner sheet 13 Waist elastic member 14 Waist gather 15 Tammy elastic member 16 Tammy gather member 17 Leg elastic member 18 Leg gather 20 Cushion forming sheet 21 Stretch member joining layer 22 Cushion forming layer 23 Folding part 24 Joining part 25 Non-joining part 30 Absorbent body 31 Absorber 32 Top sheet 33 Back sheet 34 Solid gather 35 Upper core wrap sheet 36 Lower side Core wrap sheet 37 Three-dimensional gather elastic member 100 Disposable diaper 106 Leg opening 110 Original outer body sheet 111 Original outer sheet 112 Original inner sheet 113 Original waist elastic member 115 Original tammy elastic member 117 Original leg elastic member 12 0 Original cushion forming sheet 130 Absorbent body 121 Original elastic member bonding layer 122 Original cushion forming layer 210 Sailor 220 Embossing device 221 Embossing roll 222 Anvil roll 223 Pattern block 230 Slitter 240 Guide roller 250 Bonding roller

Claims (3)

In a disposable diaper composed of a front body (1), a back body (2), and a crotch part (3) located between the front body (1) and the back body (2),
An outer sheet (11) located in either or either of the front body (1) and the back body (2);
The inner joined to the skin contact surface side of the outer sheet (11) at a position that does not reach the waist end (4) of either or both of the front body (1) and the back body (2). Sheet (12);
An absorbent main body (30) attached to the skin contact surface side of the inner sheet (12);
To the skin contact surface side of the outer sheet (11), the position in the waist end portions (4), one or more of the waist elastic members are secured in a stretched state along the width direction of the diaper (13) When,
A cushion forming sheet (20) separate from the outer sheet (11) and the inner sheet (12), which is joined to the skin contact surface side of the waist elastic member (13);
The cushion forming sheet (20)
An elastic member bonding layer (21) bonded to the waist elastic member (13);
Having a cushion forming layer (22) located on the skin contact surface side of the elastic member bonding layer (21),
The stretchable member joining layer (21) and the cushion forming layer (22) are joined intermittently so that the joined portion and the non-joined portion are continuous along the extending direction of the waist stretchable member (13). ,
The cushion forming sheet (20) is formed by a sheet member in which the stretchable member bonding layer (21) and the cushion forming layer (22) are integrated.
The cushion forming sheet (20) includes the stretchable member bonding layer (21) positioned on the skin non-contact surface side with the folded portion (23) as a boundary, and the cushion forming layer (22) positioned on the skin contact surface side. And is formed ,
The cushion-forming sheet (20) has a skin contact surface side of the waist elastic member (13) such that the folded portion (23) is located at a position protruding from a waist opening edge of the outer sheet (11). Disposable diapers joined to . In a method for manufacturing a disposable diaper comprising a front body (1), a back body (2), and a crotch part (3) located between the front body (1) and the back body (2),
A step of obtaining an exterior body;
Obtaining a cushion-forming sheet;
Joining the exterior body and the cushion forming sheet,
The step of obtaining the exterior body includes
For the skin contact surface side of the outer sheet (11) located in either or either of the front body (1) and the back body (2),
The inner sheet (12) is joined to a position not reaching the waist end (4) of either or both of the front body (1) and the back body (2),
Fixing one or more waist elastic members (13) in a stretched state along the width direction of the diaper at the position at the waist end (4);
It is a step of obtaining an outer package (10) including the outer sheet (11), the inner sheet (12), and the waist elastic member (13),
The step of obtaining the cushion forming sheet includes:
Folding one sheet member to form the elastic member joining layer (21) and the cushion forming layer (22),
The cushion forming layer (22) is intermittently bonded to the skin contact surface side of the elastic member bonding layer (21) such that the bonded portion and the non-bonded portion are continuous,
A step of obtaining a cushion-forming sheet (20) including the elastic member joining layer (21) and the cushion-forming layer (22);
The step of joining the exterior body and the cushion forming sheet includes:
In the cushion forming sheet (20), the continuous direction of the joined portion and the non-joined portion in the cushion forming sheet (20) coincides with the extending direction of the waist elastic member (13) in the exterior body (10). the elastic member joining layer (21), Ri step der of bonding to the skin contact surface side of the waist elastic member (13) in said outer body (10),
The cushion-forming sheet (20) has a skin contact surface of the waist elastic member (13) such that the folded portion (23) is located at a position protruding from the waist opening edge of the outer sheet (11). The manufacturing method of the disposable diaper joined to the side . The step of obtaining the cushion forming sheet includes:
After folding the cushion-forming sheet (20) toward the skin contact surface side and forming the stretchable member bonding layer (21) and the cushion-forming layer (22),
It is a step of intermittently joining the stretchable member joining layer (21) and the cushion forming layer (22) so that the joining part and the non-joining part are continuous.
The manufacturing method of the disposable diaper of Claim 2 .

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