JP6125876B2 - Method for manufacturing disposable diapers - Google Patents

Description

  The present invention relates to a method for manufacturing a disposable diaper.

A composite stretchable material composed of a first nonwoven fabric sheet portion and a second nonwoven fabric sheet portion overlapping each other, and an elastic member disposed between the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion. Because
Each of the nonwoven sheet portions is formed with a recess and a protrusion in the thickness direction of the nonwoven sheet portion,
The concave portions and the convex portions, which are alternately and repeatedly formed in a first direction, extend along a second direction orthogonal to the first direction to define a concavo-convex row,
The concavo-convex rows are separated from each other by a non-concave region extending without including the concave portion and the convex portion along the first direction;
The convex part protrudes from the thickness direction position of the non-concave area of the corresponding nonwoven fabric sheet part,
The concave portion formed between the two convex portions adjacent to each other reaches the position in the thickness direction of the non-concave region,
While the non-concave regions of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion face each other, the convex portion of the first nonwoven fabric sheet portion faces the second nonwoven fabric sheet portion and the The non-concave regions where the convex portions of the second nonwoven fabric sheet portion are overlapped so as to face the first nonwoven fabric sheet portion and the elastic members in a state of extending in the first direction are aligned with each other Placed between
The non-concave regions aligned with each other are joined via an elastic member,
The convex part of the first nonwoven fabric sheet part enters the concave part of the second nonwoven sheet part, and the convex part of the second nonwoven sheet part is inside the concave part of the first nonwoven sheet part. In,
A composite stretchable material has already been invented (see Patent Document 1).

  Further, a graphic sheet (pattern sheet) is arranged between sheets constituting the disposable diaper, and the graphic (pattern) formed on the graphic sheet is positioned outside the graphic sheet (exterior sheet). Disposable diapers that can be visually recognized through are known (see Patent Document 2 as an example).

Japanese Patent Application No. 2011-225253 JP 2001-54536 A

  When the composite stretchable material as described in Patent Document 1 is used in the waistline portion of a disposable diaper, that is, a part generally called a waist gather and a fit gather, the thickness at the time of contraction is thin, and consequently the body of the wearer It will be in close contact with the touch and feel good. Furthermore, this composite stretchable material is thin when contracted compared to conventional gathers, and is difficult to deform in the thickness direction, so that large wrinkles are difficult to form. Thereby, there is an advantage that it is difficult for the heel to be caught on the wearer's foot when worn, and the wearer can easily wear the disposable diaper.

  However, when manufacturing such a so-called 3P (three-piece) disposable diaper using such a composite stretchable material for the waist part of the disposable diaper, taking into account the rationality in manufacturing, the graphic is applied to one of the nonwoven sheet parts. In general, after the sheets are joined, the sheet is shaped so as to form a concave portion and a convex portion.

  In this case, the concave portion and the convex portion are formed on the graphic sheet together with the non-woven sheet portion. Then, since the graphic sheet is stretched, it may be difficult to visually recognize the graphic formed on the graphic sheet. Thereby, there exists a possibility that the appearance (appearance) of a disposable diaper may fall.

  Accordingly, an object of the present invention is to provide a disposable diaper that is in close contact with the wearer's body, is easy to be worn by the wearer, and that the graphic formed on the graphic sheet is easily visible, and thus has an excellent appearance. It is in providing the method of manufacturing.

In order to achieve the above object, the present invention provides:
A method for manufacturing a disposable diaper including a longitudinal direction and a transverse direction orthogonal to the longitudinal direction, and comprising a waist opening and a pair of leg openings,
A composite composed of a first nonwoven fabric sheet portion and a second nonwoven fabric sheet portion overlapping each other, and an elastic member and a graphic sheet disposed between the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion. Producing a stretchable material;
Forming the disposable diaper using the composite stretchable material in a waistline portion;
Including
The step of manufacturing the composite stretchable material includes:
A graphic sheet joining step of joining the graphic sheet to any one of the nonwoven sheet portions;
Of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion, the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are formed so that at least a portion where the graphic sheet is joined is not shaped. A shaping stage for shaping,
Defining a plurality of concavo-convex regions comprising convex and concave portions that are alternately repeated along the first direction and extend in the second direction;
Defining at least one non-recessed area that separates these uneven areas from each other in the second direction;
The shaping stage;
An elastic member disposing step of disposing the elastic member to which the adhesive stretched in the first direction is applied on one of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion; ,
Overlapping in which the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are overlapped and joined so that the uneven regions and the non-recessed regions are aligned with each other with respect to the second direction. Stages,
Including
In the graphic sheet, a graphic is formed on the surface facing outward when worn in the center in the transverse direction of the waistline portion,
In the graphic forming portion which is the portion where the graphic is formed in the central portion in the transverse direction of the waistline portion, the contraction force of the elastic member is substantially prevented from acting.
A method of manufacturing a disposable diaper is provided.

  According to the present invention, a disposable diaper is produced which is in close contact with the wearer's body, is easy to be worn by the wearer, and in addition, the graphic formed on the graphic sheet is easy to visually recognize and thus has excellent appearance. A method can be provided.

The front overhead view which shows the disposable diaper of embodiment. The expanded view of the disposable diaper of FIG. Schematic of the apparatus for manufacturing a composite elastic material. The perspective view of the missing-tooth gear roll and the continuous gear roll which comprise a shaping apparatus. FIG. 5 is a front view of the missing gear roll and the continuous gear roll of FIG. 4. The side view of the gear roll of FIG. The elements on larger scale of FIG. 6 in a short pitch area | region. The elements on larger scale of FIG. 6 in a long pitch area | region. The front view and sectional drawing of a composite elastic material before folding one nonwoven fabric sheet part. The front view and sectional drawing of a composite elastic material after folding up one nonwoven fabric sheet part. FIG. 10 is an enlarged perspective view of a cut portion of an X portion of the composite stretchable material of FIG. 9. The exploded view of the composite elastic material of FIG. The front view of FIG. 10 which expanded the cross-section periphery of the elastic member. In the missing tooth portion of the missing gear roll, the circumferential direction of the missing gear roll and the continuous gear roll is linearly expanded, and the short pitch biting portion disposed between and deformed between the missing tooth gear roll and the continuous gear roll. The expanded cross-sectional image figure of the meshing part periphery with the nonwoven fabric sheet located. The discontinuous gear roll and the continuous gear roll in the discontinuous tooth portion of the partial gear roll, in which the peripheral direction of the partial gear roll and the continuous gear roll is linearly developed, and the short pitch biting portion arranged and deformed between them. The expanded cross-section image figure of the meshing part periphery with the nonwoven fabric sheet located in FIG. The discontinuous gear roll and the continuous gear roll at the discontinuous tooth portion of the missing gear roll, in which the circumferential direction of the missing gear roll and the continuous gear roll is linearly developed, and the long pitch biting portion disposed between them and deformed The expanded cross-section image figure of the meshing part periphery with the nonwoven fabric sheet located in FIG. The cross-sectional schematic in the uneven | corrugated area | region of the front member in the disposable diaper of a comparative example. The cross-sectional schematic in the uneven | corrugated area | region of the front side member in the disposable diaper of embodiment. The cross-sectional schematic in the uneven | corrugated area | region of the front side member in the modification of the disposable diaper of embodiment. The diagram which shows an example of the shape before the composite elastic material of embodiment is compressed in a 2nd direction. The diagram which shows an example of the shape after the composite elastic material of embodiment was compressed by the 2nd direction. The diagram which shows an example of the shape before the composite elastic | stretch material formed from the two nonwoven fabric sheet parts which are not shaped is compressed to a 2nd direction. The diagram which shows an example of the shape after the composite elastic material formed from the two nonwoven fabric sheet parts which are not shaped is compressed to the 2nd direction. The figure explaining the size of the test piece of a compressive strength test. The schematic perspective view of the test piece of a compressive strength test. The graph which shows an example of transition of time and compressive force in a compressive strength test.

  The invention will be described in more detail with reference to the above-mentioned drawings. It should be noted that the drawings may not be drawn to the same size, scale, or shape as actual components in order to facilitate understanding of the present invention and simplify the description of the drawings. .

  The disposable diaper of the present invention will be described as a so-called 3P (three-piece) diaper in the embodiments described later, and is a so-called pant-type diaper, for example, having any structure and shape such as a side panel, all-in-one, inner / outer, etc. Includes disposable diapers.

(Embodiment)
FIG. 1 is a front overhead view showing a disposable diaper 1 according to an embodiment of the present invention, which includes one waistline opening WO and a pair of leg hole openings LO. The disposable diaper 1 of the embodiment is a so-called 3P (three piece) diaper. FIG. 2 is a development view of the disposable diaper 1 of FIG. In the disposable diaper 1 of FIG. 2, the front area FA and the rear area RA are separated in the vertical direction T, and the crotch area CA is located between the front area FA and the rear area RA. In the drawings, it should be noted that not all of the creases described in the concavo-convex area 41, which will be described later, may be described for ease of viewing the drawings.

  The disposable diaper 1 of the embodiment has a substantially rectangular shape composed of a top sheet, a back sheet, an absorbent element 3 composed of an absorber disposed between the top sheet and the back sheet, and a composite stretchable material 5. It includes at least a front member 5F and a rear member 5R. The composite stretchable material 5 includes a nonwoven fabric sheet 6, an elastic member 7 and a graphic sheet 8. Referring to FIG. 2, the absorbent element 3 extends in the longitudinal direction T from the front region FA to the rear region RA through the crotch region CA, that is, from the abdomen side of the wearer to the back side through the crotch.

  A top sheet is provided in the skin contact side which contacts a wearer's skin at the time of wear. The top sheet is formed of a liquid-permeable sheet such as a hydrophilic nonwoven fabric or woven fabric, an apertured plastic film, or an apertured hydrophobic nonwoven fabric.

  The back sheet is provided on the opposite side of the top sheet. The back sheet is formed from a leak-proof (liquid-impermeable) plastic film, a hardly liquid-permeable fiber nonwoven fabric, a laminate thereof, or the like. For example, it can be formed mainly from a plastic film or a laminate of a nonwoven fabric and a plastic film.

  The absorbent body absorbs the body fluid of the wearer, and is formed by an absorbent core such as pulverized pulp or superabsorbent polymer, and an absorbent sheet such as a tissue covering the absorbent core.

  Referring to FIG. 1, a graphic G is formed on the graphic sheet 8 disposed at the center in the transverse direction T of the waistline portion WP so as to face the outer side (the opposite side of the wearer's skin) when worn. The graphic G can be viewed from the outside. The graphic G is, for example, a character such as a manufacturer name or a product name, or a picture such as a character or a mark. In the present invention, a portion where the graphic G of the disposable diaper 1 is formed is referred to as a graphic forming portion 5G.

  In the disposable diaper according to the embodiment, referring to FIG. 2, the front member 5F is disposed in the front region FA, and the rear member 5R is disposed in the rear region RA. The front member 5F is joined to one of the longitudinal end portions 3LE of the absorbent element 3, and the rear member 5R is joined to the other of the longitudinal end portions 3LE of the absorbent element 3. A leg-hole opening forming portion 1LO that forms a leg-hole opening LO is formed by a portion that is narrower than the front area FA and the rear area RA of the crotch area CA.

  Furthermore, in the disposable diaper 1 according to the embodiment, referring to FIG. 2, the front member 5 </ b> F composed of one composite stretchable material 5 is crossed in the transverse direction of the front region FA from one of the transverse end portions FAE of the front region FA. A rear member 5R, which extends over the other end FAE and is composed of another composite stretchable material 5, has a transverse end of the rear region RA from one of the transverse ends RAE of the rear region RA. It extends over the other part of the part RAE.

  Hereafter, the composite elastic material 5 which is a component of the disposable diaper 1 which concerns on embodiment is demonstrated in detail. First, the example of the manufacturing method of the composite elastic material 5 is demonstrated, referring FIGS.

  FIG. 3 is a schematic view of an apparatus 10 for producing the composite stretchable material 5. Referring to FIG. 3, the nonwoven fabric sheet 6 constituting the composite stretchable material 5 is wound and held around the nonwoven fabric sheet feeding portion 11, and from there, the material transport direction MD, that is, the first direction D <b> 1 (FIG. 4 and the like). Is unwound.

  The graphic sheets 8 that are intermittently conveyed one by one are intermittently joined to the nonwoven fabric sheet 6 unwound at the joining portion 9 while being aligned at a predetermined position. At this time, although not particularly illustrated, an adhesive which is a hot melt in this example is applied in advance to one or both of the nonwoven fabric sheet 6 and the graphic sheet 8 in order to join them.

  Next, the bonded nonwoven fabric sheet 6 and graphic sheet 8 are transferred to the preheating roll 13. The preheating roll 13 preheats the bonded nonwoven fabric sheet 6 so as to be easily deformed, and is set to 50 to 130 ° C. in this example. The preheating temperature is determined according to the type of the sheet to be preheated.

  Unlike the nonwoven fabric sheet 6, the graphic sheet 8 is usually made of a resin film or the like as will be described later, and has a melting point lower than that of the nonwoven fabric. For this reason, when heat is applied to the graphic sheet 8, the graphic sheet 8 may shrink, making it difficult to visually recognize the graphic G formed on the graphic sheet 8. For this reason, in the preheating roll 13, the heat insulating material partially comprised from rubber | gum etc. is attached to the part through which the graphic sheet 8 passes so that such heat may not be applied to the graphic sheet 8. . In this way, the graphic sheet 8 can be prevented from shrinking due to preheating.

  The nonwoven fabric sheet 6 and the graphic sheet 8 that have passed through the preheating roll 13 are then transferred to the shaping device 15. In this example, the shaping device 15 includes a toothless gear roll 15A and a continuous gear roll 15B.

  FIG. 4 is a perspective view of the missing gear roll 15A and the continuous gear roll 15B constituting the shaping device 15 according to this example. As shown in FIG. 4, the continuous gear roll 15 </ b> B has a plurality of continuous teeth 27 that are spaced apart in the circumferential direction and protrude in the radial direction, and each of these continuous teeth is continuous in the width direction. Further, the toothless gear roll 15A has a plurality of discontinuous teeth 29 spaced in the circumferential direction and projecting in the radial direction, and each of these discontinuous teeth 29 is improper in the width direction by at least one missing tooth portion 31. It is continuous, and these missing tooth portions 31 are aligned in the circumferential direction.

  The nonwoven fabric sheet 6 and the graphic sheet 8 that have passed through the preheating roll 13 pass between the intermittent gear roll 15A and the continuous gear roll 15B that mesh with each other and rotate in opposite directions. Then, the nonwoven fabric sheet 6 is partially extended in the first direction D1, and each of the recesses 51 extends in the second direction D2 that is orthogonal to the first direction D1 and that is the transverse direction of the nonwoven fabric sheet 6 (see FIG. 10) and the convex part 53 (FIG. 10) are formed. The concave portions 51 and the convex portions 53 that are alternately and repeatedly formed in the first direction D1 define the concave and convex regions 41 (FIGS. 8 and 10), and these concave and convex regions 41 separate the non-protrusive regions 43 (FIGS. 8 and 10). Is formed on the nonwoven fabric sheet 6.

  FIG. 5 shows a front view of the missing gear roll 15A and the continuous gear roll 15B of FIG. In this example, the width Wvc of the missing tooth portion 31c at the center of the missing tooth gear roll 15A is 2 mm, and the width Wvs of the missing tooth portion 31s other than the missing tooth portion at the center of the missing tooth gear roll 15A is 1 mm. The widths Wg of the continuous portions of the continuous teeth 29 are all common and 4 mm. However, the dimension of each component of the missing gear roll 15A and the continuous gear roll 15B is not limited to the above dimensions. The reason why the center of the central missing tooth portion 31c is wider than the other missing tooth portion 31s is that the nonwoven fabric sheet 6 is folded when the nonwoven fabric sheet 6 described later is folded.

  In this example, the discontinuous teeth 29 are arranged in six rows in the second direction D2. However, this number of rows of discontinuous teeth 29 is for simplifying the drawing, and in practice, the number of rows of discontinuous teeth 29 is larger than this in accordance with the size of the disposable diaper 1 of the embodiment. It has become. The number of rows of discontinuous teeth 29 can be changed according to the size of the disposable diaper 1, the dimensions of each part of the shaping device 15, and the like.

  FIG. 6 is a side view of the gear rolls 15A and 15B in FIG. The side views of the toothless gear roll 15A and the continuous gear roll 15B are the same and will be described with reference to one drawing. Referring to FIG. 6, both the missing gear roll 15A and the continuous gear roll 15B include long pitch areas 15AL and 15BL and short pitch areas 15AS and 15BS on their outer peripheral surfaces. The interval along the direction perpendicular to the width direction of the tops of the discontinuous teeth 29 adjacent in the circumferential direction of the toothless gear roll 15A is longer in the long pitch area 15AL than in the short pitch area 15AS, and in the circumferential direction of the continuous gear roll 15B. The interval along the direction perpendicular to the width direction between the tops of adjacent continuous teeth 27 is longer in the long pitch region 15BL than in the short pitch region 15BS.

  7A shows a partially enlarged view of FIG. 6 in the short pitch areas 15AS and 15BS, and FIG. 7B shows a partially enlarged view of FIG. 6 in the long pitch areas 15AL and 15BL. In this example, the heights THS and THL of the teeth 27 and 29 of the toothless gear roll 15A and the continuous gear roll 15B are about 1 mm. Further, in this example, the interval TPS between the tops of the teeth 27 and 29 adjacent to the circumferential direction of the gear rolls 15A and 15B located in the short pitch regions 15AS and 15BS is about 1.91 mm, and the long pitch regions 15AL and 15BL The distance TPL between the apexes of the teeth 27 and 29 adjacent to each other in the circumferential direction of the gear rolls 15A and 15B is about 3.44 mm. However, the size and shape of each component of the toothless gear roll 15A and the continuous gear roll 15B are not limited to those described above and illustrated. As a matter of course, in the shaping apparatus 15, the continuous teeth 27 and the discontinuous teeth 29 provided in the short pitch areas 15AS and 15BS are engaged with each other, and the long pitch areas 15AL and 15BL are provided. The teeth 27 and the discontinuous teeth 29 are engaged with each other.

  Returning to FIG. 3, the thread-like elastic member 7 is wound and stored around the elastic member feeding portion 17, and is transferred to the adhesive application portion 19 by being unwound therefrom. The elastic member 7 is given a predetermined tension in advance, and the subsequent process is performed while the tension is maintained. In this example, the tension is such that the elastic member bonding magnification (= (length of elastic material in the stretched state when bonded to the nonwoven fabric sheet portion) ÷ (length of contracted state of elastic material)) is 3. It is given to the elastic member 7.

  In the adhesive application unit 19, the adhesive is placed around the elastic member 7 </ b> A that has been transferred from the elastic member feeding unit 17 by placing the elastic member 7 </ b> A along a portion where the adhesive is discharged from a slit nozzle (not shown). Applied continuously or intermittently. In this example, an adhesive is applied in addition to the portion of the elastic member 7 </ b> A that overlaps the graphic sheet 8. Therefore, in this example, it is sufficient that the adhesive is not applied to at least the portion of the elastic member 7A that overlaps the graphic forming portion 5G, but there may be a covering. In this example, the adhesive is a hot melt adhesive, but is not limited thereto.

  Next, in this example, the elastic member 7 </ b> B is disposed on the non-concave area 43 of one of the shaped nonwoven fabric sheets in the joining portion 21. The composite stretchable material 5A at this time is shown in FIG.

  Referring to FIG. 8, an uneven region 41 is formed in the short pitch biting portion 5PS formed by a part of the nonwoven fabric sheet 6 that is bitten by the continuous teeth 27 and the discontinuous teeth 29 located in the short pitch zones 15AS and 15BS. Is done. On the other hand, a long pitch biting portion 5PL composed of a part of the nonwoven fabric sheet 6 and the graphic sheet 8 bitten by the continuous teeth 27 and the discontinuous teeth 29 located in the long pitch areas 15AL and 15BS of the shaping device 15. The concave-convex region 41, that is, the concave portion 51 (FIG. 10) and the convex portion 53 (FIG. 10) are not formed. The reason why the uneven region 41 is not formed in the long pitch biting portion 5PL will be described later.

  Next, the composite stretchable material 5 </ b> A in the state of FIG. 8 is transferred to the folding device 23. In this example, the folding device 23 is a winding sailor. The folding device 23 folds the composite stretchable material 5A with the central axis CL (FIG. 8) as a folding line, and the one side portion 6U of the nonwoven fabric sheet 6 is placed on the other side portion 6L. 43 are overlaid so that they are aligned. As a result, the uneven | corrugated area | region 41 is also mutually aligned. As a result, the composite stretchable material 5A in the state shown in FIG. 8 becomes the composite stretchable material 5B in the state shown in FIG.

  In this example, the folding device 23 folds the composite stretchable material 5A along the central axis CL. However, as long as the folding device 23 is along a fold line parallel to the non-concave region 43, any position is necessary. The nonwoven fabric sheet 6 may be folded at two places.

  Furthermore, in this example, the composite stretchable material 5 is manufactured by overlapping two nonwoven fabric sheet portions 6U and 6L in one nonwoven fabric sheet 6. In another example, the composite stretchable material 5 is formed by separately shaping one nonwoven sheet and another nonwoven sheet joined to the graphic sheet 8 by the shaping device 15 described above, and thereafter these nonwoven sheets. The sheets are manufactured by overlapping so that the graphic sheet 8 is disposed between them.

  Returning to FIG. 3, the composite stretchable material 5B that has passed through the folding device 23 is transferred to the laminating press 25, and pressure is applied in the thickness direction DT. Thereby, joining with the adhesive agent between the members 6U, 6L, and 8 becomes more reliable.

  Finally, in this example, by using the roll cutter 26, the blade of the roll cutter 26 is inserted from the lower nonwoven fabric sheet 6L side (the side corresponding to the wearer's skin side in the disposable diaper 1), so that the graphic forming portion 5G Each of the elastic members 7 that extend through is cut at one place. Thereby, in the graphic formation part 5G, the contraction force of the elastic member 7 is made not to act. In another embodiment, the blade of the roll cutter 26 is inserted from the upper nonwoven fabric sheet 6U side (the side corresponding to the outer side in the disposable diaper 1).

  In this way, the final composite stretchable material 5 is completed.

  As described above, in this example, the elastic members 7 are arranged in the first direction D1 between the non-concave regions 43 of the upper nonwoven fabric sheet portion 6U and the lower nonwoven fabric sheet portion 6L, which are spaced apart from each other and aligned with each other. The disposable diaper 1 extends in the transverse direction L. However, in another example, at least a part of the elastic member 7 extends between the uneven regions 41 of the nonwoven fabric sheet portions 6U and 6L.

In this example, the nonwoven fabric sheet 6 is an SMS nonwoven fabric weighing 15 g / m ² . However, the present invention is not limited to this. As the nonwoven fabric used, a spunbond nonwoven fabric, a melt blown nonwoven fabric, a heat roll nonwoven fabric, an SMS nonwoven fabric combining a spunbond nonwoven fabric and a melt blown nonwoven fabric, an air-through nonwoven fabric, a spunlace nonwoven fabric, an airlaid nonwoven fabric, and the like can be used. Moreover, as a raw material of a nonwoven fabric sheet, polyethylene, polypropylene, polyester, acrylic, or the like can be used.

  For the nonwoven fabric sheet 6, it is preferable to use a long-fiber nonwoven fabric formed by spinning directly without cutting the fibers, such as an SMS nonwoven fabric or a spunbond nonwoven fabric. From the viewpoint that the strength of the nonwoven fabric sheet necessary for the shaping treatment is less likely to decrease, the elongation is high, and further, the nonwoven fabric sheet 6 itself is thinner and flatter than flat fiber nonwoven fabrics (flatness). ) Because it can make high fabrics.

  In this example, Lycra (registered trademark) 470 dtex is used for the elastic material 7. However, the present invention is not limited to this. An elastic yarn such as urethane spandex can be used for the elastic material 7. As the fineness, it is preferable to use a plurality of elastic yarns of about 30 to 1500 dtex and use elastic yarns having the same fineness or different finenesses. If it is 30 dtex or less, the number of elastic yarns used per unit width may increase and the production equipment may be increased. If it is 1500 dtex or more, the interval between adjacent elastic yarns increases, and the concave portion 51 and the convex portion 53 (see FIG. This is because the meshing of 10) may be uneven. As a material for the elastic member 7, synthetic rubber such as styrene-butadiene, butadiene, isoprene, or neoprene, natural rubber, EVA, SIS, SEBS, SEPS, stretchable polyolefin, polyurethane, or the like can be used.

  Furthermore, in this example, a polyethylene resin film is used for the graphic sheet 8. However, the present invention is not limited to this. For the graphic sheet 8, for example, a polypropylene resin film or the like can be used.

  Hereafter, the structure of the composite elastic material 5 manufactured by the said manufacturing method is demonstrated.

  10 shows an enlarged perspective view of a cut portion of the X portion located in the short pitch biting portion 5PS of the composite stretchable material 5 of FIG. 9, and FIG. 11 shows an exploded view of the composite stretchable material 5 of FIG. . Referring to FIGS. 10 and 11, the composite stretchable material 5 in this portion is composed of an upper nonwoven sheet portion 6U and a lower nonwoven sheet portion 6L that are overlapped with each other, and an elastic material disposed between these nonwoven sheet portions. 7 and a graphic sheet 8. In the upper nonwoven fabric sheet portion 6U and the lower nonwoven fabric sheet portion 6L, as described above, the plurality of uneven regions 41 extending linearly substantially in parallel with each other in the first direction D1 are formed in the second direction D2 by the non-recessed regions 43. It is formed so as to be separated from each other.

  Each of the uneven regions 41 includes concave portions 51 and convex portions 53 that are alternately and repeatedly formed in the first direction. Specifically, in the uneven region 41, the convex portion 53L of the lower nonwoven fabric sheet portion 6L enters the concave portion 51U of the upper nonwoven fabric sheet portion 6U, and the convex portion 53U of the upper nonwoven fabric sheet portion 6U is a concave portion of the lower nonwoven fabric sheet portion 6L. It has entered 51L. Therefore, the uneven regions 41 of the upper nonwoven fabric sheet portion 6U and the lower nonwoven fabric sheet portion 6L are adjacent to each other. On the other hand, the non-concave regions 43 formed in the upper nonwoven fabric sheet portion 6U and the lower nonwoven fabric sheet portion 6L are separated from each other in the thickness direction DT.

  12 is a front view of FIG. 10 in which the periphery of the cross section of the elastic member 7 is enlarged. Referring to FIG. 12, the two nonwoven fabric sheet portions 6U and 6L are joined to each other by the adhesive HM applied in the adhesive application section 19 via the elastic member 7 in the non-concave regions 43U and 43L. Can understand. Referring to FIG. 12, in this example, the adhesive HM is distributed so as to cover the entire periphery of the elastic member 2. In another example, the adhesive is applied only to a portion where the elastic member 7 and the non-concave regions 43U and 43L are joined.

  Here, the mechanism by which the nonwoven fabric sheet portions 6U and 6L are shaped into the shapes as shown in FIGS. 10 and 11 in the short pitch biting portion 5PS will be described. FIG. 13A and FIG. 13B show a short-pitch biting state in which the peripheral direction of the missing gear roll 15A and the continuous gear roll 15B is linearly expanded, and the short-tooth bite 15A and the continuous gear roll 15B are arranged and deformed therebetween. The expanded cross-sectional image figure of the meshing part periphery with the nonwoven fabric sheet 6 in the part 5PS is shown. FIG. 13A shows a cross-sectional view of the missing tooth portion 31 of the missing tooth gear roll 15A, and FIG. 13B shows a sectional view of the discontinuous tooth 29 portion of the missing tooth gear roll 15A.

  Referring to FIGS. 13A and 13B, on the other hand, as shown in FIG. 13A, the nonwoven fabric sheet 6 introduced into the missing tooth portion 31 of the missing gear roll 15 </ b> A is transferred to the continuous gear roll 15 </ b> B by the radius of the continuous gear roll 15 </ b> B. A non-concave region 43 is formed without being deformed although pushed outward in the direction. On the other hand, as shown in FIG. 13B, the non-woven fabric sheet 6 bitten between the discontinuous teeth 29 of the missing gear roll 15A and the continuous teeth 27 of the continuous gear roll 15B is locked to the tooth tip portions 33A and 33B. Will be. By doing so, the tooth tip portion 33B, the tooth tip portion 33A and the tooth tip portion 33B adjacent to each other in a three-point bend shape are stretched. As a result, the convex portion 53 having the tooth tip portion 33A as the top is formed by plastic deformation beyond the range in which the nonwoven fabric sheet 6 is elastically deformed, that is, permanent deformation instead of temporary deformation.

  Furthermore, it is extended between the tooth tip portion 33A, the tooth tip portion 33B and another tooth tip portion 33A that are adjacent to each other in a three-point bend shape, thereby forming a recess 53 having the tooth tip portion 33B as a bottom. At this time, the non-convex region 43 of the nonwoven fabric sheet 1 pressed by the continuous gear roll 15B at the toothless portion 31 of the missing gear roll 15A and the tooth tip portion 33B of the continuous gear roll 15B at the discontinuous tooth 29 portion of the missing gear roll 15A are locked. The position of the radial direction in each gear roll 15A, 15B with the bottom part of the recessed part 51 of the nonwoven fabric sheet 6 to become becomes substantially the same. That is, the thickness in the nonwoven fabric sheet 6 becomes substantially the same. Therefore, even after the concavo-convex region 41 and the non-concave region 43 are formed on the nonwoven fabric sheet 6, they exist on substantially the same surface. Here, the said surface is defined as the virtual reference plane RP about each nonwoven fabric sheet part 6U and 6L. Here, the reference plane RP is planar, and the non-concave area 43 is expanded on the reference plane RP. In addition, since each nonwoven fabric sheet part 6U and 6L is each provided with the softness | flexibility, the reference plane RP is not necessarily planar.

  Therefore, in terms of the relationship between the convex portion 53 and the reference surface RP, the convex portion 53 protrudes from the reference surface RP, that is, from the non-concave region 43 in the thickness direction. The concave portion 51 reaches the non-concave region 43 between the two convex portions 53 adjacent to each other.

  Further, a mechanism in which the convex portion 53 enters the concave portion 51 in the manufacturing process will be described here.

  Referring to FIG. 10, it can be understood that the convex portions 53 are separated from the reference surfaces RP of the upper nonwoven fabric sheet 6U and the lower nonwoven fabric sheet 6L by an amount protruding from the reference surface RP. That is, the non-concave regions 43U and 43L facing each other between the upper nonwoven fabric sheet 6U and the lower nonwoven fabric sheet 6L are separated from each other. This is because one side of the shaping device 15 is a missing gear roll 15A and the other is a continuous gear roll 15B, so that the convex portion 53 protrudes in only one direction from the reference plane RP, and the side having the convex portion 53. The nonwoven fabric sheets 6U and 6L are superposed so that the surfaces thereof face each other, and thus the respective reference surfaces RP of the nonwoven fabric sheets 6U and 6L are superimposed on different outer surfaces of the composite stretchable material 5. To be achieved. Therefore, the elastic member 7 extended in the space defined by a fixed space | interval can be arrange | positioned between the non-uneven | corrugated area | regions 43U and 43L of each nonwoven fabric sheet 6U and 6L. Eventually, by disposing the elastic member 7 between the nonwoven fabric sheet portions 6U and 6L, the operation of the convex portion 53 entering the concave portion 51 is not hindered.

  Furthermore, it can be explained by the following mechanism that the convex portion 53 enters the concave portion 51 in the manufacturing process.

  Since the nonwoven fabric is generally soft and easily deformed, in order to transport the nonwoven fabric sheet in the manufacturing process, a constant tension is usually applied in the material transport direction MD, that is, the first direction D1. In this example, the folding device 23 is used when folding the composite stretchable material 5A in the above step.

  When passing through the folding device 23, tension is further applied to the nonwoven fabric sheet portion 6U by the folding device 23 in the first direction D1. Specifically, this tension is applied by a sailor edge (not shown) of the entraining sailor which is one specific embodiment of the folding device 23. Thereby, upper nonwoven fabric sheet part 6U will extend in the 1st direction D1 rather than lower nonwoven fabric sheet part 6L. As a result, the uneven | corrugated pitch (length per period along the 1st direction of the repetition of the recessed part 51 and the convex part 53 currently formed in the uneven | corrugated area | region 41) of the uneven | corrugated area | region 41 of the upper nonwoven fabric sheet part 6U is a lower nonwoven fabric sheet. It will be slightly larger than the uneven pitch of the uneven region 41 of the portion 6L.

  After that, when the upper nonwoven fabric sheet portion 6U is overlaid on the lower nonwoven fabric sheet portion 6L, the tension is released and the tension applied before the introduction to the folding device 23 is applied. Will return. Next, the uneven pitch returns to the state before the composite stretchable material 5 </ b> A is introduced into the folding device 23. Therefore, the relative positions of the concave portions 51U and convex portions 53U of the upper nonwoven fabric sheet portion 6U and the convex portions 53L and concave portions 51L of the lower nonwoven fabric sheet portion 6L change. As a result, when the concavo-convex pitch of these portions becomes the same as each other when the tension is released, the shape of the concave portion 51 and the convex portion 53 contributes to offset by a half pitch, thereby causing the convex portion 53 to be concave. 51.

  In the composite stretchable material 5, when the nonwoven fabric sheet 6 is stretched in the thickness direction DT in the uneven region 41, when the composite stretchable material 5 is in a contracted state, the thickness of the composite stretchable material 5 in the uneven region 41 is It becomes thicker than the thickness in the non-convex region 43. Therefore, the touch when the wearer touches the composite stretchable material 5 is good. The non-concave area 43 hardened by the adhesive applied around the elastic member 7 protrudes from the uneven area 41, and the non-concave area 43 touches the wearer's body before the uneven area 41. This is because it prevents the user from feeling a foreign object. For the same reason, it is more preferable that the diameter of the elastic member 7 is slightly smaller than the interval between the non-concave regions 43 aligned with each other.

  In the above, the manufacturing method at the time of using the folding apparatus 23 was described. In another example, the composite stretchable material 5 as described above is manufactured without using the folding device 23 by separately shaping two non-woven sheets into the same shape and overlapping them. In this case, when the nonwoven fabric sheets are overlapped with each other, a higher tension is applied to one nonwoven fabric sheet in the first direction than the other nonwoven fabric sheet. Thereby, the same structure as the case where two nonwoven fabric sheet parts 6U and 6L of one nonwoven fabric sheet 6 are piled up can be taken. This is because the convex portions 53U and 53L of the nonwoven fabric sheet portions 6U and 6L enter the concave portions 51L and 51U of the nonwoven fabric sheet portions 6L and 6U for the reason described above. However, it should be noted that when the weights of the two nonwoven fabric sheets and the thickness of the fibers are different from each other, it is necessary to adjust the tension applied to each nonwoven fabric sheet so that the uneven pitch of each other is matched.

  Further, here, in the long pitch biting portion 5PL, the nonwoven fabric sheet portions 6U and 6L and the graphic sheet 8 are bitten by the teeth 27 and 29 located in the long pitch region 15AL of the missing gear roll 15A and the continuous gear roll 15B. Regardless, the reason why it is not shaped will be described with reference to FIG. 13C. FIG. 13C shows a state in which the circumferential direction of the missing gear roll 15A and the continuous gear roll 15B is linearly developed, and the missing gear roll 15A and the continuous gear roll 15B, and the long pitch biting portion 5PL arranged and deformed therebetween. The expanded cross-sectional image figure of the meshing part periphery with the nonwoven fabric sheet 6 and the graphic sheet 8 is shown.

  In the missing gear roll 15A and the continuous gear roll 15B, as described above, in the long pitch areas 15AL and 15BS, the intervals between the tops of the teeth 27 and 29 are longer than in the short pitch areas 15AS and 15BS. Therefore, in the long pitch regions 15AL and 15BS, the nonwoven fabric sheet 6 and the graphic sheet 8 are less stretched than the short pitch regions 15AS and 15BS, particularly the graphic sheet 8. In the toothless gear roll 15A and the continuous gear roll 15B according to the above-described example, the interval between the tops of the teeth 27 and 29 adjacent in the circumferential direction is extended until the nonwoven fabric sheet 6 is plastically deformed in the short pitch regions 15AS and 15BS. On the other hand, in the long pitch areas 15AL and 15BL, the nonwoven fabric sheet 6 and the graphic sheet 8 are selected at least in a range where the graphic sheet 8 is elastically deformed, that is, in a range where the graphic sheet 8 is temporarily deformed rather than permanently. Yes. This is because if the graphic sheet 8 is stretched and shaped, the graphic G formed on the graphic sheet 8 is deformed, so that it is difficult to visually recognize the graphic G.

  However, the degree of stretching for plastic deformation of the nonwoven fabric sheet 6 and the graphic sheet 8 varies depending on the material and thickness thereof. Therefore, it is preferable to determine the optimum distance between the apexes of the teeth 27 and 29 in the short pitch areas 15AS and 15BS and the long pitch areas 15AL and 15BL, for example, through experiments. In addition, the degree of stretching of the sheets 6 and 8 (nonwoven fabric sheet 6 and graphic sheet 8) can be changed by changing not only the distance between the tops of the teeth 27 and 29 but also the height of the teeth 27 and 29. it can.

  In the above example, the teeth 27 and 29 are provided in the long pitch areas 15AL and 15BL, but the teeth 27 and 29 may not be provided in the long pitch areas 15AL and 15BL. This is because the graphic sheet 8 is not shaped and the graphic G is easily visible. (In this case, the long pitch areas 15AL and 15BL can also be referred to as “toothless areas”.) At this time, the graphic sheet 8 passes between the long pitch areas 15AL and 15BL of the missing gear roll 15A and the continuous gear roll 15B. . Naturally, in this case, the uneven region 41, that is, the concave portion 51 and the convex portion 53 are not formed in the nonwoven fabric sheet portions 6U and 6L passing between the long pitch regions 15AL and 15BL. That is, the nonwoven fabric sheet portions 6U and 6L passing between the long pitch regions 15AL and 15BL of the missing gear roll 15A and the continuous gear roll 15B are not shaped.

  However, as in the above example, the teeth 27 and 29 are provided in the long pitch areas 15AL and 15BL, and when the sheets 6 and 8 are bitten, the tooth tip portions 33A and 33B lock the sheets 6 and 8. This makes it possible to suppress the useless movement of the sheets 6 and 8 and thus to realize controlled feeding of the sheets 6 and 8.

  By the way, as explained at the beginning of the description relating to the embodiment, the disposable diaper 1 of the embodiment is manufactured using the above-described manufacturing method so as to fit the size of the disposable diaper 1, and is appropriately cut and stretched. The material 5 is provided as a front member 5F and a rear member 5R. At this time, in the disposable diaper 1 of the embodiment, the composite stretchable material 5 is composed of the composite stretchable material 5 such that the first direction D1 of the composite stretchable material 5 is substantially aligned with the transverse direction L of the disposable diaper 1. Positioning so that the second direction D2 is substantially aligned with the longitudinal direction T of the disposable diaper 1, and the upper nonwoven sheet portion 6U is located on the outside and the lower nonwoven sheet portion 6L is located on the skin side of the wearer Is done.

  Hereafter, with reference to FIG. 14A and FIG. 14B, the effect | action that it is easy to visually recognize the graphic G of the disposable diaper 1 of embodiment is demonstrated. FIG. 14A is a schematic cross-sectional view of the uneven region of the front member 5F in the disposable diaper of the comparative example, and FIG. 14B is a schematic cross-sectional view of the uneven region 41 of the front member 5F in the disposable diaper 1 of the embodiment. In FIG. 14A and FIG. 14B, the joining location of each structural member 6U, 6L, 7, 8 of the front side member 5F is shown by showing the dotted line corresponding to the application location of the adhesive agent HM. The front member 5F of the comparative example is provided with teeth similar to the teeth 27 and 29 provided in the short pitch regions 15AS and 15BS in the above example over the entire circumference of the missing gear roll 15A and the continuous gear roll 15B. It is shaped by the shaping device 15. That is, the front member 5F of the comparative example is different from the front member 5F of the embodiment, and the long pitch biting portion 5PL also has the same uneven pitch as that of the short pitch forming portion 5PS of the front member 5F of the embodiment, and is uniform throughout. Is shaped.

  As described in the example of the manufacturing method described above, in the disposable diaper 1 according to the embodiment, no adhesive is applied to the elastic member 7 in the graphic forming unit 5G, and the elastic member 7 is cut at one place. ing. The disposable diaper of a comparative example is also made the same. Therefore, the cut end portion 7E of the elastic member contracts as illustrated, and the contraction force of the elastic member 7 does not substantially act on the graphic forming portion 5G. In this case, the graphic forming portion 5G located at the center in the transverse direction T of the front member 5F as shown in FIG. 14A has the same load as the portion corresponding to the side WPE (FIG. 1) of the waistline portion. Unlike the comparative example in which the shape is applied, the graphic sheet 8 of the disposable diaper 1 of the embodiment shown in FIG. 14B is not shaped, and more specifically, the graphic forming portion 5G of the front member 5F. There is no shaping.

  Thereby, compared with the disposable diaper 1 of the comparative example, the disposable diaper 1 of the embodiment is not shaped on the graphic sheet 8 and does not extend the graphic G formed on the graphic sheet 8. It is easy to see and is excellent in appearance of disposable diapers.

  Further, the front member 5F of the disposable diaper 1 of the embodiment includes a long pitch biting portion 5PL that is bitten by the long pitch regions 15AL and 15BL of the shaping device 15, and the portion is not shaped, and thus stretched. Not. Therefore, in the long pitch biting part 5PL, there is little damage of the nonwoven fabric sheet 6 and the graphic sheet 8, and intensity | strength is high compared with the conventional disposable diaper.

  Further, if the cut end 7 of the elastic member can be viewed from the outside, it is not preferable in terms of appearance. Therefore, in order to further improve the appearance of the disposable diaper, a disposable diaper as shown in FIG. 14C is further proposed. FIG. 14C is a schematic cross-sectional view of the uneven region 41 of the front member 5F in the modified disposable diaper according to the embodiment. In the disposable diaper of the modified example, a concealing portion 5PH having an uneven pitch shorter than that of the short pitch biting portion 5PS is formed between the long pitch biting portion 5PL and the short pitch biting portion 5PS. Therefore, in the part corresponding to the concealing part 5PH of the gear rolls 15A and 15B, that is, the part between the long pitch areas 15AL and 15BL and the short pitch areas 15AS and 15BS, the interval between the tops of the adjacent teeth 27 and 29 is It is shorter than TPS in the short pitch areas 15AS and 15BS.

  In the disposable diaper according to this modification, the cut end portion 7E of the elastic member 7 overlaps the concealing portion 5PH. Accordingly, since the cut end portion 7E is difficult to visually recognize from the outside by the concealment portion 5PH having more folds than the other portions, the disposable diaper according to this modified example is the disposable diaper 1 according to the embodiment from the viewpoint of appearance. Better than.

  From this, the mechanism which the disposable diaper 1 of embodiment is easy to wear compared with the conventional disposable diaper is demonstrated.

  When the wearer wears the pants-type disposable diaper 1, the wearer's feet touch the waistline portion WP (FIG. 1), in particular by touching the side WPE (FIG. 1) of the waistline portion. Thus, the force acts in the direction in which the wearer's foot is passed, and in particular in the longitudinal direction T.

  In the disposable diaper 1 of the embodiment, the composite stretchable material 5 is disposed on the waistline portion WP, and the elastic force of the elastic member 7 does not act on the graphic forming portion 5G. In the part WPE, the structure as shown in FIG. 10 is maintained.

  As described above, the composite stretchable material 5 has a shape in which the concave portions 51 and the convex portions 53 are alternately formed in the first direction in the concave and convex region 41. As can be understood from the cross section on the near side of FIG. 10, the cross section along the first direction of the uneven region 41 has a corrugated shape, and this shape is disposed inside a general cardboard. It works like the center of the cross-sectional waveform. Furthermore, the uneven | corrugated area | region 41 of two nonwoven fabric sheet parts 6U and 6L is mutually adjacent, More specifically, the convex parts 53U and 53L of the nonwoven fabric sheet parts 6U and 6L are the recessed parts 51L of the nonwoven fabric sheet parts 6L and 6U, Since it has entered 51U, the two nonwoven sheet portions 6U and 6L support each other and cooperate. As a result, the rigidity of the composite stretchable material 5 with respect to the compressive force in the second direction D2, and hence the disposable diaper 1 in the longitudinal direction T is higher than that of the composite stretchable material formed from two non-shaped nonwoven fabric sheet portions. It will be expensive.

  15A and 15B are diagrams showing examples of shapes before and after the composite stretchable material 5 is compressed in the second direction, respectively. 16A and 16B are examples of shapes before and after the composite stretchable material 5 ′ formed from the two non-shaped nonwoven fabric sheet portions 6 ′ is compressed in the second direction, respectively. FIG. Even when a compressive force is applied in the second direction, the composite stretchable material 5 is less likely to bend between the elastic members 7 due to the compression rigidity resulting from the shaped shape and configuration in the concavo-convex region 41, that is, the seat. It is hard to bend. Referring to FIG. 15B, the composite stretchable material 5 is not bent at the uneven region 41, but is slightly bent at the non-recessed region 43. On the other hand, referring to FIG. 16B, in the non-shaped composite stretchable material 5 ′, when a compressive force is applied in the second direction, the nonwoven fabric sheet portion 6 positioned between the elastic members 7 Since 'moves freely without generating a force due to its shape, the interval between the elastic members 7 is shortened. Accordingly, the nonwoven fabric sheet portion 6 ′ protrudes in the thickness direction, so that large wrinkles are likely to occur in the composite stretchable material 5 ′ that is not shaped. From the above, it can be understood that the composite stretchable material 5 has higher compressive strength in the second direction D2 than the conventional composite stretchable material 5 '. As a result, the disposable diaper 1 of the embodiment does not easily generate a large wrinkle that may cause the wearer's foot to be caught during the process of passing the wearer's foot from the waist opening WO to the leg opening LO during wearing. Furthermore, it becomes easy to transmit the force in the vertical direction T applied when the wearer wears the disposable diaper 1. Therefore, the disposable diaper 1 of embodiment is easier to wear than the conventional disposable diaper.

  Furthermore, in order to confirm that the compressive rigidity of the composite stretchable material 5 is high, a compressive strength test described below was performed.

-Test method-
The compressive strength test carried out for this purpose is a test similar to the ring crush test (JIS P8126) used for the compressive strength test of paper and paperboard. In this compressive strength test, as shown in FIG. 17A, a test piece 61 having a length of 100 mm in the first direction and 20 mm in the second direction is prepared. Next, as shown in FIG. 17B, the test piece 61 is formed into a ring shape, and ends thereof are overlapped by 2 mm, and a stapler (the stapler needle 63 is shown in FIG. 17B). It is formed by being joined at only one place at substantially the center.

  In order to carry out this compressive strength test, the test piece 61 is placed on the test bench, and the compressive force is vertically lowered with respect to the entire upper edge of the test piece 61 until the test piece 61 buckles. Applied. FIG. 18 is a graph showing an example of the transition of time T [s] and compression force Fc [N] in the compression strength test. Referring to FIG. 16, it can be understood that a compressive force is gradually applied to the test piece 61 and then the test piece 61 cannot buckle the compressive force at the time indicated by reference numeral 65 in FIG. The compressive force applied at the time of buckling is used as an evaluation standard for the compressive strength test.

  This compressive strength test was performed on the samples shown below.

(Example)
The test piece 61 of the example was prepared from the composite stretchable material 5 manufactured by the example of the above-described manufacturing method, and the test piece 61 having the size of the above-described test piece 61 was used. In the test piece 61 of an Example, the nonwoven fabric sheet 6 is shape | molded by the uniform uneven | corrugated pitch with the shaping | molding apparatus 15 whose space | interval of the adjacent teeth 27 and 29 is 1 mm, and the space | interval of the elastic members 7 is the space | interval. An SMS nonwoven fabric of 5 mm and weighing 15 g / m ² was used.

(Comparative example)
The composite stretchable material 5 ′ prepared in exactly the same manner as the composite stretchable material 5 except that the non-shaped nonwoven fabric sheet portion 6 ′ is used is the same size as the test piece 61 described above. .

  The results of the compressive strength test are shown below. In addition, the following measurement results are average values of the measurement results of the three test pieces in both the examples and the comparative examples.

  As shown in Table 1, it was confirmed that the composite stretchable material 5 of the embodiment had sufficiently higher compressive strength in the second direction than the conventional composite stretchable material that was not shaped.

In summary, according to the disposable diaper 1 of the embodiment, the following operational effects can be achieved.
(1) Since the graphic sheet 8 is not shaped, in particular, the graphic forming portion 5G is not shaped, the graphic G formed on the graphic sheet 8 can be easily seen, and consequently the disposable diaper 1 Good appearance.
(2) The composite stretchable material 5 manufactured in the example of the manufacturing method described above is disposed on the waistline portion WP of the disposable diaper 1 where the wearer's foot is easily caught. Therefore, in the waist part WP of the disposable diaper 1 of the present invention, a large heel is not formed unlike the conventional disposable diaper, and the disposable diaper 1 of the present invention is in close contact with the wearer's body and feels good.

(3) Furthermore, a structure as shown in FIG. 10 is formed in the side portion WPE of the waistline portion, which is the portion where the wearer's foot is most easily caught. Therefore, since it becomes easy to transmit the force of the vertical direction T applied when making a wearer wear the disposable diaper 1, it is easy to make a wearer wear the disposable diaper 1. FIG.
(4) Moreover, it is preferable that the composite elastic material 5 has a more excellent touch from the viewpoint of touching the wearer's skin. As described above, since the thickness of the composite stretchable material 5 when it is in the contracted state is thicker in the uneven region 41 than in the non-recessed region 43, it is hardened by the adhesive applied around the elastic member 7. The uneven | corrugated area | region 43 does not touch a wearer's skin directly. As a result, the touch when touching the composite stretchable material 5 is good.

  (5) Moreover, it is preferable that the composite elastic material 5 has more excellent aesthetics from the viewpoint of being visually recognized from the outside. With the configuration of the composite stretchable material 5 in which the convex portion 53 enters the concave portion 51, regular wrinkles as formed can be formed even in the contracted state. As a result, the composite stretchable material 5 that is generally thin and has a smooth surface can be produced, so that the wearer's foot can easily slip on the surface when worn, and thus the wearer can easily wear the disposable diaper 1. .

  (6) Moreover, in the disposable diaper of embodiment, since the long-fiber nonwoven fabric is used as a raw material of the composite elastic material 5, it is thinner than using a short-fiber nonwoven fabric as a raw material, and has a high planarity. 5 can be formed. Therefore, it is easier to pass the foot through the disposable diaper 1 and the wearer can easily wear the disposable diaper 1.

  (7) The long pitch biting portion 5PL is not shaped, and the nonwoven fabric sheet 6 and the graphic sheet 8 are less damaged and high in strength at the portion.

  It should be noted that all features that can be understood by those skilled in the art from the present specification, drawings, and claims, even if these features are described in combination only in relation to certain other features. As long as the features are not explicitly excluded, or unless the technical aspects are impossible or meaningless combinations, independently and additionally with other features or groups of features disclosed herein, any Can be combined and combined.

  For example, the present invention includes the following modified embodiments.

  In the present invention, it is only necessary that the contraction force of the elastic member 7 does not substantially act in the graphic forming portion 5G. In another embodiment, the elastic member 7 is not cut, but the graphic forming portion 5G. The elastic member 7 is intermittently disposed so that the elastic member 7 is not disposed on the surface.

  In the example of the method for manufacturing the composite stretchable material 5 described above, the adhesive is not applied to the graphic forming portion 5G on the elastic member 7, but the blade of the roll cutter 26 is inserted into the portion to be positioned in the graphic forming portion 5G. Each of the elastic members 7 is cut at one place. However, in another example, an adhesive is applied to the entire elastic member 7. Then, by using a roll cutter having a larger number of blades than the roll cutter 26 of the above-described example, the elastic member 7 is finely divided at a plurality of locations to the extent that the elastic member 7 cannot exert a contracting force in the graphic forming unit 5G. Disconnect. In this way, the contraction force of the elastic member 7 can be substantially prevented from acting.

  Referring to FIG. 14A, in the front member 5F of the disposable diaper 1 of the embodiment, that is, the composite stretchable material 5, the graphic sheet 8 is superposed so as to be positioned outside the elastic member 7 when the disposable diaper 1 is worn. Yes. At this time, as described above, when the adhesive is applied to the entire elastic member 7 to cut it finely, the cut piece of the elastic member 7 remains on the spot, and this can be visually recognized. From the viewpoint of appearance, it is not preferable. Since the cut piece of the elastic member 7 exists in the position which overlaps with the graphic sheet 8, the cut piece of the elastic member 7 is a graphic by arrange | positioning the graphic sheet 8 outside the elastic member 7 like embodiment. It is concealed by the sheet 8. Therefore, even in such a case, the disposable diaper 1 of the embodiment is preferable from the viewpoint of appearance.

  In the disposable diaper 1 according to the above-described embodiment, the central portion in the transverse direction L of the waistline portion WP where the graphic sheet 8 is located is not shaped. Therefore, when the uneven | corrugated area | region 41 is provided with the recessed part 51 and the convex part 53 which are repeated alternately along the cross direction L and is extended in the vertical direction T partially, specifically in the side part WPE of a waist part. I can say that. In consideration of the effect of easily wearing the disposable diaper 1 described above, it is sufficient that at least the side part WPE of the waistline portion is shaped, in other words, the concave portion 51 and the convex portion 53 are formed at least on the side part WPE of the waistline portion. What is necessary is just to be provided as mentioned above.

  In the composite stretchable material 5 manufactured by the above example, the long pitch biting portion 5PL is formed over the entire width in the second direction. However, from the viewpoint of appearance, the long pitch biting portion 5PL may not be formed over the entire width in the second direction, and only a part, that is, only the graphic forming portion 5G has the long pitch biting portion 5PL. What is necessary is just to be provided. In particular, a portion generally called a waist gather in the vicinity of the waistline opening WO of the waistline portion WP is preferably shaped similarly to the side portion WPE of the waistline portion. It is because the touch of the part becomes favorable.

  In the composite stretchable material 5 manufactured according to the above-described example, the roll cutter 26 is used for cutting the elastic member 7, but in another example, the elastic member 7 is cut by applying heat and pressure with a heat embossing device. To do. This is advantageous because the elastic member 7 can be cut without cutting the nonwoven fabric sheet 6.

  In the disposable diaper 1 according to the embodiment, the graphic sheet 8 is disposed only on the front member 5F, but the graphic sheet 8 may be disposed only on the rear member 5R, or both the front member 5F and the rear member 5R. A graphic sheet 8 may be arranged.

  In the disposable diaper 1 according to the embodiment, the upper nonwoven fabric sheet portion 6U is positioned on the outside, and the lower nonwoven fabric sheet portion 6L is positioned on the wearer's skin side. In another embodiment, 6 U of upper nonwoven fabric sheet parts are located in a wearer's skin side, and 6 L of lower nonwoven fabric sheet parts are located outside.

  The present invention is defined as follows.

(1) A method of manufacturing a disposable diaper that includes a longitudinal direction and a transverse direction orthogonal to the longitudinal direction, and includes a waistline opening and a pair of leghole openings,
A composite composed of a first nonwoven fabric sheet portion and a second nonwoven fabric sheet portion overlapping each other, and an elastic member and a graphic sheet disposed between the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion. Producing a stretchable material;
Forming the disposable diaper using the composite stretchable material in a waistline portion;
Including
The step of manufacturing the composite stretchable material includes:
A graphic sheet joining step of joining the graphic sheet to any one of the nonwoven sheet portions;
Of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion, the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are formed so that at least a portion where the graphic sheet is joined is not shaped. A shaping stage for shaping,
Defining a plurality of concavo-convex regions comprising convex and concave portions that are alternately repeated along the first direction and extend in the second direction;
Defining at least one non-recessed area that separates these uneven areas from each other in the second direction;
The shaping stage;
An elastic member disposing step of disposing the elastic member to which the adhesive stretched in the first direction is applied on one of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion; ,
Overlapping in which the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are overlapped and joined so that the uneven regions and the non-recessed regions are aligned with each other with respect to the second direction. Stages,
Including
In the graphic sheet, a graphic is formed on the surface facing outward when worn in the center in the transverse direction of the waistline portion,
In the graphic forming portion which is the portion where the graphic is formed in the central portion in the transverse direction of the waistline portion, the contraction force of the elastic member is substantially prevented from acting.
A method of manufacturing disposable diapers.

(2) The shaping step includes a step of passing the non-woven sheet portion to which the graphic sheet is joined between a continuous gear roll and a toothless gear roll rotating in opposite directions while meshing with each other,
The continuous gear roll has a plurality of continuous teeth spaced apart in the circumferential direction, and each continuous tooth is continuous in the width direction;
The toothless gear roll has a plurality of discontinuous teeth spaced in the circumferential direction, and each discontinuous tooth is discontinuous in the width direction by at least one missing tooth portion. Aligned in the direction,
A method for producing the disposable diaper according to (1).

(3) The continuous gear roll and the toothless gear roll include a short pitch area and a long pitch area,
The continuous teeth and the discontinuous teeth located in the long pitch region are meshed with each other, and the continuous teeth and the discontinuous teeth located in the short pitch region are meshed,
In the continuous gear roll, the interval between the tops of the continuous teeth adjacent in the circumferential direction located in the long pitch region is longer than the interval between the tops of the continuous teeth adjacent in the circumferential direction positioned in the short pitch region. ,
Before the Kiketsuha gear roll, the interval between the top of the discontinuous teeth circumferentially adjacent located at the long pitch region, said short pitch region said discontinuous teeth circumferentially adjacent located at the top of each other Longer than the interval,
The sheet entrained by the continuous teeth and the discontinuous teeth located in the short pitch area is formed with the recesses and the protrusions, while the continuous teeth and the irregularities located in the long pitch area are formed. In the sheet bitten by continuous teeth, the concave portion and the convex portion are not formed,
The graphic sheet is caught by the trailing teeth and the discontinuous teeth located in front Symbol length pitch range,
A method for producing the disposable diaper according to (2).

(4) The continuous gear roll and the toothless gear roll include a short pitch area and a long pitch area,
While the continuous teeth and the discontinuous teeth are provided in the short pitch area, the continuous teeth and the discontinuous teeth are not provided in the long pitch area,
The continuous teeth and the discontinuous teeth located in the short pitch region are meshed,
In the sheet bitten by the continuous teeth and the discontinuous teeth located in the short pitch region, the concave portion and the convex portion are formed,
The graphic sheet passes between the long pitch region of the continuous gear roll and the toothless gear roll,
A method for producing the disposable diaper according to (2).

(5) The non-woven fabric sheet portion passing between the long pitch regions of the continuous gear roll and the non-tooth gear roll is not shaped,
(3) The method to manufacture the disposable diaper as described in (4).

(6) Furthermore, in the said graphic formation part, the step which cut | disconnects each said elastic member in one place or several places,
The method to manufacture the disposable diaper as described in any one of (1)-(4).

(7) The elastic member extends in the transverse direction between the non-convex regions of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion, which are aligned with each other while being separated from each other.
(1) The method to manufacture the disposable diaper as described in any one of (6).

(8) In the composite stretchable material, the graphic sheet is overlaid so as to be positioned outside the elastic member when the disposable diaper is worn.
The method to manufacture the disposable diaper as described in any one of (1)-(7).

(9) The first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are formed from a long fiber nonwoven fabric,
The method to manufacture the disposable diaper as described in any one of (1)-(8).

(10) In the concave and convex regions of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion located at least on the side portion of the waistline portion, the convex portion of the first nonwoven fabric sheet portion is the second And the convex portion of the second nonwoven fabric sheet portion enters the concave portion of the first nonwoven fabric sheet portion.
The method to manufacture the disposable diaper as described in any one of (1)-(9).

(11) Each of the convex portions protrudes in the thickness direction from the non-convex region,
Each of the concave portions reaches the non-concave region between the two convex portions adjacent to each other.
(1) The method to manufacture the disposable diaper as described in any one of (10).

(12) The first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion that overlap each other are formed in a single nonwoven fabric sheet,
The single nonwoven sheet is folded along a fold line parallel to the transverse direction and overlaid on each other;
The method to manufacture the disposable diaper as described in any one of (1)-(11).

(13) The elastic member having a contraction force does not exist in the graphic forming unit.
The method to manufacture the disposable diaper as described in any one of (1)-(12).

(14) A concealing portion having an uneven pitch shorter than the graphic forming portion and the side portion of the waistline portion is provided between the graphic forming portion and the side portion of the waistline portion.
The disposable diaper according to (13).

DESCRIPTION OF SYMBOLS 1 Disposable diaper 5 Composite stretchable material 5G Graphic formation part 6 Nonwoven fabric sheet 6U Upper nonwoven fabric sheet part (1st or 2nd nonwoven fabric sheet part)
6L lower nonwoven sheet portion (second or first nonwoven sheet portion)
7 Elastic member 8 Graphic sheet 41 Uneven region 43 Non-uneven region 51 Concave portion 53 Convex portion D1 First direction D2 Second direction WO Trunk opening LO Leg opening T Longitudinal direction L Transverse direction WP Trunk region G Graphic

Claims (14)

A method for manufacturing a disposable diaper including a longitudinal direction and a transverse direction orthogonal to the longitudinal direction, and comprising a waist opening and a pair of leg openings,
A composite composed of a first nonwoven fabric sheet portion and a second nonwoven fabric sheet portion overlapping each other, and an elastic member and a graphic sheet disposed between the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion. Producing a stretchable material;
Forming the disposable diaper using the composite stretchable material in a waistline portion;
Including
The step of manufacturing the composite stretchable material includes:
A graphic sheet joining step of joining the graphic sheet to any one of the nonwoven sheet portions;
Of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion, the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are formed so that at least a portion where the graphic sheet is joined is not shaped. A shaping stage for shaping,
Defining a plurality of concavo-convex regions comprising convex and concave portions that are alternately repeated along the first direction and extend in the second direction;
Defining at least one non-recessed area that separates these uneven areas from each other in the second direction;
The shaping phase;
An elastic member disposing step of disposing the elastic member to which the adhesive stretched in the first direction is applied on one of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion; ,
Overlapping in which the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion are overlapped and joined so that the uneven regions and the non-recessed regions are aligned with each other with respect to the second direction. Stages,
Including
In the graphic sheet, a graphic is formed on the surface facing outward when worn in the center in the transverse direction of the waistline portion,
In the graphic forming portion which is the portion where the graphic is formed in the central portion in the transverse direction of the waistline portion, the contraction force of the elastic member is substantially prevented from acting.
A method of manufacturing disposable diapers. The shaping step includes passing the non-woven sheet portion to which the graphic sheet is bonded between a continuous gear roll and a non-tooth gear roll rotating in opposite directions while meshing with each other;
The continuous gear roll has a plurality of continuous teeth spaced apart in the circumferential direction, and each continuous tooth is continuous in the width direction;
The toothless gear roll has a plurality of discontinuous teeth spaced in the circumferential direction, and each discontinuous tooth is discontinuous in the width direction by at least one missing tooth portion. Aligned in the direction,
A method for producing the disposable diaper according to claim 1. The continuous gear roll and the toothless gear roll include a short pitch area and a long pitch area,
The continuous teeth and the discontinuous teeth located in the long pitch region are meshed with each other, and the continuous teeth and the discontinuous teeth located in the short pitch region are meshed,
In the continuous gear roll, the interval between the tops of the continuous teeth adjacent in the circumferential direction located in the long pitch region is longer than the interval between the tops of the continuous teeth adjacent in the circumferential direction positioned in the short pitch region. ,
Before the Kiketsuha gear roll, the interval between the top of the discontinuous teeth circumferentially adjacent located at the long pitch region, said short pitch region said discontinuous teeth circumferentially adjacent located at the top of each other Longer than the interval,
The sheet entrained by the continuous teeth and the discontinuous teeth located in the short pitch area is formed with the recesses and the protrusions, while the continuous teeth and the irregularities located in the long pitch area are formed. In the sheet bitten by continuous teeth, the concave portion and the convex portion are not formed,
The graphic sheet is caught by the trailing teeth and the discontinuous teeth located in front Symbol length pitch range,
A method for producing the disposable diaper according to claim 2. The continuous gear roll and the toothless gear roll include a short pitch area and a long pitch area,
While the continuous teeth and the discontinuous teeth are provided in the short pitch area, the continuous teeth and the discontinuous teeth are not provided in the long pitch area,
The continuous teeth and the discontinuous teeth located in the short pitch region are meshed,
In the sheet bitten by the continuous teeth and the discontinuous teeth located in the short pitch region, the concave portion and the convex portion are formed,
The graphic sheet passes between the long pitch region of the continuous gear roll and the toothless gear roll,
A method for producing the disposable diaper according to claim 2. The non-woven fabric sheet portion passing between the long pitch region of the continuous gear roll and the non-tooth gear roll is not shaped,
The method to manufacture the disposable diaper of Claim 3 or 4. Further, the graphic forming unit includes a step of cutting each of the elastic members at one place or a plurality of places.
The method to manufacture the disposable diaper of any one of Claims 1-5. The elastic member extends in the transverse direction between the non-concave regions of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion, which are spaced apart from each other and aligned with each other.
The method to manufacture the disposable diaper of any one of Claims 1-6. In the composite stretchable material, the graphic sheet is overlaid so as to be positioned outside the elastic member when the disposable diaper is worn.
The method to manufacture the disposable diaper of any one of Claims 1-7. The first nonwoven sheet portion and the second nonwoven sheet portion are formed from a long-fiber nonwoven fabric,
The method to manufacture the disposable diaper of any one of Claims 1-8. At least in the uneven region of the first nonwoven fabric sheet portion and the second nonwoven fabric sheet portion located on the side portion of the waistline portion, the convex portion of the first nonwoven fabric sheet portion is the second nonwoven fabric sheet. The convex portion of the second nonwoven fabric sheet portion enters the concave portion of the first nonwoven fabric sheet portion, while entering the concave portion of the portion,
The method to manufacture the disposable diaper of any one of Claims 1-9. Each of the convex portions protrudes in the thickness direction from the non-convex region,
Each of the concave portions reaches the non-concave region between the two convex portions adjacent to each other.
The method to manufacture the disposable diaper of any one of Claims 1-10. The first nonwoven sheet portion and the second nonwoven sheet portion overlapping each other are formed in a single nonwoven sheet;
The single nonwoven sheet is folded along a fold line parallel to the transverse direction and overlaid on each other;
The method to manufacture the disposable diaper of any one of Claims 1-11. In the graphic forming portion, the elastic member having a contracting force does not exist,
The method to manufacture the disposable diaper of any one of Claims 1-12. Between the graphic forming part and the side part of the waistline part, a concealing part having a concavo-convex pitch shorter than the graphic forming part and the side part of the waistline part is provided,
A method for producing the disposable diaper according to claim 13.

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