JP6192021B2 - 吸収性物品の製造方法 - Google Patents
吸収性物品の製造方法 Download PDFInfo
- Publication number
- JP6192021B2 JP6192021B2 JP2015194543A JP2015194543A JP6192021B2 JP 6192021 B2 JP6192021 B2 JP 6192021B2 JP 2015194543 A JP2015194543 A JP 2015194543A JP 2015194543 A JP2015194543 A JP 2015194543A JP 6192021 B2 JP6192021 B2 JP 6192021B2
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- JP
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- Prior art keywords
- absorber
- sheet
- absorbent body
- layer
- absorbent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Description
包装シートの上面における幅向中間部分に、ホットメルト接着剤を塗布して第1接着剤層を形成した後、この第1接着剤層上に、繊維及び高吸収性ポリマー粒子を混合集積した吸収体を載せ、前記吸収体の下面及び前記包装シートを前記第1接着剤層を介して接着する、第1接着工程と、
前記包装シート上の吸収体の上面の全幅にわたり、ホットメルト接着剤を塗布して第2接着剤層を形成した後、前記包装シートにおける前記吸収体の幅方向両側に位置する部分を、前記吸収体の上側にそれぞれ折り返し、これら折り返した部分の先端部を重ね合わせて連結部を形成するとともに、この折り返した部分及び前記吸収体の上面を前記第2接着剤層を介して接着する、第2接着工程とを経て、
前記吸収体を前記包装シートで包装してなる吸収要素を製造し、
この製造した吸収要素を用いて吸収性物品を製造する、吸収性物品の製造方法において、
前記第1接着工程で、前記第1接着剤層を、前記吸収体の幅及び前記吸収体の厚みの総和よりも幅広く形成し、
前記第2接着工程で、前記吸収体の少なくとも幅方向両端部では、前記折り返した部分に塗布した第1接着剤層及び前記吸収体の上面に塗布した前記第2接着剤層を介して、前記折り返した部分及び前記吸収体の上面を接着する、
ことを特徴とする、吸収性物品の製造方法。
本発明者は、製造設備の開発過程で、包装シート巻付けタイプの吸収要素の製造工程に、吸収体形状の崩れやすさを助長する原因が隠れているのを発見した。すなわち、包装シート巻付けタイプの吸収要素では、製造に際して、吸収体を転写する際に吸収体の下面と包装シートの中間部とを接着した後、包装シートの両側部分を折り返して吸収体の上面に接着することになるため、吸収体の表裏両側を同条件で接着することができない。ここで、包装シートの両側部分を折り返して吸収体の上面に接着するときには、吸収体の上面に予めホットメルト接着剤を塗布し、これに包装シートの両側部分を折り返して接着すると、吸収体の上面形状が安定するという利点があったため、このような手法が採用されてきた。しかし、吸収体の表面はプレス装置で押し固めたとしても低密度で、凹凸が大きい構造である。そのため、吸収体にホットメルト接着剤を塗布して包装シートに接着した場合は、同じホットメルト接着剤の使用量(単位面積当たりの重量を意味する。以下同じ。)で、包装シートにホットメルト接着剤を塗布して吸収体と接着した場合と比べると、接着が相対的に弱くなる。つまり、包装シートの折り返し時における吸収体の上面形状の安定性を確保するために採用してきた塗布方式が、製品における吸収体の形状の崩れを引き起こすおそれを生み出していたのである。
特に、吸収体に接着するホットメルト接着剤は、吸収阻害を引き起こす一因となる場合があり、その使用量は必要最小限であることが望まれる。よって、上述のような意図しない接着力の低下があると、包装シートによる形状維持作用が低下しやすい。
本発明は、このような知見を得たことによりなされたものである。本発明の製造方法によると、吸収体の下面側(包装シートが連続する側)では、第1接着剤のみで包装シートの内面と吸収体との接着がなされるのに対して、吸収体の上面側(包装シートの連結部を有する側)では、少なくとも幅方向両端部の領域において、第1接着剤層及び第2接着剤層の二層により包装シートの内面と吸収体との接着がなされる。その結果、吸収体の下面側よりも、接着力が低下しやすい吸収体の上面側(包装シートの連結部を有する側)において少なくとも幅方向両端部の領域におけるホットメルト接着剤の使用量を、吸収体の反対側よりも多くすることができる。よって、吸収体及び包装シートを接着するためのホットメルト接着剤の総使用量を抑制しつつ、吸収体の形状の崩れを効果的に抑制できるようになる。
前記第1接着工程から前記第2接着工程までの間に、前記吸収体をその全幅にわたり押し固めるプレス工程を行わない、請求項1記載の吸収性物品の製造方法。
第1接着工程から第2接着工程までの間に吸収体の全幅にわたるプレス工程を行うと、吸収体の幅方向両側にはみ出す第1接着剤層がプレス装置に付着するおそれがある。従来は、第1接着工程から第2接着工程までの間に吸収体の全幅にわたるプレス工程が行われており、プレス装置へのホットメルト接着剤の付着を防止する必要があったため、第1接着工程で、第1接着剤層を吸収体の幅よりも幅広く塗布することは想定されていなかったものである。
前記吸収体における繊維:高吸収性ポリマー粒子が、重量比で50:50〜20:80である、請求項1又は2記載の吸収性物品の製造方法。
本項記載のように高吸収性ポリマー粒子の含有率が高い吸収体であると、吸収体の幅方向両端部の形状崩れが発生しやすい。また、このように繊維含有率が低い吸収体では転写後のプレス工程を行わなくても製造が可能である。よって、本発明の製造方法は本項記載のような吸収体の場合に好適である。
図1〜図6は、パンツタイプ使い捨ておむつの一例を示している。断面図における点模様部分はその表側及び裏側に位置する各構成部材を接合する接合手段としての接着剤を示しており、ホットメルト接着剤などのベタ、ビード、カーテン、サミット若しくはスパイラル塗布などにより、また弾性伸縮部材の固定部分はこれに代えて又はこれとともにコームガンやシュアラップ塗布などの弾性伸縮部材の外周面への塗布により形成されるものである。各構成部材を接合する接合手段としてはヒートシールや超音波シール等の素材溶着による固定手段を用いることもできる。
外装体12F,12Bは、前身頃Fを構成する部分である前側外装体12Fと、後身頃Bを構成する部分である後側外装体12Bとからなり、前側外装体12F及び後側外装体12Bは脚側で連続しておらず、離間されている。この離間距離12dは150〜250mm程度とすることができる。図示しないが、この離間部分における内装体200の裏面の露出部分の一部(例えば前側外装体12Fと後側外装体12Bとの間に露出する部分の前後方向全体にわたるが、内装体200の前後端まで延びず、また幅方向両側縁も内装体200の両側縁までは達しない程度)又は全体を覆うように、不織布等からなる股間部カバーシートを貼り付けることもできる。また、図9及び図10に示すように、外装体12が、前身頃Fから後身頃Bにかけて股間を通り連続する一体的なものとすることもできる。つまり、前身頃F及び後身頃Bを個別に構成する外装体12F,12Bが前者の形態に相当し、前身頃F及び後身頃Bを一体的に構成する外装体12が後者の形態に相当する。
内装体200の形状、構造は特に限定されず、例えば以下に述べる形状、構造を採用することができる。内装体200は任意の形状を採ることができるが、図示の形態では長方形である。内装体200は、図3〜図5に示されるように、装着者の肌側となる液透過性トップシート30と、液不透過性シート11と、これらの間に介在された吸収要素50とを備えているものであり、吸収機能を担う本体部である。符号40は、トップシート30を透過した液を速やかに吸収要素50へ移行させるために、トップシート30と吸収要素50との間に設けられた中間シート(セカンドシートとも呼ばれる)を示しており、符号60は、内装体200の両脇に排泄物が漏れるのを防止するために、内装体の吸収面の幅方向両側に沿って延在された、装着者の脚周りに向かって立ち上がる部分である脚周りギャザー60を示している。
トップシート30は、有孔又は無孔の不織布や、多孔性プラスチックシート等、液透過性素材であれば特に限定無く利用できるが、図3及び図4に示す形態のようにトップシート30が脚周りギャザー60の液不透過性シート64の被覆材を兼ねる場合には不織布が用いられる。また、このうち不織布は、その原料繊維が何であるかは、特に限定されない。例えば、ポリエチレンやポリプロピレン等のオレフィン系、ポリエステル系、ポリアミド系等の合成繊維、レーヨンやキュプラ等の再生繊維、綿等の天然繊維などや、これらから二種以上が使用された混合繊維、複合繊維などを例示することができる。さらに、不織布は、どのような加工によって製造されたものであってもよい。加工方法としては、公知の方法、例えば、スパンレース法、スパンボンド法、サーマルボンド法、メルトブローン法、ニードルパンチ法、エアスルー法、ポイントボンド法等を例示することができる。例えば、柔軟性、ドレープ性を求めるのであれば、スパンボンド法、スパンレース法が、嵩高性、ソフト性を求めるのであれば、エアスルー法、ポイントボンド法、サーマルボンド法が、好ましい加工方法となる。
図7及び図8に示す形態のように、トップシート30の裏側に、トップシートより親水性に優れる中間シート(「セカンドシート」とも呼ばれている)40を設けることができる。この中間シート40は、吸収した液の吸収体からの逆戻り現象を防止し、トップシート30上のさらっとした肌触りを確保するためのものである。中間シート40は省略することもできる。
吸収体56の裏側に設けられる液不透過性シート11の素材は、特に限定されるものではないが、例えば、ポリエチレンやポリプロピレン等のオレフィン系樹脂等からなるプラスチックフィルムを例示することができる。液不透過性シート11には、近年、ムレ防止の観点から好まれて使用されている不透液性かつ透湿性を有する素材を用いることが好ましい。透湿性を有するプラスチックフィルムとしては、ポリエチレンやポリプロピレン等のオレフィン系樹脂中に無機充填剤を混練して、シートを成形した後、一軸又は二軸方向に延伸して得られた微多孔性プラスチックフィルムが広く用いられている。
吸収要素50は、吸収体56と、この吸収体56の全体を包む包装シート58とを有する。
吸収体56は、パルプ繊維や合成繊維等と、高吸収性ポリマー粒子とを混合集積したものである。吸収体56の繊維目付けとしては、綿状パルプや短繊維を積繊する場合は、例えば100〜300g/m2程度とすることができる。合成繊維を用いる場合、その繊度は例えば1〜16dtex、好ましくは1〜10dtex、さらに好ましくは1〜5dtexとすることができる。
包装シート58としては、ティッシュペーパ、特にクレープ紙、不織布、ポリラミ不織布、小孔が開いたシート等の液透過性素材を用いることができる。ただし、高吸収性ポリマー粒子が抜け出ないシートであるのが望ましい。クレープ紙に換えて不織布を使用する場合、親水性のSMS不織布(SMS、SSMMS等)が特に好適であり、その材質はポリプロピレン、ポリエチレン/ポリプロピレン複合材などを使用できる。目付けは、5〜40g/m2、特に10〜30g/m2のものが望ましい。
包装シート58の内面、吸収体56と対向する部分の全体はホットメルト接着剤H1,H2を介して吸収体56の外面に接着される。また、連結部58cにおける包装シート58の端部が重なり合う部分も、ホットメルト接着剤H3を介して接合される。包装シート58及び吸収体56を接着するホットメルト接着剤H1,H2は、図13に示すように吸収体56に対してはある程度浸透して含浸層562を形成し、包装シート58に対しては殆ど浸透しないか、又は浸透するが吸収体56に対するよりも浸透しないことにより接着層561を形成することが望ましい。
図14〜図16は、上述した吸収要素50を製造するための設備・工程の一例を示している。図14及び図15に示される区間(a)〜(d)が、図16に示される(a)〜(d)の断面状態と対応している。この製造設備100では、まずパルプシート56Fを解繊機101で解繊して得られるパルプ繊維及び高吸収性ポリマー粒子56Pが、横向きに配置され回転駆動される積繊ドラム102の上方から供給される。積繊ドラム102の外周面には、回転方向を前後方向とする吸収体型102mが凹状に形成されるとともに、吸収体型102mの底面に多数の図示しない吸引孔が形成されており、パルプ繊維及び高吸収性ポリマー粒子の供給位置で、吸収体型102m内の吸引孔からの吸引により、吸収体型102m内にパルプ繊維及び高吸収性ポリマー粒子の混合物が集積されて吸収体56が形成される。
脚周りギャザー60は、内装体200の吸収面の幅方向両側に沿って延在された、装着者の脚周りに向かって立ち上がる部分であり、トップシート30上を伝わって横方向に移動する尿や軟便を遮断し、横漏れを防止するために設けられているものである。
明細書中で以下の用語が使用される場合、明細書中に特に記載が無い限り、以下の意味を有するものである。
・「前後(縦)方向」とは腹側(前側)と背側(後側)を結ぶ方向を意味し、「幅方向」とは前後方向と直交する方向(左右方向)を意味する。
・「展開状態」とは、収縮や弛み無く平坦に展開した状態を意味する。
・「伸長率」は、自然長を100%としたときの値を意味する。
・「目付け」は次のようにして測定されるものである。試料又は試験片を予備乾燥した後、標準状態(試験場所は、温度20±5℃、相対湿度65%以下)の試験室又は装置内に放置し、恒量になった状態にする。予備乾燥は、試料又は試験片を相対湿度10〜25%、温度50℃を超えない環境で恒量にすることをいう。なお、公定水分率が0.0%の繊維については、予備乾燥を行わなくてもよい。恒量になった状態の試験片から米坪板(200mm×250mm、±2mm)を使用し、200mm×250mm(±2mm)の寸法の試料を切り取る。試料の重量を測定し、20倍して1平米あたりの重さを算出し、目付けとする。
・「厚み」は、自動厚み測定器(KES−G5 ハンディー圧縮試験機)を用い、荷重:10gf/cm2、及び加圧面積:2cm2の条件下で自動測定する。
・吸水量は、JIS K7223−1996「高吸水性樹脂の吸水量試験方法」によって測定する。
・「吸水速度」は、2gの高吸収性ポリマー及び50gの生理食塩水を使用して、JIS K7224‐1996「高吸水性樹脂の吸水速度試験法」を行ったときの「終点までの時間」とする。
・「剛軟度」は、JIS L 1096:2010「織物及び編物の生地試験方法」の「8.21.1 A法(45°カンチレバー法)」を意味する。
・「溶融粘度」は、JIS Z 8803にしたがい、ブルックフィールドB型粘度計(スピンドルNo.027)を用いて、温度140℃で測定されるものである。
・試験や測定における環境条件についての記載が無い場合、その試験や測定は、標準状態(試験場所は、温度20±5℃、相対湿度65%以下)の試験室又は装置内で行うものとする。
・各部の寸法は、特に記載が無い限り、自然長状態ではなく展開状態における寸法を意味する。
Claims (3)
- 包装シートの上面における幅向中間部分に、ホットメルト接着剤を塗布して第1接着剤層を形成した後、この第1接着剤層上に、繊維及び高吸収性ポリマー粒子を混合集積した吸収体を載せ、前記吸収体の下面及び前記包装シートを前記第1接着剤層を介して接着する、第1接着工程と、
前記包装シート上の吸収体の上面に、ホットメルト接着剤を塗布して第2接着剤層を形成した後、前記包装シートにおける前記吸収体の幅方向両側に位置する部分を、前記吸収体の上側にそれぞれ折り返し、これら折り返した部分の先端部を重ね合わせて連結部を形成するとともに、この折り返した部分及び前記吸収体の上面を前記第2接着剤層を介して接着する、第2接着工程とを経て、
前記吸収体を前記包装シートで包装してなる吸収要素を製造し、
この製造した吸収要素を用いて吸収性物品を製造する、吸収性物品の製造方法において、
前記第1接着工程で、前記第1接着剤層を、前記吸収体の幅及び前記吸収体の厚みの総和よりも幅広く形成し、
前記第2接着工程で、前記吸収体の少なくとも幅方向両端部では、前記折り返した部分に塗布した第1接着剤層及び前記吸収体の上面に塗布した前記第2接着剤層を介して、前記折り返した部分及び前記吸収体の上面を接着する、
ことを特徴とする、吸収性物品の製造方法。 - 前記第1接着工程から前記第2接着工程までの間に、前記吸収体をその全幅にわたり押し固めるプレス工程を行わない、請求項1記載の吸収性物品の製造方法。
- 前記吸収体における繊維:高吸収性ポリマー粒子が、重量比で50:50〜20:80である、請求項1又は2記載の吸収性物品の製造方法。
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