RU2635153C2 - Method for producing composite sheet - Google Patents

Abstract

FIELD: textile, paper.

SUBSTANCE: method for producing a composite nonwoven sheet comprises: a stage of creating protrusions and depressions consisting in feeding the first sheet-shaped element to the engagement section between the first shaft and the second shaft and thus creating protrusions and depressions in the first sheet-shaped element; an intermediate stage of producing a semi-finished composite sheet by applying the second sheet-shaped element to the first sheet-shaped element and attaching the second sheet-shaped element to the portions of the first sheet-shaped element which correspond to the protrusions on the first shaft and thus forming a plurality of the first connected portions; and a coupling stage consisting in the use of the third shaft, the peripheral surface of which has protrusions and depressions, the shape of which is different from the shape of the protrusions and depressions of the first shaft, and forming the second connected portion on the semi-finished composite sheet. The second connected portion is formed in accordance with a model in which one first connected portion is connected to another first connected portion adjacent to it.

EFFECT: creation of composite sheets for absorbent products which have strength and excellent appearance.

18 cl, 10 dwg

Description

FIELD OF THE INVENTION

The present invention relates to a method for manufacturing a composite sheet made of two sheet-shaped elements, wherein one sheet-shaped element has a plurality of protruding parts.

State of the art

A composite non-woven material is already known made by: forming a composite non-woven material by joining a non-woven material of a spunbond production method at a plurality of points with at least one surface of an elastic material; applying a load to this composite nonwoven material by pulling the material in a certain direction; and then, relieving the load in order to loosen the tension of the nonwoven fabric of the spinneret production method and make the composite nonwoven fabric loose (see Patent Document 1). This composite nonwoven fabric is used as side straps on pull-on diapers. In addition, in addition to the method described in patent document 1, there are known methods described in patent documents 2 and 3 and aimed at the manufacture of composite sheets with many protruding parts.

However, in the nonwoven fabric described in Patent Document 1, slack of the nonwoven fabric of the spunbond production method is achieved by plastic deformation thereof, so it is not easy to ensure that the slack of the nonwoven fabric is always the same size with good reproducibility. Due to the presence of such deficiencies inherent in traditional composite sheets, the applicant has previously proposed a method for manufacturing a composite sheet to overcome these disadvantages (see Patent Document 4). The method for producing a composite sheet described in Patent Document 4 involves the use of a device for producing a composite sheet comprising a first shaft, the peripheral surface of which has protrusions and depressions, and a second shaft, the protrusions and depressions on the surface of which have a shape that engages with the protrusions and hollows of the first shaft. This method includes the following steps: feeding the first sheet-shaped member into the engaging section between the shafts and thereby creating protrusions and depressions in the first sheet-shaped member; applying a second sheet-shaped element to the first sheet-shaped element while holding the first sheet-shaped element in the state in which the protrusions and depressions were created on the peripheral surface of the first shaft by suction through the suction channels available in the first shaft; and connecting the second sheet-shaped element to the first sheet at locations located on the protrusions of the first shaft.

List of references

Patent Literature

Patent Document 1: JP5-59655 A

Patent Document 2: JP10-245757 A

Patent Document 3: JP2-18036 A

Patent Document 4: Japanese Patent No. 4627077

SUMMARY OF THE INVENTION

The present invention relates to an improvement in the method for manufacturing a composite sheet described in Patent Document 4, in particular, relates to a method for producing a composite sheet suitable for producing sheets having an unrivaled appearance and strength.

The inventors conducted various studies aimed at further improving the method of manufacturing a composite sheet described in Patent Document 4, and found that the appearance and bond strength of a composite sheet can be improved by forming in a composite sheet provided with protrusions and depressions and obtained by the production method in question. , an additional connecting section corresponding to a separate connection model, different from the connection model of the first element in the form of a sheet and th element in the form of a sheet of the composite sheet.

The present invention was made on the basis of this finding and relates to a method for manufacturing a composite sheet in which the connected sections are formed by partially joining the first sheet-shaped element and the second sheet-shaped element and in which the first sheet-shaped element protrudes in areas other than the connected sections, and forms many protruding sections, each of which is hollow inside. This method includes: the stage of creating protrusions and depressions, which consists in feeding the sheet-shaped element to the meshing section between the first shaft, the peripheral surface of which has protrusions and depressions, and the second shaft, the peripheral surface of which has protrusions and depressions of such a shape that they enter engagement with the protrusions and depressions of the first shaft, and thus creating protrusions and depressions in the first sheet-shaped member; an intermediate production step of manufacturing a semi-finished composite sheet by applying a second sheet-shaped element to the first sheet-shaped element while holding the first sheet-shaped element in the state in which the protrusions and depressions were made on the peripheral surface of the first shaft and the connection the first sheet-shaped element and the second sheet-shaped element in those portions of the first sheet-shaped element that correspond to the protrusions on the first shaft, and thus formed ia a plurality of first connected portions; and a connection step, comprising connecting the first sheet-shaped element and the second sheet-shaped element, which form a semi-finished composite sheet, in areas corresponding to the protrusions of the third shaft, the peripheral surface of which has protrusions and depressions, the shape of which is different from the shape of the protrusions and depressions of the first shaft, in a state where the side of the semi-finished composite sheet formed by the first element in the form of a sheet is held on the peripheral surface of the third shaft, and thus forming a second joint inennogo site on the semi-finished composite sheet. The second connected portion is formed in accordance with a model in which one first connected portion is connected to another adjacent first connected portion.

The present invention also relates to a composite sheet in which the connected sections are formed by multiple joining of the first sheet-shaped element and the second sheet-shaped element, and in which the first sheet-shaped element protrudes in areas other than the connected sections, and forms a plurality of protruding sections, hollow inside. Connected sections include: a plurality of first connected sections arranged according to a regular, discontinuous model; and a second connected portion that connects the plurality of first connected portions adjacent to each other.

Brief Description of the Drawings

FIG. 1 is an enlarged perspective view of one example of a composite sheet of the present invention produced by implementing the manufacturing method of the present invention.

FIG. 2 is a schematic top view (explanatory diagram of models of the first and second connected sections) on the side of the first sheet-shaped element (top layer) of the composite sheet shown in FIG. one.

FIG. 3 is a diagram explaining the main parts of one embodiment of a device for manufacturing a composite sheet used to implement a manufacturing method in accordance with the present invention.

FIG. 4 is a perspective view illustrating the main parts of the first shaft of the manufacturing device shown in FIG. 3.

FIG. 5 is an exploded perspective view of a portion of a first shaft of the manufacturing device shown in FIG. 3.

FIG. 6 is a perspective view illustrating the main parts of the third shaft of the manufacturing device shown in FIG. 3.

In FIG. 7 (a) -7 (d) are diagrams corresponding to FIG. 2, modified examples of a composite sheet of the present invention produced by implementing a production method in accordance with the present invention.

Description of Embodiments

The present invention is further described in accordance with preferred variants of its implementation with reference to the drawings. First, with reference to FIG. 1 and 2 describe one example of a composite sheet of the present invention produced by implementing a method of manufacturing a composite sheet of the present invention. As shown in FIG. 1 and 2, in the composite sheet 1 of the present invention, the connected sections 4, 5 (the first connected sections 4 and the second connected sections 5) are formed by partially joining the first sheet-shaped element and the second sheet-shaped element (upper layer 2 and lower layer 3) . The first sheet-shaped element (top layer 2) has protrusions in sections different from the connected sections 4, 5, and forms a plurality of protruding sections 6, each of which is hollow inside. The upper layer 2 and the lower layer 3 are partially connected to each other in the connected sections 4, 5 and are not connected in the protruding sections 6. It should be noted that the direction X in FIG. 1 and 2 corresponds to the direction (CD; the transverse direction relative to the movement of the material in the machine) perpendicular to the direction of movement (MD; the direction of movement of the material in the machine), in which the sheets move during the production of composite sheet 1; the Y direction corresponds to the direction of movement of the sheet (MD).

We describe composite sheet 1 in more detail. The composite sheet 1 is formed by an upper layer 2, which is a first sheet-shaped element, and a lower layer 3, which is a second sheet-shaped element. The upper layer 2 forms the upper surface 1a of the composite sheet 1, the lower layer 3 forms the lower surface 1b of the composite sheet 1. In cases where the composite sheet 1 is used as the upper sheet of the absorbent article, the upper surface 1a (the first sheet-shaped element) is a surface facing the user's skin (surface opposing the skin) when this product is in the toe, and the lower surface 1b (the second element in the form of a sheet) is the surface facing the side opposite to the skin of the user (Not withstanding the skin surface) when the product is in a sock.

The upper layer 2 and the lower layer 3, each, usually formed by one of various non-woven materials or films. Examples of non-woven materials include non-woven materials made by napping, spunbond production method, melt blowing, staple fiber weaving and needle-punched method. In cases where the upper layer 2 and the lower layer 3 is a film, in particular in cases where the composite sheet 1 is used as the upper sheet of the absorbent article, it is preferable to perforate the film used as the upper layer 2 and the lower layer 3 to create film the holes and make it permeable to liquids.

In the composite sheet 1, two types of connected sections 4, 5 are formed, following different models. In the connected sections 4, 5, the upper layer 2 (the first element in the form of a sheet) and the lower layer 3 (the second element in the form of a sheet) are fused with each other and form a single whole. In this embodiment, the plurality of first connected sections 4, each of which in a plan view is in the shape of a quadrangle, is formed in accordance with a regular, discontinuous model, and a second connected section 5 is formed so that it connects the first connected section 4 to another adjacent to him, the first connected section 4 (in accordance with the model, which connects many adjacent first connected sections 4, 4).

The regular arrangement pattern of the first connected sections 4 in the present embodiment is a model in which a plurality of imaginary polygons are placed on one surface of the composite sheet so that there is no space between them, and where the first connected sections 4, each of which has given shape, are at all vertices of each polygon. More specifically, as shown in FIG. 2, this model is a model in which a plurality of imaginary hexagons (essentially regular hexagons) are placed on the same surface of the composite sheet 1 like honeycombs, and where the first connected sections 4, each of which in a plan view is rectangular, are six the vertices of each hexagon. According to this model, the set of imaginary hexagons of the same shape (the shape of each hexagon is created by the six first connected sections) form a series of hexagons in which the hexagons are lined up in the Y (MD) direction, while there is no space left between them, and the set such rows of hexagons are placed in the X direction (CD), and there is no space left between them. The rows of hexagons are arranged so that the steps of the hexagons in two adjacent rows to each other in the X direction are offset from each other; in this embodiment, in two rows adjacent to each other in the X direction, the hexagons are offset in the Y direction by half a step (half the length in the MD direction of an imaginary hexagon). There are three imaginary hexagons around each first connected portion 4, and one first connected portion 4 is the apex of three imaginary hexagons surrounding this first connected portion. As shown in FIG. 2, a plurality of first connected sections 4 arranged in accordance with the described regular model form a series of connected sections consisting of a plurality of first connected sections 4 staggered in the Y direction, and a plurality of such rows of connected sections are arranged in the X direction at predetermined intervals .

The second connected portion 5 forms a continuous line and continuously overlaps all of the first connected sections 4 arranged in accordance with the regular, discontinuous model described above. Each area surrounded by this continuous second connected portion 5 forms a hexagon in a plan view. Therefore, the second connected portion 5 is formed so that it includes straight segments, each of which is oriented in a direction intersecting with both the X direction and the Y direction. The width of the second connected portion 5 (i.e., the length in the direction perpendicular to the direction in which the line segment is oriented) is constant and unchanged.

As shown in FIG. 1 and 2, each of the plurality of protruding portions 6 (i.e., the unconnected portions between the upper layer 2 and the lower layer 3) is surrounded by: six first connected portions 4 forming a hexagon in a plan view; and a second connected portion 5, having a hexagonal shape in a plan view and being continuous, therefore connecting all six of the first connected sections 4. Each of the plurality of protruding sections 6 is in a plan view essentially hexagonal and generally has a flat, substantially , hexagonal prismatic shape with rounded ribs. That is, a plurality of protruding portions 6, each of which is substantially hexagonal in a plan view, are located on the upper surface 1a of the composite sheet 1 so that the opposite sides of adjacent protruding portions 6, 6 are parallel to each other, with some space, that is, are arranged essentially like honeycombs, and this space forms a second connected portion 5.

As shown in FIG. 1 and 2, the plurality of protruding sections 6 are staggered. In the present context, “staggered arrangement” means an arrangement where a plurality of rows of protruding portions 6 — each row includes a plurality of protruding portions 6 located in the same direction at equal intervals — are placed in a direction perpendicular to the indicated one direction and the protruding portions 6 in two adjacent rows to each other in a direction perpendicular to the indicated one direction, shifted relative to each other (preferably shifted by half a step). More specifically, it can be said that the protruding sections 6 are staggered in those cases where, if a plurality of rows, each of which includes a plurality of protruding sections 6, arranged in the same direction at equal intervals, protrude in a direction perpendicular to the indicated one direction, the protruding figures of the protruding sections 6 in a particular row are located between (preferably in the middle) the protruding figures of the protruding sections 6 in another row adjacent to the specified row. It should be noted that in the context of the present invention, the expression "staggered" covers not only the forms in which the plurality of protruding sections 6 are perfectly aligned with the above explanation, but also those forms in which there are slight unintentional deviations in the arrangement, caused, for example, by distortions unavoidable in production. When the protruding sections 6 are staggered, as described above, in cases where the composite sheet 1 is used as the top sheet of the absorbent article, the pressure exerted on the skin of the wearer by the absorbent article is evenly distributed and sufficient absorption is achieved, in addition, absorption and fluid retention occurs evenly throughout the composite sheet 1.

Since the connected sections 4, 5, as described above, are formed in the composite sheet 1 of the present invention, the protruding sections 6 are clearly visible, the shape of each protruding section 6 is obvious, therefore, the sheet has a wonderful appearance. In addition, since the two sheet-shaped elements (the upper layer 2 and the lower layer 3) are connected by the connected section 5 in addition to the connected sections 4, the sheet has sufficient strength, and the protruding sections 6 are favorably supported. Moreover, the upper surface 1a has a shape with protrusions and depressions formed by the connected sections 4, 5 and the protruding sections 6, thus, in cases where the composite sheet 1 is used, for example, as the upper sheet of an absorbent product, such as a diaper disposable or diaper, in the presence of the upper surface 1A with the shape of the protrusions and depressions as opposed to the skin surface, the contact area between the upper sheet (composite sheet 1) and the skin of a person using an absorbent product, menshaetsya, air permeability is increased, thereby effectively preventing the occurrence of such undesirable phenomena such as heat, moisture accumulation and rash. In addition, in the connected sections 4, 5, the fibers forming the upper layer 2 and the lower layer 3 constituting the composite sheet 1 are fused to a film state, and the connected sections are liquid impermeable, and the liquid here can hardly penetrate through the composite layer 1 into direction of its thickness. That is, in cases where the composite sheet 1 is used, for example, as the top sheet of an absorbent article, even if the excreted fluid, such as urine, enters the connected sections 4, 5, the released liquid in the connected sections 4, 5 cannot penetrate through the composite sheet 1 in the direction of its thickness and flows down along the upper surface 1a (surface opposing the skin) along the connected sections 4, 5, in particular along the continuous linear second connected section 5. Therefore, the connected sections 4, 5 can olnyat as guides for the fluid regulating fluid flow in a plane and enabling fluid distribution plane. In addition, since the protruding portions 6 are hollow inside, they provide a masking effect for the absorbent product, that is, the color of the released liquid absorbed by the absorbent element located on the non-skin-opposing side of the top sheet (composite sheet 1) is weakened when viewed from the side of the top sheet .

From the point of view of more reliable achievement of the above effects, it is preferable that the dimensions of the parts of the composite sheet 1 are as follows.

The area of each first connected portion 4 is preferably 0.6 mm ² or more, more preferably 0.8 mm ² or more, preferably 1.4 mm ² or less, more preferably 1.2 mm ² or less, more specifically, preferably from 0.6 to 1.4 mm ² , more preferably 0.8 to 1.2 mm ² .

From the point of view of improving the visibility of the connected section 5, ensuring the strength of the connection of the connected section 5 and ensuring the durability of the shafts (first and second shafts described below) used to form the connected section 5, the width of the second connected section 5 (i.e., the length in the direction perpendicular to the direction in which the line segment is oriented) is preferably 0.2 mm or more, more preferably 0.5 mm or more. In addition, it is preferable that the width of the second connected portion 5 is such that the second connected portion does not protrude beyond the first connected portions 4 when the first connected portions 4 overlap, that is, it is already narrower than the width of the first connected portion 4.

The apparent thickness of the composite sheet 1 (the thickness of the composite sheet in the region where the protruding portions 6 are formed) under a pressure of 0.36 kPa is preferably 0.5 mm or more, more preferably 1.0 mm or more, preferably 5.0 mm or less , more preferably 4.0 or less, more specifically, preferably from 0.5 to 5.0 mm, more preferably from 1.0 to 4.0 mm.

Next, with reference to the composite sheet manufacturing apparatus shown in FIG. 3-7, a method for manufacturing a composite sheet of the present invention is explained; for example, a production method of the composite sheet 1 described above is taken. As shown in FIG. 3, the manufacturing device 10 of the present invention includes: a first shaft 11, the peripheral surface of which has protrusions and depressions; a second shaft 21, the peripheral surface of which has protrusions and depressions of such a shape that they engage with the protrusions and depressions of the first shaft 11; a support shaft 22 (connecting means by which the first connected sections 4 are formed) located so that its peripheral surface is opposed to the peripheral surface of the first shaft 11; a third shaft 31, the peripheral surface of which has protrusions and depressions, the shape of which is different from the shape of the protrusions and depressions of the first shaft 11; connection means 40, by means of which, together with the third shaft 31, a second connected portion 5 is formed on the sheet in the manufacturing process (prefabricated 1 ’composite sheet); and a fourth shaft 41, located so that its peripheral surface is opposed to the peripheral surface of the first shaft 11 and the peripheral surface of the third shaft 31.

The first shaft 11 and the second shaft 21 are arranged so that the protrusions and depressions on the peripheral surface of each of these shafts are engaged with each other. The first shaft 11 and the support shaft 22 are located so that the upper part of each protrusion 14 on the peripheral surface of the first shaft 11 abuts against the peripheral surface of the support shaft 22.

In FIG. 4 is a perspective view of the main parts of the first shaft 11. FIG. 5 is an exploded perspective view of a portion of a first shaft. The first shaft 11 is formed by: connecting a plurality of gears 11a, consisting of spur gears with the same gear module, and spacers 11b; fastening these parts 11a, 11b concentrically on the rotary axis 12 of the shaft so as to obtain the shape of the shaft. The thickness of the spacer 11b is preferably from 0.5 to 2.0, more preferably from 0.8 to 1.2, of the thickness of the gear 11a. In this embodiment, the gear 11a and the spacer 11b have the same width. Each gear 11a and spacer 11b has a hole in the center, a rotating axis 12 is inserted into each of these holes. The gears 11a, spacers 11b and rotating axis 12 have a cutout (not shown) into which a key (not shown) is inserted. Due to this, the gears 11a and the spacers 11b do not spin on the axis.

As shown in FIG. 5, the gear 11a has a diameter different from the diameter of the spacer 11b, the diameter of the teeth of the spacers 11b is substantially equal to the diameter of the disk portion of the gear 11a without teeth; the diameter of the tops of the teeth of the gear 11a is larger than the spacers 11b.

In the first shaft 11, one gear 11a, located on both sides of the same spacer 11b, form a gear group 13, including a set of these three parts; a plurality of gear groups 13 forms a first shaft. As shown in FIG. 4, in each gear group 13, two gears 11a, 11a are arranged so that the teeth of the respective gears 11a, 11a are in a line in the direction of the rotating axis of the shaft 11, that is, are arranged so that the teeth of the corresponding gears 11a, 11a are opposed to each other in the direction of the rotating axis of the shaft 11 with a certain distance (the distance corresponding to the thickness of the spacer 11b). In this case, the “direction of the rotating axis of the shaft 11” means the direction in which the rotating axis 12 is oriented, and corresponds to the X direction in FIG. 1 and 2.

When thus connecting two gears 11a, 11a and one spacer 11b (each gear group 13) on the peripheral surface of the first shaft 11, protrusion regions 13A with protrusions (protrusions 14) are created, which are used to create protrusions and depressions on the sheet being manufactured (the first sheet-shaped element 2 '), and the region 13B where the protrusions are not formed, while the regions 13A, 13B are arranged alternately in the direction of the rotating axis of the shaft 11. The protrusion forming region 13A is formed by the peripheral surface of the gear 11a, and each protrusion 14 is formed by a tooth of the gear 11a. The horizontal projection shape of the end surface of the apex of each protrusion 14 (the gear teeth 11a) corresponds to the horizontal projection shape of the first connected portion 4 of the composite sheet 1, and in this embodiment, it is quadrangular. On the other hand, the region 13B without protrusions is formed by the peripheral surface of the spacer 11b. Although there are teeth on the peripheral surface of the spacer 11b, the diameter of the tooth peaks of the spacer is substantially equal to the diameter of the diskless gear portion 11a, as described above (see FIG. 5); thus, the teeth of the spacer 11b are not involved in creating protrusions and depressions on the sheet being manufactured (first element 2 ’in the form of a sheet).

At least two sets of gear groups 13 are used. Gear groups 13 are positioned so that the steps of the protrusions and troughs in adjacent gear groups 13, 13 are offset from each other. In this embodiment, in adjacent gear groups 13, 13, the position of the protrusions and troughs is shifted half a step in the direction of rotation of the shaft 11.

As shown in FIG. 5, in each gear group 13, a plurality of spaces 16 are formed between two gears 11a, 11a (in the region 13B without protrusions) located at a predetermined interval along the direction of rotation of the shaft 11. Each space 16 is formed by two gears 11a, 11a and a spacer 11b, located between the gears 11a, 11a. More specifically, each space 16 is delimited by the opposing side surfaces of the respective gears 11a, 11a and two adjacent teeth of the spacer 11b. Space 16 is open outside area 13B without protrusions.

In the gear wheel 11a there are many holes 17 surrounding the central hole through which the rotating axis 12 is inserted. The holes 17 have the same diameter and are located at the same distance from the center of the gear wheel. The angle formed between adjacent holes 17, 17 and the center of the gear is the same for any two adjacent holes. The number of holes 17 in each gear 11a is the same as the number of teeth on the spacer 11b. During the assembly of each gear group 13, the gears 11a and the spacer 11b are positioned so that each hole 17 is in the space between adjacent teeth of the spacer 11b. In a state where each gear group 13 is assembled and the gear groups 13 are arranged so that the steps of the protrusions and troughs are offset relative to each other, the holes 17 in the gears 11a are connected in the direction of the rotating axis of the shaft 12, and a plurality of suction channels 18 are formed inside the shaft 11, each of which is oriented in the direction of the rotating axis. The suction channels 18 communicate with the respective spaces 16 described above.

At least one end of each suction channel 18 is in communication with a suction device (not shown), such as a fan or vacuum pump. Thus, when the suction operation is carried out using the suction device, air is sucked in from the spaces 16 of the region 13B without protrusions along the suction channels 18. Since the first shaft 11 is equipped with a similar mechanism for sucking air from the spaces 16, the design of the first shaft 11 allows holding the sheet on its peripheral surface by suction from the inside of the shaft.

The second shaft 21 has a design similar to the first shaft 11, except that its diameter (the diameter of the tooth tips) is smaller than that of the first shaft 11. The peripheral surface of the second shaft has protrusions and depressions that engage with protrusions and depressions on the peripheral surface the first shaft 11. Note, however, that the second shaft 21, unlike the first shaft 11, is not equipped with an air suction mechanism, and thus, its design does not allow holding the sheet on its peripheral surface by suction from the inside her side of the shaft.

The support shaft 22 has a circular cylindrical body of revolution, mounted rotatably around a rotating axis, and is located so that the peripheral surface of the body of rotation is opposed to the peripheral surface of the first shaft 11. The peripheral surface of the support shaft 22 has no protrusions and depressions and, essentially (macroscopically) is flat and smooth. The support shaft 22 is provided with heating means (not shown) and is designed so that heat from the heating means is supplied through the heat conduction to its peripheral surface, which comes into contact with the sheet being processed (second element 3 ’in the form of a sheet). It should be noted that the first shaft 11 can be equipped with a similar heating means in order to increase the efficiency of creating protrusions and depressions on the first sheet-shaped element and the molding properties of the first connected sections.

As shown in FIG. 6, the third shaft 31 has a circular cylindrical body of revolution 33 fixed for rotation about a rotating axis 32, the shape of the peripheral surface of the body of revolution 33 has protrusions and depressions other than protrusions and depressions on the peripheral surface of the first shaft 11. The shape of the protrusions and depressions on the peripheral the surface of the body of revolution 33 corresponds to the shape of the protrusions and depressions on the side of the upper layer 2 of the composite sheet 1; a plurality of depressions 34, each of which in a top view has the shape of a hexagon, is located so that the opposite sides of adjacent depressions 34, 34 are parallel to each other with the presence of some space between them (i.e., they are located essentially like honeycombs), in this a protrusion 35 is formed in space. In this case, the expression “top view” means cases where the shape having protrusions and depressions of the peripheral surface of the shaft 31 is viewed from the outside in the direction perpendicular to the peripheral surface (i.e., in the direction orthogonal to rule rotating shaft 31).

As further described below, having a protrusion and a hollow shape of the peripheral surface of the third shaft 31 (body of revolution 33) is a shape that engages with the sheet in the manufacturing process (side of the first element 2 'in the form of a sheet of the prefabricated 1' composite sheet), which protrusions and depressions were made by pressing against the peripheral surface of the first shaft 11 having protrusions (protrusions 14) and depressions. That is, the peripheral surface of the third shaft 31 having protrusions and depressions has a shape that fits on the periphery malarial surface projections and depressions of the first element 2 'in the form of semi-finished composite sheet 1 sheet'. In this embodiment of the invention, in order to achieve such an engaging shape between the shaft and the sheet under production, the shaft is shaped so that if the peripheral surface of the first shaft 11 and the peripheral surface of the third shaft 31 are each virtually expanded in a plane and laid on top of each other on the other hand, the center of each cavity 34 on the peripheral surface of the third shaft 31 will coincide with the center of each region on the peripheral surface of the first shaft 11, which is surrounded by many (six in this embodiment inventions) of the protrusions 14 (the teeth of the gears 11a) on the peripheral surface of the first shaft 11 and determines the presence of a corresponding protruding portion formed on a sheet being manufactured (in this embodiment of the invention, a portion that eventually becomes the corresponding protruding portion 6 on the composite sheet 1) by compression with the protrusions and depressions of the first shaft 11. Therefore, although having the protrusions and depressions, the shape of the peripheral surface of the third shaft 31 is different from the protrusion pits and depressions of the shape of the peripheral surface of the first shaft 11 having protrusions and depressions of the shape of the peripheral surface of the third shaft 31 can accommodate the protrusions and depressions of the first element 2 'in the form of a sheet of the prefabricated 1' composite sheet, and, thus, the first element 2 'in the form of a sheet the semi-finished product 1 'of the composite sheet in which the protrusions and depressions are made is held on the peripheral surface of the third shaft 31 in a state where the first sheet-shaped member 2' is engaged with the protrusions and depressions on the peripheral surface third shaft.

Many thin air holes (not shown) are formed in those areas on the peripheral surface of the third shaft 31 where the protrusions 34 are located, and a suction channel (not shown) communicating with the air holes and with a suction device (not shown), such as a fan or vacuum a pump formed inside the third shaft 31. When the suction operation is carried out using the suction device, air is drawn in from the air holes through the suction channels. Since the third shaft 31 is provided with a similar mechanism for sucking air from the air holes in the peripheral surface, the construction of the third shaft 31 allows holding the sheet on its peripheral surface by suction from the inside of the shaft.

The connecting means 40 is opposed to the peripheral surface of the third shaft 31 and, together with the third shaft 31, forms a connected portion (second connected portion 5) in the sheet being manufactured (semi-finished product 1 'of the composite sheet), which extends between the two parts 31, 40. B In this embodiment, a known ultrasonic welding device is used as the connection means 40.

The basic structure of the fourth shaft 41 is similar to that of the support shaft 22: the fourth shaft has a circular cylindrical body of revolution rotatably fixed about a rotating axis, the peripheral surface of the body of revolution has no protrusions and depressions and is essentially (macroscopically) flat and smooth. Many thin air holes (not shown) are formed in the peripheral surface of the fourth shaft 41, and a suction channel (not shown) in communication with the air holes and a suction device (not shown), such as a fan or vacuum pump, is formed inside the fourth shaft 41. When the suction operation is carried out using the suction device, the air is sucked from the air holes through the suction channels. Since the fourth shaft 41 is provided with a similar mechanism for sucking air from the air holes in the peripheral surface, the construction of the fourth shaft 41 allows holding the sheet on its peripheral surface by suction from the inside of the shaft.

As described above, in the manufacturing device 10, the construction of each shaft: the first shaft 11, the third shaft 31 and the fourth shaft 41 allows the sheet to be held on the peripheral surface by suction from the inside of the shaft. Thus, in the method for manufacturing the composite sheet 1 described below, the sheet in the manufacturing process (prefabricated composite 1 ′ of the composite sheet) can move from the stage of forming the first connected sections 4 (intermediate production stage) to the stage of forming the second connected section 5 (connection stage) without any or a phase shift of the protrusions and troughs on the sheet in the manufacturing process, thereby the second connected portion 5 can be made on predetermined sections of the semi-finished product 1 'composition a thick sheet on which the first connected sections 4 have already been made with higher accuracy.

In addition, in the method for manufacturing the composite sheet 1 described below, from the point of view of preventing a phase shift of the protrusions and depressions on the sheet that is in the process of production (semi-finished product 1 'of the composite sheet) during the transition from the formation stage of the first connected sections 4 (intermediate production stage) to the step of forming the second connected portion 5 (connection step), it is preferable that the production device 10 has the following distinctive features A or B.

Distinctive feature A: thanks to the transmission of the driving force from the same source by means of known gears, V-belt drive rollers, etc. the shafts 11, 21, 22, 31, 41 of the production device 10 rotate synchronously.

A distinctive feature B: the production device 10 is equipped with the same number of servomotors as the number of shafts 11, 21, 22, 31, 41; shafts and servomotors are connected in a one-to-one correspondence; rotation control of each shaft can be controlled by a servomotor connected to this shaft.

The following describes a method of manufacturing a composite sheet 1 by using the manufacturing device 10 of the above construction. Firstly, a ribbon-shaped first sheet-shaped element 2 ', which is a material for manufacturing the top layer 2, is unwound from an initial convolution of textile material (not shown), in addition, a ribbon-shaped second sheet-shaped element 3', which is a material for the manufacture of the lower layer 3, unwind from the original convolution of a textile material (not shown). Then, as shown in FIG. 3, the unwound first sheet-shaped element 2 ’is fed into the engaging section between the first shaft 11 and the second shaft 21, thereby creating protrusions and depressions on the first sheet-shaped element 2’ (stage for creating protrusions and depressions).

When creating protrusions and depressions on the first sheet-shaped member 2 ', the first sheet-shaped member 2' is provided with a plurality of depressions (depressed portions) formed when pressed against the plurality of protrusions 14 on the shaft 11 when two shafts 11, 21 mesh with each other another, in this case, depressions are formed in accordance with the regular model of the first connected sections 4 on the above-mentioned composite sheet 1, that is, in accordance with the same model as “a model in which a plurality of imaginary hexagons are placed on one surface of the sheet like about the honeycombs, and where the first connected sections 4, each of which has a given shape (the shape of a quadrangle in a top view), are located at the six vertices of each hexagon ", and the protrusions are formed in each area, which in the top view has the shape of a hexagon and which is surrounded by six hollows (depressed areas). On the first element 2 ’in the form of a sheet on which protrusions and depressions are made, the bottom of each depression (depressed portion), i.e. the portion that comes into contact with the upper end of the protrusion 14 on the first shaft 11 becomes the first connected portion 4 on the composite sheet 1 in the next stage (intermediate production stage), while the protruding portion formed in the region having a hexagonal shape in plan view, in the end, it becomes the protruding section 6 of the composite sheet 1.

At the stage of creating the protrusions and depressions through the first shaft 11, suction is performed, as described above. The suction is controlled so that it takes place in the engaging section between the first shaft 11 and the second shaft 21, is stored in the section where the first sheet-shaped element 2 'and the second sheet-shaped element 3' are connected to each other, and up to the section where the first shaft 11 and the fourth shaft 41 approach each other as much as possible (i.e., the sections where the semi-finished product 1 'of the composite sheet moves). Thus, the first sheet-shaped element 2 'on which the protrusions and depressions were made by engagement between the first shaft 11 and the second shaft 21 comes into close contact with the peripheral surface of the shaft 11 due to the suction force acting in the spaces 16 available in region 13B without protrusions of the first shaft 11, thereby maintaining the state in which the protrusions and depressions were made. If the suction is not carried out, the first element 2 ’in the form of a sheet will rise above the peripheral surface of the first shaft 11, because of which it will not be possible to produce a sheet with a given shape of the protrusions and depressions.

Further, as shown in FIG. 3, the semi-finished product 1 ′ of the composite sheet is produced by: applying a second sheet-shaped member 3 ′ uncoiled separately onto the first sheet-shaped member 2 ′ while holding the first sheet-shaped member 2 ′ on the peripheral surface of the first shaft 11 in that state in which protrusions and depressions were created; and connecting the first sheet-shaped member 2 'and the second sheet-shaped member 3' in those portions of the first sheet-shaped member 2 'that correspond to the protrusions 14 on the first shaft 11 (i.e., on the lower parts of the depressions (depressed sections)) , and thus creating a plurality of first connected sections 4 (see FIG. 2) (intermediate production stage).

In this embodiment, a method for laminating and compressing a sheet laminate formed by a first sheet-like member 2 ’and a second sheet-like member 3’ between the first shaft 11 and the support shaft 22, as shown in FIG. 3, is used as a method of joining the second sheet-shaped element 3 ’with the first sheet-shaped element 2’ in an intermediate production step. Both the first shaft 11 and the support shaft 22 or only the support shaft 22 are preheated to a predetermined temperature, and when layering / compression between the shafts 11, 22, the first sheet-shaped element 2 'located on the protrusions 14 (i.e., on the teeth of the gears wheels 11a) in the projection forming region 13A (see FIG. 4) of the first shaft 11, is connected to the second sheet-shaped member 3 'by fusion, and the fused sections become the first connected sections 4.

It should be noted that in FIG. 2 shows the correspondence between the plurality of first connected portions 4 of the composite sheet 1 and a portion of the first shaft 11 (gear groups 13). As shown in FIG. 2, on the composite sheet 1 there is a portion where three rows 13 ’, each of which is oriented in the Y (MD) direction, are lined up in the X (CD) direction; each of these rows 13 ’on the composite sheet 1 is an area formed by one gear group 13 of the first shaft 11 at the stage of the protrusions and troughs and the intermediate production stage. In addition, each row 13 ’on the composite sheet 1 is formed so that three rows 13A’, 13B ’, each of which is oriented in the Y direction, are lined up in the X direction; row 13A 'is a region formed by region 13A of the protrusions of the first shaft 11 at the stage of creating the protrusions and troughs and an intermediate production stage, and row 13B' is the region formed by region 13B without protrusions of the first shaft 11 at the stage of creating the protrusions and troughs and intermediate production stage. In each row 13A ′ of the composite sheet 1, a plurality of first connected portions 4 are formed at predetermined intervals in the Y direction (i.e., at intervals corresponding to the distance between the two protrusions 14, 14 adjacent to each other in the direction of rotation of the shaft 11) in the order corresponding to the protrusions 14 (the teeth of the gear 11a) in the region 13A of the formation of the protrusions. On the other hand, in the region 13B without protrusions, as described above, protrusions 14 are not formed, thus, in the row 13B ’of the composite sheet 1, the first connected portion 4 is not formed. In addition, each protruding section 6 on the composite sheet 1 is defined at the stage of creating the protrusions and depressions and the intermediate production stage: one gear group 13 of the first shaft 11; and a protrusion forming region 13A, which is closer to said one gear group 13 in each of two gear groups 13 adjacent to said one gear group 13 in the direction of the rotary axis of the shaft 11.

In this embodiment, as shown in FIG. 3, by using a fourth shaft 41 arranged so that its peripheral surface is opposed to the peripheral surface of the first shaft 11 and the third shaft 31, the prefabricated composite sheet 1 'obtained in the intermediate production step is directly transferred from the peripheral surface of the first shaft 11 to the peripheral surface of the fourth shaft 41, after which the semi-finished product 1 'of the composite sheet is directly transferred from the peripheral surface of the fourth shaft 41 to the peripheral surface of the third shaft and 31.

More specifically, the tape-shaped semi-finished product 1 'of the composite sheet first, when the first shaft 11 rotates, enters the section closest to the fourth shaft 41, in a state in which its first sheet-shaped member 2' is suction-drawn and held on the peripheral surface of the first shaft 11, after which moves to the peripheral surface of the fourth shaft 41 in the nearest section. The tape-shaped semi-finished product 1 'of the composite sheet, received on the peripheral surface of the fourth shaft 41, during rotation of the fourth shaft 41 is moved to the section closest to the third shaft 31, in a state in which its second sheet-shaped element 3' is drawn by suction and held on the peripheral surface the fourth shaft 41, after which it moves to the peripheral surface of the third shaft 31 in the nearest section. The movement from the fourth shaft 41 to the third shaft 31 is carried out so that the side of the first element 2 ’in the form of a sheet of semi-finished product 1’ of the composite sheet, provided with protrusions and depressions, faces the peripheral surface of the third shaft 31.

The protrusion and trough shape of the peripheral surface of the third shaft 31 (rotation body 33) is a shape that engages with the side of the first element 2 ’in the form of a prefabricated sheet 1’ of a composite sheet on which protrusions and troughs were made at an intermediate production stage. Thus, as shown in FIG. 3, the tape-shaped semi-finished product 1 'of the composite sheet, moved to the peripheral surface of the third shaft 31, is in a state where the side of the first sheet-shaped member 2' on which the protrusions and depressions are made is suction drawn and held on the peripheral surface of the third shaft 31. B in this state, when the prefabricated composite sheet 1 'is fixed, a plurality of protruding portions of the first element 2' in the form of a sheet of the prefabricated sheet 1 'of the composite sheet, i.e. a plurality of protruding portions formed in respective regions, each of which has a hexagonal shape in a plan view and each of which is surrounded by six first connected sections 4, is embedded in corresponding depressions 34 on the peripheral surface of the third shaft 31, each of which has a hexagonal shape in a plan view and is surrounded by a protrusion 35. From the point of view of preventing collapse of the protruding sections of the semi-finished product 1 'of the composite sheet during insertion into the corresponding depressions 34 of the third shaft 31, is it is preferable that the depth of the depressions 34 be the same or greater than the height of the protruding portion, i.e. the height of the protrusion 14 of the first shaft 11 (gear teeth 11A).

Further, two sheet-shaped elements 2 ′, 3 ′ that form the prefabricated 1 ′ of the composite sheet are joined in a portion corresponding to the protrusion 35 of the third shaft 31 in a state where the side of the first sheet-shaped element 2 ′ of the prefabricated sheet 1 ′ of the composite sheet is held on the peripheral surface of the third shaft 31, thus, on the semi-finished product 1 ′ of the composite sheet, a second connected portion 5 (see FIG. 2) is performed (connection step). At this connection stage, the prefabricated composite sheet 1 'is held on the peripheral surface of the third shaft 31 (rotation body 33) in a state where the side of the first sheet-shaped member 2' on which the protrusions and depressions are made is engaged with the protrusions and depressions on the peripheral the surface of the third shaft.

In this embodiment, the prefabricated composite sheet 1 ′, which is in a state when it is held on the peripheral surface of the third shaft 31, is ultrasonically welded on the side of the second sheet member 3 ′ in the form of the prefabricated sheet 1 ′ of the composite sheet by means of joint 40, which is located opposite the peripheral surface of the third shaft and acts as an ultrasonic welding device. Thus, the sections of the elements 2 ’, 3’ corresponding to the protrusion 35 of the third shaft 31 are fused and connected to each other, forming a second connected section 5, which is continuous and overlaps all the first connected sections 4 formed earlier. In other words, all of the first connected sections 4 overlap the second connected section 5. It should be noted that, depending on the location of the first connected sections 4 and the second connected section 5, there may be first connected sections 4 that are not covered by the second connected section 5 on the side or end sections of the sheet; however, provided that the first connected sections 4 always overlap the second connected section 5 in other places, we can say that "all the first connected sections 4 overlap the second connected section 5".

The composite sheet 1 shown in FIG. 1 and 3, obtained as described above. As described above, the method of manufacturing a composite sheet of the present invention relates to an improvement in the method of manufacturing a composite sheet described in Patent Document 4, which is an earlier application filed by the applicant, and the composite sheet 1 obtained by implementing the production method of the present embodiment has significantly improved appearance and durability. More specifically, in the production method according to the present embodiment, the prefabricated composite sheet 1 ′ having on its one surface (on the side of the first sheet-shaped member 2 ′) a plurality of first connected sections 4 arranged in accordance with a regular, discontinuous model, receive at an intermediate production stage; on one of the surfaces of the prefabricated composite 1 'of the composite sheet, the second connected portion 5 is additionally formed at the joining step following the intermediate production stage, while the second connected portion 5 is characterized by a different model than the model of the first joined sections 4 (i.e., a model providing connection of one first connected portion 4 with another first connected portion 4 closest to it), thus, the resulting composite sheet 1 is modified and improved from point z rhenium of its appearance in comparison with the prefabricated 1 'composite sheet (composite sheet obtained by implementing the production method described in patent document 4), which is a semi-finished product of composite sheet 1. In addition, the strength is also increased by increasing the bonding area and the process connection (welding process) twice in those areas where the first connected sections are superimposed on the second connected section 5.

In addition, the composite sheet 1 can be successfully used in absorbent articles such as disposable diapers, diapers or incontinence pads. In general, an absorbent article is formed from: a liquid permeable top sheet; liquid impervious bottom sheet; a liquid retaining absorbent element located between the two sheets. Composite sheet 1 is well suited to be used as a component of an absorbent article such as a top sheet, a bottom sheet, a base sheet of a fastening tape in disposable diapers (so-called disposable diapers), provided with a fixing tape, a sheet of a supporting tape to which are attached fixing tapes, or the main sheet for wings in sanitary pads with wings, and can also be used as a cloth for a loop in a mechanical clamp, a sheet for cleaning, btiraniya etc.

In addition, unlike the technology described in Patent Document 1, the manufacturing device 10 of the present embodiment has the advantage that it is suitable for creating protruding portions on a composite sheet, such as protruding portions 6, with a predetermined step, of a constant size and good reproducibility. In addition, due to the presence of spaces 16 between the gears 11a, the advantage is provided that a large number of small protruding sections with an extremely small pitch between them is possible without fail, since the shape of the peripheral surface of the shaft used having protrusions and depressions is maintained. In addition, the pitch and size of the protruding sections can be freely changed simply by replacing the combinations of gears and their width. The ability to create many small protruding sections with a small pitch between them is an advantage in terms of obtaining the top sheet, pleasant to the touch, having wonderful elastic tactile qualities and producing a pleasant visual impression.

In FIG. 7 shows modified examples of composite sheets obtained by implementing the manufacturing method of the present invention. As for these modified examples, mainly distinctive features are explained, rather than the composite sheet 1 described above, and similar distinctive features are provided with the same reference numbers and are not explained. The description of composite sheet 1 is applicable accordingly to those distinctive features that are not specifically described in this section. The composite sheets 1A-1D shown in FIG. 7 are similar to the composite sheet 1 described above in that the second connected portion 5 is formed in accordance with a model such that the second connected portion 5 connects one first connected portion 4 to another first connected portion 4 adjacent thereto. Composite sheets 1A-1D and composite sheet 1 have a similar structure except for the model of the second connected portion (s) 5. In addition, the second connected sections 5 of the composite sheets 1A-1D shown in FIG. 7 are similar in that they include straight line segments, each of which is oriented in a direction intersecting both the X (CD) direction and the Y (MD) direction. In addition, the second connected portion 5 in the above-described composite sheet 1 is formed as continuous and overlapping all of the first connected sections 4; however, the second connected portions of the composite sheets 1A-1D shown in FIG. 7 are not continuous, thus, in each of the composite sheets 1A-1D, a plurality of second connected sections 5 are formed, each of which overlaps only a portion of the plurality of first connected sections 4. In the composite sheets 1A-1D shown in FIG. 7, the same effects are achieved as those described with respect to the composite sheet 1 above.

In the composite sheet 1A shown in FIG. 7 (a), the second connected portion 5 is formed so that it has a plurality of straight line segments 51, each of which is between the two first connected sections 4, 4 adjacent to each other in a direction intersecting both the X direction and the Y direction. Many segments of line 51 are oriented in one direction and have the same length, and only one segment of line 51 departs from one first connected section 4, and two or more segments of line 51 do not depart from one first connected section 4.

In the composite sheet 1B shown in FIG. 7 (b), the second connected portion 5 is formed so that it has a plurality of straight line segments 51, as well as a plurality of straight line segments 52, each of which is between two first connected sections 4, 4. Two first connected sections 4, 4 overlapping one line segment 52 are adjacent to each other in a direction intersecting the following three directions: X direction, Y direction, and the direction in which the line segment 51 is oriented. In addition, there are regions P in the composite sheet 1B, each of which includes a plurality about the lines of line 51 formed at predetermined intervals in the Y direction and the region Q, each of which includes a plurality of segments of line 52 formed at predetermined intervals in the Y direction, the regions P and Q in the X direction are alternately arranged. Line 51 and line 52 adjacent to each other in the X direction are symmetrical about an imaginary line (not shown) parallel to the Y direction.

In the composite sheet 1C shown in FIG. 7 (c), the second connected portion 5 is formed so that it has a plurality of continuous linear portions 53, each of which is oriented in the Y direction so that it passes through the plurality of first connected portions 4 in a row of connected portions consisting of a plurality of first connected portions 4 staggered in the Y direction. Each continuous linear portion 53 is formed so that two types of straight line segments 53 a, 53 b, each of which is oriented in a direction intersecting both the X direction and the Y direction, are connected ineny continuously in the Y direction, while there is no space between them, and each continuous linear section in the top view has a zigzag shape. Two continuous linear sections 53, 53 adjacent to each other in the X direction are symmetrical about an imaginary straight line (not shown) extending in the Y direction in the middle between two continuous linear sections 53, 53.

In the composite sheet 1D shown in FIG. 7 (d), the second connected portion 5 is formed so that there are many continuous linear sections 54, each of which is oriented in the X direction so that it passes through the many first connected sections 4. Each continuous linear section 54 is formed so that two such as straight sections 54a, 54b, each of which is oriented in a direction intersecting both the X direction and the Y direction, and straight sections 54c oriented in the X direction are continuously connected in the X direction, while there is no gap between them no space.

The present invention is not limited to the foregoing embodiments. For example, the configuration of the first shaft 11 (the configuration of the gear groups, the shape of the protrusions and depressions on the peripheral surface, etc.) is not limited to the described embodiment of the invention and can be appropriately changed depending on the shape of the protrusions and depressions of the composite sheet that is to be manufactured object. In addition, the second shaft 21 does not have to have the same structure as the first shaft 11, provided that it has a shape that engages with the first shaft 11. The technologies related to the manufacturing device described in patent document 4 are applicable appropriately to the present invention.

In addition, in the described embodiment, the connection means 40 was an ultrasonic welding device. However, in the context of the present invention, the connecting means is not limited to this, and a shaft (hot shaft) with a structure similar to the support shaft 22 can be used. In addition, an ultrasonic welding device with a structure similar to the connection device 40 can be used instead of the support shaft 22.

With regard to the described embodiments of the present invention, further disclosed are the following additional distinctive features (methods for the production of composite sheet and composite sheets).

A method for manufacturing a composite sheet is proposed in which the connected sections are formed by partially joining the first sheet-shaped element and the second sheet-shaped element and in which the first sheet-shaped element is protruded in areas other than the connected sections and forms a plurality of protruding sections, each of which are hollow inside, while this method includes:

the stage of creating protrusions and depressions, which consists in feeding the first element in the form of a sheet into the engagement section between the first shaft, the peripheral surface of which has protrusions and depressions, and the second shaft, the peripheral surface of which has protrusions and depressions of such a shape that they engage with the protrusions and depressions of the first shaft, and thus creating protrusions and depressions in the first sheet-shaped member;

an intermediate production step of manufacturing a semi-finished composite sheet by applying a second sheet-shaped member to the first sheet-shaped member while holding the first sheet-shaped member on the peripheral surface of the first shaft in the state in which the protrusions and depressions were made, and the joints the first sheet-shaped element and the second sheet-shaped element in those portions of the first sheet-shaped element that correspond to the protrusions on the first shaft, and thus formed and a plurality of first connected sections; and

the connection stage, which consists in connecting the first element in the form of a sheet and the second element in the form of a sheet, which form a semi-finished composite sheet, in areas corresponding to the protrusions of the third shaft, the peripheral surface of which has protrusions and depressions, the shape of which is different from the shape of the protrusions and depressions of the first shaft , in a state where the side of the semi-finished composite sheet formed by the first sheet-shaped member is held on the peripheral surface of the third shaft, and thus forming the second joint ennogo portion semifinished product for the composite sheet;

wherein the second connected portion is formed in accordance with a model in which one first connected portion is connected to another adjacent first portion adjacent to it.

In said method for manufacturing a composite sheet, by using a fourth shaft arranged so that its peripheral surface is opposed to the peripheral surface of the first shaft and the peripheral surface of the third shaft, the prefabricated composite sheet obtained in the intermediate production step is directly transferred from the peripheral surface of the first shaft to the peripheral surface the fourth shaft and is held on the peripheral surface of the fourth shaft, after which the semi-finished composite th sheet is transferred directly from the peripheral surface of the fourth shaft to the peripheral surface of the third shaft.

The design of the first shaft, the third shaft and the fourth shaft is such that it allows holding the sheet on their peripheral surface by suction from the inside of the shaft.

In the claimed method of manufacturing a composite sheet

having the protrusions and depressions of the peripheral surface of the third shaft has a shape containing, on the peripheral surface, the protrusions and depressions of the first element in the form of a sheet of prefabricated composite sheet; and

at the stage of joining, the semi-finished composite sheet is held on the peripheral surface of the third shaft in the state in which the side of the first sheet-shaped element on which the protrusions and depressions were made is engaged with the protrusions and depressions on the peripheral surface of the third shaft.

If the peripheral surface of the first shaft and the peripheral surface of the third shaft are virtually deployed in a plane and stacked on top of each other, the center of each cavity on the peripheral surface of the third shaft coincides with the center of each region on the peripheral surface of the first shaft, which is surrounded by many protrusions on the peripheral surface of the first shaft and defines the presence of a corresponding protruding section formed on a sheet in the process of production by compression with the protrusions and depressions of the first shaft.

In this case, the first shaft is formed by connecting a plurality of gears, consisting of spur gears with the same gear module, and spacers, fastening gears and spacers concentrically on the rotating axis of the shaft so as to obtain a shaft shape.

In the method of the present invention, a support shaft is used which is positioned so that its peripheral surface is opposed to the peripheral surface of the first shaft;

and the first shaft and the support shaft or only the support shaft are preheated to a predetermined temperature; and

in an intermediate production step, the first sheet-shaped member and the second sheet-shaped member are laminated to each other and compressed between the first shaft and the support shaft.

In the joining step, the prefabricated composite sheet in a state where the prefabricated composite sheet is held on the peripheral surface of the third shaft is ultrasonically welded from the side of the second member in the form of a prefabricated composite sheet sheet.

A composite sheet is also proposed in which the connected sections are formed by partially joining the first sheet-shaped element and the second sheet-shaped element and in which the first sheet-shaped element is protruded in areas other than the connected sections and forms a plurality of protruding sections, each of which hollow inside, while

connected sections include: a plurality of first connected sections arranged according to a regular, intermittent pattern; and a second connected portion that connects the plurality of first connected portions adjacent to each other.

In said composite sheet, a plurality of protruding sections are staggered.

Further, in said composite sheet, the regular arrangement pattern of the first connected sections is a model in which a plurality of imaginary polygons are placed on one surface of the composite sheet so that no space remains between them, and where are the first connected sections, each of which has a predetermined shape, are at all the vertices of each polygon,

wherein all the first connected sections overlap the second connected section, and

the second connected portion is formed so that it includes a straight line segment oriented in a direction that intersects both the direction of movement of the sheet during production of the composite sheet and the direction perpendicular to this direction of movement.

The said model is a model in which a plurality of imaginary hexagons (essentially regular hexagons) are placed on one surface of the composite sheet like honeycombs, and where the first connected sections, each of which is rectangular in the plan view, are located at the six vertices of each hexagon.

Said region surrounded by a second connected portion is in the form of a hexagon in a plan view, and

the protruding portion is surrounded by six first connected portions forming a hexagon in a plan view, and a second connected section having a hexagonal plan view and being continuous, therefore connecting all six of the first connected portions, and

the protruding portion has a substantially hexagonal prismatic shape, which is a hexagon in a plan view.

In the claimed composite sheet

a plurality of straight line segments forming a second connected portion is oriented in the same direction and has the same length, and

only one straight line segment departs from one first connected section, and two or more straight line segments do not depart from one first connected section.

In the specified composite sheet

there are regions P, each of which includes many straight line segments formed at predetermined intervals in the MD direction (the direction of movement of the sheet during the production of the composite sheet), and Q regions, each of which includes many other straight line segments formed at predetermined intervals in the direction MD, and the regions P and Q are alternately arranged in the direction CD (direction perpendicular to MD), while segments of a different type are oriented in a direction different from the segments in region P; and

one line segment and another line segment adjacent to each other in the CD direction are symmetrical with respect to an imaginary line (not shown) parallel to the MD direction.

In this case, the second connected section is formed so that there are many continuous linear sections 53, each of which is oriented in the MD direction so that it passes through the many first connected sections in a row of connected sections, consisting of many first connected sections arranged in a checkerboard pattern in the direction of MD, and

each continuous linear section in a top view has a zigzag shape.

The second connected portion is formed so that there are many continuous linear sections, each of which is oriented in the direction of the CD so that it passes through the many first connected sections.

The specified composite sheet is used as the top sheet for an absorbent article.

The first connected sections and the second connected section of the considered composite sheet are formed as two types of connected sections corresponding to different models.

In the claimed composite sheet in the first connected sections and the second connected section, the fibers constituting the first sheet-shaped element and the second sheet-shaped element are fused to a film state.

Industrial Applicability

In accordance with the method of manufacturing a composite sheet of the present invention, it is possible to obtain a composite sheet having a remarkable appearance and strength. In addition, the composite sheet of the present invention can be produced by implementing the manufacturing method of the composite sheet of the present invention and can be properly used as components (top sheet, etc.) of absorbent articles, such as disposable diapers or diapers. In particular, in cases where the composite sheet of the present invention is used as the top sheet of an absorbent article, the top sheet may have excellent liquid distribution ability and remarkable ability to mask absorbed liquid.

Claims (27)

1. A method of manufacturing a composite non-woven sheet in which the connected sections are formed by partially joining the first sheet-shaped element and the second sheet-shaped element and in which the first sheet-shaped element is protruded in areas other than the connected sections and forms a plurality of protruding sections, each of which is hollow inside, while this method includes: the stage of creating protrusions and depressions, which consists in feeding the first element in the form of a sheet into the engagement section between the first shaft, the peripheral surface of which has protrusions and depressions, and the second shaft, the peripheral surface of which has protrusions and depressions of such a shape that they engage with the protrusions and depressions of the first shaft, and thus creating protrusions and depressions in the first sheet-shaped member; an intermediate production step of manufacturing a semi-finished composite sheet by applying a second sheet-shaped element to the first sheet-shaped element while holding the first sheet-shaped element on the peripheral surface of the first shaft in the state in which the protrusions and depressions were made, and the joints the first sheet-shaped element and the second sheet-shaped element in those portions of the first sheet-shaped element that correspond to the protrusions on the first shaft, and thus formed and a plurality of first connected sections; and the connection stage, which consists in connecting the first element in the form of a sheet and the second element in the form of a sheet, which form a semi-finished composite sheet, in areas corresponding to the protrusions of the third shaft, the peripheral surface of which has protrusions and depressions, the shape of which is different from the shape of the protrusions and depressions of the first shaft , in a state where the side of the semi-finished composite sheet formed by the first sheet-shaped member is held on the peripheral surface of the third shaft, and thus forming the second joint ennogo portion semifinished product for the composite sheet; wherein the second connected portion is formed in accordance with a model in which one first connected portion is connected to another adjacent first portion adjacent to it. 2. A method of manufacturing a composite sheet according to claim 1, in which, through the use of a fourth shaft arranged so that its peripheral surface is opposed to the peripheral surface of the first shaft and the peripheral surface of the third shaft, the prefabricated composite sheet obtained at the intermediate production stage is directly transferred from the peripheral the surface of the first shaft to the peripheral surface of the fourth shaft and is held on the peripheral surface of the fourth shaft, after which the semi-finished component itnogo sheet is transferred directly from the peripheral surface of the fourth shaft to the peripheral surface of the third shaft. 3. A method of manufacturing a composite sheet according to claim 2, in which the design of the first shaft, third shaft and fourth shaft is such that it allows holding the sheet on their peripheral surface by suction from the inside of the shaft. 4. A method of manufacturing a composite sheet according to claim 1, in which: having the protrusions and depressions of the peripheral surface of the third shaft has a shape containing, on the peripheral surface, the protrusions and depressions of the first element in the form of a sheet of prefabricated composite sheet; and at the stage of joining, the semi-finished composite sheet is held on the peripheral surface of the third shaft in the state in which the side of the first sheet-shaped element on which the protrusions and depressions were made is engaged with the protrusions and depressions on the peripheral surface of the third shaft. 5. A method of manufacturing a composite sheet according to claim 4, in which, if the peripheral surface of the first shaft and the peripheral surface of the third shaft are virtually deployed in a plane and superimposed on each other, the center of each cavity on the peripheral surface of the third shaft will coincide with the center of each region on the peripheral surface the first shaft, which is surrounded by many protrusions on the peripheral surface of the first shaft and determines the presence of a corresponding protruding portion formed on a sheet in production By compressing with projections and recesses of the first shaft. 6. A method of manufacturing a composite sheet according to claim 1, wherein the first shaft is formed by connecting a plurality of gears consisting of spur gears with the same gear module, and spacers, fastening the gears and spacers concentrically on the rotating axis of the shaft so as to obtain shaft shape. 7. A method of manufacturing a composite sheet according to claim 1, wherein, in the joining step, the semi-finished composite sheet is in a state where the semi-finished composite sheet is held on the peripheral surface of the third shaft, is subjected to ultrasonic welding from the second element in the form of a sheet of semi-finished composite sheet. 8. A composite sheet for absorbent products, produced by the method according to claim 1, in which the connected sections are formed by partially connecting the first element in the form of a sheet and the second element in the form of a sheet and in which the first element in the form of a sheet is issued in areas other than the connected sections , and forms many protruding sections, each of which is hollow inside, while connected sections include: a plurality of first connected sections arranged according to a regular intermittent pattern; and a second connected portion that connects the plurality of first connected portions adjacent to each other. 9. The composite sheet according to claim 8, wherein the plurality of protruding sections are staggered. 10. The composite sheet according to claim 8, wherein the regular arrangement of the first connected sections is a model in which a plurality of imaginary polygons are placed on one surface of the composite sheet so that there is no space left between them, and where the first connected sections, each of which has a given shape, are at all vertices of each polygon. 11. The composite sheet according to claim 10, in which all the first connected sections overlap the second connected section. 12. The composite sheet according to claim 10, in which the second connected portion is formed so that it includes a straight line segment oriented in a direction that intersects both the direction of movement of the sheet during production of the composite sheet and the direction perpendicular to this direction of movement. 13. The composite sheet of claim 10, wherein the model is a model in which a plurality of imaginary hexagons (essentially regular hexagons) are placed on one surface of the composite sheet like honeycombs and where the first connected sections, each of which is rectangular in a plan view shape, are at the six vertices of each hexagon. 14. The composite sheet according to claim 10, in which the area surrounded by the second connected portion, in a plan view, has the shape of a hexagon. 15. The composite sheet according to claim 12, in which a plurality of straight line segments forming a second connected portion is oriented in the same direction and has the same length, and only one straight line segment departs from one first connected section, and two or more straight line segments do not depart from one first connected section. 16. The composite sheet according to claim 8, which composite sheet is used as a top sheet for an absorbent article. 17. The composite sheet according to claim 8, in which the first connected sections and the second connected section are formed as two types of connected sections corresponding to different models. 18. The composite sheet of claim 8, wherein in the first connected sections and the second connected section, the fibers constituting the first sheet-shaped member and the second sheet-shaped member are fused to a film state.

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