TW201404963A - 複合薄片及複合薄片之製造方法 - Google Patents

複合薄片及複合薄片之製造方法 Download PDF

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Publication number
TW201404963A
TW201404963A TW102114834A TW102114834A TW201404963A TW 201404963 A TW201404963 A TW 201404963A TW 102114834 A TW102114834 A TW 102114834A TW 102114834 A TW102114834 A TW 102114834A TW 201404963 A TW201404963 A TW 201404963A
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Taiwan
Prior art keywords
elastic
elastic sheet
sheet
composite sheet
joint
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Application number
TW102114834A
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English (en)
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TWI588313B (zh
Inventor
Satoshi Mitsuno
Jun Okuda
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Uni Charm Corp
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/2457—Parallel ribs and/or grooves

Abstract

為了提供一種具有彈性薄片及非彈性薄片的複合薄片且能提昇透氣性之複合薄片及該複合薄片之製造方法。複合薄片(1)係將彈性薄片(11)和非彈性薄片(12)經由多數個接合部(13)互相接合並積層。彈性薄片(11)形成有與接合部(13)重疊並且朝橫方向X延伸的第1凹條部(14)和第1凸條部(15)。第1凸條部(15)係其內部由構成彈性薄片(11)的纖維填滿。非彈性薄片(12)形成有與接合部(13)重疊並且朝縱方向Y延伸的第2凹條部(16)和第2凸條部(17)。在第2凹條部(16)，於接合部(13)使彈性薄片(11)和非彈性薄片(12)接觸，在第2凸條部(17)，使非彈性薄片(12)與彈性薄片(11)分離，在該等薄片之間形成有空隙(18)。

Description

複合薄片及複合薄片之製造方法
本發明是關於一種複合薄片及複合薄片之製造方法，更詳述之，該複合薄片係包含彈性薄片和非彈性薄片之複合薄片，可使用於拋棄式紙尿布、拋棄式大小便訓練褲、拋棄式失禁褲、拋棄式生理用褲、拋棄式吸收墊等。
以往，包含彈性薄片和非彈性薄片之複合薄片為眾所周知。例如，專利文獻1揭示有使用了彈性薄片和非彈性薄片之複合薄片的拋棄式紙尿布。該拋棄式紙尿布係於與肌膚相對向面使用彈性薄片，於與非肌膚相對向面使用非彈性薄片。以使彈性薄片拉伸的狀態接合非彈性薄片，藉此在非彈性薄片形成多數個襞摺。藉由形成襞摺而在尿布和衣服之間形成空隙，實現良好的透氣性。
以往，包含彈性薄片和非彈性薄片的複合薄片之製造方法為眾所周知。例如，專利文獻2揭示有一種製造複合薄片之方法，係藉由具備砧部和發射部(horn)的超音波系統，將非彈性薄片之不織布層和彈性薄片之彈 性基層互相接合以製造複合薄片之方法。
[先行技術文獻] [專利文獻]
[專利文獻1]日本特開2008-148834號公報(JP2008-148834A)
[專利文獻2]日本特開2008-526552號公報(JP2008-526552A)
根據專利文獻1所揭示的複合薄片，彈性薄片成為平坦狀。若這種平坦面與穿用者的肌膚相對向，會與穿用者的肌膚緊貼，使透氣性降低。
根據專利文獻2所揭示的複合薄片之製造方法，雖然記載著使用共擠出彈性薄膜作為彈性基層，但未提及關於具有彈性的纖維不織布。
本發明之課題在於提供一種具有彈性薄片及非彈性薄片的複合薄片且能使透氣性提昇的複合薄片及該複合薄片之製造方法。
本發明具有第1發明和第2發明。
第1發明係有關複合薄片的改良，該複合薄片具有縱方向及與縱方向正交之橫方向，將形成一面並且至少能朝前述橫方向彈性地伸縮之彈性薄片與形成另一面之非彈性薄片互相接合而成。
第1發明為前述複合薄片中，其特徵在於，前述彈性薄片及前述非彈性薄片係藉由分別朝前述縱方向及前述橫方向分離的多數個接合部而互相接合，前述彈性薄片具有：與前述接合部重疊並且朝前述橫方向延伸的第1凹條部，及與前述第1凹條部鄰接且朝前述橫方向延伸的複數個第1凸條部，前述非彈性薄片具有：與前述接合部重疊並且朝前述縱方向延伸的第2凹條部，及與前述第2凹條部鄰接且朝前述縱方向延伸的複數個第2凸條部。
第2發明係有關複合薄片之製造方法的改良，該複合薄片具有：接合彈性薄片及非彈性薄片的多數個接合部、與前述接合部重疊並且形成於前述彈性薄片的第1凹條部、與前述第1凹條部鄰接的第1凸條部、與前述接合部重疊並且形成於前述非彈性薄片的第2凹條部、以及朝與前述第1凸條部交叉的方向延伸的第2凸條部。
第2發明為前述複合薄片之製造方法中，其特徵在於，包含：將構成前述彈性薄片的彈性帶體藉由第1捲出輥搬運的製程；將前述彈性帶體經由夾輥朝具有超音波發射器(sonic horn)及與超音波發射器對置的砧部之超音波裝置搬運的製程：將構成前述非彈性薄片的非彈性帶體藉由第2捲出輥朝前述超音波裝置搬運的製程：及 將前述彈性帶體和前述非彈性帶體藉由前述超音波裝置接合的製程。在前述砧部的周面，設置分別朝旋轉方向及軸方向分離的多數個凸部，前述彈性帶體係接觸於前述周面而被搬運，並且前述砧部的旋轉速度比前述夾輥的旋轉速度更快。
根據本發明之尤其是其一種以上的實施態樣，在彈性薄片形成有朝橫方向延伸的第1凸條部和第1凹條部，在非彈性薄片形成朝縱方向延伸的第2凸條部和第2凹條部，因此是一種在平面方向透氣性良好的複合薄片。
1‧‧‧複合薄片
11‧‧‧彈性薄片
12‧‧‧非彈性薄片
13‧‧‧接合部
14‧‧‧第1凹條部
15‧‧‧第1凸條部
16‧‧‧第2凹條部
17‧‧‧第2凸條部
18‧‧‧空隙
31‧‧‧彈性帶體
32‧‧‧非彈性帶體
33‧‧‧第1捲出輥
36、37‧‧‧齒輪輥
40‧‧‧超音波裝置
41‧‧‧超音波發射器
42‧‧‧砧部
43‧‧‧凸部
44‧‧‧夾輥
46‧‧‧第2捲出輥
第1圖係從彈性薄片側觀察本發明之複合薄片的立體圖，是將一部分剖開之圖。
第2圖係從非彈性薄片側觀察複合薄片的立體圖，是將一部分剖開之圖。
第3圖(a)係沿第2圖之IIIA-IIIA線切斷的擴大端面圖。第3圖(b)係沿第2圖之IIIB-IIIB線切斷的擴大端面圖。
第4圖係沿第2圖之IV-IV線切斷的擴大端面圖。
第5圖係以第1圖之V圍繞的部分之放大圖。
第6圖係使用複合薄片的拋棄式穿用物品之一例，即拋棄式紙尿布之立體圖。
第7圖係表示複合薄片之製造製程的說明圖。
第8圖係以第7圖之VIII圍繞的部分之放大圖。
參照第1圖及第2圖，複合薄片1具有縱方向Y及與縱方向Y正交的橫方向X，彈性薄片11和非彈性薄片12係經由多數個接合部13互相接合並積層。接合部13例如可藉由以超音波裝置將纖維熔接而形成。
彈性薄片11包含彈性纖維，本實施形態中係藉由彈性纖維和非彈性纖維形成，在橫方向X可彈性地伸縮。亦即，使彈性薄片11朝橫方向X拉伸100%，從其拉伸狀態被解放時的殘留變形為30%以下，較佳為20%以下。第1圖及第2圖中，複合薄片1的彈性薄片11係從拉伸狀態被解放、收縮後的狀態。彈性纖維和非彈性纖維可以互相混合後形成彈性薄片，也可以藉由該等纖維形成各薄片層，再使該等薄片層積層而形成彈性薄片。
彈性纖維可以僅藉由熱可塑性彈性體形成，也可以將熱可塑性彈性體和其他樹脂混合形成。作為熱可塑性彈性體，可使用聚苯乙烯系彈性體、聚烯烴系彈性體、聚胺酯系彈性體、聚醯胺系彈性體等眾所周知者。彈性纖維的形態可以是單獨纖維或複合纖維的任一者，複合纖維可使用芯鞘型或並列型。
非彈性纖維含有熱可塑性樹脂，特別是含有聚烯烴系樹脂者為佳，也可以是聚烯烴系樹脂的單獨纖維或含有複數種類的聚烯烴系樹脂之混合纖維的任一者。又，也可以是芯鞘型纖維、並列型纖維或單獨纖維的任一者，進一步，該等纖維也可以是分割纖維。作為聚烯烴系樹脂，例如可使用聚乙烯、聚丙烯、乙烯-α烯烴共聚物等。
彈性纖維的纖維徑為約5~100μm，較佳為約10~40μm，非彈性纖維的纖維徑為約1~40μm，較佳為10~30μm，使用非彈性纖維的纖維徑比彈性纖維更細者為佳。
作為非彈性薄片12，例如可使用熱風纖維不織布、點黏合纖維不織布(熱輥纖維不織布)、水針纖維不織布、紡黏纖維不織布、熔噴纖維不織布等各種製法所製的纖維不織布。又，除了纖維不織布以外，亦可使用織布、編布或樹脂薄膜等。
參照第1圖、第3圖及第5圖，在彈性薄片11形成有：與接合部13重疊並且朝橫方向X延伸的多數個第1凹條部14、及與第1凹條部14鄰接且朝橫方向X延伸的多數個第1凸條部15。第1凸條部15的成為內部藉由構成彈性薄片11的纖維填滿的凸紋。但是，第1凸條部15不須全部由纖維填滿，只要能維持後述的薄片膨鬆度之程度即可。第1凸條部15的纖維為彎曲或捲縮(未圖示)，藉由使該等纖維拉伸即能使彈性薄片11全 體朝縱方向Y及橫方向X拉伸。特別是在橫方向X可彈性地伸縮。
參照第2圖及第4圖，在非彈性薄片12形成有：與接合部13重疊並且朝縱方向Y延伸的多數個第2凹條部16、及與第2凹條部16鄰接且朝縱方向Y延伸的多數個第2凸條部17。非彈性薄片12係於彈性薄片11朝橫方向X拉伸的狀態經由接合部13接合，藉由解除拉伸狀態，在非彈性薄片12形成朝縱方向Y延伸的第2凹條部16及第2凸條部17。在第2凹條部16，彈性薄片11和非彈性薄片12係於接合部13接觸，在第2凸條部17，非彈性薄片12與彈性薄片11分離，該等薄片之間形成空隙18。非彈性薄片12係實質地非彈性，亦即不進行彈性地伸縮，因此藉由與拉伸狀態的彈性薄片11接合，一旦該拉伸狀態被解除，則非彈性薄片12在接合部13之間鬆弛，形成第2凸條部17。
參照第5圖，接合部13係沿著朝橫方向X延伸的假想線19分離而形成複數個，並且假想線19係朝縱方向Y分離而設置複數條。在鄰接的假想線19，各接合部13係於縱方向Y不重疊的方式配置成描繪所謂的鋸齒狀花紋。藉由如此地配置，在彈性薄片11形成沿著假想線19朝橫方向X延伸的畝狀之第1凸條部15。在非彈性薄片12形成與假想線19交叉的皺摺，該皺摺成為朝縱方向Y延伸的第2凸條部17。
根據如上述之複合薄片1，彈性薄片11的第 1凸條部15朝橫方向X延伸，非彈性薄片12的第2凸條部17朝縱方向Y延伸，因此第1凸條部15和第2凸條部17交叉，能確保複合薄片1的縱方向Y及橫方向X之柔軟性。例如，於第1凸條部15及第2凸條部17皆朝縱方向Y延伸時，變得較容易沿著縱方向Y彎曲，而較難沿著橫方向X彎曲。但是，藉由朝該等凸條部15、17交叉的方向延伸，縱方向Y及橫方向X皆能彎曲，因此在複合薄片1全體皆能柔軟地彎曲。
複合薄片1的質量為約50~200g/m2，較佳為約70~120g/m2。質量係以JIS L 1906之5.2為準所測定。
複合薄片1的厚度為約1.0~5.0mm，較佳為約2.0~3.5mm。厚度係使用(日本)股份有限公司大榮科學精器製作所製THICKNESS GAUGE UF-60所測定。測定中，使用圓形加壓板，加壓板面積為20cm2，測定負載為0.3kPa。複合薄片1係於彈性薄片11形成第1凸條部15，於非彈性薄片12形成第2凸條部17，因此其厚度增加，可作為膨鬆度高的複合薄片1。特別是形成在彈性薄片11的第1凸條部15，由於其內部係藉由纖維填滿，不易被來自其外側的壓力壓潰，即使壓潰，若從壓力解放則膨鬆度回復。因而，能得到膨鬆度高、使肌膚觸感良好的複合薄片1。
複合薄片1的橫方向X的拉伸倍率為約1.0~4.0倍，較佳為1.2~3.2倍。拉伸倍率係藉由以自然狀態 下的橫方向X之尺寸除以測定對象樣本的拉伸狀態下的橫方向X之尺寸而算出。拉伸狀態係指複合薄片1的非彈性薄片12的皺摺延伸，拉伸至第2凸條部17和第2凹條部16大致呈平坦狀態之狀態；自然狀態係指解除拉伸狀態，在20℃、60%RH雰圍下放置60分鐘以上之後的狀態。
複合薄片1係平面方向透氣性為約60~120m3/m2/min，較佳為約70~110m3/m2/min。平面方向透氣性係使用(日本)KATO TECH股份有限公司製KES-F8透氣性試驗機測定。將複合薄片1切斷成100mm×100mm作為樣本，在樣本上載置空氣遮蔽板，由給排氣時通過樣本表面的空氣之透氣阻力值算出透氣度。空氣遮蔽板使用調整成0.3g/cm2的壓克力製板。
參照第6圖，如上述之複合薄片1可使用於拋棄式穿用物品之一例的拋棄式紙尿布2。拋棄式紙尿布2具有：縱方向Y及與縱方向Y正交的橫方向X、及穿用者的肌膚相對向面及其相反側之非肌膚相對向面，且包含主體(chassis)21及配置在主體21的肌膚相對向面之吸收體29。主體21具有前腰部域22、後腰部域23、及位於前後腰部域22、23間的褲襠域24。主體21的兩側部25藉由以斷續地延伸之接縫部接合而連結前後腰部域22、23，形成腰部開口及腿部開口。
主體21包含：伸縮性的前後腰部薄片26、27，係位於非肌膚相對向面，並且構成前後腰部域22、 23及褲襠域24的一部分：及非伸縮性的褲襠薄片28，係連結該等前後腰部薄片26、27並且構成褲襠域24。前後腰部薄片26、27及褲襠薄片28的內側配置有吸收體29。吸收體29例如可將由絨毛漿和超吸收性聚合物粒子等混合所構成的吸液性芯，藉由以液擴散性薄片(未圖示)覆蓋而形成。
作為如上述之前後腰部薄片26、27，可使用複合薄片1。本實施形態中，複合薄片1的縱方向Y配置成與尿布的縱方向Y一致，彈性薄片11位於肌膚相對向面。藉由使用複合薄片1，使主體21至少在前後腰部域22、23能與穿用者緊貼。又，由於在複合薄片1的彈性薄片11形成第1凸條部15及第1凹條部14，因此在與穿用者的肌膚之間形成間隙，能確保透氣性。由於在非彈性薄片12形成第2凸條部17及第2凹條部16，因此在與衣服之間形成間隙，能確保透氣性。亦即，在尿布的肌膚相對向面及非肌膚相對向面皆形成間隙，因此能維持更良好的透氣性。
第1凸條部15及第2凸條部17藉由朝互相交叉的方向延伸，而維持薄片全體的柔軟性，因此前後腰部薄片26、27能順應穿用者的動作，而能預防尿布偏移。
在如上述之尿布使用複合薄片1時，亦可讓彈性薄片11位於非肌膚相對向面。於該情形，尿布2的肌膚相對向面及非肌膚相對向面皆形成皺摺，因此能維持良好的透 氣性。
在尿布2由於能藉由在前後腰部薄片26、27使用複合薄片1而確保透氣性，因此能預防因為汗等水分使尿布2緊貼於穿用者的腰部。若腰部薄片緊貼於腰部則尿布2穿脫困難，但可防範於未然。又，藉由確保透氣性，可預防尿布2內悶濕，並預防穿用者的肌膚起疹子等的肌膚問題。
如上述之複合薄片1可藉由第7圖所示之方法製造。複合薄片1具有：形成彈性薄片11的彈性帶體31、及形成非彈性薄片12的非彈性帶體32。彈性帶體31，例如可使用採用熱可塑性聚胺酯彈性體的連續纖維作為彈性纖維、採用聚丙烯的連續纖維作為非彈性纖維之纖維不織布。熱可塑性聚胺酯彈性體的纖維徑為約25μm，聚丙烯的纖維徑為約21μm，且含有47%(質量比)之熱可塑性聚胺酯彈性體。
彈性帶體31例如以約45.5m/min的速度由第1捲出輥33搬運。經搬運的彈性帶體31係藉由複數個預熱輥34加熱，且被搬運到齒輪延伸裝置。預熱輥34被加熱至約80℃。
齒輪延伸裝置具有：加熱至約80℃的一對第1夾輥35、加熱至約55℃的一對齒輪輥36、37、及一對第2夾輥38。第1夾輥35的速度為約45.5m/min，第2夾輥38的速度為約54.5m/min。亦即，藉由邊在第1及第2夾輥35、38間使彈性帶體31拉伸，邊通過齒輪輥 36、37之間，使彈性帶體31邊加熱邊朝機械方向MD延伸。經延伸的彈性帶體31被搬運到冷卻輸送帶39予以冷卻。在冷卻輸送帶39的搬運速度為約50.0m/min。
經延伸加工的彈性帶體31被搬運到超音波裝置40。超音波裝置40包含超音波發射器41及輥狀的砧部42。在砧部42的周面以描繪鋸齒狀花紋的方式形成複數個凸部43。參照第8圖，凸部43在砧部42的周面全域形成有多數個，直徑約0.8mm，高度約1.0mm。朝旋轉方向R鄰接的凸部43的間距P1為約6.1mm，朝與其交叉的軸方向S鄰接的凸部43的間距P2為約6.0mm。間距係指從一方之凸部43的中心到另一方之凸部43的中心之尺寸。彈性帶體31以接觸而環抱砧部42周面的方式被搬運。砧部42的旋轉速度為約100m/min。
在超音波裝置40的上游，配置有搬運彈性帶體31的一對第3夾輥44，在下游配置有一對第4夾輥45。第3夾輥44的速度為約54.5m/min，第4夾輥45的速度為約100m/min。彈性帶體31係從第3夾輥44經由超音波裝置40被搬運到第4夾輥45，藉由該等旋轉速度的相異，彈性帶體31特別是在第3夾輥44及砧部42之間，邊在機械方向MD被拉伸邊被搬運。如此地將彈性帶體31在機械方向MD拉伸時，與機械方向MD交叉的方向之尺寸被縮小，造成所謂的寬度縮小。但是，由於在砧部42的周面形成有複數個凸部43，因此彈性帶體31的纖維鈎住凸部43而能抑制寬度縮小。
在邊接觸於砧部42邊被搬運的彈性帶體31，積層從第2捲出輥46搬運來的非彈性帶體32。非彈性帶體32可使用含有熱可塑性樹脂的纖維不織布，例如採用表層部使用聚丙烯、聚乙烯共聚物、芯部使用聚丙烯之表層-芯型的紡黏纖維不織布。非彈性帶體32的質量為約28.4g/m2，厚度約0.31mm。第2捲出輥46的速度為約100m/min。
積層後的彈性帶體31及非彈性帶體32係藉由超音波發射器41和砧部42而形成接合部13。亦即，彈性帶體31及非彈性帶體32的熱可塑性合成樹脂係藉由超音波而熔接且互相接合。超音波發射器41為頻率約20KHz、壓力300N/160mm。
形成有接合部13的彈性帶體31及非彈性帶體32之積層體，於通過第4夾輥45後，彈性帶體31的拉伸狀態被解除。彈性帶體31的拉伸狀態被解除後，彈性帶體31在機械方向MD收縮，因此非彈性帶體32在接合部13之間撓曲而形成皺摺，藉由該皺摺形成朝與機械方向MD交叉的方向延伸的第2凸條部17。由於在形成有接合部13的部分，非彈性帶體32與彈性帶體31接合，因此其成為第2凹條部16(參照第2圖及第4圖)。
彈性帶體31的拉伸狀態被解除後，朝交叉方向寬度縮小的狀態也被解除，因此交叉方向的尺寸變大。亦即，構成彈性帶體31的纖維被配向成在機械方向MD 被拉伸前，係朝機械方向MD及交叉方向隨機地延伸，但藉由在第3及第4夾輥44、45之間被拉伸而沿著機械方向MD延伸。藉此，彈性帶體31在機械方向MD延伸，並且在交叉方向使其尺寸變小。該拉伸狀態被解除後，配向於機械方向MD的纖維之至少一部分欲返回原來的狀態，使得經拉伸的纖維的一部分成為朝厚度方向隆起，形成膨鬆度高。隆起而成為膨鬆度高的部分形成第1凸條部15，而形成有接合部13的部分由於不會形成膨鬆度高，因此成為第1凹條部14(參照第1圖、第3圖及第5圖)。在彈性帶體31，藉由形成接合部13且形成膨鬆度高的第1凸條部15，使第1凸條部15的纖維變得稀疏，可更進一步提昇平面方向透氣性。
表1中，顯示在如上述之裝置中所製造的複合薄片1的其他實施例。實施例1係根據上述條件製造的複合薄片1，實施例2~6係顯示從實施例1中的設定變更製造裝置的各設定之情形，並顯示各情形中的彈性帶體31之特性，及所製造的複合薄片1之特性。表中的拉伸倍率係對應上述說明書段落0024的拉伸倍率者。實施例1~6皆能得到具有所要的拉伸倍率及平面方向透氣性之複合薄片1。
比較例中，彈性帶體31和非彈性帶體32不是藉由超音波裝置接合，而使藉由熱熔接著材接合。熱熔接著材係使用含有聚苯乙烯系彈性體之熱熔，藉由簾幕型塗布機，以噴嘴間距5mm、質量2g/m2塗布於非彈性帶體32。比 較例中，以與實施例1同樣的裝置設定製造。比較例的複合薄片相較於實施例的複合薄片，在平面方向透氣性低，可推測是未形成有第1及第2凸條部。又，雖然表1中未記載，但彈性帶體31和非彈性帶體32之接合強度比實施例小，為實施例1的40%左右。
如上述之製造方法中，在砧部42未形成有凸部43之情形，經拉伸的彈性帶體31的寬度縮小變得顯著。若彈性帶體31大幅地寬度縮小，特別是彈性帶體31的兩側部會變厚，與內側的厚度不均會變大。於接合該彈性帶體31和非彈性帶體32之情形，變厚時，接合強度容易變小，薄的時候容易變大。因而，接合部形成時會有接合強度出現不均的可能性。但是，本發明係於砧部42形成凸部43，由於能抑制寬度縮小，因此能抑制接合部的強度不均。
另一方面，為了在彈性帶體31形成第1凸條部15，彈性帶體31必須某種程度寬度縮小。因而，設置於砧部42的凸部43不是完全預防彈性帶體31寬度縮小者，而是形成第1凸條部15，且控制於抑制接合部的接合強度不均之程度者。
本實施形態中，接合部13係藉由超音波裝置40形成，但也可以藉由壓花加工等之熱封來形成。但是於該情形，由於在接合部形成時，彈性帶體或非彈性帶體全體被加熱，因此薄片容易受到熱所造成的損傷，不易形成膨鬆度高。
超音波裝置40的凸部43係使用圓形者，但不限定於此，也可以使用菱形、橢圓形、矩形等者，其剖面積為約0.1~10mm2較佳。若剖面積為0.1mm2以下，被接合的面積減少，複合薄片1的彈性薄片11和非彈性薄片12容易剝離。若剖面積為10mm2以上，於接合部薄膜 化時，其面積變大使肌膚觸感變差。凸部43的間距P1及P2為約1~20mm較佳，若為1mm以下則非彈性薄片12的第2凸條部17不易形成，若為20mm以上則有複合薄片1的厚度變得過大之可能性。凸部43的高度尺寸為約0.1~2.0mm，較佳可為約0.2~1.0mm。通常，纖維不織布的厚度大多為0.3~2.0mm，因為該等纖維不織布確實地形成接合部13。凸部43為鋸齒狀花紋，但不限定於此。但是，為了控制彈性帶體31的交叉方向中寬度縮小，凸部43在砧部42的旋轉方向分離且設置複數個較佳。
本實施形態中，彈性帶體31被實施齒輪延伸加工，但其非必要構成。但是，藉由將包含彈性纖維和非彈性纖維的彈性帶體31進行齒輪延伸，能使非彈性纖維延伸，使彈性帶體31(彈性薄片11)拉伸時的楊氏模數降低，而能得到柔軟的肌膚觸感。本實施形態中，齒輪輥36、37的齒輪節距為約1~10mm，較佳為約2~6mm。若齒輪節距為1mm以下，則必須使齒輪的齒變薄，帶體有被齒切斷之可能性，若為10mm以上，則延伸倍率變低而有使伸縮性不充分之可能性。齒輪的嚙入深度可為約0.5mm以上，若更小則有帶體的延伸不充分之可能性。延伸加工前後的帶體延伸倍率為約30~400%，較佳可為約50~200%。若延伸倍率為30%以下則帶體無法充分地延伸，若為400%以上則經延伸的帶體的纖維容易被切斷而脫落。
以上記載的有關本發明之揭示，至少可摘要成下述事項。
第1發明相關之複合薄片1具有縱方向Y及與縱方向Y正交的橫方向X，形成一面並且至少能朝前述橫方向彈性地伸縮之彈性薄片11與形成另一面之非彈性薄片12互相接合。
第1發明係上述複合薄片1以包含以下各點為特徵。
前述彈性薄片11及前述非彈性薄片12係藉由分別朝前述縱方向Y及前述橫方向X分離的多數個接合部13而互相接合。
前述彈性薄片11具有：與前述接合部13重疊並且朝前述橫方向X延伸的第1凹條部14、及與前述第1凹條部14鄰接且朝前述橫方向X延伸的複數個第1凸條部15。
前述非彈性薄片12具有：與前述接合部13重疊並且朝前述縱方向Y延伸的第2凹條部16、及與前述第2凹條部16鄰接且朝前述縱方向Y延伸的複數個第2凸條部17。
上述第1發明至少可包含下述實施形態。
(1)前述彈性薄片11及前述非彈性薄片12係分別由含有熱可塑性樹脂的纖維不織布形成，前述彈性薄片11和前述非彈性薄片12係於前述接合部13熔接。
(2)前述彈性薄片11具有彈性纖維和非彈性纖維。
(3)前述非彈性薄片12係於前述第2凸條部17，與前述彈性薄片11分離而形成空隙18。
(4)前述彈性薄片11係於前述第1凸條部15，至少其一部分接觸於前述非彈性薄片12。
(5)前述接合部13係沿著朝前述橫方向X延伸的假想線19而分離設置，前述假想線19係朝前述橫方向X分離且配置複數條，鄰接的前述假想線19中的前述接合部13，係於前述縱方向Y具有互相不重疊的位置關係。
第2發明相關之複合薄片1之製造方法，具有：接合彈性薄片11及非彈性薄片12的多數個接合部13、與前述接合部13重疊並且形成於前述彈性薄片11的第1凹條部14、與前述第1凹條部14鄰接的第1凸條部15、與前述接合部13重疊並且形成於前述非彈性薄片12的第2凹條部16、以及朝與前述第1凸條部15交叉的方向延伸的第2凸條部17。
第2發明係上述複合薄片1之製造方法以包含以下各點為特徵。
包含：將構成前述彈性薄片11的彈性帶體31藉由第1捲出輥33搬運的製程；將前述彈性帶體31經由夾輥44朝具有超音波發射器41及與超音波發射器41對置的砧部42之超音波裝置40搬運的製程；將構成前述非彈性薄片12的非彈性帶體32藉由第2捲出輥46朝前述超音波裝置40搬運的製程；以及 將前述彈性帶體31和前述非彈性帶體32藉由前述超音波裝置40接合的製程； 在前述砧部42的周面，設置分別朝旋轉方向及軸方向分離的多數個凸部43，前述彈性帶體31係接觸於前述周面而被搬運，並且前述砧部42的旋轉速度比前述夾輥44的旋轉速度更快。
上述第2發明至少可包含下述實施形態。
(1)前述彈性帶體31係於前述砧部42和前述夾輥44之間，在機械方向MD被拉伸，並且其拉伸後，在與前述機械方向MD正交的交叉方向的尺寸比拉伸前較小。
(2)進一步包含將前述彈性帶體31藉由一對齒輪輥36、37延伸加工的製程，在經延伸加工的前述彈性帶體31形成前述接合部13。
本發明的說明書及申請專利範圍內，用語「第1」「第2」「第3」及「第4」只是為了區別相同名稱的要素、位置等所使用。
1‧‧‧複合薄片
11‧‧‧彈性薄片
12‧‧‧非彈性薄片
13‧‧‧接合部

Claims (9)

  1. 一種複合薄片，係具有縱方向及與縱方向正交之橫方向，將形成一面並且至少能朝前述橫方向彈性地伸縮之彈性薄片與形成另一面之非彈性薄片互相接合而成，其特徵為，前述彈性薄片及前述非彈性薄片係藉由分別朝前述縱方向及前述橫方向分離的多數個接合部而互相接合，前述彈性薄片具有：與前述接合部重疊並且朝前述橫方向延伸的第1凹條部、及與前述第1凹條部鄰接且朝前述橫方向延伸的複數個第1凸條部，前述非彈性薄片具有：與前述接合部重疊並且朝前述縱方向延伸的第2凹條部、及與前述第2凹條部鄰接且朝前述縱方向延伸的複數個第2凸條部。
  2. 如申請專利範圍第1項之複合薄片，其中，前述彈性薄片及前述非彈性薄片係分別由含有熱可塑性樹脂的纖維不織布而形成，前述彈性薄片和前述非彈性薄片係於前述接合部熔接。
  3. 如申請專利範圍第1或2項之複合薄片，其中，前述彈性薄片具有彈性纖維和非彈性纖維。
  4. 如申請專利範圍第1或2項之複合薄片，其中，前述非彈性薄片係於前述第2凸條部，與前述彈性薄片分離而形成空隙。
  5. 如申請專利範圍第1或2項之複合薄片，其中，前述彈性薄片係於前述第1凸條部，至少其一部分接觸於前 述非彈性薄片。
  6. 如申請專利範圍第1或2項之複合薄片，其中，前述接合部係沿著朝前述橫方向延伸的假想線而分離設置，前述假想線係朝前述橫方向分離且配置複數個，鄰接的前述假想線中的前述接合部，係於前述縱方向具有互相不重疊的位置關係。
  7. 一種複合薄片之製造方法，該複合薄片具有：接合彈性薄片及非彈性薄片的多數個接合部、與前述接合部重疊並且形成於前述彈性薄片的第1凹條部、與前述第1凹條部鄰接的第1凸條部、與前述接合部重疊並且形成於前述非彈性薄片的第2凹條部、以及朝與前述第1凸條部交叉的方向延伸的第2凸條部；其特徵為，該製造方法包含：將構成前述彈性薄片的彈性帶體藉由第1捲出輥搬運的製程；將前述彈性帶體經由夾輥朝具有超音波發射器(sonic horn)及與超音波發射器對置的砧部之超音波裝置搬運的製程：將構成前述非彈性薄片的非彈性帶體藉由第2捲出輥朝前述超音波裝置搬運的製程：及將前述彈性帶體和前述非彈性帶體藉由前述超音波裝置接合的製程，在前述砧部的周面，設置分別朝旋轉方向及軸方向分離的多數個凸部，前述彈性帶體係接觸於前述周面而被搬 運，並且前述砧部的旋轉速度比前述夾輥的旋轉速度更快。
  8. 如申請專利範圍第7項之製造方法，其中，前述彈性帶體係於前述砧部和前述夾輥之間，在機械方向被拉伸，並且其拉伸後，在與前述機械方向正交的交叉方向的尺寸比拉伸前較小。
  9. 如申請專利範圍第7或8項之製造方法，進一步包含將前述彈性帶體藉由一對齒輪輥延伸加工的製程，在經延伸加工後的前述彈性薄片形成前述接合部。
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