TWI717546B - 伸縮片的製造方法 - Google Patents

伸縮片的製造方法 Download PDF

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Publication number
TWI717546B
TWI717546B TW106127052A TW106127052A TWI717546B TW I717546 B TWI717546 B TW I717546B TW 106127052 A TW106127052 A TW 106127052A TW 106127052 A TW106127052 A TW 106127052A TW I717546 B TWI717546 B TW I717546B
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Taiwan
Prior art keywords
elastic film
sheet
roller
stretch
roll
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TW106127052A
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English (en)
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TW201808627A (zh
Inventor
竹內寅成
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日商大王製紙股份有限公司
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Publication of TW201808627A publication Critical patent/TW201808627A/zh
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F5/00—Orthopaedic methods or devices for non-surgical treatment of bones or joints; Nursing devices; Anti-rape devices
    • A61F5/44—Devices worn by the patient for reception of urine, faeces, catamenial or other discharge; Portable urination aids; Colostomy devices
    • A61F5/4404—Details or parts
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/15585—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers
    • A61F13/15593—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers having elastic ribbons fixed thereto; Devices for applying the ribbons
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本發明提供一種伸縮片的製造方法，其能夠抑制縮幅。 本發明的伸縮片的製造方法，包括： 供給步驟，其使能夠伸縮的彈性薄膜30以伸長狀態介於不具有伸縮性的第一片層21與不具有伸縮性的第二片層22之間；及， 接合步驟，其是在該供給步驟中，藉由熱熔融裝置，由前述第一片層21和前述第二片層22的外側，對隔開間隔的多數個接合部區域施加熱熔融能量而使前述彈性薄膜30熔融，從而使前述第一片層21和前述第二片層22在多數個接合部直接或隔著彈性薄膜30接合在一起。 並且，使彈性薄膜30通過對向輥63與夾持輥65之間並圍繞對向輥63後，圍繞砧輥60，藉由使砧輥60的圓周速率比對向輥63的圓周速率更快來使彈性薄膜30伸長。

Description

伸縮片的製造方法
本發明有關一種伸縮片的製造方法，該伸縮片是以第一片層與第二片層夾持彈性薄膜而成。
吸收性物品，例如在拋棄式尿布中，為了提升對身體表面的合身性，一般而言是在腿圍或腰圍等適當的部位賦予伸縮性。作為用以賦予伸縮性的方法，先前已廣泛地採用將橡膠線等細長狀彈性伸縮構件在長度方向上伸長的狀態下進行固定的方法，但是，在希望以一定程度的寬度來賦予伸縮性的情況下，則採用將橡膠線以在寬度方向上隔開間隔地並排配置的狀態來進行固定的態樣。
另一方面，取代平行地配置而成的複數根橡膠線，亦提案有一種具有不織布/彈性體薄膜/不織布的結構之伸縮片(例如參照專利文獻1)，其被按壓成面狀並賦予伸縮性且考慮了觸感而作成。
專利文獻1除了揭示了在第一外層、第二外層及彈性薄膜(彈性體)整體上均不形成孔之無孔形態，亦揭示了形成有貫穿第一外層、第二外層及彈性薄膜整體的孔之有孔形態。
若是無孔形態，當將伸縮片例如作為構成拋棄式尿布的背面的薄片來使用時，因為沒有透氣性，所以會產生濕悶等問題。 另一方面，專利文獻1的有孔形態，則是在第一外層與第二外層之間供給連續並在輸送方向(MD)上伸縮的彈性薄膜，且在特定的位置藉由直接地熔接來使第一外層和第二外層結合後，使拉伸力作用在正交方向(CD)上，藉此，在結合部位形成有貫穿第一外層、彈性薄膜及第二外層整體的貫穿孔，從而確保透氣性；該彈性薄膜具有比第一片層和第二片層更高的熔點或不具有熔點。
不論是何種方式，若彈性薄膜(彈性體)在輸送方向上伸長，便會產生彈性薄膜的寬度變短也就是縮幅(neck-in)減少。由於會產生該縮幅，所以為了要獲得具有期望的寬度的積層片，便需要準備比第一外層和第二外層的各自的寬度更寬的彈性薄膜，而這會造成材料的成本變高。 又，有關實際上被積層的薄片的CD方向，伴隨彈性薄膜的縮幅，在寬度方向中央與寬度方向兩側部會產生伸縮應力變得不同的現象，所以當將積層而成的伸縮片用於製品例如拋棄式尿布時，有時會產生無法獲得均勻的伸縮應力的問題。
另一方面，專利文獻2揭示了一種方法，其設有複數個延伸輥，並在圍繞該等延伸輥的過程中實行延伸。該方法亦已針對「收縮」進行研究，藉由縮短延伸輥間的距離來謀求「收縮」(necking，也就是縮幅)抑制的效果，但是該方法被認為無法表現充分的效果。 [先前技術文獻] (專利文獻)
專利文獻1：日本特許第4562391號公報(美國2002/0016122 A1) 專利文獻2：日本特表2014-520589號公報(美國2014/0130956 A1)
因此，本發明主要欲解決的問題在於提供一種伸縮片的製造方法，其能夠抑制縮幅。
解決上述欲解決的問題的本發明，如下所述。
(基本形態) 本發明的伸縮片的製造方法，其是製造能夠伸縮的伸縮片的方法，包括： 供給步驟，其使能夠伸縮的彈性薄膜以伸長狀態介於不具有伸縮性的第一片層與不具有伸縮性的第二片層之間；及， 接合步驟，其是在該供給步驟中，在使前述彈性薄膜以伸長狀態介於前述第一片層與前述第二片層之間的狀態下，藉由熱熔融裝置，由前述第一片層和前述第二片層的外側，對隔開間隔的多數個接合部區域施加熱熔融能量而使前述彈性薄膜熔融，從而使前述第一片層和前述第二片層在多數個接合部直接或隔著彈性薄膜接合在一起； 其中，前述熱熔融裝置具有砧輥(anvil roll)與超音波焊頭(ultrasonic horn)，前述砧輥在其外表面形成有在輥長方向和外圓周方向上隔開間隔的多數個突部， 與前述砧輥分離地配置有對向輥， 並配置有與前述對向輥相對應並可夾持前述彈性薄膜之夾持輥(nip roller)； 並且，前述彈性薄膜在通過前述對向輥與前述夾持輥之間的夾持位置並圍繞前述對向輥後，圍繞前述砧輥，藉由使前述砧輥的圓周速率比前述對向輥的圓周速率更快來使前述彈性薄膜伸長，並且藉由前述砧輥的突部的群與前述超音波焊頭來實行接合。
藉由本發明的其中一實施形態所獲得的伸縮片，並未形成貫穿該第一片層和第二片層的孔。這點異於日本特許第4562391號公報的第5圖或第7圖所示的伸縮片。
另一方面，藉由在輸送方向將彈性薄膜以伸長狀態供給至接合之處，便能夠在彈性薄膜與接合部的至少前述輸送方向的邊界部分處形成貫穿孔。後續將詳細地說明該貫穿孔形成的理由。
熱熔融裝置具有砧輥與超音波焊頭，該熱熔裝置是藉由施加的能量來使第一片層、第二片層及彈性薄膜中的至少一層的至少一部分熔融的手段。
並可認為：對於伴隨彈性薄膜的伸長而造成縮幅的往寬度方向中央的移動力，砧輥的突部群的凹凸會成為阻礙而可抑制縮幅。
在本發明中，與砧輥分離地配置有對向輥，並配置有與前述對向輥相對應並可夾持彈性薄膜之夾持輥。 前述彈性薄膜在通過前述對向輥與前述夾持輥之間的夾持位置並圍繞前述對向輥後，圍繞前述砧輥，藉由使前述砧輥的圓周速率比前述對向輥的圓周速率更快來使前述彈性薄膜伸長。 亦即，因為前述彈性薄膜在前述對向輥與前述夾持輥之間被夾持，所以藉由使砧輥的圓周速率比夾持輥的圓周速率更快，便能夠實質地從夾持位置使前述彈性薄膜開始伸長(延伸)。 進一步，可認為彈性薄膜在圍繞對向輥後，因為彈性薄膜會圍繞砧輥，所以該等輥表面之間的阻力亦可抑制縮幅。
並且，可認為藉由夾持的存在，彈性薄膜的至少在與前述對向輥表面之間的阻力會變大，而對抑制縮幅有所貢獻。
在比前述夾持位置的更上游側中，不使前述彈性薄膜伸長，即便使其伸長，亦期望相對於需要的伸長率設為50%以下。
因此，根據本發明適合的實施形態，從前述夾持位置開始伸長，或者從前述夾持位置開始進行超過需要的伸長率的50%的伸長。
期望夾持位置與前述接合位置之間的距離未滿250mm。尤其期望是30mm～200mm。 若使彈性薄膜在通過前述接合位置之後，在前述接合位置的下游側的10mm以下的距離處從前述砧輥分離，則能夠達成下述的期望的狀態：從前述夾持位置至前述彈性薄膜離開前述砧輥的位置之間的距離未滿260mm。
期望砧輥是凸面輥而不是平坦的輥。認為藉由是凸面輥，與凸面輥表面之間的彈性薄膜的阻力會變大，而能夠對抑制縮幅有所貢獻。
前述接合部的配置的一例是交錯狀。
在其中一實施形態中，當以展開狀態來觀察前述砧輥時，期望單位面積內所包含的前述突部的群的總面積所佔的突部面積率至少在輥長上不同。
另一方面，藉由在輸送方向上將彈性薄膜以伸長狀態供給至接合之處，便能夠在彈性薄膜與接合部的至少前述輸送方向的邊界部分處形成貫穿孔。
在本發明的接合部中，例如具有下述的接合形態例。 (1)第一片層和第二片層部分熔融並接合在彈性薄膜上，亦即是第一片層和第二片層隔著彈性薄膜來接合的形態。 (2)彈性薄膜熔融並轉移至第一片層和第二片層中，而第一片層和第二片層直接進行接合而非隔著彈性薄膜的形態。 (3)是(1)形態與(2)形態中間的形態，該形態是彈性薄膜的兩表面部分熔融而轉移至第一片層和第二片層中，但是由於彈性薄膜仍部分地殘留，所以第一片層和第二片層是隔著殘留的彈性薄膜進行接合。
在該等形態之中，尤其，在(2)的形態和(3)的形態中，在接合部與非接合部會產生彈性薄膜強度的差異。因此，在下述情況下，若在伸縮方向上以機械力或人力使製品伸長，接合部與非接合部的邊界部分會產生斷裂，該等情況是：一旦將保持著伸長的伸縮片的伸長狀態釋放而使伸縮片收縮從而作成製品後；或，將保持著伸長的伸縮片與其他構件結合後，一旦解放伸長狀態來使伸縮片收縮而作成製品後。 其結果，可形成貫穿孔。
形成有貫穿孔的製品，具有可確保透氣性的優點。貫穿孔，沒有必要形成在所有的接合部中，即便形成在一部分的接合部中仍可表現透氣性。當彈性薄膜僅能夠在輸送方向上伸縮時，貫穿孔會成為從接合部的邊緣往輸送方向延伸的形狀。當彈性薄膜能夠在輸送方向(MD)和與輸送方向正交之方向(例如CD方向)兩者上伸縮時，貫穿孔會成為從接合部的邊緣往兩方向延伸的形狀，依據情況有時會在接合部的周圍成為環狀的形狀。
如先前所述，本發明的彈性薄膜因為一般使用彈性體，所以能夠在輸送方向(MD)和正交方向(CD)伸縮。
前述接合部，除了如圓形那樣不具有方向性的形態之外，亦可提供正交方向(寬度方向：CD)的長度比輸送方向(MD)的長度更長的形態。
用以實施本發明方法的彈性薄膜的熔點，較佳是80～145℃左右，第一片層和第二片層的熔點較佳是85～190℃左右，尤其較佳是130～190℃左右，又，第一片層和第二片層的熔點與表現較低的熔點的彈性薄膜30的熔點之間的差，較佳是50～80℃左右。 作為適合的具體例，前述彈性薄膜的熔點是95～125℃，第一片層的熔點是超過125℃～160℃，更佳是130～160℃，第二片層的熔點是超過125℃～160℃，更佳是130～160℃。
當以展開狀態觀察砧輥時，期望單位面積內所包含的突部的群的總面積所佔的突部面積率至少在輥長上不同。 突部對應於前述接合部。作為接合部的適合例，接合部的面積是0.14～3.5mm2 。又，期望前述接合部的面積率是1.8～22.5%。
伸縮區域中的接合部的面積率是1.8~22.5%。
此處，所謂的「面積率」意指對象部分在單位面積中所佔的比例，是將對象區域(例如伸縮區域)中的對象部分(例如接合部、貫穿孔的開口)的總面積除以該對象區域的面積並以百分率表示的值，尤其是所謂的「接合部的面積率」，意指在伸縮方向上伸長至彈性極限為止的狀態的面積率。
又，伸縮片在自然長度狀態中的前述貫穿孔的開口的面積，適當是接合部的面積的超過1倍~1.5倍。
貫穿孔的開口的面積，意指該伸縮結構在自然長度的狀態中的值，當貫穿孔的開口的面積在彈性薄膜的表面與背面不同等情況、或在厚度方向上不均勻時則意指最小值。
本說明書中的接合部面積率，能夠藉由決定說明在後的砧輥的突起部的大小、形狀、分離間隔、輥長方向及輥圓周方向的配置圖案等來選擇。
後述所謂的「伸縮應力」，意指依據日本工業規格JIS K7127：1999「塑膠：拉伸特性的試驗方法」，藉由拉伸試驗所測得的「伸長至彈性極限的50%為止時的應力(N/35mm)」，該拉伸試驗是將初期夾具間隔(標線間距離)設為50mm並將拉伸速度設為300mm/分鐘。當無法切割出寬度35mm的試驗片時，則以能夠切割出的寬度作成試驗片，然後將測定值設為換算成35mm的值。 當對象區域較小而無法採取充分的試驗片時，只要是伸縮應力的比較，即使是適當小的試驗片，至少能夠進行比較。
又，在後述的實施形態中，當區域內的複數個伸縮應力不同時，用以證明伸縮應力不同的試驗片該如何採取便成為問題。在該情況，能夠採取下述方式：不欲求得伸縮應力的絕對值，而是為了比較伸縮應力，對伸縮片的各部位採取試驗片，並藉由從自然狀態的100%的長度伸長至150%的長度時的應力，來比較個別的試驗片的應力大小。
如上述，根據本發明，成為一種伸縮片的製造方法，其能夠抑制縮幅並降低材料成本。
以下，一邊參照圖式，一邊詳細地說明本發明的實施形態。
本發明的伸縮片能夠用於吸收並保持體液的吸收性物品中，例如拋棄式尿布、衛生棉、吸收襯墊等。
伸縮片，如第5圖～第8圖所示，在第一片層21與第二片層22之間，積層有能夠在前述前後方向上伸縮的彈性薄膜30，且前述第一片層21和前述第二片層22是直接或隔著彈性薄膜30以隔開間隔的多數個接合部40來進行接合；該第一片層21不具有伸縮性，例如是由不織布所構成；該第二片層22不具有伸縮性，例如是由不織布所構成。 此處，所謂的第一片層21和第二片層22「不具有伸縮性」，並非意指完全無法伸縮，而是意指相較於彈性薄膜的伸縮性程度，實質上不伸縮。
當在接合時，例如，如表示本發明中的第一接合例的第9圖所示，在具有突部60a之砧輥60與超音波焊頭61之間，供給第一片層21、彈性薄膜30及第二片層22，並藉由超音波焊頭61施加超音波熔融能量，例如主要是藉由熔融彈性薄膜30來接合第一片層21和前述第二片層22，該突部60a是以特定的圖案形成在砧輥60的外表面上而成。
與前述砧輥60相對向地配置有對向輥63。又，對於對向輥63，設置有夾持彈性薄膜30之夾持輥65。並以砧輥60的圓周速率比對向輥63和夾持輥65的圓周速率更快的方式來進行旋轉。 在此種裝置的構造中，彈性薄膜30在通過利用對向輥63與夾持輥65來夾持彈性薄膜30的夾持位置後，圍繞對向輥63的外圓周，之後，使彈性薄膜30圍繞砧輥60。
此時，藉由使進行驅動旋轉的砧輥60的圓周速率比對向輥63和夾持輥65的圓周速率更快，可使彈性薄膜30伸長，並且藉由砧輥60的突部60a的群與超音波焊頭61來實行接合。
此時，藉由選擇使砧輥60的圓周速率比對向輥63的圓周速率更快的速度差，便能夠設定彈性薄膜30在製造過程中的伸長率(以將自然狀態的長度設為100%時為基準)。
在第9圖的例中，雖然砧輥60與對向輥63並未夾持彈性薄膜30，仍是以接近的方式來配置。並且，相對於對向輥63，彈性薄膜30以超過90度且未滿180度的圍包角(wrap angle) θ的方式來圍繞對向輥63。從與夾持輥65之間的夾持位置算起的圍包角α則設為大致90度。 相對於砧輥60，彈性薄膜30和第二片層22則是以約90度的圍包角β來圍繞。
砧輥60、對向輥63及夾持輥65的配置能夠適當選擇。例如，如表示第二接合例的第10圖所示，砧輥60與對向輥63並未夾持彈性薄膜30，而是以稍微分離的方式來配置。又，在第10圖的例子中，在到達夾持輥65的位置前，彈性薄膜30並未與對向輥63接觸。 其結果，相對於對向輥63，彈性薄膜30以未滿90度的圍包角α來圍繞對向輥63。 相對於砧輥60，彈性薄膜30和第二片層，以未滿90度的圍包角β來圍繞。 為了抑制縮幅，從彈性薄膜30離開對向輥63的分離位置至接著開始圍繞砧輥60的位置為止的距離是50mm以下，期望是10mm以下，尤其期望是5mm以下。
在表示第三接合例的第11圖的例中，砧輥60與對向輥63雖然並未夾持彈性薄膜30，仍是以接近的方式來配置。並且，夾持輥65被配置成面對於對向輥63，並且彈性薄膜30以超過90度且未滿180度的圍包角α來圍繞對向輥63。
上述的第一接合例~第三接合例，是彈性薄膜30從對向輥63與夾持輥65的夾持位置開始伸長(延伸)的例子，但是如表示作為第四接合例的第12圖的例子，藉由下述方式亦能夠進行兩段的伸長(延伸)，該方式是在預捲輥62與預夾輥64之間夾持彈性薄膜30，並且在對向輥63與夾持輥65之間夾持彈性薄膜30，且藉由階段性地加快預捲輥62和預夾輥64的圓周速率、對向輥63和夾持輥65的圓周速率、砧輥60的圓周速率來進行。
藉由附加同樣的構造，亦能夠進行三段以上的伸長(延伸)。
第13圖中表示調查了從夾持位置至接合位置為止的分離距離與縮幅率之間的關係的結果。
根據該第13圖，縮幅率不僅是與夾持位置與接合位置之間的距離成正比地變高，當夾持位置與接合位置之間的距離是250mm以上時，縮幅率會急遽地變高。因此，在第9圖所示的例中，期望從彈性薄膜30中的對向輥63與夾持輥65的夾持位置至砧輥60的接合位置為止的距離是設為250mm以下。尤其期望是180mm以下。
又，為了抑制縮幅，期望相對於對向輥63，從彈性薄膜30的夾持位置至彈性薄膜30的分離位置為止的圍包角α是30度~300度(更期望是45度~120度)。為了抑制縮幅，期望砧輥60的圍包角β是30度～270度(更期望是45度～120度)。
如由第13圖的結果能夠推測出的那樣，如第12圖的例子，相較於如第一接合例～第三接合例那樣的一段伸長(延伸)，若實行階段性伸長(延伸)，因為從夾持位置至接合位置為止的分離距離會變得更長，所以不佳。期望是如第一接合例～第三接合例那樣的一段伸長(延伸)，並期望在比該夾持位置上游側中不實行彈性薄膜的伸長。
砧輥60適合的是如第14圖所示的凸面輥。期望砧輥60的長度是1000mm左右。 凸起量能夠適當選擇，並能夠依據情況藉由冷卻輥端部來調整凸起量。
另一方面，砧輥60的突部60a，能夠以越靠近輥長中央越密集的方式來形成，若是此種形態，因為中央部熱膨脹最多，所以容易賦予凸起。
另一方面，砧輥60的材質期望使用模具鋼(die steel)，又，焠火(quenching)硬度以HRC計，最合適的是60～61。
第6圖概要性地圖示已接合後的伸縮片在伸長狀態中的剖面(但是，並未形成貫穿孔)。若解放伸縮片的輸送方向(第7圖的左右方向)的伸長狀態，則如第7圖(概要圖)所示，藉由彈性薄膜30的收縮力可進行收縮，若施加外力則能夠伸長。然而，若使該伸縮片的該伸縮方向例如與拋棄式尿布的前後方向設為一致，則拋棄式尿布便能夠在前後方向上伸縮。若使該伸縮方向例如與拋棄式尿布的寬度方向設為一致，則拋棄式尿布便能夠在腰周或腰圍方向上進行伸縮。
並且，伸縮片除了在製品的製造產線內製造，亦能夠在製成伸縮片的網之後，將裁切為期望的面積所獲得的伸縮片使用於製品的特定部位中。 在先前的拋棄式尿布中，一般是藉由在薄片上並排地固定複數根橡膠線來製造，但是由於橡膠線或對薄片進行固定用的熱熔黏合劑的劣化而造成品質下降、及從製造時穩定的生產性來看較差。該等問題點能夠藉由上述的伸縮片來解決。 並且，若觀察第7圖的收縮狀態便可得知，因為伸縮片的外表面會產生規則且細緻的皺褶或襞，所以對穿戴者的肌膚的觸感良好。
另一方面，在上述例中，是使彈性薄膜30熔融來接合第一片層21與第二片層22而成的例子。此時，有下述態樣：(1)第一片層21或第二片層22在彈性薄膜30的表面上接合的態樣；(2)彈性薄膜30的表面部分熔融，並浸入第一片層21和第二片層22各自的纖維間來進行接合的態樣；(3)彈性薄膜30的整體幾乎熔融，並浸入第一片層21和第二片層22各自的纖維間來進行接合的態樣等。在本發明中，層間的接合態樣並未限定在該等例。 在該等態樣之中的(3)等的態樣中，能夠將其評價為第一片層21與第二片層22直接接合，也就是不隔著彈性薄膜地進行接合。 上述(1)～(3)的態樣，可以是彈性薄膜30的熔點比第一片層21和第二片層22的熔點更低的情況，亦可以是彈性薄膜30的熔點比第一片層21和第二片層22的熔點更高的情況。此時，是下述形態：第一片層21及/或第二片層22的彈性薄膜30側表面部分，經活性化或經熔融而接合在彈性薄膜30上。 進一步，除了彈性薄膜30進行部分熔融以外，亦可以是藉由第一片層21及/或第二片層22也進行熔融來接合的形態。 第一片層21及/或第二片層22是不織布，不織布的纖維可以具有芯和鞘的結構。在該情況中，例如能夠僅熔融纖維的鞘成分來幫助接合。
在本發明的伸縮片中，除了可使接合部的形狀、大小及配置相同以外，能夠選擇該區域的單位面積內所包含的接合部的總面積佔單位面積的比例，亦即能夠選擇接合部的面積率。
第1圖是接合部的配置圖案(近似於以展開狀態觀察砧輥時的突部群的配置圖案)例的平面圖。 作為在伸縮方向上伸長至彈性極限的狀態下的接合部面積率，如參照第1圖所示，是將單位面積S內所包含的接合部40,40等的總面積所佔的比例以百分率表示而得。作為該情況中的單位面積S，期望是以包含10個以上的接合部這樣的大小來設定(若個數較少會不易實行伸縮應力的比較)。在第1圖的例中，包含有13個接合部。又，決定單位面積S的外形，除了正方形以外，亦可以是長方形或圓等其他形狀。
接合部40的一例是第1圖所示的圓形。當然亦可以是橢圓或長方形等形狀。第1圖的Lm是在輸送方向上的排列間隔長度，Lc是在與輸送方向正交之正交方向(交叉方向：CD)上的排列間隔長度，Pm是在輸送方向(MD)上的間距長度，Pc是在正交方向(交叉方向：CD)上的間距長度。
第2圖~第6圖中顯示了藉由伸縮片內的區域來改變接合部面積率的態樣。
第2圖，是有關區域A、B的圖，其是藉由將接合部面積設為A<B來使伸縮應力成為A>B的關係。
例如，若比較間距長度Pm和間距長度Pc較長的情況A、與間距長度Pm和間距長度Pc較短的情況B，相較於間距長度Pm和Pc較短的情況B(接合部面積率較高的情況)，間距長度Pm和Pc較長的情況A(接合部面積率較低的情況)的伸長率較大。其結果，伸縮應力成為A>B的關係。
第2圖的形態，因為在第2圖的橫方向的伸縮應力是依各個區域而不同，所以使伸縮應力較大的A區域對應於吸收性物品的寬度方向中央區域。並且，伸縮應力較小(也就是伸縮較小)的B區域則對應於位於中央的A區域的兩個外側。
第3圖的情況，是下述例，其是在中間區域內，針對前後方向中間的A區域，在其前後方向配置伸縮應力較小的B區域而成。該例因為能夠使前後的B領域、B領域，對應於拋棄式尿布的前後方向端部，並且在該前後方向端部，由於伸縮應力較小，所以形狀穩定性良好，因此對於穿戴者而言容易穿戴。
在本發明中，接合部面積率的不同，除了配置圖案的疏密之外，亦能夠藉由改變接合部面積來實行。 為了理解此形態，在第4圖中表示了下述例子：在區域C中，配置多數個小接合部，且設為與區域D相同的接合部面積。藉由將接合部面積設為A＜C＝D，便能夠作成伸縮應力A＞C＝D的關係。
能夠適當選擇彈性薄膜的厚度、材料、變形和應力特性、熔點等物性。藉由選擇該彈性薄膜、對彈性薄膜賦予的超音波熔融能量及在製造伸縮片時的彈性薄膜的伸長率之間的關係等，便能夠如第8圖所示，在結合部40的周圍形成貫穿孔31。作為第一片層21和第二片層22，例如當藉由不織布來形成時，因為不織布可表現透氣性，所以藉由貫穿孔31的形成，便能夠在伸縮片的表面和背面表現透氣性。因此，例如當用於拋棄式尿布的外形片或外裝片時，透氣性良好。
透氣貫穿孔31被形成的理由雖然並不明確，但是藉由超音波熔融能量使彈性薄膜30熔融，且藉由砧輥60的突部60a所實行的按壓，藉此便會使結合部40薄層化。此時，可認為：彈性薄膜30亦進行薄層化，並且結合部40的周圍部達到斷裂強度，所以藉由作用在伸長的彈性薄膜30上的伸縮應力，彈性薄膜30便開始斷裂，並收縮至平衡之處而產生開孔。
在第15圖中，示意性地表示在圓形的突部60a的情況中所產生的接合部40上的貫穿孔31的形成例。在結合部40的輸送方向(伸長方向)的兩側，形成有大致為新月狀的貫穿孔31。
結合部，能夠設為在與伸長方向(輸送方向：MD)正交之方向(交叉方向：CD)上較長的形狀。當在該情況中，例如第16圖所示，能夠形成較大開孔的半圓形的貫穿孔31，在欲提高透氣性的情況是適合的手段。
另一方面，不必在所有的結合部都形成貫穿孔31。如果在要求確實地形成貫穿孔31的情況、或要求形成較大開孔的情況，則能夠採用第15圖所示的方法。 亦即，如第17圖(b)所示，使形成有結合部40之伸縮片，通過具有突條或突起64a之一對輥64之間，在其中一個輥64上的突起64a會嵌入另一個輥64上的鄰接的突起64a和突起64a之間，並對伸縮片施加變形力而能夠形成貫穿孔31。
另外，各個接合部40和貫穿孔31在自然長度狀態中的形狀，能夠設為：正圓型、橢圓形、長方形等多角形(包含線狀或弧狀的形狀)、星形、雲形等任意的形狀。各個接合部40的大小，只要適當決定即可，若過大則接合部40的硬度對觸感造成的影響會變大，若過小則接合面積較少，會變得無法充分地黏著材料彼此，因此，通常的情況中，各個接合部40的面積較佳是設為0.14～3.5mm2 左右。各個貫穿孔31的開口面積，為了經由貫穿孔31來形成接合部，只要比接合部大即可，較佳是設為接合部面積的1～1.5倍左右。
又，作為本發明的接合部，可以是由主伸縮部直接過渡至非伸縮區域，亦能夠形成其中間的轉變伸縮部。 各區域中的各個接合部40的面積和面積率，通常的情況，較佳是如下所示。 (非伸縮區域) 接合部40的面積：0.14～3.5mm2 (尤其是0.25～1.0mm2 )。 接合部40的面積率：16～45%(尤其是25～45%)。 (主伸縮部) 接合部40的面積：0.14～3.5mm2 (尤其是0.14～1.0mm2 )。 接合部40的面積率：1.8～19.1%(尤其是1.8～10.6%)。 (轉變伸縮部) 接合部40的面積：0.14～3.5mm2 (尤其是0.25～1.0mm2 )。 接合部40的面積率：8～22.5%(尤其是12.5～22.5%)。
接合部40和貫穿孔31的平面排列能夠適當決定，較佳是規則地重複的平面排列，除了如下述那樣規則地重複的平面排列之外，亦能夠設為接合部40的群(群單位的排列可以規則，亦可以不規則，亦可以是花紋或文字狀等)規則地重複的平面排列，該規則地重複的平面排列是如第18圖(a)所示的斜方格子狀、如第18圖(b)所示的六角格子狀(該圖案亦被稱為交錯狀)、如第18圖(c)所示的正方格子狀、如第18圖(d)所示的矩形格子狀、如第18圖(e)所示的平行格子狀(如圖示，以多數且平行地朝斜方向的列的群相互地交叉的方式來設置2群的形態)等(該等包含相對於伸縮方向以未滿90度的角度傾斜而成者)。接合部40和貫穿孔31的排列形態，在主伸縮部、轉變伸縮部及非伸縮區域中，除了設為相同之外，亦能夠設為不同。
彈性薄膜30並無特別限定，只要是其本身具有彈性的樹脂薄膜便能夠使用，而無特別限定，例如能夠使用藉由T型模(T-die)法或充氣成形法(inflation molding)等擠出成形來將1種或兩種以上的熱塑性彈性體的混合物加工成薄膜狀而成的薄膜，該熱塑性彈性體是苯乙烯系彈性體、烯烴系彈性體、聚酯系彈係體、聚醯胺系彈性體及聚胺酯系彈性體等。又，作為彈性薄膜30，除了無孔的彈性薄膜之外，為了透氣，亦能夠使用一種形成有多數的孔或狹縫之彈性薄膜。尤其，較佳是下述彈性薄膜30，其在伸縮方向中的拉伸強度是8～25N/35mm，在與伸縮方向正交之方向中的拉伸強度是5～20N/35mm，在伸縮方向中的拉伸伸度是450～1050%及在與伸縮方向正交之方向中的拉伸伸度是450～1400%。再者，拉伸強度和拉伸伸度(斷裂伸度)，除了使用拉伸試驗機(例如島津公司製造的AUTOGRAPH AGS-G100N(型號))，並將試驗片設為寬度35mm×長度80mm的長方形狀以外，意指依據日本工業規格JIS K7127：1999「塑膠：拉伸特性的試驗方法」，藉由將初期夾具間隔(標線間距離)設為50mm並將拉伸速度設為300mm/分鐘所測得的值。彈性薄膜30的厚度並無特別限定，較佳是20～40μm左右。又，彈性薄膜30的基重並無特別限定，較佳是30～45g/m2 左右，特別較佳是30～35g/m2 左右。
〈說明書中的用語的說明〉 說明書中的以下用語，若在說明書中並未特別記載，則具有以下的意思。 ‧「伸長率」意指將自然長度設為100%時的值。 ‧「基重」是以下述方式進行測定。將樣品或試驗片預備乾燥後，放置到標準狀態（試驗場所的溫度為20±5℃、相對濕度為65%以下）下的試驗室或裝置內，來使其成為恆重(constant weight)的狀態。預備乾燥，是指在相對濕度為10～25%、溫度不超過50℃之環境下使樣品或試驗片成為恆重。再者，關於法定水分率為0.0%之纖維，可不進行預備乾燥。由呈恆重量的狀態之試驗片，使用樣品採取用的模板(200mm×250mm、±2mm)，切取200mm×250mm(±2mm)的尺寸的樣品。測量樣品的重量，並乘20倍來計算出每1平方公尺的重量，來作為基重。 ‧當並未記載試驗或測定中的環境條件時，該試驗或測定設為在標準狀態(試驗場所的溫度為20±5℃、相對濕度為65%以下)的實驗室或裝置內實行。 [產業的可利用性]
本發明的伸縮片，除了能夠利用於褲型拋棄式尿布以外，亦能夠全面性地利用於黏貼型或襯墊型等各種拋棄式尿布、衛生棉等具備伸縮構造之吸收性物品中。
又，能夠在吸收性物品的製造產線內一邊實行接合，一面製造本發明中的伸縮片來作為例如構成吸收性物品的背面的薄片。
A～D‧‧‧區域 21‧‧‧第一片層 22‧‧‧第二片層 30‧‧‧彈性薄膜 31‧‧‧貫穿孔 40‧‧‧接合部 60‧‧‧砧輥 60a‧‧‧砧輥的突部 61‧‧‧超音波焊頭 62‧‧‧預捲輥 63‧‧‧對向輥 64‧‧‧預夾輥 64a‧‧‧預夾輥的突起 65‧‧‧夾持輥 α‧‧‧圍包角 β‧‧‧圍包角 θ‧‧‧圍包角 Lc‧‧‧在正交方向上的排列間隔長度 Lm‧‧‧在輸送方向上的排列間隔長度 Pc‧‧‧在正交方向上的間距長度 Pm‧‧‧在輸送方向上的間距長度
第1圖是接合部的配置圖案的例子的平面圖。
第2圖是接合部面積率不同的例子的概要平面圖。
第3圖是接合部面積率不同的其他例的概要平面圖。
第4圖是接合部面積率不同的另外一例的概要平面圖。
第5圖是伸縮片在接合前的說明用剖面圖。
第6圖是伸縮片在接合狀態的說明用剖面圖。
第7圖是伸縮片在收縮狀態的說明用剖面圖。
第8圖是形成有貫穿孔之伸縮片在接合狀態的說明用剖面圖。
第9圖是本發明中的第一接合例的概要圖。 第10圖是本發明中的第二接合例的概要圖。 第11圖是本發明中的第三接合例的概要圖。 第12圖是本發明中的第四接合例的概要圖。 第13圖是產生縮幅的實驗結果的圖表。 第14圖是凸面輥的說明圖。 第15圖是貫穿孔的形成例的說明用平面圖。 第16圖是態樣不同的貫穿孔的形成例的說明用平面圖。 第17圖是強制性的貫穿孔的形成例的說明用剖面圖。 第18圖是顯示接合部的各種排列例的平面圖。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記) 無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記) 無
21‧‧‧第一片層
22‧‧‧第二片層
30‧‧‧彈性薄膜
60‧‧‧砧輥
60a‧‧‧砧輥的突部
61‧‧‧超音波焊頭
63‧‧‧對向輥
65‧‧‧夾持輥
α‧‧‧圍包角
β‧‧‧圍包角
θ‧‧‧圍包角

Claims (5)

  1. 一種伸縮片的製造方法，其是製造能夠伸縮的伸縮片的方法，其特徵在於，該製造方法包括：供給步驟，其使能夠伸縮的彈性薄膜以伸長狀態介於不具有伸縮性的第一片層與不具有伸縮性的第二片層之間；及，接合步驟，其是在該供給步驟中，在使前述彈性薄膜以伸長狀態介於前述第一片層與前述第二片層之間的狀態下，藉由熱熔融裝置，由前述第一片層和前述第二片層的外側，對隔開間隔的多數個接合部區域施加熱熔融能量而使前述彈性薄膜熔融，從而使前述第一片層和前述第二片層在多數個接合部直接或隔著彈性薄膜接合在一起；其中，前述熱熔融裝置具有砧輥與超音波焊頭，前述砧輥在其外表面形成有在輥長方向和外圓周方向上隔開間隔的多數個突部，與前述砧輥分離地配置有對向輥，並配置有與前述對向輥相對應並可夾持前述彈性薄膜之夾持輥；並且，前述彈性薄膜在通過前述對向輥與前述夾持輥之間的夾持位置並圍繞前述對向輥後，圍繞前述砧輥，藉由使前述砧輥的圓周速率比前述對向輥的圓周速率更快來使前述彈性薄膜伸長，並且藉由前述砧輥的突部的群與前述超音波焊頭來實行接合； 從前述夾持位置至前述彈性薄膜離開前述對向輥的位置為止的圍包角α是30度~300度，前述砧輥的圍包角β是30度~270度；從前述夾持位置算起至與接合位置之間的距離，未滿250mm，該接合位置是前述砧輥的突部的群與前述超音波焊頭實行接合之處。
  2. 如請求項1所述之伸縮片的製造方法，其中，在比前述夾持位置更上游側中，不實行前述彈性薄膜的伸長。
  3. 如請求項1所述之伸縮片的製造方法，其中，前述砧輥是凸面輥。
  4. 如請求項1所述之伸縮片的製造方法，其中，前述突部的配置是交錯狀。
  5. 如請求項1所述之伸縮片的製造方法，其中，在前述接合步驟中，在整個前述接合部區域並未形成孔，而是使前述第一片層和前述第二片層殘留，並且在前述彈性薄膜與前述接合部的至少前述伸長方向的邊界部分處形成貫穿孔。
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