WO2010098206A1 - ロール状シートの製造方法、及び、ロール状シートの製造装置 - Google Patents
ロール状シートの製造方法、及び、ロール状シートの製造装置 Download PDFInfo
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- WO2010098206A1 WO2010098206A1 PCT/JP2010/051921 JP2010051921W WO2010098206A1 WO 2010098206 A1 WO2010098206 A1 WO 2010098206A1 JP 2010051921 W JP2010051921 W JP 2010051921W WO 2010098206 A1 WO2010098206 A1 WO 2010098206A1
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- laminated sheet
- compression
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- winding
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 100
- 238000007906 compression Methods 0.000 claims abstract description 193
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/06—Embossing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/582—Tearability
- B32B2307/5825—Tear resistant
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
Definitions
- the present invention relates to a roll sheet manufacturing method and a roll sheet manufacturing apparatus.
- a laminated sheet is formed by compressing and integrating a plurality of stacked fiber sheets, and the laminated sheet moving in the continuous direction is accumulated in a movement path of the laminated sheet, and the laminated sheet
- the present invention relates to a manufacturing method and a manufacturing apparatus for manufacturing a roll-shaped sheet by winding up a sheet.
- the roll sheet is used as a raw material when manufacturing an absorbent article such as a tampon, for example.
- a laminated sheet is formed by compressing and integrating a plurality of stacked fiber sheets, and the laminated sheet moving in the continuous direction is moved. The accumulation in the path and the winding of the laminated sheet are performed. Accumulating the laminated sheets includes forming a loop of the laminated sheets by winding the laminated sheets around the peripheral surface of the rotating roller. Moreover, winding up the laminated sheet includes winding the laminated sheet around a winding core located downstream of the rotating roller.
- the laminated sheet when the laminated sheet is compressed, the tensile strength is improved, but the rigidity (strain) of the laminated sheet is also increased. Due to such an increase in rigidity of the laminated sheet, there is a possibility that problems may occur in the process of accumulating the laminated sheet and the process of winding up the laminated sheet. For example, in the step of accumulating the laminated sheets, if the rigidity is high, the laminated sheets are inappropriately bent and easily meander when they are wound around the circumferential surface of the rotating roller. Further, in the step of winding the laminated sheet, if the rigidity is high, the laminated sheet does not wind well around the winding core.
- the present invention has been made in view of the above problems, and the object of the present invention is to suppress meandering of a laminated sheet formed by compressing and integrating a plurality of stacked fiber sheets. While being wound around the peripheral surface of the rotating roller, it is wound around the winding core appropriately.
- the main present invention is to form a laminated sheet by compressing and integrating a plurality of overlapped fiber sheets, and the laminated sheet moving in a continuous direction thereof.
- a roll-shaped sheet manufacturing method comprising accumulating in a movement path of a laminated sheet and winding up the laminated sheet, wherein forming the laminated sheet includes a first region, The first compression forming the laminated sheet in which the degree of compression is higher than that of the first region and the second regions along the intersecting direction intersecting the continuous direction are alternately arranged in the continuous direction, and after the first compression And the second compression forming the laminated sheet in which at least the first region of the first region and the two regions is compressed, and storing the laminated sheet The looping of the laminated sheet is performed after the second compression, which is performed after the first compression step, and includes forming a loop of the laminated sheet by winding the laminated sheet around a circumferential surface of a rotating roller.
- a laminated sheet formed by compressing and integrating a plurality of overlapped fiber sheets is wound around the circumferential surface of a rotating roller while suppressing meandering, and is appropriately wound around a winding core. Can be wound into a roll.
- FIG. 2 is a view showing the appearance and use of a roll sheet 1.
- FIG. 3 is a diagram showing a flow of a manufacturing process of a roll sheet 1 It is the figure which showed the fiber sheet manufacturing apparatus. It is a schematic explanatory drawing about a main manufacturing process. It is a figure which shows the flow of a main manufacturing process. It is the figure which showed the main manufacturing apparatus 20 typically.
- FIG. 7A is a front view of the compression rollers 23a and 23b.
- FIG. 7B is a view showing a peripheral surface of the upper compression roller 23a.
- FIG. 7C is a cross-sectional view taken along the line AA in FIG. 7B. It is a figure of the pattern formed in the surrounding surface of pattern roller 24a, 24b.
- FIG 4 is a side view of the second accumulator 25. It is a figure which shows the winding mechanism 26.
- FIG. It is a figure which shows the lamination sheet 7 formed at a 1st embossing process. It is sectional drawing of the lamination sheet 7 in which delamination occurred. It is a figure which shows the lamination sheet 7 formed at a 2nd embossing process.
- 14A to 14E are views showing the movement of each part of the winding mechanism 26 during the exchange operation. It is a figure which shows the modification of the main manufacturing apparatus.
- a laminated sheet is formed by compressing and integrating a plurality of overlapped fiber sheets, and the laminated sheet moving in the continuous direction is
- a roll-shaped sheet manufacturing method comprising accumulating in a movement path of a laminated sheet and winding up the laminated sheet, wherein forming the laminated sheet includes a first region, The first compression forming the laminated sheet in which the degree of compression is higher than that of the first region and the second regions along the intersecting direction intersecting the continuous direction are alternately arranged in the continuous direction, and after the first compression And the second compression forming the laminated sheet in which at least the first region of the first region and the two regions is compressed, and storing the laminated sheet Forming the loop of the laminated sheet by winding the laminated sheet around a circumferential surface of a rotating roller, and winding the laminated sheet is performed after the second compression. And winding the laminated sheet around a winding core positioned downstream of the rotating roller.
- the second region intermittently arranged in the continuous direction of the laminated sheet in the first compression serves as a folding point after the first compression, so that the laminated sheet rotates. It is appropriately wound around the peripheral surface of the roller and is appropriately wound around the winding core. As a result, the laminated sheet can be wound around the peripheral surface of the rotating roller while meandering is suppressed, and the laminated sheet can be appropriately wound.
- the laminated sheet is provided with stretchability that can be appropriately expanded and contracted in the continuous direction, and the meandering can be effectively suppressed when the laminated sheet is wound around the peripheral surface of the rotating roller.
- each length of the non-compressed regions arranged at both ends of the laminated sheet in the intersecting direction is in the intersecting direction of the laminated sheet. It is good also as being 1/4 or less of length. In the case where the above length relationship is satisfied, each of the high compression region and the non-compression region is ensured in the laminated sheet by a space suitable for each region to function effectively.
- each of the plurality of fiber sheets is composed of a plurality of fiber pieces, and the length of the low compression region in the continuous direction is a plurality of the fiber pieces. It is good also as being 0.3 times or more of average length and being below this average length. In such a case, as a result of imparting an appropriate tensile strength to the laminated sheet, even if the laminated sheet is moved in the continuous direction while applying tension to the laminated sheet, the laminated sheet is torn (along the continuous direction). It is possible to prevent the phenomenon of tearing) and the loss of fibers (a phenomenon in which the fibers come out so that the surface of the laminated sheet becomes fluffy).
- storing the laminated sheets may be performed after the first compression and before the second compression is performed.
- delamination delamination will be described later
- the stretchability stretchability flexibility
- a laminated sheet forming unit that forms a laminated sheet by compressing and integrating the plurality of stacked fiber sheets, and the laminated sheet moving in the continuous direction is accumulated in the movement path of the laminated sheet.
- a first compression section that forms a plurality of the laminated sheets in which a plurality of second regions along a direction that intersects the continuous direction and that are alternately arranged in the continuous direction are positioned downstream of the first compression section.
- a second compression unit that forms the laminated sheet in which at least the first region is compressed out of the first region and the two regions, and the storage unit is downstream of the first compression unit.
- the winding unit is located downstream of the second compression unit and the rotating roller. Also, a roll sheet manufacturing apparatus having a core around which the laminated sheet is wound can be realized.
- Such a roll-shaped sheet manufacturing apparatus has the above-described effects, and wraps the laminated sheet around the peripheral surface of the rotating roller while suppressing meandering, and appropriately winds the laminated sheet around the winding core. Is possible.
- the first compression unit is a pair of compression rollers that rotate while sandwiching the plurality of fiber sheets, and one of the pair of compression rollers is surrounded by one of the compression rollers. Projections that protrude from the peripheral surface and extend along the rotation axis of the one compression roller may be intermittently disposed on the surface in the circumferential direction of the one compression roller.
- the roll sheet 1 is obtained by winding a sheet (specifically, a laminated sheet 7 to be described later) composed of fibers such as rayon and cotton as illustrated in FIG.
- FIG. 1 is a diagram showing the appearance and application of the roll sheet 1.
- the shape of the roll-shaped sheet 1 according to the present embodiment will be described.
- the winding length (the length of the sheet wound to produce the roll-shaped sheet 1) is about 135 m, and the winding diameter (outer diameter) is about 800 mm, and the width (the length in the direction intersecting the continuous direction) is about 50 mm.
- the roll sheet 1 as described above is used, for example, as a material (raw material) when manufacturing an absorbent article such as a tampon. If it demonstrates concretely, as shown in FIG. 1, the roll-shaped sheet
- seat 1 will be drawn out in the continuous direction, the said drawn-out part will be cut into arrow feather shape, and the sheet piece 2 will be formed.
- a cotton body 3 shown in FIG.
- the cotton body 3 has appropriate absorbability and is used, for example, as a tampon.
- the string 8 is provided to pull out the tampon (that is, the cotton body 3) from the vaginal cavity after using the tampon.
- FIG. 2 is a diagram illustrating a flow of a manufacturing process of the roll sheet 1.
- the manufacturing process of the roll sheet 1 includes a fiber sheet manufacturing process S001, a main manufacturing process S002, and a recovery process S003.
- S001 fiber sheet manufacturing process
- S002 main manufacturing process
- S003 recovery process
- the fiber sheet manufacturing process is a process for manufacturing the fiber sheet 6 as a component of the roll sheet 1. This step is executed by the fiber sheet manufacturing apparatus 10 shown in FIG.
- FIG. 3 is a view showing the fiber sheet manufacturing apparatus 10.
- the fiber sheet manufacturing apparatus 10 includes a card machine 11, a focusing device 12, a press device 13, and a first accumulator 14.
- the card machine 11 opens the cocoon-like fiber lump 4, spins fiber pieces from the fiber lump 4, and continuously supplies a thin cloth-like web 5 composed of the fiber pieces.
- the web 5 is continuously discharged from the opening 11a formed in the casing of the card machine 11 (see FIG. 3).
- the basis weight (total weight of the fiber pieces contained per unit area) of each part of the web 5 is substantially uniform, specifically about 3.5 g / m 2.
- the width of the web 5 is about 1400 mm.
- the fiber pieces constituting the web 5 have an average length of about 38 mm and an average fineness of about 3.3 dtex.
- the average length (average fineness) is the length (fineness) with the highest appearance frequency in the distribution of the length (fineness) of the fiber pieces constituting the web 5.
- the said web 5 is a continuous direction rather than the tensile force along the width direction (direction crossing a continuous direction). It is more tough against the tensile force along.
- the converging device 12 is for compressing and converging the web 5 continuously supplied from the card machine 11 along its width direction.
- the focusing device 12 includes a pair of left and right guide plates 12a (see FIG. 3) arranged so as to form a substantially Y shape when viewed in a plan view.
- the bundling device 12 bounces the web 5 supplied from the card machine 11 by a drawing device (not shown) so that the web 5 passes between the guide plates 12a. More specifically, the distance between the guide plates 12a on the downstream side in the moving direction of the web 5 is narrower than the distance on the upstream side in the moving direction. When passing between, it is folded in the width direction while forming pleats (see FIG. 3).
- the width of the web 5 is reduced to about 50 mm when the web 5 passes between the guide plates 12a.
- the web 5 since the web 5 is strong against the tensile force along the continuous direction, the web 5 is tensioned along the continuous direction while the focusing device 12 focuses the web 5. However, the web 5 can be pulled without tearing.
- the pressing device 13 compresses the converged web 5 in the thickness direction to form the fiber sheet 6.
- the press device 13 includes a pair of upper and lower press rollers 13a and 13b shown in FIG. 3, and the web 5 is rotated by rotating the press rollers 13a and 13b with the web 5 sandwiched between the press rollers 13a and 13b. Is compressed to form a fiber sheet 6 having a predetermined thickness from the web 5.
- the fiber sheet 6 having a basis weight of about 110 g / m 2 and a width of about 50 mm is formed.
- the fiber sheet 6 is a sheet formed by compressing the web 5, the composition thereof is the same as that of the web 5.
- the fiber sheet 6 is composed of a plurality of fiber pieces, and the average length and the average fineness of the plurality of fiber pieces coincide with the values described above.
- the upper press roller 13a is a smooth roller having a flat peripheral surface
- the lower press roller 13b has an uneven surface having peripheral surfaces alternately arranged in the circumferential direction. Laura.
- the web 5 after convergence can be easily compressed to a predetermined thickness.
- the lower press roller 13b may be a roller having a knurled peripheral surface. In such a case, it is possible to form the fiber sheet 6 with appropriate flexibility.
- both the press rollers 13a and 13b may be smooth rollers.
- the first accumulator 14 temporarily accumulates the fiber sheet 6 continuously supplied from the press device 13 and appropriately sends out the accumulated fiber sheet 6. As shown in FIG. 3, the first accumulator 14 puts the fiber sheet 6 into a box 14a having an open upper end surface, and sends out the fiber sheet 6 by a conveyor 14b disposed in the box 14a.
- the speed at which the fiber sheet 6 is put into the box 14a (in other words, the speed at which the fiber sheet 6 is supplied from the press device 13) is larger than the speed at which the fiber sheet 6 is sent out of the box 14a. Yes. For this reason, the fiber sheet 6 is accumulated in the box 14a with the slack attached.
- the first accumulator 14 having such a configuration functions as a buffer when the processing is interrupted or the processing speed is reduced in a subsequent process due to a trouble or the like.
- the accumulation amount of the fiber sheet 6 in the box 14a is monitored by a sensor (not shown). Then, according to the detection result of the sensor, the accumulated amount is adjusted by adjusting the feeding speed of the fiber sheet 6 (more precisely, the pulling speed when the fiber sheet 6 is pulled into the first embossing mechanism 23 described later). Is adjusted.
- a plurality (specifically, eight) of fiber sheet manufacturing apparatuses 10 having the above-described configuration are installed.
- Each of the plurality of fiber sheet manufacturing apparatuses 10 is synchronized, and supplies the fiber sheet 6 toward the subsequent process (that is, the main manufacturing process). That is, the plurality (eight) of fiber sheets 6 manufactured by the plurality of fiber sheet manufacturing apparatuses 10 move toward the main manufacturing process.
- the main manufacturing process is a process for manufacturing the roll-shaped sheet 1 from a plurality (eight) of fiber sheets 6 supplied from a plurality of fiber sheet manufacturing apparatuses 10. That is, the manufacturing method of the roll-shaped sheet 1 implement
- This process is performed by the main manufacturing apparatus 20 (an example of a manufacturing apparatus for the roll sheet 1) as shown in FIG.
- FIG. 4 is a schematic explanatory diagram of the main manufacturing process.
- the main manufacturing process will be outlined below.
- each of the plurality of fiber sheets 6 moves toward the main manufacturing apparatus 20 in the continuous direction.
- the plurality of fiber sheets 6 are stacked before being thrown into the main manufacturing apparatus 20.
- a laminated sheet 7 having a basis weight of about 880 g / m 2 is formed from the plurality of fiber sheets 6.
- the formed laminated sheet 7 moves in the apparatus along the continuous direction (the longitudinal direction of the laminated sheet 7 and is labeled MD direction in FIG. 4). During this time, tension is applied to the laminated sheet 7 along the continuous direction.
- the laminated sheet 7 is wound around the winding core 21 at the end (downstream side end) of the movement path.
- the winding core 21 of the present embodiment is a cylindrical body having an outer diameter of about 85 mm.
- the laminated sheet 7 is wound up to a predetermined winding diameter, the laminated sheet 7 is cut. Finally, the cut end of the laminated sheet 7 in a wound state is temporarily fixed with a tape, and when the laminated sheet 7 is removed from the winding core 21, the roll sheet 1 is completed. Details of the main manufacturing process and the main manufacturing apparatus 20 will be described later in the section of the main manufacturing process of this embodiment.
- the main manufacturing process of this embodiment is a compression process S011 in which a laminated sheet 7 is formed by compressing and integrating a plurality of stacked fiber sheets 6, and moving in the continuous direction.
- FIG. 5 is a diagram showing the flow of the main manufacturing process. Each process described above is executed by a mechanism in charge of each process in the main manufacturing apparatus 20 described above.
- each sheet of the fiber sheet 6 and the laminated sheet 7 is a continuous direction in which the sheets are continuous, and the movement direction when the sheets move is referred to as the MD direction. Is called the CD direction.
- FIG. 6 is a diagram schematically showing the main manufacturing apparatus 20.
- the compression step S011 of the present embodiment is divided into two stages, and includes a first embossing step S111 as the first compression performed first and a second embossing step S112 as the second compression performed later ( (See FIG. 5).
- the first embossing step is a step of compressing and embossing the plurality of fiber sheets 6 in order to integrate the plurality of overlapped fiber sheets 6 to form a laminated sheet 7, which is illustrated in FIG.
- the first embossing mechanism 23 is executed.
- the first embossing mechanism 23 is an example of a first compression unit, and specifically includes a pair of upper and lower compression rollers 23a and 23b (see FIG. 6).
- the pair of compression rollers 23a and 23b rotate around the rotation shaft 23e along the CD direction while sandwiching the plurality of fiber sheets 6 between the compression rollers 23a and 23b.
- the plurality of fiber sheets 6 are compressed and integrated to form a laminated sheet 7.
- Each of the compression rollers 23a and 23b has a circumferential surface (in detail) on the outermost (upper and lower) fiber sheets 6 while rotating with the plurality of fiber sheets 6 sandwiched between the compression rollers 23a and 23b. Rubs a peripheral surface of a large-diameter portion 23c described later.
- the fiber sheet 6 accumulated in the box 14a of each first accumulator 14 is drawn out from the box 14a and moves downstream in the MD direction, and is drawn between the compression rollers 23a and 23b.
- each compression roller 23a, 23b Describing the shape of each compression roller 23a, 23b, as shown in FIG. 7A, each compression roller 23a, 23b includes a large diameter portion 23c and a small diameter portion 23d having different outer diameters.
- FIG. 7A is a front view of the compression rollers 23a and 23b.
- the large diameter portion 23c is located at the center in the CD direction of each compression roller 23a, 23b.
- the small diameter portion 23d is located at both ends in the CD direction, and the outer diameter thereof is shorter than the outer diameter of the large diameter portion 23c.
- the length of the large diameter portion 23c in the CD direction is different between the compression rollers 23a and 23b.
- the length in the CD direction of the large diameter portion 23c of the upper compression roller 23a is larger than the width of the fiber sheet 6.
- the length in the CD direction of the large diameter portion 23 c of the lower compression roller 23 b is somewhat shorter than the width of the fiber sheet 6.
- the large-diameter portion 23c of the lower compression roller 23b has a flat peripheral surface.
- the large-diameter portion 23c of the upper compression roller 23a (corresponding to one of the pair of compression rollers 23a and 23b) has a peripheral surface on which a regular pattern is formed. The pattern will be described.
- the peripheral surface of the large-diameter portion 23c of the upper compression roller 23a protrudes from the peripheral surface and extends along the rotation shaft 23e of the upper compression roller 23a.
- the protruding portions 23f are intermittently disposed in the circumferential direction of the upper compression roller 23a.
- FIG. 7B is a view showing a peripheral surface of the upper compression roller 23a.
- the protrusion 23f has a substantially rectangular shape when viewed in a plan view (see FIG. 7B), and has a substantially trapezoidal shape when viewed in a side view (see FIG. 7C). Specifically, the dimension of the protrusion 23f is approximately 1.5 mm, the length of the compression roller 23a in the circumferential direction is approximately 6 mm, and the length of the top surface in the circumferential direction is approximately 2 mm. Yes, and the length in the direction along the rotation shaft 23e is about 40 mm.
- the protruding portion 23f having the above-described shape extends from one end to the other end of the large-diameter portion 23c in the direction along the rotating shaft 23e (that is, the CD direction), and is intermittently provided with an interval of about 15 mm between the protruding portions 23f. Are arranged.
- the second embossing step is performed after the first embossing step, and in order to form the laminated sheet 7 having a predetermined thickness, the compressed embossing in the first embossing step is performed on the laminated sheet 7 formed in the first embossing step. It is a process of applying a compression embossing different from the process. This process is a preliminary process of the winding process, and is performed in order to appropriately wind the laminated sheet 7.
- a tensile force along the circumferential direction acts on the laminated sheet 7, particularly a portion located on the radially outer side.
- the laminated sheet 7 does not have a sufficient tensile strength against the tensile force, the laminated sheet 7 is torn along the MD direction due to the tensile force, or wrinkles are generated on the surface of the laminated sheet 7. there is a possibility.
- the tensile strength of the laminated sheet 7 increases as it is compressed in the thickness direction.
- the laminated sheet 7 formed in the first embossing process is compressed in the thickness direction to form a thinner laminated sheet 7.
- the laminated sheet 7 has sufficient tensile strength with respect to the tensile force.
- the second embossing process is executed by the second embossing mechanism 24 shown in FIG.
- the 2nd embossing mechanism 24 is an example of a 2nd compression part, and is specifically a pair of upper and lower pattern rollers 24a and 24b (refer FIG. 6).
- the pair of pattern rollers 24a and 24b are positioned downstream of the pair of compression rollers 23a and 23b in the MD direction, and a rotation shaft 24c along the CD direction is sandwiched between the pattern rollers 24a and 24b while sandwiching the laminated sheet 7. Rotate around the center. As a result, a laminated sheet 7 having a predetermined thickness is formed.
- Each of the pattern rollers 24a and 24b is synchronized with a winding mechanism 26 described later, and the rotation speed thereof is the same as the winding speed when winding the laminated sheet 7 in the winding process.
- Each pattern roller 24a, 24b has a large-diameter portion located at the center in the CD direction of each pattern roller 24a, 24b and small-diameter portions located at both ends in the CD direction, like the compression rollers 23a, 23b.
- the large diameter portions of the pattern rollers 24a and 24b are somewhat longer in the CD direction than the width of the laminated sheet 7, so that the laminated sheet 7 passes when the laminated sheet 7 passes between the pattern rollers 24a and 24b. Abuts almost the entire surface of the surface. That is, the second embossing mechanism 24 performs compression embossing over substantially the entire area of the laminated sheet 7.
- FIG. 8 is a diagram of patterns formed on the peripheral surfaces of the pattern rollers 24a and 24b.
- the substantially square-shaped convex portion 24d has the sides inclined at about 45 degrees with respect to the circumferential direction of the pattern rollers 24a and 24b, and the entire area of the peripheral surface. Are regularly arranged.
- One side of the convex portion 24d is about 2.3 mm, and an interval of about 1 mm is formed between the convex portions 24d.
- the second embossing mechanism 24 having the above-described configuration forms the laminated sheet 7 that is somewhat thinner than the step formed in the first embossing step. And the thickness of the lamination sheet 7 formed in the 2nd embossing process is maintained until the stage which winds up this lamination sheet 7, and manufactures the roll-shaped sheet 1 is carried out.
- the roll-shaped sheet 1 as a raw material of an absorbent article such as a tampon is required to have an appropriate absorbency (liquid absorbency), and the absorbency is the thickness of the laminated sheet 7 constituting the roll-shaped sheet 1. Dependent.
- the laminated sheet 7 is compressed to a thickness corresponding to the desired absorbability in the second embossing step so that the roll sheet 1 has the desired absorbency.
- the operation of the second embossing mechanism 24 and the laminated sheet 7 formed in the second embossing step will be described in detail later.
- This step is executed by the second accumulator 25 as an example of the storage unit in the main manufacturing apparatus 20 (see FIG. 6).
- the second accumulator 25 is located on the downstream side of the first embossing mechanism 23 and is located on the upstream side of the second embossing mechanism 24. Therefore, in the present embodiment, the accumulation process is performed after the first embossing process S111 and before the second embossing process S112 is performed (see FIG. 5).
- the second accumulator 25 includes a dancer roller 25a as an example of a rotating roller and a fixed roller 25b (see FIG. 6).
- the dancer roller 25a is a roller positioned on the downstream side of the first embossing mechanism 23, and rotates around a rotation shaft 25c along the CD direction.
- a plurality of dancer rollers 25a are provided so as to be arranged along the MD direction.
- the rotation shaft 25c of each dancer roller 25a is fixed to a support frame 25d.
- FIG. 9 is a side view of the second accumulator 25 (viewed from the MD direction).
- a weight member 25f is connected to the support frame 25d via a connecting belt 25e.
- the connecting belt 25e is hung on the lifting bar 25g, and the support frame 25d and the weight member 25f are suspended from the lifting bar 25g. Further, the lift bar 25g reciprocates along the vertical direction, and the reciprocation is realized by controlling the balance between the load of the weight member 25f and the tension applied to the laminated sheet 7.
- each dancer roller 25a is in a state in which the laminated sheet 7 is hung on the peripheral surface and is slightly lifted upward by the weight member 25f.
- tension is applied to the laminated sheet 7 hung on the peripheral surface of the dancer roller 25a.
- the magnitude of this tension depends on the moving speed of the laminated sheet 7 that moves downstream from the second embossing mechanism 24.
- the second embossing mechanism 24 stops that is, when the rotation of the pattern rollers 24a and 24b stops
- the laminated sheet 7 Of these the portion located downstream of the portion sandwiched between the pattern rollers 24a and 24b stops.
- the lift bar 25g rises when the tension falls below the load of the weight member 25f, and falls when the tension exceeds the load of the weight member 25f.
- each dancer roller 25a reciprocates along with the support frame 25d along the vertical direction.
- the fixed roller 25b is positioned below the dancer roller 25a in the vertical direction and rotates around a rotation axis along the CD direction.
- a plurality of fixed rollers 25b are also provided so as to be aligned along the MD direction.
- the second accumulator 25 having the above-described configuration forms the loop 7a of the laminated sheet 7 by winding the laminated sheet 7 around the circumferential surfaces of the dancer rollers 25a and the fixed rollers 25b (in other words, the dancer roller 25a has a circumferential surface thereof.
- the laminated sheet 7 is hung around to form the loop 7a).
- the laminated sheet 7 moving in the MD direction is accumulated in the moving path by the length of the loop 7a (hereinafter, loop amount). That is, in the accumulation step, the laminated sheet 7 moving in the MD direction is wound around the peripheral surfaces of the dancer roller 25a and the fixed roller 25b, thereby forming the loop 7a and temporarily placing the laminated sheet 7 in the movement path. This is a process of accumulating.
- the loop 7 a of the laminated sheet 7 is a portion of the laminated sheet 7 that is hung on the peripheral surface of the dancer roller 25 a and has a substantially ⁇ shape.
- a plurality of loops 7a (six in this embodiment) are formed along the MD direction (see FIG. 6).
- the total loop amount of the plurality of loops 7 a corresponds to the total accumulated amount of the laminated sheets 7 accumulated by the second accumulator 25.
- each dancer roller 25a moves the dancer rollers 25a up and down by moving the lift bar 25g up and down.
- each dancer roller 25a is about 1600 mm above the position where the fixed roller 25b is located from a position about 400 mm above the position where the fixed roller 25b is located in the vertical direction (hereinafter referred to as bottom dead center). It reciprocates in a range up to an upper position (hereinafter referred to as top dead center).
- the loop amount of the loop 7a that is, the accumulated amount of the laminated sheet 7 changes.
- the reciprocating movement of the dancer roller 25a can change the time for which the laminated sheet 7 is accumulated in the movement path (hereinafter, accumulation time).
- the moving speed when the laminated sheet 7 is moved in the MD direction while being wound around the peripheral surfaces of the dancer roller 25a and the fixed roller 25b is the same as the winding speed when the laminated sheet 7 is taken up. It is.
- the take-up mechanism 26 is an example of a take-up part, and is located downstream of the second embossing mechanism 24.
- the winding mechanism 26 includes a turntable 27, a winding core 21, a cutter 28, a tape applicator 29, and a pressing roller 30.
- FIG. 10 is a view showing the winding mechanism 26.
- the turntable 27 is a disk member that rotates around a central axis 27a along the CD direction.
- the winding core 21 is positioned on the downstream side of the dancer roller 25a and the second embossing mechanism 24, and is fitted on a winding core shaft 27b protruding from the surface of the turntable 27 along the CD direction.
- the winding core shaft 27b rotates integrally with the winding core 21 in response to a driving force from a rotation mechanism (not shown).
- a rotation mechanism not shown
- the turntable 27 of this embodiment includes two core shafts 27b, and the core 21 is fitted to each core shaft 27b.
- the other winding core 21 exists in a standby state (state in which the lamination sheet 7 is not wound).
- the two cores 21 are separated from each other by an interval corresponding to a rotation amount of about 180 degrees in the rotation direction of the turntable 27. Further, the rotation speed of the winding core 21 (that is, the winding speed when winding the laminated sheet 7) is variable.
- the turntable 27 includes a roller shaft 27c positioned approximately in the middle of the two winding shafts 27b in the rotation direction, and a guide roller 27d is rotatably supported by the roller shaft 27c (see FIG. 10). .
- the laminated sheet 7 is hung on the peripheral surface of the guide roller 27d on the upstream side of the core 21 around which the laminated sheet 7 is wound.
- the guide roller 27d regulates the moving direction of the laminated sheet 7 so that the laminated sheet 7 moves toward the winding core 21, and bends the laminated sheet 7 to apply tension to the laminated sheet 7.
- the cutter 28 While the laminated sheet 7 is wound around the winding core 21, the cutter 28 is separated from the laminated sheet 7, and comes into contact with the laminated sheet 7 when the laminated sheet 7 is wound by a predetermined length.
- the laminated sheet 7 is cut.
- the tape applicator 29 is connected to the peripheral end surface of the winding core 21 that has been in the standby state until now on the upstream end of the laminated sheet 7 (more details Then, the part which became the upstream end newly by cutting the laminated sheet 7) is pasted with an adhesive tape.
- the pressing roller 30 sandwiches the laminated sheet 7 between the cutter 28 and the cutter 28 when the cutter 28 cuts the laminated sheet 7, and the laminated sheet 7 is attached to the winding core 21 by the tape applicator 29. 7 is pressed against the peripheral surface of the winding core 21 (see, for example, FIGS. 14B and 14C). As shown in FIG. 10, the pressing roller 30 is rotatably supported at the tip of an arm 30a, and the arm 30a is swingable about a swing shaft 30b on which the laminated sheet 7 is hung. is there.
- the winding process of winding the laminated sheet 7 around the winding core 21 is performed by the cooperation of each part of the winding mechanism 26, and the winding process is also performed.
- the winding core 21 is replaced, and setting for winding the laminated sheet 7 around the winding core 21 that has been in a standby state is performed.
- the laminated sheet 7 is wound at a winding speed of about 54 m / min in the winding process. That is, in the main manufacturing apparatus 20, the laminated sheet 7 moves in the MD direction at the same moving speed as the winding speed. Further, during steady operation, each part of the main manufacturing apparatus 20 is in the state shown in FIG. Specifically, in the second accumulator 25, tension (tension) applied to the laminated sheet 7 hung on the peripheral surface of the dancer roller 25a and the load of the weight member 25f so that each dancer roller 25a stops at the bottom dead center. Are in equilibrium. In the winding mechanism 26, the cutter 28 and the tape applicator 29 are located at positions separated from the laminated sheet 7. In such a state, the plurality of overlapped fiber sheets 6 are thrown into the main manufacturing apparatus 20.
- a first embossing process is first performed. That is, the plurality of fiber sheets 6 are drawn between the pair of compression rollers 23a and 23b in a rotating state. At this time, the center part in CD direction (crossing direction which cross
- FIG. 11 is a view showing the laminated sheet 7 formed in the first embossing step. The laminated sheet 7 will be described. As shown in the figure, a compressed area 7m that is compressed is arranged at the center in the CD direction, and an uncompressed area 7n that is not compressed is arranged at both ends in the CD direction. ing.
- the central portion in the CD direction of the plurality of fiber sheets 6 is further compressed by being crushed by the protruding portion 23f provided in the large diameter portion 23c of the upper compression roller 23a at regular intervals in the MD direction. .
- the compressed region 7m of the laminated sheet 7 two regions having different degrees of compression are alternately arranged in the MD direction (continuous direction) (see FIG. 11).
- the laminated sheet 7 in which the low compression regions 7p and the high compression regions 7q are alternately arranged in the MD direction is formed by the first embossing step.
- the low-compression region 7p is a region as a first region (comparison concept with a second region described below).
- the high compression area 7q is an area as a second area having a higher degree of compression than the first area and extending along the CD direction.
- the degree of compression refers to the degree of change in the number of fiber pieces contained per unit volume (that is, fiber density) before and after compression, and specifically, the amount of change in thickness before and after compression. is there.
- the thickness of the low compression region 7p is about 13 mm
- the thickness of the high compression region 7q is about 2 mm.
- the first embossing step is a step of forming the laminated sheet 7 in which a plurality of low compression regions 7p and high compression regions 7q are alternately arranged in the MD direction.
- the length (about 15 mm) of the low compression region 7p in the MD direction is 0.3 times or more the average length (about 38 mm) of the plurality of fiber pieces constituting each fiber sheet 6, and
- the laminated sheet 7 is formed so as to be equal to or less than the average length. If the length of the low compression region 7p is within the above range, the bonding between the fiber pieces oriented along the MD direction in the low compression region 7p is strengthened, and the tensile force of the laminated sheet 7 against the tensile force along the MD direction is increased.
- the length of the low-compression region 7p is not limited to the above range.
- the length is within the above range. It is desirable.
- a laminated sheet in which a plurality of low compression regions 7p and high compression regions 7q are alternately arranged in the MD direction, and uncompressed regions 7n are arranged at both ends in the CD direction. 7 is formed.
- the non-compressed area 7n is more flexible than the compressed area 7m, and the non-compressed area 7n is arranged so as to be continuous along the MD direction. Elasticity will be provided.
- the high compression region 7q and the non-compression region 7n function effectively.
- the length in the CD direction of each of the uncompressed regions 7n arranged at both ends of the laminated sheet 7 in the CD direction is the length of the laminated sheet 7 in the CD direction (about 50 mm). Is less than or equal to 1/4, specifically, about 7 mm to 10 mm.
- the laminated sheet 7 having the above shape is easily formed by the first embossing mechanism 23.
- the first embossing mechanism 23 is a pair of compression rollers 23a and 23b, and a protrusion 23f extending along the CD direction is formed on the peripheral surface of one (upper) compression roller 23a. Are arranged intermittently in the circumferential direction. Then, if a plurality of overlapped fiber sheets 6 are sandwiched between the compression rollers 23a and 23b in a rotating state, a laminated sheet 7 in which a plurality of low compression regions 7p and high compression regions 7q are alternately arranged in the MD direction. Is easily formed.
- the laminated sheet 7 formed in the first embossing process moves to the downstream side in the MD direction and is eventually thrown into the second accumulator 25. And the accumulation
- the laminated sheet 7 is wound around the peripheral surface of the dancer roller 25a that is pulled up by the weight member 25f, the laminated sheet 7 is in the second accumulator 25 in a state where tension is applied. Will be moved. During this time, delamination due to the tension occurs in the high compression region 7q of the laminated sheet 7. As shown in FIG. 12, delamination is a phenomenon in which a plurality of fiber sheets 6 integrated as a laminated sheet 7 are separated so as to maintain an integrated state.
- FIG. 12 is a cross-sectional view of the laminated sheet 7 where delamination has occurred. When delamination occurs, the thickness of the high compression region 7q of the laminated sheet 7 increases somewhat, so that the stretchability (stretch flexibility) in the high compression region 7q is temporarily recovered.
- the laminated sheet 7 temporarily accumulated in the second accumulator 25 leaves the second accumulator 25 and further moves downstream in the MD direction. Thereafter, a second embossing process is performed in the second embossing mechanism 24. That is, the laminated sheet 7 is drawn between the pair of pattern rollers 24a and 24b in a rotating state.
- FIG. 13 is a view showing the laminated sheet 7 formed in the second embossing step.
- the laminated sheet 7 will be described.
- an embossed region 7x in which a lattice-like embossed pattern is formed is disposed in a substantially central area of the laminated sheet 7 at the center in the CD direction.
- the embossed region 7x is composed of regularly arranged square-shaped depressions 7y and non-depressions 7z surrounding the depressions 7y.
- the embossed area 7x is substantially the same width as the laminated sheet 7 (more specifically, from the laminated sheet 7). Is a region having a slightly shorter width).
- the second embossing step is performed so that the degree of compression of the embossed region 7x is lower than the degree of compression of the high-compressed region 7q.
- the second embossing step is a CD including at least the low compression region 7p (in this embodiment, the entire compression region 7m) of the low compression region 7p (first region) and the high compression region 7q (second region).
- This is a step of forming a laminated sheet 7 having a predetermined thickness in which the whole (direction center portion) is compressed.
- the laminated sheet 7 having a thickness (specifically, the thickness of the non-recessed portion 7z) compressed to about 3.5 mm is formed.
- the roll-shaped sheet 1 manufactured from the laminated sheet 7 exhibits a desired quality (specifically, absorbability). Become.
- the laminated sheet 7 formed in the second embossing process further moves downstream in the MD direction.
- the laminated sheet 7 moves in the MD direction while the movement direction is regulated by the guide roller 27d, and is wound around the winding core 21 in a rotating state at the end of the movement path. That is, the winding process by the winding mechanism 26 is performed, and the laminated sheet 7 is wound at the winding speed described above.
- the dancer roller 25a rises, the total loop amount of the loop 7a of the laminated sheet 7 formed by the second accumulator 25, that is, the total accumulated amount of the laminated sheet 7 increases.
- the accumulation time of the laminated sheet 7 in the second accumulator 25 becomes long (in this embodiment, it becomes longer by about 16 seconds).
- the amount of the laminated sheet 7 that can be accumulated in the second accumulator 25 increases, and therefore, in the laminated sheet 7 only for a time corresponding to the increased amount (that is, an increase in the accumulation time), It is possible to stop the portion located on the downstream side of the portion sandwiched between the pattern rollers 24a and 24b. That is, it is possible to stop the flow of the laminated sheet 7 to the winding mechanism 26 by the increase in the accumulation time while continuing to operate the mechanism upstream of the second embossing mechanism 24.
- FIG. 14A the cutter 28 approaches the laminated sheet 7, and the pressing roller 30 pushes down while bending the laminated sheet 7 by the swing of the arm 30a.
- 14A to 14E are views showing the movement of each part of the winding mechanism 26 during the exchange operation.
- the cutter 28 and the pressing roller 30 sandwich the laminated sheet 7 therebetween.
- the pressing roller 30 presses the laminated sheet 7 against the circumferential surface of the winding core 21 on which the laminated sheet 7 has not yet been wound (hereinafter, the winding core 21 in the standby state). In this state, the cutter 28 cuts the laminated sheet 7 in the vicinity of the winding core 21 in the standby state.
- the cutter 28 is separated from the laminated sheet 7, while the tape applicator 29 is connected to the upstream end of the laminated sheet 7 pressed against the peripheral surface of the winding core 21 in the standby state. Move to abut.
- the tape applicator 29 attaches the upstream end of the laminated sheet 7 to the peripheral surface of the winding core 21 in the standby state, and then returns to the original position after being separated from the laminated sheet 7.
- the replacement of the winding core 21 is completed.
- the pressing roller 30 returns to the original position by the swing of the arm 30a, and the winding core 21 to which the upstream end of the laminated sheet 7 is attached (thereby The winding core 21) that has been in the standby state rotates, and the laminated sheet 7 is wound around the winding core 21. That is, the interrupted winding process is resumed.
- the stack that has been stopped between the pattern rollers 24a and 24b The sheet 7 again moves downstream in the MD direction and flows into the winding mechanism 26.
- the wound core 21 the core 21 on which the laminated sheet 7 has already been wound (hereinafter referred to as the wound core 21) has become the downstream end of the laminated sheet 7 (the downstream end by cutting with the cutter 28). Rotate until part is taken up and then stop. Thereafter, the roll-shaped laminated sheet 7 (that is, the roll-shaped sheet 1) is removed from the wound core 21 by a removing device (not shown).
- the turntable 27 rotates simultaneously with the resumption of the winding process.
- the turntable 27 rotates 180 degrees, as shown in FIG. 14E, the arrangement position of each part of the winding mechanism 26 becomes the same arrangement position as in the steady operation. Thereafter, the operation of the main manufacturing apparatus 20 is switched again from the replacement operation to the steady operation. Note that the time required from the interruption to the resumption of the winding process is about 5 seconds, which is sufficiently shorter than the increase in the accumulation time (about 16 seconds).
- each dancer roller 25a is located at the top dead center in the second accumulator 25, and the accumulated amount of the laminated sheet 7 in the second accumulator 25 is larger than the accumulated amount in the steady operation.
- the dancer roller 25a rises, it increases by the increased amount. Therefore, in switching from the replacement operation to the steady operation, only the difference from the accumulated amount during the steady operation (that is, the increase due to the rise of the dancer roller 25a) is required to move each dancer roller 25a from the top dead center to the bottom dead center. It is necessary to take up the laminated sheet 7 and reduce the accumulated amount in the second accumulator 25 by the difference.
- the rotation speed of the winding core 21, that is, the winding speed of the laminated sheet 7 is set to the speed at the time of steady operation (specifically, approximately 115 seconds) after the resumption of the winding process. Faster than about 54 m / min) (specifically, about 58 m / min).
- tensile_strength (tension) lower than the load of the weight member 25f is applied to the part of the laminated sheet 7 hung on the peripheral surface of the dancer roller 25a. Accordingly, the lifting bar 25g is lowered, and each dancer roller 25a is also lowered toward the bottom dead center.
- the laminated sheet 7 formed by compressing and integrating the plurality of stacked fiber sheets 6 is used.
- the accumulating step in the second accumulator 25
- the laminated sheet 7 can be appropriately wound around the winding core 21 in a winding process (in the winding mechanism 26).
- the laminated sheet 7 In order to properly wind up the laminated sheet 7, it is necessary to compress the laminated sheet 7 in the thickness direction. This is because, as described above, the tensile strength against the tensile force acting on the laminated sheet 7 when the laminated sheet 7 is wound up increases as the laminated sheet 7 is compressed in the thickness direction. However, when the laminated sheet 7 is compressed in the thickness direction, the tensile strength is increased, but the rigidity (strain) of the laminated sheet 7 is increased. The higher the rigidity is, the more difficult it is to bend the laminated sheet 7 along the peripheral surface of the winding core 21. As a result, there is a possibility that the laminated sheet 7 cannot be successfully wound around the winding core 21.
- the lamination sheet 7 is hung around the circumferential surface of the dancer roller 25a to form the loop 7a of the lamination sheet 7 in the accumulation process, if the rigidity of the lamination sheet 7 is high (that is, the elasticity of the lamination sheet 7 is increased).
- the laminated sheet 7 bends and meanders at an inappropriate position (originally, the laminated sheet 7 which is folded by the dancer roller 25a and moves along the vertical direction moves in a direction inclined with respect to the vertical direction). There is a risk.
- the meandering of the laminated sheet 7 occurs remarkably when tension is applied to the laminated sheet 7 wound around the peripheral surface of the dancer roller 25a. Further, if the tension varies when the operation of the main manufacturing apparatus 20 is switched, meandering is more likely to occur.
- the compression process (process for forming the laminated sheet 7) is divided into a first embossing process (first compression process) and a second embossing process (second compression process).
- first compression process first compression process
- second embossing process second compression process
- high compression regions 7q second regions along the CD direction (cross direction) are intermittently arranged in the MD direction (continuous direction).
- the laminated sheet 7 is appropriately wound around the peripheral surface of the dancer roller 25a and is appropriately wound around the winding core 21.
- the lamination sheet 7 formed at the 1st embossing process will be easy to bend
- the laminated sheet 7 is wound around the circumferential surface of the dancer roller 25a after the first embossing process, the laminated sheet 7 is bent along the circumferential surface so as to form an appropriate loop 7a and is normally formed by the dancer roller 25a. Wrapped. As a result, it is possible to prevent the laminated sheet 7 that is wound around the peripheral surface of the dancer roller 25a from being bent and meandering at an inappropriate position.
- the above effects are more effective when tension is applied to the laminated sheet 7 that is wound around the peripheral surface of the dancer roller 25a and the tension fluctuates. That is, when the operation of the main manufacturing apparatus 20 is switched, as described above, the tension varies and the laminated sheet 7 is likely to meander. Even in such a situation, as a result of the high compression region 7q functioning as a folding start point, the laminated sheet 7 is appropriately wound around the peripheral surface of the dancer roller 25a, and the meandering is effectively suppressed.
- the laminated sheet 7 when the laminated sheet 7 compressed to a predetermined thickness is formed in the second embossing process and the laminated sheet 7 is wound up, the laminated sheet 7 has the high compression region 7q as a fold starting point due to the above action. It bends appropriately along the peripheral surface of the winding core 21. As a result, the laminated sheet 7 is appropriately wound around the winding core 21 and is wound well.
- the second embossing step is performed so that the degree of compression of the embossed region 7x is lower than the degree of compression of the high-compressed region 7q in order to leave a trace of the high-compressed region 7q.
- the function as a folding start point of the high compression region 7q can be sufficiently exhibited while the laminated sheet 7 is compressed to a predetermined thickness in the second embossing step to increase the tensile strength of the laminated sheet 7. That is, it becomes possible to prevent the above-described problems (occurrence of inappropriate creases and separation of the laminated sheet 7 from the core 21) while increasing the tensile strength.
- the formation time of the high-compressed region 7q (that is, the first embossing step) Since the embossing region 7x is formed at a different point in time (that is, the second embossing step), a trace of the high compression region 7q remains. For this reason, even if the degree of compression of the embossed region 7x becomes approximately the same as the degree of compression of the high-compressed region 7q, the high-compressed region 7q exhibits a function as a folding point, and a good winding of the laminated sheet 7 is achieved. Realized.
- a plurality of low compression regions 7p and high compression regions 7q are alternately arranged in the MD direction, and uncompressed regions 7n that are not compressed are arranged at both ends in the CD direction.
- the laminated sheet 7 thus formed is formed.
- the laminated sheet 7 is provided with elasticity that can be appropriately expanded and contracted in the MD direction.
- uncompressed regions 7n are arranged at both ends of the laminated sheet 7 in the CD direction, and the length of each of the uncompressed regions 7n in the CD direction is 1 of the length of the laminated sheet 7 in the CD direction. / 4 or less.
- each of the high compression region 7q and the non-compression region 7n is secured in the laminated sheet 7 by a space suitable for the function of each region. That is, the above length relationship is suitable for the high compression region 7q to function as a folding point and the non-compression region 7n to impart appropriate stretchability to the laminated sheet 7.
- route is performed after a 1st embossing process until a 2nd embossing process is performed. That is, the laminated sheet 7 is wound around the peripheral surface of the dancer roller 25a before the thickness reaches a predetermined thickness (thickness at the stage of winding). Thereby, the aforementioned delamination occurs in the high compression region 7q. Due to the occurrence of the delamination, the stretchability (stretch flexibility) in the high compression region 7q is temporarily recovered. As a result, meandering of the laminated sheet 7 can be more effectively suppressed. Although delamination occurs in the high compression region 7q, the strength against tension is sufficiently increased. Therefore, in the accumulation step (in the second accumulator 25), the laminated sheet 7 can be appropriately moved in the MD direction without tearing while being tensioned.
- the set values, dimensional values, shapes, and the like described above are merely examples for exhibiting the effects of the present invention, and do not limit the present invention.
- the 1st embossing mechanism 23 is a pair of upper and lower compression rollers 23a and 23b, and the protrusion part 23f is a periphery of this compression roller 23a on the surrounding surface of one (upper side) compression roller 23a.
- the protrusion part 23f is a periphery of this compression roller 23a on the surrounding surface of one (upper side) compression roller 23a.
- it is intermittently arranged in the direction and the peripheral surface of the other (lower) compression roller 23b is a flat surface, it is not limited to this.
- a recess (not shown) that can be fitted to the protruding portion 23f may be intermittently disposed on the peripheral surface of the other compression roller 23b in the circumferential direction of the other compression roller 23b.
- the second embossing mechanism 24 is a pair of upper and lower pattern rollers 24a and 24b, and each pattern roller 24a and 24b has a peripheral surface on which a lattice pattern is formed. It is not limited to.
- the second embossing mechanism 24 may be a pair of upper and lower rollers, and at least one of the pair of rollers may be a smooth roller having a flat peripheral surface.
- region are alternately arranged in multiple numbers by MD direction.
- the present invention is not limited to this.
- the laminated sheet 7 in which the uncompressed region (that is, the non-compressed region 7n) is arranged as the first region is formed. It is also good to do.
- the lamination sheet 7 in which the compression area
- the present invention is not limited to this.
- the laminated sheet 7 in which the non-compressed region 7n is arranged is provided with a stretchability that can be appropriately expanded and contracted in the MD direction as described above, so that the meandering of the laminated sheet 7 can be effectively suppressed. I can do it. In this respect, the above embodiment is more desirable.
- route is performed after a 1st embossing process until a 2nd embossing process is performed, it is limited to this.
- the accumulation step may be performed after the second embossing step and before the winding step is performed. That is, as shown in FIG. 15, the second embossing mechanism 24 may be disposed between the first embossing mechanism 23 and the second accumulator 25.
- FIG. 15 is a modification of the main manufacturing apparatus 20.
- the pair of nip rollers 31a and 31b are disposed immediately before the winding mechanism 26, and the rotation of the pair of nip rollers 31a and 31b is controlled so that the laminated sheet 7 is wound during the replacement operation. It is possible to stop flowing into the mechanism 26. More specifically, the nip rollers 31a and 31b rotate while sandwiching the laminated sheet 7 during the steady operation to move the laminated sheet 7 toward the take-up mechanism 26, whereas the laminated sheet 7 is sandwiched during the replacement operation. The part which is located on the downstream side of the portion sandwiched between the nip rollers 31a and 31b in the laminated sheet 7 is stopped.
- the laminated sheet 7 is appropriately wound around the circumferential surface of the dancer roller 25 a while suppressing meandering in the accumulation process, and the laminated sheet 7 is appropriately wound around the winding core 21 in the winding process. It can be wound well.
- the laminated sheet 7 at the stage of being wound around the peripheral surface of the dancer roller 25a has already been compressed to a predetermined thickness, and the aforementioned delamination is unlikely to occur.
- delamination is likely to occur, and due to the delamination, the stretchability (stretch flexibility) of the high compression region 7q is temporarily recovered, and the meandering of the laminated sheet 7 can be more effectively suppressed. .
- the above embodiment is more desirable.
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Abstract
Description
先ず、ロール状シート1について説明する。ロール状シート1は、図1に図示されるような、レーヨンやコットン等の繊維により構成されるシート(具体的には、後述の積層シート7)をロール状に巻いたものである。図1は、ロール状シート1の外観及び用途を示した図である。本実施形態に係るロール状シート1の形状について説明すると、巻き長(ロール状シート1を製造するために巻き取られるシートの長さ)が約135mであり、巻取り径(外径)が約800mmであり、幅(連続方向と交差する方向における長さ)が約50mmである。
次に、ロール状シート1の製造方法について、図2を参照しながら説明する。図2は、ロール状シート1の製造プロセスの流れを示す図である。ロール状シート1の製造プロセスは、図2に示すように、繊維シート製造工程S001、メイン製造工程S002、及び、回収工程S003から構成される。以下、各工程について説明する。
繊維シート製造工程は、ロール状シート1の構成要素としての繊維シート6を製造するための工程である。本工程は、図3に図示された繊維シート製造装置10によって実行される。図3は、繊維シート製造装置10を示した図である。繊維シート製造装置10は、図3に示すように、カード機11と、集束装置12と、プレス装置13と、第1アキュムレータ14を有する。
メイン製造工程は、複数の繊維シート製造装置10から供給される複数(8枚)の繊維シート6からロール状シート1を製造するための工程である。すなわち、本工程にて実現されるロール状シート1の製造方法は、本発明のロール状シート1の製造方法に相当する。本工程は、図4に示すようにメイン製造装置20(ロール状シート1の製造装置の一例)によって実行される。図4は、メイン製造工程についての概略説明図である。以下、メイン製造工程について概説する。
回収工程は、メイン製造工程にて製造されたロール状シート1を不図示のハンガーにより挟んで掴み、ロール状シート1を掴んだ状態のハンガーを所定の集積場まで搬送し、当該集積場にてロール状シート1をハンガーからリリースしてロール状シート1を積み重ねていく工程である。
次に、本実施形態のメイン製造工程について詳しく説明する。本実施形態のメイン製造工程は、図5に示すように、重ね合わせた複数の繊維シート6を圧縮して一体化させることにより積層シート7を形成する圧縮工程S011と、その連続方向に移動している積層シート7を該積層シート7の移動経路内に蓄積させておく蓄積工程S012と、積層シート7を巻き取る巻き取り工程S013とを有する。図5は、メイン製造工程の流れを示す図である。上記の各工程は、既述のメイン製造装置20のうち、当該各工程を担当する機構によって実行される。
本工程は、図6に図示されたメイン製造装置20のうち、積層シート形成部の一例としての圧縮装置22により実行される。図6は、メイン製造装置20を模式的に示した図である。また、本実施形態の圧縮工程S011は、二段階に分かれており、先に行われる第1圧縮としての第1エンボス工程S111と、後に行われる第2圧縮としての第2エンボス工程S112を有する(図5参照)。
第1エンボス工程は、重ね合わせた複数の繊維シート6を一体化させて積層シート7を形成するために、上記複数の繊維シート6に対して圧縮エンボス加工を施す工程であり、図6に図示された第1エンボス機構23により実行される。
第2エンボス工程は、第1エンボス工程後に行われ、所定厚みの積層シート7を形成するために、第1エンボス工程にて形成された積層シート7に対して、第1エンボス工程での圧縮エンボス工程とは異なる圧縮エンボス加工を施す工程である。本工程は、巻き取り工程の事前工程であり、積層シート7を適切に巻き取るために行われる。
本工程は、メイン製造装置20のうち、蓄積部の一例としての第2アキュムレータ25により実行される(図6参照)。第2アキュムレータ25は、第1エンボス機構23よりも下流側に位置し、第2エンボス機構24よりも上流側に位置する。したがって、本実施形態では、蓄積工程が、第1エンボス工程S111後、第2エンボス工程S112が行われるまでの間に行われることになる(図5参照)。
本工程は、第2エンボス工程後に、メイン製造装置20のうちの巻き取り機構26により行われる(図6参照)。巻き取り機構26は、巻き取り部の一例であり、第2エンボス機構24よりも下流側に位置する。巻き取り機構26は、図10に示すように、ターンテーブル27と、巻き芯21と、カッター28と、テープ貼り機29、押さえローラ30とを有する。図10は、巻き取り機構26を示す図である。
以下、メイン製造装置20の動作例について説明する。なお、以下では、所定の巻き取り速度にて積層シート7を巻き取っている間の動作例(以下、定常動作)と、積層シート7の巻き取りを中断してから巻き芯21を交換して巻き取りを再開するまでの動作例(以下、交換動作)とに分けて説明する。
定常動作では、巻き取り工程において約54m/minの巻き取り速度にて積層シート7を巻き取る。つまり、メイン製造装置20内において積層シート7は、巻き取り速度と同じ移動速度にてMD方向へ移動することになる。また、定常動作中、メイン製造装置20の各部は、図6に示す状態にある。具体的に説明すると、第2アキュムレータ25では、各ダンサローラ25aが下死点で静止するように、ダンサローラ25aの周面に掛けられた積層シート7に掛かる張力(テンション)と錘部材25fの荷重とが均衡している。また、巻き取り機構26では、カッター28、及び、テープ貼り機29がそれぞれ積層シート7から離間した位置に位置している。かかる状態において、重ね合わせられた複数の繊維シート6がメイン製造装置20内に投じられる。
積層シート7が所定長さ分巻き取られると、巻き取り工程が中断し、メイン製造装置20の動作が定常動作から交換動作へと切り替わる。そして、交換動作への切り替えに際して、第2アキュムレータ25では各ダンサローラ25aが上死点に向けて約1200mm上昇する。詳しく説明すると、巻き取り工程が中断すると、第2エンボス機構24よりも上流側の機構(第1エンボス機構23、第2アキュムレータ25)が稼動し続ける一方で、第2エンボス機構24の運転(すなわち、パターンローラ24a、24bの回転)が停止する。これにより、積層シート7のうち、パターンローラ24a、24b間に挟まれた箇所よりも下流側に位置する部分が停止し、ダンサローラ25aの周面に掛けられた積層シート7に掛かる張力が、低下して錘部材25fの荷重を下回るようになる。これに伴い、昇降バー25gが上昇し、各ダンサローラ25aも上死点に向けて上昇する。
以上までに説明してきたメイン製造装置20の構成(メイン製造工程の手順)により、本実施形態では、重ね合わせた複数の繊維シート6を圧縮して一体化させることにより形成される積層シート7を、蓄積工程(第2アキュムレータ25内)において蛇行を抑制しつつダンサローラ25aの周面に適切に掛け回すことが出来る。さらに、上記積層シート7を、巻き取り工程(巻き取り機構26内)において巻き芯21に適切に巻き付けて良好に巻き取ることが出来る。以下、本実施形態の有効性について詳しく説明する。
上記実施形態には、主として本発明に係るロール状シート1の製造方法及び製造装置について説明したが、上記実施形態は本発明の理解を容易にするためのものであり、本発明を限定するものではない。本発明は、その趣旨を逸脱することなく、変更、改良され得ると共に、本発明にはその等価物が含まれることはもちろんである。また、上述した設定値、寸法値、及び、形状等は本発明の効果を発揮させるための一例に過ぎず、本発明を限定するものではない。
Claims (7)
- 重ね合わせた複数の繊維シートを圧縮して一体化させることにより積層シートを形成することと、その連続方向に移動している前記積層シートを該積層シートの移動経路内に蓄積させておくことと、前記積層シートを巻き取ることとを有するロール状シートの製造方法であって、
前記積層シートを形成することは、
第1領域と、該第1領域よりも圧縮度合いが高く前記連続方向と交差する交差方向に沿った第2領域とが前記連続方向において交互に複数配置されるよう前記積層シートを圧縮する第1圧縮を行うことと、
前記第1圧縮後に行われ、前記第1領域及び前記2領域のうち、少なくとも前記第1領域が圧縮されるよう前記積層シートを圧縮する第2圧縮を行うこととを有し、
前記積層シートを蓄積させておくことは、前記第1圧縮後に行われ、前記積層シートを回転ローラの周面に掛け回すことにより該積層シートのループを形成することを含み、
前記積層シートを巻き取ることは、前記第2圧縮後に行われ、前記回転ローラよりも下流側に位置する巻き芯に前記積層シートを巻き付けることを含むことを特徴とするロール状シートの製造方法。 - 請求項1に記載のロール状シートの製造方法において、
前記第1圧縮では、
前記第1領域としての低圧縮領域と、前記第2領域としての高圧縮領域とが前記連続方向において交互に複数配置され、かつ、前記交差方向における両端部に圧縮されていない非圧縮領域が配置された前記積層シートを形成することを特徴とするロール状シートの製造方法。 - 請求項2に記載のロール状シートの製造方法において、
前記交差方向において前記積層シートの両端部に配置された前記非圧縮領域の各々の、該交差方向における長さは、前記積層シートの該交差方向における長さの1/4以下となっていることを特徴とするロール状シートの製造方法。 - 請求項3に記載のロール状シートの製造方法において、
複数の前記繊維シートの各々は、複数の繊維片により構成されており、
前記連続方向における前記低圧縮領域の長さは、
複数の前記繊維片の平均長さの0.3倍以上であり、かつ、該平均長さ以下であることを特徴とするロール状シートの製造方法。 - 請求項1~請求項4のいずれか1項に記載のロール状シートの製造方法において、
前記積層シートを蓄積させておく工程は、前記第1圧縮後、前記第2圧縮が行われるまでの間に行われることを特徴とするロール状シートの製造方法。 - 重ね合わせた複数の繊維シートを圧縮して一体化させることにより積層シートを形成する積層シート形成部と、その連続方向に移動している前記積層シートを該積層シートの移動経路内に蓄積させておく蓄積部と、前記積層シートを巻き取る巻き取り部とを有するロール状シートの製造装置であって、
前記積層シート形成部は、
第1領域と、該第1領域よりも圧縮度合いが高く前記連続方向と交差する方向に沿った第2領域とが前記連続方向において交互に複数配置されるよう前記積層シートを圧縮する第1圧縮部と、
前記第1圧縮部よりも下流側に位置し、前記第1領域及び前記2領域のうち、少なくとも前記第1領域が圧縮されるよう前記積層シートを圧縮する第2圧縮部とを有し、
前記蓄積部は、
前記第1圧縮部よりも下流側に位置し、前記積層シートが周面に掛け回されることにより該積層シートのループを形成する回転ローラを有し、
前記巻取り部は、
前記第2圧縮部及び前記回転ローラよりも下流側に位置し、前記積層シートが巻き付けられる巻き芯を有することを特徴とするロール状シートの製造装置。 - 請求項6に記載のロール状シートの製造装置において、
前記第1圧縮部は、複数の前記繊維シートを挟み込みながら回転する一対の圧縮ローラであり、
一対の前記圧縮ローラのうち、一方の圧縮ローラの周面には、該周面から突出し前記一方の圧縮ローラの回転軸に沿って伸びた突出部が、前記一方の圧縮ローラの周方向において断続的に配置されていることを特徴とするロール状シートの製造装置。
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AU2010218993A1 (en) | 2011-09-01 |
BRPI1005689A2 (pt) | 2018-07-17 |
CL2011001998A1 (es) | 2012-05-04 |
MX2011008866A (es) | 2011-09-15 |
CN102333651A (zh) | 2012-01-25 |
AR075700A1 (es) | 2011-04-20 |
CO6430448A2 (es) | 2012-04-30 |
JP2010194818A (ja) | 2010-09-09 |
US20130068388A1 (en) | 2013-03-21 |
JP5452949B2 (ja) | 2014-03-26 |
CA2751546A1 (en) | 2010-09-02 |
EP2402160A1 (en) | 2012-01-04 |
EA201101108A1 (ru) | 2012-08-30 |
EP2402160A4 (en) | 2013-10-16 |
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