WO2014006902A1

WO2014006902A1 - Method for manufacturing a composite body of continuous sheets for an absorbent article and apparatus of the same

Info

Publication number: WO2014006902A1
Application number: PCT/JP2013/004143
Authority: WO
Inventors: Yoshikazu Ogasawara; Shinichi Ishikawa
Original assignee: Unicharm Corporation
Priority date: 2012-07-06
Filing date: 2013-07-03
Publication date: 2014-01-09
Also published as: CN104349757A; CN104349757B; JP2015521865A; JP6220795B2

Abstract

The present invention relates a method for manufacturing a composite body (1a) of a continuous sheet for an absorbent article. The outer circumferential surface (21a) of the holding roller (21) has individual face portions (21p) formed adjacent to each other in the rotational direction (Dc), and adjacent face portions (21p) are linked via a corner portion (21c) extending in the CD direction.

Description

METHOD FOR MANUFACTURING A COMPOSITE BODY OF CONTINUOUS SHEETS FOR AN ABSORBENT ARTICLE AND APPARATUS OF THE SAME

The present invention relates to a method and an apparatus for manufacturing a compositie body of continuous sheets for an absorbent article such as a disposable diaper.

Conventionally, in a production line for absorbent articles such as disposable diapers and sanitary napkins, as shown in FIG. 1, cut films 103 having a predetermined length are cut off and created from a continuous film 103a, and the

resultant cut films

103, 103, ... are adhered onto a continuous sheet 105a made of a nonwoven fabric, etc. at a predetermined adhering pitch in the continuous direction of the continuous sheet 105a with spaces between the

adjacent cut films

103, 103.

As an example of the above method, PTL 1 discloses a method using an anvil roller 121 rotating in a circumferential direction Dc, a cutter roller 131 positioned to oppose the anvil roller 121 to rotate synchronously, and a press roller 143 placed on the downstream side of the cutter roller 131 in the circumferential direction Dc.

[PTL 1] JP 2007-260875A

To state the above-described method more specifically, first, a suction section (not shown) that suctions the continuous film 103a to hold the film is provided for substantially the entire outer circumferential surface 121a of the anvil roller 121 which rotates at a predetermined peripheral speed value V121. The continuous film 103a is transported towards the outer circumferential surface 121a. In this regard, the transport speed value V103a of the continuous film 103a is set at a value lower than the peripheral speed value V121. Therefore, the outer circumferential surface 121a of the anvil roller 121 holds a portion 103e at the leading edge of the continuous film 103a in the surface contact state while allowing the portion 103e to relatively slip (slide) behind with respect to the outer circumferential surface 121a.

Meanwhile, on the outer circumferential surface 121a of the anvil roller 121, there is provided a receiving blade 123 for receiving a cutter blade 133 of the cutter roller 131. When the receiving blade 123 passes by the position where the cutter roller 131 is placed, the continuous film 103a on the outer circumferential surface 121a is sandwiched between the cutter blade 133 of the cutter roller 131 and the receiving blade 123 to cut and separate the portion 103e at its leading edge, thereby producing a cut film 103.

The cut film 103 cut off from the continuous film 103a is then held on the outer circumferential surface 121a of the anvil roller 121 with no relative sliding involved, and thus transported in the circumferential direction Dc at the peripheral speed value V121 of the anvil roller 121. At this time, a spacing D103 is formed between the present cut film 103 and the subsequently cut-off cut film 103 based on the speed difference between the peripheral speed value V121 and the above-described transport speed value V103a.

Finally, when the cut film 103 passes by the position facing the press roller 143 on the transport pathway in the circumferential direction Dc, the cut film 103 is adhered on the continuous sheet 105a transported on the press roller 143 at a speed value V105a approximately the same as the peripheral speed value V121. In this way, the cut film 103 is adhered on the continuous sheet 105a with spacing between the adjacent cut films 103.

However, the inventor(s) has noted that the cut film 103, which is very thin and soft, is likely to be wrinkled on occasions such as when the cut film 103 is suctioned to the outer circumferential surface 121a of the anvil roller 121. If the cut film 103 having a wrinkle is adhered on the continuous sheet 105a, such a wrinkle may remain unremoved on the end product. Depending on the product, this may not only worsen the appearance but also impair the original function to be exerted by the product. For example, when the cut film 103 is an anti-leakage film for preventing liquid to leak outside from an absorbent body of a disposable diaper, the wrinkle may serve as a groove through which liquid excretion can flow, causing liquid leakage and thus significantly detracting from the commodity value of the diaper.

The present invention has been conceived in view of the conventional problem described above, and an objective of the present invention is to prevent or reduce wrinkling of a cut sheet that may occur such as when a cut film cut off from a first continuous sheet is bonded to a second continuous sheet to manufacture a composite body of continuous sheets.

In order to address the above problem, a primary aspect of the invention is directed to a manufacturing method for a composite body of a continuous sheet for an absorbent article, the method cutting and creating a cut sheet from a first continuous sheet, and overlaying and bonding the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the method including:
transporting at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction with a first transport mechanism;
rotating a holding roller at a peripheral speed value higher than the first transport speed value and holding the first continuous sheet transported from the first transport mechanism, on an outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
cutting and creating the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with a blade member provided on the outer circumferential surface of the holding roller; and
feeding the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and overlaying and bonding the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.

Another aspect of the invention is directed to a manufacturing apparatus for a composite body of a continuous sheet for an absorbent article, the apparatus configured to cut and create a cut sheet from a first continuous sheet, and to overlay and bond the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the apparatus including:
a first transport mechanism configured to transport at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction;
a holding roller mechanism that includes a holding roller provided with at least one blade member on an outer circumference the holding roller, the holding roller mechanism being configured to rotate the holding roller at a peripheral speed value higher than the first transport speed value and to hold the first continuous sheet transported from the first transport mechanism, on the outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
a cutter roller configured to cut and create the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with the blade member provided on the outer circumferential surface of the holding roller; and
a bonding mechanism configured to feed the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and to overlay and bond the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.

Other features of the invention will become clear from the description of the present specification with reference to the accompanying drawings.

According to the present invention, wrinkles that may be made when a cut sheet, such as a cut film created by being cut off from the first continuous sheet, is bonded to the second continuous sheet to manufacture a composite body of continuous sheets can be prevented or reduced.

FIG. 1 is a schematic side view of a conventional manufacturing apparatus 110. FIG. 2A is a schematic plan view of a back-side sheet 1. FIG. 2B is a schematic plan view of an intermediate component 1a as the original sheet for the back-side sheet 1. FIG. 3 is a schematic side view of a manufacturing apparatus 10 of the present embodiment. FIG. 4A is an external perspective view of an anvil roller 21 with ingenuity exercised to prevent or reduce wrinkling of a cut film 3. FIG. 4B is a schematic enlarged view of a portion where ingenuity is exercised to an outer circumferential surface 21a of the roller 21. FIG. 5 is a schematic enlarged view of a portion neighboring the press roller 43. FIG. 6A is an external perspective view of the anvil roller 21 where planar portions 21p and corner portions 21c are formed only in a holding range R1 on the outer circumferential surface 21a. FIG. 6B is a partial enlarged view of the outer circumferential surface 21a of the roller 21. FIG. 7A is an external perspective view of the anvil roller 21 where planar portions 21p and corner portions 21c are formed only in range R5 on the outer circumferential surface 21a. FIG. 7B is a partial enlarged view of the outer circumferential surface 21a of the roller 21.

At least the following matters will become clear from the description of the present specification with reference to the accompanying diagrammatic drawings. An embodiment of the invention is described accordingly, by way of example only.

A manufacturing method for a composite body of a continuous sheet for an absorbent article, the method cutting and creating a cut sheet from a first continuous sheet, and overlaying and bonding the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the method including:
transporting at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction with a first transport mechanism;
rotating a holding roller at a peripheral speed value higher than the first transport speed value and holding the first continuous sheet transported from the first transport mechanism, on an outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
cutting and creating the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with a blade member provided on the outer circumferential surface of the holding roller; and
feeding the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and overlaying and bonding the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.

According to the manufacturing method for a composite body of continuous sheets described above, a corner portion extending in an intersecting direction intersecting the transport direction is formed on the outer circumferential surface of the holding roller. Therefore, when relatively sliding the first continuous sheet behind with respect to the outer circumferential surface, the first continuous sheet is slightly caught and the like on the corner portion, resulting in being pulled in the rotational direction of the holding roller, whereby wrinkles on the first continuous sheet are smoothed out quickly. Thus, the cut sheets created by being cut off from the first continuous sheet can be prevented or restrained from wrinkling.

Note that, the first continuous sheet relatively sliding behind with respect to the outer circumferential surface of the holding roller means that the first continuous sheet experiences backward slip relative to the rotating outer circumferential surface of the holding roller (upstreamside in the rotational direction).

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desirable that
the outer circumferential surface of the holding roller has, as a range in the rotational direction, a holding range configured to hold the cut sheet, and
the corner portion is formed in at least the holding range.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the corner portion is formed in at least the aforementioned holding range within the range in the rotational direction of the holding roller. Therefore, when the first continuous sheet relatively slides behind with respect to the outer circumferential surface, the corner portion in the holding range passes by at least an upstream side end portion of a portion corresponding to the cut sheet of the first continuous sheet. By this arrangement, the corner portion can smooth out wrinkles on this upstream sdie end portion, and as a result, the cut sheets created by being cut off from the first continuous sheet can be prevented or restrained from wrinkling.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the outer circumferential surface of the holding roller has, as ranges in the rotational direction, a holding range configured to hold the cut sheet and a non-holding range not configured to hold the cut sheet,
the holding range has the corner portion formed, and
the non-holding range includes a range where the corner portion is not formed.

According to the manufacturing method for a composite body of continuous sheets described above, it is unnecessary to form the corner portions and the face portions over the entirety of the outer circumferential surface of the holding roller. This can reduce the cost and labor for processing the outer circumferential surface of the holding roller.

Also, since the corner portion is formed in the holding range where the cut sheet is held, wrinkle smoothing can be performed for at least some part of the portion corresponding to the cut sheet when the cut sheet is in a state of the first continuous sheet.

In the manufacturing method for a continuous sheet composite body for an absorbent article described above, it is desired that
a plurality of the corner portions are formed over an entirety of the holding range.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, a plurality of corner portions are formed over the entirety of the aforementioned holding range within the range in the rotational direction of the holding roller. Therefore, when the first continuous sheet relatively slides behind with respect to the outer circumferential surface, the corner portion located at the downstream side end of the holding range passes by substantially the entire length of the portion of the first continuous sheet corresponding to the cut film without fail. Thus, this corner portion can perform wrinkle smoothing for substantially the entire length of the portion corresponding to this cut sheet. As a result, wrinkling of the cut sheet created by being cut off from the first continuous sheet can be prevented or restrained over substantially the entire length thereof. Also, with the plurality of corner portions formed over the entirety of the holding range, many corner portions pass by the portion of the first continuous sheet corresponding to the aforementioned cut sheet during the relative sliding. As a result, a large wrinkle smoothing effect can be obtained.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the outer circumferential surface of the holding roller has a plurality of the corner portions formed thereon over an entire circumference along the rotational direction.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, a plurality of corner portions are formed on the outer circumferential surface of the holding roller over substantially the entire circumference in the rotational direction. Therefore, the portion of the first continuous sheet corresponding to the cut sheet is subjected to wrinkle smoothing by either one of the corner portions at all times when relatively sliding with respect to the outer circumferential surface, and as a result, a large wrinkle smoothing effect can be obtained.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the outer circumferential surface of the holding roller has, as a range in the rotational direction, a range configured to hold a downstream side end portion of the cut sheet, and
the corner portion is formed in at least the range where the downstream end portion is configured to be held.

According to the manufacturing method for a composite body of continuous sheets described above, the aforementioned corner portion is formed in the range of the outer circumferential surface where the downstream side end portion of the cut sheet is held. Therefore, when the first continuous sheet relatively slides behind with respect to the outer circumferential surface, this corner portion passes along at least an area from the portion of the first continuous sheet corresponding to an upstream side end portion of the cut sheet to the portion corresponding to the downstream side end portion of the cut sheet without fail. By this arrangement, the corner portion can smooth out wrinkles on substantially the entire length of the portion of the first continuous sheet corresponding to the aforementioned cut sheet, and as a result, the cut sheet created by being cut off from the first continuous sheet can be prevented or restrained from wrinkling over substantially the entire length thereof.

Also, in some cases, formation of the corner portions and the face portions can be limited to the range where the downstream side end portion of the cut sheet is held, in the range in the rotational direction. In such cases, the cost and labor for the processing of the outer circumferential surface of the holding roller can be greatly reduced.

In the manufacturing method for a continuous sheet composite body for an absorbent article described above, it is desired that
the face portions formed adjacent to the corner portion on the outer circumferential surface of the holding roller are planar portions.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the aforementioned face portions are planar portions. Therefore, when the corner portion and its neighboring aforementioned face portion pass by the joining position with the second continuous sheet, first, the corner portion presses the cut sheet against the second continuous sheet to perform bonding. Thereafter, using a portion bonded by the corner portion as the pivot point of rotation, a portion of the cut sheet held on the planar portion adjacent on the upstream side of the corner portion is inclined toward the second continuous sheet substantially at one time, whereby the aforementioned portion is overlaid on the second continuous sheet. Accordingly, each of the portions of the cut sheet that correspond to the aforementioned face portions can be overlaid on the second continuous sheet with the stability that may be obtained when a sheet having fold lines for forming a polygon is overlaid on the second continuous sheet by sequentially inclining the sectioned portions one after another using the corresponding fold lines as the start point. Thus, even while overlaying on the second continuous sheet, the portions of the cut sheet can be easily kept in a flat state, and as a result, wrinkling can be effectively prevented.

Also, since the aforementioned face portion adjacent to the corner portion on the upstream side is planar, a wide wedge-shaped space can be secured between a portion of the cut film held on the aforementioned face portion and the second continuous sheet, compared with the case where this face portion is an arc surface, and this allows air from this space to be discharged easily. Thus, an event where air enters the space between the cut sheet and the second continuous sheet to be sealed therein during bonding can be effectively prevented, and as a result, occurrence of swell-like wrinkles can also be prevented.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the outer circumferential surface of the holding roller has a plurality of holes provided,
a plurality of the holes are provided side by side in the intersecting direction in each of a plurality of the face portions formed adjacent to the corner portion on the outer circumferential surface of the holding roller, and
the holes are configured to hold the first continuous sheet and the cut sheet on the outer circumferential surface of the holding roller by suction through the holes.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, since a plurality of the aforementioned holes are formed in each of the aforementioned plurality of face portions, each face portion can reliably hold the corresponding portion of the cut sheet, and this also contributes to prevent or restrain wrinkling.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
a distribution density of the plurality of the holes is higher in the face portions than in a portion other than the face portions on the outer circumferential surface of the holding roller.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, during wrinkle smoothing by the corner portion, the first continuous sheet can be firmly suctioned and held by the face portions located on both sides of the corner portion in the rotational direction. This can enhance the wrinkle smoothing effect of the corner portion.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that the bonding is performed by a bonding mechanism,
the bonding mechanism including
a transport mechanism configured to transport the second continuous sheet at a speed value approximately the same as the peripheral speed value of the holding roller and
a press roller configured to press the second continuous sheet against the cut sheet held on the outer circumferential surface of the holding roller to perform bonding, and
a diameter of the press roller and a mean diameter of the holding roller are in a non-integer multiple relationship.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the diameter of the press roller and the mean diameter of the holding roller have a non-integer multiple relationship therebetween. Therefore, a situation in which the aforementioned corner portions on the outer circumferential surface of the holding roller always abut against specific positions on the outer circumferential surface of the press roller can be effectively prevented. In other words, the positions on the outer circumferential surface of the press roller against which the aforementioned corner portions of the holding roller abut can be shifted in the rotational direction with each rotation, dispersing the positions against which the corner portions abut. By this arrangement, uneven wear (local wear) of the outer circumferential surface of the press roller can be effectively prevented, and as a result, the clearance between the holding roller and the press roller, which should be managed and adjusted precisely from the standpoint of prevention of wrinkling and accuracy of bonding, can be easily managed to fall within a target range for the long run.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the corner portion extends linearly in an intersecting direction intersecting the transport direction.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, since the above corner portion is formed to extend linearly in the intersecting direction, tensile force for removing wrinkles can be imparted in substantially evenly in the intersecting direction. And hereby, the wrinkle-preventing effect can be improved.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
a cross-sectional shape of the holding roller is a convex polygon.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the cross-sectional shape of the holding roller is a convex polygon. Therefore, the first continous sheet is further certainly pulled in the rotational direction of the holding roller and hereby the wrinkles existing in the first continuous sheet are quickly removed. And as a result, wrinkles can be further restrained from forming on the cut sheet cut and created from this first continuous sheet.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
a cross-sectional shape of the holding roller is a regular polygon.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the cross-sectional shape of the holding roller is a regular polygon so that the difference in the peripheral speed values between face portions of the holding roller can be controlled over the entire circumference.

In the manufacturing method for a composite body of continuous sheets for an absorbent article described above, it is desired that
the face portions and the corner portion are formed on a protrusion portion protruding outward in a radial direction of the holding roller compared to surrounding portions of the outer circumferential surface of the holding roller.

According to the manufacturing method for a composite body of continuous sheets for an absorbent article described above, the face portions and the corner portion are formed on a protrusion portion. Therefore, the first continous sheet is further certainly pulled in the rotational direction of the holding roller and hereby the wrinkles existing in the first continuous sheet is further quickly removed. And as a result, wrinkles can be further restrained from forming on the cut sheet cut and created from this first continuous sheet.

Further, a manufacturing apparatus for a composite body of a continuous sheet for an absorbent article, the apparatus configured to cut and create a cut sheet from a first continuous sheet, and to overlay and bond the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the apparatus including:
a first transport mechanism configured to transport at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction;
a holding roller mechanism that includes a holding roller provided with at least one blade member on an outer circumference the holding roller, the holding roller mechanism being configured to rotate the holding roller at a peripheral speed value higher than the first transport speed value and to hold the first continuous sheet transported from the first transport mechanism, on the outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
a cutter roller configured to cut and create the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with the blade member provided on the outer circumferential surface of the holding roller; and
a bonding mechanism configured to feed the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and to overlay and bond the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.

According to the manufacturing apparatus for a composite body of continuous sheets described above, a corner portion extending in the intersecting direction intersecting the transport direction is formed on the outer circumferential surface of the holding roller. Therefore, when relatively sliding behind with respect to the outer circumferential surface, the first continuous sheet is slightly caught and the like on the aforementioned corner portion, resulting in being pulled in the rotational direction of the holding roller, whereby wrinkles on the first continuous sheet are smoothed out quickly. Thus, this cut sheet created by being cut off from the first continuous sheet can be prevented or restrained from wrinkling.

===Embodiment===
The manufacturing apparatus 10 for a composite body of continuous sheets of the present embodiment manufactures an intermediate component 1a as the original sheet for a back-side sheet 1 of a disposable diaper as an example of the composite body of continuous sheets. FIG. 2A is a schematic plan view of the back-side sheet 1, and FIG. 2B is a schematic plan view of the intermediate component 1a being the original sheet for the back-side sheet 1.

The back-side sheet 1 shown in FIG. 2A is a composite sheet 1 including an outer sheet 5 constituting the exterior of the diaper and a liquid-impermeable anti-leakage film 3 adhered to the inner surface (the surface on the wearer's skin side) of the outer sheet 5. On the anti-leakage film 3, absorbent bodies not shown made by sequentially forming pulp fibers, a liquid-permeable front-side sheet not shown and the like are placed on top of one another and fixed, whereby the base of the diaper is produced.

Examples of the material of the outer sheet 5 include soft nonwoven fabrics having resin fibers as the main material, and the like, and nonwoven fabric is used in this example. Examples of the material of the anti-leakage film 3 include soft resin films such as a polyethylene film, and the like, and resin film is used in this example.

The intermediate component 1a being the original sheet for the back-side sheet 1 is a continuous body before being divided into units of back-side sheets 1 at a product pitch P as shown in FIG. 2B. That is, the intermediate component 1a includes a continuous web 5a made of a nonwoven fabric as the original fabric for the outer sheet 5 and has a plurality of cut

anti-leakage films

3, 3, ... adhered on the continuous web 5a at an adhering pitch P3, which is substantially the same as the product pitch P, in the continuous direction. The manufacturing apparatus 10 of the present embodiment manufactures such an intermediate component 1a. In other words, the manufacturing apparatus 10 first cuts and creates the cut films 3 as the anti-leakage films 3 from the continuous film 3a as the original film for the anti-leakage films 3, and oberlays the cut films 3 on the continuous web 5a as the original fabric for the outer sheets 5 at an adhering pitch P3 in the continuous direction and bonds the cut films 3 thereto, whereby the intermediate component 1a is manufactured. However, the present invention is not to be limited to manufacturing such intemediate component 1a.

The manufacturing apparatus 10 will be described hereinafter in detail.

FIG. 3 is a schematic side view of the manufacturing apparatus 10. As used herein, the width direction of the continuous film 3a is also referred to as a "CD direction." The CD direction is orthogonal to the transport direction that is the continuous direction of the continuous film 3a, which corresponds to the "intersecting direction", and is oriented in a direction penetrating the plane of the paper, in FIG. 3. Also, the CD direction is parallel to the width direction of the continuous web 5a for the outer sheet 5. Note that, any direction orthogonal to the CD direction is also referred to as the "MD direction". In other words, the MD direction is any direction parallel to the plane of the paper of FIG. 3, and, to put it yet another way, the MD directin is any direction defined by the up-down direction and the front-rear direction orthogonal to each other as shown in FIG. 3.

Also, the "continuous film 3a" and the "cut film 3" respectively correspond to the "first continuous sheet" and the "cut sheet", and the "continuous web 5a" corresponds to the "second continuous sheet".

As shown in FIG. 3, the manufacturing apparatus 10 includes: (1) a continuous film transport mechanism 11 that transports the continuous film 3a in the MD direction at a first transport speed value V3a; (2) an anvil roller mechanism 20 that rotates an anvil roller 21 at a peripheral speed value V21 higher than the first transport speed value V3a, thereby holding the continuous film 3a transported from the continuous film transport mechanism 11 on an outer circumferential surface 21a of the anvil roller 21 while allowing the continuous film 3a to relatively slide behind with respect to the outer circumferential surface 21a; (3) a cutter roller 31 that cuts and creates the cut sheet 3 from the continuous film 3a by sandwiching the continuous film 3a between the cutter roller 31 and a receiving blade 23 placed on the outer circumferential surface 21a of the anvil roller 21; and (4) a bonding mechanism 40 that feeds the continuous web 5a for the outer sheet 5 towards the cut film 3, which has been cut off from the continuous film 3a and held on the outer circumferential surface 21a of the anvil roller 21 with no relative sliding involved, at a second transport speed value V5a that is approximately the same as the aforementioned peripheral speed value V21, thereby overlaying the cut film 3 on and bonding it to the continuous web 5a.

The continuous film transport mechanism 11 (corresponding to the first transport mechanism) is a suction belt conveyer, for example. That is, the mechanism 11 has an endless belt 12 having a plurality of suction holes (not shown) formed through its outer circumferential surface as the transport surface, and suctions the continuous film 3a to the outer circumferential surface of the endless belt 12 in a surface contact state by suction through the suction holes. The endless belt 12 is driven to travel around in this suctioning state, to transport the continuous film 3a in the MD direction at the aforementioned first transport speed value V3a. Note that the continuous film transport mechanism 11 is not limited to a suction belt conveyer. For example, a pinch roller apparatus that transports the continuous film 3a with a pair of upper and lower drive rollers rotating in opposite directions towards each other while pinching the continuous film 3a, etc. may be used.

The anvil roller mechanism 20 (corresponding to the holding roller mechanism) has the anvil roller 21 as the main body, which is driven to rotate around a rotary axis C21 extending in the CD direction. The outer circumferential surface 21a of the anvil roller 21 has a holding function of holding a sheet-like object by winding the sheet-like object around the surface in a surface contact state, and by this function, holds the continuous film 3a and the cut film 3 in a surface contact state. In this example, the holding function is realized by a plurality of

suction holes

21h, 21h, ... (not shown in FIG. 3; see FIGS. 4A and 4B) formed through the outer circumferential surface 21a. That is, by the suction through the

suction holes

21h, 21h, ..., the outer circumferential surface 21a of the anvil roller 21 bears suction force, and the suction force becomes the holding force for holding the aforementioned continuous film 3a and the cut film 3. Note that the method of imparting a holding force to the outer circumferential surface 21a is not limited to this. For example, another method such as a method using the attraction force of static electricity may be used.

The aforementioned continuous film 3a is fed onto the outer circumferential surface 21a of the anvil roller 21 in a substantially tangential direction of the outer circumferential surface 21a, and wound around and held on the outer circumferential surface 21a in a surface contact state by the holding force described above. The position Pwst at which widing on the outer circumferential surface 21a starts is located on the upstream side of the placement position P31 of the cutter roller 31 in the rotational direction Dc by a predetermined angle.

The peripheral speed value V21 of the anvil roller 21 is set at a speed value larger than the first transport speed value V3a of the continuous film 3a as described above. Therefore, the continuous film 3a is held on the outer circumferential surface 21a of the anvil roller 21 in a surface contact state while relatively sliding behind with respect to the outer circumferential surface 21a. In other words, the continuous film 3a gradually moves toward the downstream side in the rotational direction Dc based on the above-described first transport speed value V3a while sliding on the outer circumferential surface 21a.

A receiving blade 23 (corresponding to the blade member) that receives a cutter blade 33 of the cutter roller 31 is provided on the outer circumferential surface 21a of the anvil roller 21. When the receiving blade 23 passes by the placement position P31 of the cutter roller 31, the continuous film 3a on the outer circumferential surface 21a is sandwiched between the receiving blade 23 and the cutter blade 33 of the cutter roller 31, which rotates in response to the movemento of the anvil roller 31, whereby the continuous film 3a is cut to separate a portion 3e at the leading edge thereof. The separated portion 3e at the leading edge becomes the cut film 3.

The separated cut film 3 is thereafter held on the outer circumferential surface 21a of the anvil roller 21 with no relative sliding involved, and thus is transported integral with the outer circumferential surface 21a towards the downstream side in the rotational direction Dc at a peripheral speed value V21 of the anvil roller 21. At this time, a spacing D3 is formed between the present cut film 3 and the subsequent cut film 3 cut and created based on the speed difference between the peripheral speed value V21 and the transport speed value V3a of the aforementioned continuous film 3a.

The bonding mechanism 40 is placed at a position on the downstream side of the placement position P31 of the cutter roller 31 in the rotational direction Dc. The bonding mechanism 40 has a transport mechanism 41 such as transport rollers 41 that transport the continuous web 5a for the outer sheet 5 along a route in a substantially tangential direction of the outer circumferential surface 21a of the anvil roller 21 at the speed value V5a approximately the same as the peripheral speed value V21 of the anvil roller 21, and also has a press roller 43 that presses the aforementioned continuous web 5a running along the above route against the cut sheet 3 held on the outer circumferential surface 21a of the anvil roller 21.

The transport mechanism 41, in this example, includes rollers 41 having a cross-sectional shape of a circle each of which is driven to rotate around a rotary axis C41 extending in the CD direction. The press roller 43 is also a roller having a cross-sectional shape of a circle that is driven to rotate around a rotary axis C43 extending in the CD direction, for example, and a peripheral speed value V43 thereof is controlled to be approximately equal to the peripheral speed value V21 of the anvil roller 21. Note however that the press roller 43 may be a follower roller rotated with a rotative force obtained by contact with the continuous web 5a.

By the time the cut film 3 on the outer circumferential surface 21a of the anvil roller 21 passes by the placement position P43 of the press roller 43, hot-melt adhesive is already applied to one face, of the two surfaces of the cut film 3, facing the continuous web 5a. For example, in the example of FIG. 3, hot-melt adhesive is applied when the cut film 3 passes by the placement position of the hot-melt adhesive application apparatus 70 with the continuous film 3a in a state before being held on the outer circumferential surface 21a of the anvil roller 21.

A clearance CL between an outer circumferential surface 43a of the press roller 43 and the outer circumferential surface 21a of the anvil roller 21 is set at a value by which both the cut film 3 and the continuous web 5a can be slightly pressed in their thickness directions by both the anvil roller 21 and the press roller 43 when the cut film 3 passes by the position of the press roller 43.

Accordingly, when the cut film 3 held on the outer circumferential surface 21a of the anvil roller 21 passes by the placement position P43 of the press roller 43, the cut film 3 on the outer circumferential surface 21a is pressed against and bonded to the continuous web 5a, which allows the cut film 3 to be delivered to the continuous web 5a from the outer circumferential surface 21a. In this way, the intermediate component 1a of the back-side sheet 1 is finished.

By the way, ingenuity to prevent or reduce wrinkling of the cut film 3 is exercised on the outer circumferential surface 21a of the anvil roller 21. FIG. 4A is an external perspective view of the anvil roller 21 to which ingenuity is excercised, and FIG. 4B is a schematic enlarged view of the portion where ingenuity is excercised to the outer circumferential surface 21a.

As is apparent from FIG. 4A, a number of band-shaped planar portions 21p in the CD direction are formed on the entirety of the outer circumferential surface 21a of the anvil roller 21 in the rotational direction Dc, except where the receiving blades 23 are positioned. The anvil roller 21 therefore has a shape of a regular polygonal column whose cross-sectional shape is of a regular polygon as a whole. More specifically, the

planar portions

21p, 21p, ... have the same rectangular shape, each having a long side in the CD direction and a short side in the rotational direction Dc. Also, as shown in FIG. 4B, the

planar portions

21p, 21p adjacent in the rotational direction Dc are coupled to each other via a linear corner portion 21c extending in the CD direction. Note that, the planar portion 21p corresponds to the face portion 21p.

With such an anvil roller 21 in a regular polygonal shape having a number of

corner portions

21c, 21c, ... on the outer circumferential surface 21a, when the continuous film 3a held on the outer circumferential surface 21a relatively slides behind along the outer circumferential surface 21a with respect to the rotational direction Dc of the roller 21, the continuous film 3a is slightly caught on the

corner portions

21c, 21c, ... on the outer circumferential surface 21a, resulting in the continuous film 3a being pulled to the downstream side in the rotational direction Dc, whereby wrinkles of the continuous film 3a can be smoothed out quickly. Since the cut film 3 is created by being cut from such a smoothed-out continuous film 3a, wrinkling of the cut film 3 is resultantly prevented or reduced.

Also, since the corner portions 21c are formed to be linear in the CD direction in this example, the tensile force for wrinkle smoothing can be imparted substantially uniformly in the CD direction. This also contributes to preventing or reducing wrinkling.

Moreover, with such an anvil roller 21 having a cross-sectional shape of a regular polygon, wrinkling that may occur when the cut film 3 is bonded to the continuous web 5a can also be effectively prevented. FIG. 5 is an explanatory view of this, which is a schematic enlarged view of a portion neighboring the press roller 43.

As shown in FIG. 5, when each corner portion 21c and its neighboring planar portion 21p on the outer circumferential surface 21a of the anvil roller 21 pass by the placement position P43 of the press roller 43 that is a position P5a that joins with the continuous web 5a, first, the corner portion 21c presses the cut film 3 against the continuous web 5a to perform bonding. Thereafter, using the portion 3c of the cut film 3 bonded by the corner portion 21c as the pivot point of rotation, a portion 3p of the cut film 3 held on the aforementioned planar portion 21p adjacent on the upstream side of the corner portion 21c is inclined towards the continuous web 5a substantially at one time, whereby the aforementioned portion 3p is overlaid on the continuous web 5a. Accordingly, each of the portions 3p of the cut sheet 3 that correspond to the aforementioned planar portions 21p can be overlaid on the continuous web 5a with stability that may be obtained when a sheet having fold lines for forming a polygon is overlaid on the continuous web 5a by sequentially inclining the sectioned portions one after another using the corresponding fold lines 3c as the start point. Thus, the portions 3p of the cut film 3 can be easily kept in an approximately flat state even when being overlaid on the continuous web 5a, and as a result, wrinkling during the bonding can be effectively prevented.

Also, since the face portion 21p adjacent to the corner portion 21c on the upstream side is planar as described above, a wide wedge-shaped space SP can be secured between the portion 3p of the cut film 3 held on the planar portion 21p and the continuous web 5a, compared with the case where this face portion 21p is a curved face, and this allows air from this space SP to be discharged easily. Thus, an event where air enters the space between the cut film 3 and the continuous web 5a to be sealed therein during bonding can be effectively prevented, and as a result, occurrence of swell-like wrinkles can also be prevented.

The number of corners (the number of corner portions) of the regular polygonal column of the anvil roller 21 may vary depending on the diameter of the anvil roller 21. For example, when the diameter (mean diameter) of the anvil roller 21 is 200 to 600 mm, the number of corners is 60 to 180.

While the anvil roller 21 was described to have a cross-sectional shape of a regular polygon as an example, the invention is not limited to this. The cross-sectional shape of the anvil roller 21 need not be a regular polygon as long as it is a convex polygon (where the interior angle of each corner portion 21c is less than 180^O). For example, the anvil roller 21 may be a convex polygonal column (a column whose cross-sectional shape is a convex polygon) that has a plurality of sizes of

planar portions

21p, 21p, ..., as the above planar portions 21p, whose short sides have different lengths, and such

planar portions

21p, 21p, ... having short sides with different lengths are arranged repeatedly in the rotational direction Dc in a predetermined order. Note however that, viewing the configuration of this example microscopically, the

planar portions

21p, 21p whose short sides have different lengths tend to move at different peripheral speeds to one another. It is therefore desirable to have a cross-sectional shape of a regular polygon as shown in FIG. 4A.

Further, while the planar portions 21p and the corner portions 21c were formed over the entire width of the anvil roller 21 in the CD direction in the above embodiments, the present invention is not limited to such. For example, the planar portions 21p and the corner portions 21c need not be formed in areas A2, A2 of the outer circumferential surface 21a of the anvil roller 21 that extend from area A3 for holding the continuous film 3 towards the ends in the CD direction, and the areas A2, A2 may be kept in a curved shape. In other words, with regard to the CD direction, the planar portions 21p and the corner portions 21c should at least be formed in area A3 that holds the continuous film 3.

Similarly, with regard to the rotational direction Dc, also, the planar portions 21p and the corner portions 21c may be selectively formed only in predetermined ranges R1 for reducing the cost and labor for the processing of the outer circumferential surface 21a. In other words, in order to form the anvil roller 21 in a regular polygonal column as described above, a number of planar portions 21p and corner portions 21c need to be processed over the entirety of the outer circumferential surface 21a. Therefore, to avoid this, the planar portions 21p and the corner portions 21c may be selectively formed only in the predetermined ranges R1 of the outer circumferential surface 21a in the rotational direction Dc.

FIGS. 6A and 6B are explanatory views of an example of the above configuration. FIG. 6A is an external perspective view of the anvil roller 21, and FIG. 6B is a partially enlarged view of the outer circumferential surface 21a. In this example, the outer circumferential surface 21a has, as ranges in the rotational direction Dc, holding ranges R1 that hold the cut film 3 and non-holding ranges R2 that do not hold the cut film 3. While the planar portions 21p and the corner portions 21c are formed over the entirety of the holding ranges R1, they are not formed in the non-holding ranges R2. That is, the portions of the outer circumferential surface 21a in the non-holding ranges R2 have smooth curved faces as segments of a circle.

Incidentally, as shown in FIG. 6A, for example, each aforementioned holding range R1 refers to the range R1 that starts from position P23e1 at the downstream side end edge of the corresponding receiving blade 23 in the rotational direction Dc, to position P3e1 distanced downstream from the starting end by a length of the cut film 3. Whereas each non-holding range R2 refers to range R2 that starts from the position P3e1 on the downstream side of the aforementioned cut film 3 to position P23e1 at the downstream end edge of the receiving blade 23 located on the downstream side from the starting end in the rotational direction Dc, for example. And here, the aforementioned range R2 is called the non-holding range R2 because, while the latter non-holding range R2 holds the continuous film 3a, range R2 does not hold the cut film 3 made by being cut off the continuous film 3a.

With the anvil roller 21 configured as described above, the range in which the planar portions 21p and the corner portions 21c are formed can be limited to be only in the holding ranges R1 on the outer circumferential surface 21a. Therefore the cost and labor for the processing of the outer circumferential surface 21a of the anvil roller 21 can be reduced.

Even with the corner portions 21c formed only in the holding range R1, wrinkle smoothing can be performed for substantially the entire length of the portion of the continuous film 3a corresponding to the cut film 3, as the target of wrinkle smoothing. That is, when the continuous film 3a relatively slides behind with respect to the outer circumferential surface 21a of the anvil roller 21, a corner portion 21ce (21c) located at the downstream end of the holding range R1 passes along substantially the entire length of the portion of the continuous film 3a corresponding to the cut film 3. Therefore, the portion corresponding to the cut film 3 is subjected to wrinkle smoothing over substantially the entire length thereof. Note however that, compared with the example of forming the corner portions 21c over the entirety of the outer circumferential surface 21a as in the above-described embodiment (FIG. 4A), wrinkle smoothing action is reduced since the number of corner portions 21c over which the film passes during relative sliding is reduced.

By contrast, for the action of preventing wrinkling at the time of bonding the cut film 3 to the continuous web 5a, a comparable action to that in the above-described embodiment (FIG. 4A) can be performed. That is, since the planar portions 21p and the corner portions 21c are formed over the entire surface in the holding range R1 in the example of FIG. 6A as in the above embodiment, the motion of inclining the portion 3p held on the planar portion 21p using the portion 3c bonded by the corner portion 21c in FIG. 5 as the pivot point of rotation to overlay the portion 3p on the continuous web 5a can be achieved over the entire length of the cut film 3. Also, with regard to the air discharge action from the wedge-shape space SP between the portion 3p held on the planar portion 21p and the continuous web 5a, air is quickly discharged from over the entire length of the cut film 3. Thus, the action of preventing wrinkling at the time of bonding can be performed over the entire length of the cut film 3. Accordingly, this example is not at all inferior to the above-described embodiment (FIG. 4A).

Incidentally, the planar portions 21p and the corner portions 21c may be formed in the following manner. That is, the planar portions 21p and the corner portions 21c may be formed so that a circle formed by virtually extending the arc shape in a range where the planar portions 21p and the corner portions 21c are not formed (e.g., the non-holding range R2 in FIG. 6A) becomes a circumcircle of the planar portions 21p and the corner portions 21c, or so that it becomes an incircle thereof. Further, it may neither be the circumcircle nor the incircle. In this case, the corner portions 21c may be designed to be a corner protruding outward in the radial direction of the anvil roller 21 with its angle selected from the range of 174^O to 178^O inclusive. This angle range may also be applied to the corner portions 21c formed based on the incircle or circumcircle described above.

While no planar portions 21p nor corner portions 21c were formed over the entirety of the non-holding range R2 in the example of FIG. 6A, arrangements may be made to form the planar portions 21p and the corner portions 21c in a part of the non-holding range R2 while forming no planar portions 21p nor corner portions 21c in the remaining range thereof.

Further, in the example of FIG. 6A, a plurality of

suction holes

21h, 21h, ... (corresponding to holes) are formed side by side in the CD direction for each planar portion 21p. Therefore, each planar portion 21p can firmly hold a corresponding portion 3p (FIG. 5) of the cut film 3, and this also effectively contributes to prevention or reduction of wrinkling.

It is desirable that the distribution density of the suction holes 21h formed to the planar portions 21p (the number of suction holes 21h per unit area) are higher than the distribution density in any portion other than the planar portions 21p on the circumferential surface 21a where the suction holes 21h are formed. In the example of FIG. 6A, the former density is about four times as high as the latter density. With this arrangement, during wrinkle smoothing by the corner portion 21c, the continuous film 3a can be suctioned and held firmly by the

planar portions

21p, 21p located adjacent to the corner portion 21c in the rotational direction Dc. Thus, the wrinkle smoothing effect by the corner portion 21c can be effectively enhanced.

Furthermore, when the suction holes 21h pass by the placement position P43 (FIG. 3) of the press roller 43 in the rotational direction Dc, the suction via the suction holes 21h may be stopped, and moreover, air may be ejected outside via the suction holes 21h at this time. By this arrangement, the transfer of the cut film 3 from the anvil roller 21 onto the continuous web 5a at the placement position P43 of the press roller 43 can be performed smoothly. In this case, note that the suction through the suction holes 21h is restarted before the suction holes 21h arrive at the winding start position Pwst in the rotational direction Dc.

By the way, the range in the rotational direction Dc where the planar portions 21p and the corner portions 21c are formed on the outer circumferential surface 21a may be further reduced. FIGS. 7A and 7B are explanatory views for this: FIG. 7A is an external perspective view of the anvil roller 21, and FIG. 7B is a partial enlarged view of the outer circumferential surface 21a.

In the above example, the ranges R5 where the planar portions 21p and the corner portions 21c are formed in the rotational direction Dc are limited only to ranges R5 for holding a downstream end portion 3ed of the cut film 3, and the portions of the outer circumferential surface 21a corresponding to the remaining ranges R6 other than these ranges R5 are curved faces as segments of a roughly circle.

Even with the corner portions 21c formed only in each range R5, wrinkle smoothing can be performed for substantially the entire length of the portion of the continuous film 3a corresponding to the cut film 3. That is, when the continuous film 3a relatively slides behind with respect to the outer circumferential surface 21a of the anvil roller 21, the

corner portions

21c, 21c, ... of the range R5 pass by an area of the continuous film 3a from the portion corresponding to an upstream side end portion 3eu of the cut film 3 to the portion corresponding to the downstream side end portion 3ed thereof without fail. Therefore, the portion corresponding to the cut film 3 is subjected to wrinkle smoothing over approximately the entire length thereof. Note however that, since the corner portions 21c are formed only in the range R5, the total number of corner portions 21c further decreases from that in the above-described example of FIG. 6A, which is one corner portion 21c in the range R5 in the example of FIG. 7A. Therefore, the wrinkle smoothing action to be performed during relative sliding is further reduced.

Also, in the above example, the action of preventing wrinkling at the time of bonding the cut film 3 to the continuous web 5a is also reduced. That is, since the planar portions 21p and the corner portions 21c are formed only in the range R5 corresponding to the downstream side end portion 3ed of the cut film 3, the above wrinkle-preventing action can be performed only when the downstream side end portion 3ed of the cut film 3 is bonded to the continuous web 5a and cannot be performed during bonding of a portion 3u on the upstream side of the downstream side end portion 3ed.

Note however that, in the above example, the portion 21ap having the planar portions 21p and the corner portions 21c is a protrusion portion 21ap protruding outward in the radial direction compared to its surrounding portions of the outer circumferential surface 21a. Therefore, a large pressing force can be exerted at the time of bonding of the downstream side end portion 3ed, permitting the cut film 3 to be firmly bonded to the continuous web 5a at the downstream end portion 3ed. The portion 3u of the cut film 3 on the upstream side of the downstream side end portion 3ed is gradually overlaid on and bonded to the continuous web 5a as it is transported while being pulled in the MD direction by the downstream side end portion 3ed. At this time, wrinkles are smoothed by the pulling from the downstream side end portion 3ed. In this way, wrinkling of the cut film 3 is prevented or reduced.

Note that, in the example of FIG. 7B, only one corner portion 21c is provided in the protrusion portion 21ap. That is, in the protrusion portion 21ap, there is provided only a pair of

planar portions

21p, 21p adjacent to each other in the rotational direction Dc and one corner portion 21c between these

planar portions

21p, 21p. However, the present invention is not limited to such, and a plurality of corner portions 21c may be provided.

Incidentally, in the case of having the corner portions 21c on the outer circumferential surface 21a of the anvil roller 21 as described above, it is recommended that the diameter of the press roller 43 and the mean diameter of the anvil roller 21 have a non-integer multiple relationship therebetween. As used herein, the mean diameter of the anvil roller 21 refers to a value obtained by dividing the circumferential length of the outer circumferential surface 21a of the anvil roller 21 by the circular constant thereof.

Having the above relationship, a situation where the corner portions 21c of the anvil roller 21 abut against specific fixed positions in the outer circumferential surface 43a of the press roller 43 can be effectively prevented. In other words, the positions on the outer circumferential surface 43a of the press roller 43 against which the corner portions 21c of the anvil roller 21 abut can be shifted in the rotational direction with each rotation, dispersing the positions against which the corner portions 21c hit. By this arrangement, uneven wear (local wear) of the outer circumferential surface 43a of the press roller 43 can be effectively prevented, and as a result, the clearance between the anvil roller 21 and the press roller 43, which should be managed/adjusted precisely from the standpoint of prevention of wrinkling and accuracy of bonding, can be easily managed to fall within a target range for the long run.

===Other embodiments===
While the present invention has been described in conjunction with the embodiments, it should be understood that the above embodiments have been presented for facilitating the understanding of the invention and not for construing the invention in a limited way. It should also be understood that the invention can be changed and modified without departing from the spirit of the invention, and naturally includes equivalents thereof. For example, variations as described below can be made.

Although the planar portions 21p were taken as an example of face portions 21p formed on the outer circumferential surface 21a of the anvil roller 21 in the above embodiments, the face portions are not limited to the planar portions 21p as long as the

face portions

21p, 21p formed adjacent in the rotational direction Dc are linked to each other via a linear corner portion 21c extending in the CD direction. For example, they may be curved face portions such as arched face portions.

Although a nonwoven fabric 5a was taken as an example of the second continuous sheet in the above embodiments, and the continuous film 3a was shown as an example of the first continuous sheet, the invention is not limited to such. For example, the first continuous sheet may be a continuous film or a woven fabric, and the second continuous sheet may be a nonwoven fabric or a woven fabric.

Although a disposable diaper was taken as an example of the absorbent article in the above embodiments, the present invention is not limited to such as long as the absorbent article is an article that absorbs liquid excretion of the wearer. For example, the absorbent article may be a sanitary napkin.

This application claims the benefit of Japanese Application No. 2012-152792 the entire disclosure of which is incorporated by reference herein.

1 back-side sheet, 1a intermediate product (composite body of continuous sheet),
3 cut film (cut sheet)
3a continuous film (first continuous sheet),
3c portion, 3e portion at the leading edge, 3ed downstream side end portion, 3eu upstream side end portion,
3u portion upstream,
3p portion,
5 outer sheet, 5a continuous web (second continuous sheet),
10 manufacturing apparatus,
11 continuous film transport mechanism (first transport mechanism), 12 endless belt,
20 anvil roller mechanism (holding roller mechanism),
21 anvil roller (holding roller), 21a outer circumferential surface, 21ap protrusion portion,
21c corner portion, 21ce corner portion at the downstream end in the holding range,
21p planar portion (face portion),
21h suction hole (hole),
23 receiving blade (blade member)
31 cutter roller, 33 cutter blade,
40 bonding mechanism, 41 transport roller (transport mechanism)
43 press roller, 43a outer circumferential surface,
70 adhesive application apparatus,
A2 area, A3 area,
R1 holding range, R2 non-holding range, R5 range, R6 remaining range,
P3e1 position downstream, P23e1 position at the downstream end edge of the receiving blade,
P31 placement position, P43 placement position, Pwst winding start position,
C21 rotary axis, C41 rotary axis, C43 rotary axis,
CL clearance, SP space

Claims

A manufacturing method for a composite body of a continuous sheet for an absorbent article, the method cutting and creating a cut sheet from a first continuous sheet, and overlaying and bonding the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the method comprising:
transporting at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction with a first transport mechanism;
rotating a holding roller at a peripheral speed value higher than the first transport speed value and holding the first continuous sheet transported from the first transport mechanism, on an outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
cutting and creating the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with a blade member provided on the outer circumferential surface of the holding roller; and
feeding the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and overlaying and bonding the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein
the outer circumferential surface of the holding roller has, as a range in the rotational direction, a holding range configured to hold the cut sheet, and
the corner portion is formed in at least the holding range.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein
the outer circumferential surface of the holding roller has, as ranges in the rotational direction, a holding range configured to hold the cut sheet and a non-holding range not configured to hold the cut sheet,
the holding range has the corner portion formed, and
the non-holding range includes a range where the corner portion is not formed.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 2 or 3, wherein
a plurality of the corner portions are formed over an entirety of the holding range.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein
the outer circumferential surface of the holding roller has a plurality of the corner portions formed thereon over an entire circumference along the rotational direction.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein
the outer circumferential surface of the holding roller has, as a range in the rotational direction, a range configured to hold a downstream side end portion of the cut sheet, and
the corner portion is formed in at least the range where the downstream end portion is configured to be held.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to any of claims 1 to 6, wherein
the face portions formed adjacent to the corner portion on the outer circumferential surface of the holding roller are planar portions.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to any of claims 1 to 7, wherein
the outer circumferential surface of the holding roller has a plurality of holes provided,
a plurality of the holes are provided side by side in the intersecting direction in each of a plurality of the face portions formed adjacent to the corner portion on the outer circumferential surface of the holding roller, and
the holes are configured to hold the first continuous sheet and the cut sheet on the outer circumferential surface of the holding roller by suction through the holes.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 8, wherein
a distribution density of the plurality of the holes is higher in the face portions than in a portion other than the face portions on the outer circumferential surface of the holding roller.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to any of claims 1 to 9, wherein the bonding is performed by a bonding mechanism,
the bonding mechanism including
a transport mechanism configured to transport the second continuous sheet at a speed value approximately the same as the peripheral speed value of the holding roller and
a press roller configured to press the second continuous sheet against the cut sheet held on the outer circumferential surface of the holding roller to perform bonding, and
a diameter of the press roller and a mean diameter of the holding roller are in a non-integer multiple relationship.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to any of claims 1 to 10, wherein the corner portion extends linearly in an intersecting direction intersecting the transport direction.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein a cross-sectional shape of the holding roller is a convex polygon.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein a cross-sectional shape of the holding roller is a regular polygon.
A manufacturing method for a composite body of a continuous sheet for an absorbent article according to claim 1, wherein the face portions and the corner portion are formed on a protrusion portion protruding outward in a radial direction of the holding roller compared to surrounding portions of the outer circumferential surface of the holding roller.
A manufacturing apparatus for a composite body of a continuous sheet for an absorbent article, the apparatus configured to cut and create a cut sheet from a first continuous sheet, and to overlay and bond the cut sheet onto a second continuous sheet with a spacing between cut sheets adjacent to each other on the second continuous sheet in a continuous direction of the second continuous sheet, the apparatus comprising:
a first transport mechanism configured to transport at a first transport speed value the first continuous sheet in a continuous direction of the first continuous sheet as a transport direction;
a holding roller mechanism that includes a holding roller provided with at least one blade member on an outer circumference the holding roller, the holding roller mechanism being configured to rotate the holding roller at a peripheral speed value higher than the first transport speed value and to hold the first continuous sheet transported from the first transport mechanism, on the outer circumferential surface of the holding roller while allowing the first continuous sheet to relatively slide behind with respect to the outer circumferential surface of the holding roller;
a cutter roller configured to cut and create the cut sheet from the first continuous sheet by sandwiching the first continuous sheet in cooperation with the blade member provided on the outer circumferential surface of the holding roller; and
a bonding mechanism configured to feed the second continuous sheet towards the cut sheet held on the outer circumferential surface of the holding roller with no relative sliding involved so to be transported in a rotational direction of the holding roller at the peripheral speed value, and to overlay and bond the cut sheet onto the second continuous sheet,
wherein individual face portions are formed adjacent to each other in the rotational direction on the outer circumferential surface of the holding roller, and adjacent face portions are linked via a corner portion extending in an intersecting direction intersecting the transport direction.