WO2014021188A1 - 使い捨て着用物品およびその製造方法 - Google Patents

使い捨て着用物品およびその製造方法 Download PDF

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Publication number
WO2014021188A1
WO2014021188A1 PCT/JP2013/070178 JP2013070178W WO2014021188A1 WO 2014021188 A1 WO2014021188 A1 WO 2014021188A1 JP 2013070178 W JP2013070178 W JP 2013070178W WO 2014021188 A1 WO2014021188 A1 WO 2014021188A1
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WO
WIPO (PCT)
Prior art keywords
web
easily breakable
granular
granular material
breakable portion
Prior art date
Application number
PCT/JP2013/070178
Other languages
English (en)
French (fr)
Inventor
梅林　豊志
Original Assignee
株式会社瑞光
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社瑞光 filed Critical 株式会社瑞光
Priority to JP2014528103A priority Critical patent/JP6271426B2/ja
Priority to US14/416,770 priority patent/US9532909B2/en
Priority to CN201380039416.8A priority patent/CN104507432B/zh
Publication of WO2014021188A1 publication Critical patent/WO2014021188A1/ja

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
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    • A61F13/5323—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad having absorbent material located in discrete regions, e.g. pockets
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/436—Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/849—Packaging machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4871—Underwear
    • B29L2031/4878—Diapers, napkins
    • 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
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/047—Perforating
    • 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
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/028—Treatment by energy or chemical effects using vibration, e.g. sonic or ultrasonic
    • 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
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins
    • 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
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • 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
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing

Definitions

  • the present invention relates to a disposable wearing article having a large number of granular bodies (hereinafter simply referred to as “granular bodies”) that swell by absorbing body fluid and a method for producing the same.
  • Patent Document 1 an absorptive core in which a large amount of granular materials are confined in many small spaces.
  • the granular material is arranged in a predetermined pattern between two base material sheets, and both base material sheets are joined to each other in a region where the granular material is not arranged.
  • the joint portion of both base sheet is bonded with a low strength so as to be separated by the separation force generated by the large number of granular materials expanding in the region. By doing so, it is possible to increase the volume of the granular material that can be accommodated between the two base material sheets.
  • an object of the present invention is to provide a disposable wearing article that can accommodate a large amount of granular materials with a simple structure and a method for producing the disposable wearing article.
  • the present invention is a disposable wearing article, A plurality of granular bodies that swell by absorbing body fluid for each of a plurality of arrangement areas partitioned from each other in a predetermined pattern are arranged between two liquid-permeable nonwoven fabrics bonded to each other at a bonding portion according to the pattern.
  • An absorbent body made, Comprising a liquid-impermeable back sheet disposed on the non-skin surface of the absorbent main body, A liquid-permeable sheet that covers the entire surface of the nonwoven fabric on the skin surface side of the two nonwoven fabrics is disposed, In at least one arrangement area of the plurality of arrangement areas in at least one of the two nonwoven fabrics, there is an easily breakable portion that breaks with a force generated when the granular material absorbs body fluid and swells. Is formed.
  • the space between the two nonwoven fabrics swells greatly, and further, when the granular body absorbs the body fluid and swells, it is formed in the arrangement area by the force generated when it swells.
  • the easily breakable portion breaks. After this breakage, a part of the granular material is pushed out from the arrangement area of the two absorbent main bodies through the breakable easily broken portion.
  • the non-skin surface side of the absorbent main body is covered with a back sheet, and the skin surface side of the absorbent main body is covered with a liquid-permeable sheet different from the nonwoven fabric of the absorbent main body.
  • the “easy-breaking portion” means that the granular material disposed between the two nonwoven fabrics does not swell, and the granular material does not substantially overflow, and the same granular material.
  • the liquid absorbs and swells it means a portion where the granular material overflows by breaking with the pressure generated in the arrangement area.
  • the “skin surface” is an inner surface that directly or indirectly contacts the wearer's skin when the worn article is worn, and the “non-skin surface” is a surface opposite to the skin surface. means.
  • FIG. 1A is a plan view of a wearing article according to an embodiment of the present invention
  • FIG. 1B is a cross-sectional view of the wearing article taken along line 1B-1B
  • FIG. 2 is an exploded perspective view of the absorbent main body of the wearing article
  • 3A is a plan view of the absorbent main body
  • FIG. 3B is a cross-sectional view thereof.
  • FIG. 4 is a schematic side view of the manufacturing apparatus for the absorbent main body.
  • FIG. 5A, FIG. 5B, and FIG. 5C are each a top view which shows the manufacturing method of this wearing article.
  • the bonding portion is an ultrasonic bonding portion formed by applying ultrasonic energy to the two non-woven fabrics, and the bonding portion is generated by a force generated when the granular body absorbs body fluid and swells.
  • the non-woven fabric has a bonding strength that does not separate from each other.
  • the easily breakable portion is formed linearly and intermittently in the nonwoven fabric. That is, the easily breakable portion is perforated.
  • Such a perforated easily breakable part becomes a large opening when the non-woven fabric having the easily breakable part is broken by the pressure of the swollen granular material in the absorbent main body. Therefore, a granular material tends to come out from an absorptive main body through an easy fracture part.
  • the ultrasonic welded non-woven fabrics are not separated from each other, and the initial shape of the arrangement pattern of the granular materials will not easily lose its shape.
  • the perforated easily breakable portion includes a plurality of holes, slits and / or notches (fissures) formed intermittently in the nonwoven fabric.
  • a plurality of perforated holes, slits, or cuts may be connected to each other to easily form a large opening.
  • the perforated “cuts” that form easily breakable portions are not substantially open when no load is applied to the nonwoven fabric. It will be hard to get out of the absorbent body through. “Incision” refers to a line that is produced without producing trimming pieces in a nonwoven fabric and that interrupts the fiber continuity.
  • the easily breakable portion may be a small hole, an elongated rectangular slit, or a diamond-shaped slit in addition to “cut”. Further, the easily breakable portion may be one in which strength is deteriorated (decreased) by hardening the nonwoven fabric with heat and making it brittle. Furthermore, the easily breakable part may be formed by being comprised with the material which is easily torn when the nonwoven fabric itself is pulled in the width direction.
  • the easily breakable portions may be provided equally in each arrangement area, or may be provided unevenly according to the amount of the granular material in each arrangement area and the site of the absorbent main body. Furthermore, it is not necessary to provide an easily breakable portion in a part of the arrangement area where the liquid absorption amount is small.
  • the carrier web is conveyed along a predetermined conveyance path while the first surface of the carrier web forming one of the two nonwoven fabrics is held by the conveyance surface of the conveyance device.
  • the easily breakable portion is easily formed by forming the easily breakable portion in the nonwoven fabric before becoming the sandwich structure.
  • the linear easily breakable portion is formed intermittently or continuously.
  • the wearing article 100 of the present embodiment includes an absorbent main body (diaper main body) 200, a front waistline portion 301, and a rear waistline portion 302.
  • the absorbent main body 200 includes a front portion 201 that covers the wearer's front torso, a back portion 202 that covers the wearer's rear torso, and a crotch portion 203 that covers the crotch between the front portion 201 and the back portion 202.
  • the absorbent main body 200 includes a front portion 201 that covers the wearer's front torso, a back portion 202 that covers the wearer's rear torso, and a crotch portion 203 that covers the crotch between the front portion 201 and the back portion 202.
  • the crotch portion 203 is connected to the front portion 201 and the back portion 202 and extends in the longitudinal direction Y orthogonal to the waistline direction X.
  • the front waistline part 301 and the back waistline part 302 may be joined together at the time of wearing, or may be joined beforehand before wearing.
  • the absorbent main body 200 may be provided with a three-dimensional gather (not shown). Moreover, you may form in the absorptive main body 200 the leg periphery part constricted along the wearer's leg part.
  • an elastic member for fitting the worn article 100 to the wearer may be provided on a portion around the leg of the absorbent main body 200.
  • this elastic member for example, a material including a plurality of thread rubbers, flat rubbers, films, or thermoplastic resins can be employed.
  • these materials may be provided in the front part 201 and the back part 202, the front waistline part 301, and the back waistline part 302 as an elastic member for fitting the wearing article 100 to a wearer.
  • the absorbent main body 200 includes a first web 21 that contacts the skin surface of the wearer, a second web 22 that does not contact the skin surface, and an absorbent core 23.
  • the core 23 is sandwiched between the first web 21 and the second web 22.
  • the first web 21 and the second web 22 shown in FIG. 3B are welded to each other along, for example, grid-like welding lines L and L extending vertically and horizontally, and sandwiching the core 23 therebetween.
  • the core 23 is surrounded by the first web 21 and the second web 22 that are welded to each other along the welding lines L and L.
  • Each welding line L is formed by a joint portion W in which the first web 21 and the second web 22 are welded continuously or intermittently.
  • the bonding part W may be an ultrasonic bonding part formed by applying ultrasonic energy to the two nonwoven fabrics 21 and 22.
  • the joint W may have a joint strength that prevents the nonwoven fabrics 21 and 22 from separating from each other in the joint W due to a force generated when the granular body 3 swells by absorbing body fluid.
  • the welding part W welded in each figure is shown by xx.
  • the first web 21 and the second web 22 in FIG. 3B include a thermoplastic resin that can be welded to each other, and both are formed of a nonwoven fabric that is liquid permeable and breathable.
  • a liquid-impermeable back sheet 24 is attached to the non-skin surface of the second web 22, and the absorbent main body 200 is covered with the back sheet 24.
  • a liquid-permeable top sheet 6 covering the entire surface of the first web 21 is disposed on the skin surface of the first web 21.
  • nonwoven fabric examples include nonwoven fabrics made of thermoplastic resin such as polypropylene, polyethylene, and polyester, and are nonwoven fabrics obtained by blending fibers that do not exhibit thermoplasticity such as cotton and rayon into the thermoplastic resin fibers. Also good.
  • the core 23 is composed of a large number of absorbent particles 3.
  • the granular material 3 is made of a well-known absorbent polymer, and generally has an average particle size of about 10 ⁇ m to 1,000 ⁇ m before water is absorbed, and swells after water absorption and has a volume several to several hundred times larger. It becomes. In each figure, the granular material 3 is shown by a large number of fine dots. Further, in FIG. 1A and FIGS. 5A to 5C, the granular material 3 is not shown in order to make the easily breakable portion 10 easy to understand.
  • the core 23 of FIG. 3A is formed by arranging each set group 30 in which a large number of the granular bodies 3 are arranged in a large number of arrangement areas D.
  • the collective groups 30 and 30 are divided and arranged in the arrangement areas D and D defined by the grid-like welding lines L and L extending in the vertical and horizontal directions. That is, the placement areas D and D in which the collective groups 30 and 30 are placed are partitioned by the welding lines L and L.
  • each aggregate group 30 is composed of a large number of granular bodies 3, and as shown in FIG. 3A, one group of the aggregate group 30 and another group connect the welding lines L, L. They are lined up in the vertical and horizontal directions. As shown in FIG. 3A, a large number (three or more) of each set group is arranged in the vertical and horizontal directions. Further, the welding lines L do not have to be completely continuous, and the welding sites may be formed intermittently to such an extent that the granular material 3 of each group 30 is difficult to move to another group 30.
  • the welding lines L and L are formed to such an extent that the granular material 3 in each set group 30 arranged in a predetermined pattern can be prevented from moving from one group of the plurality of groups to another group. It may be.
  • the group group 30 may be arranged in a predetermined pattern, and need not be regularly arranged in the vertical and horizontal directions. Further, the number (amount) of the granular bodies 3 included in each collective group 30 does not have to be equal to each other, and may be a number (amount) corresponding to the amount of body fluid excreted for each collective group 30. Good.
  • the collective group 30 may be rectangular or round, and the length or diameter of one side thereof may be about several mm to 10 mm. Further, the pitch of arrangement of the collective groups 30 and 30 may be about 10 mm to about several tens of mm.
  • each arrangement area D of the first web 21 is formed with a perforated easily breakable portion 10 including, for example, intermittently formed “notches”.
  • the easily breakable portion 10 only needs to be provided on at least one of the two nonwoven fabrics 21 and 22, and breaks by the force generated when the granular material 3 absorbs body fluid and swells. That is, in the case of the present embodiment, when the easily breakable portion 10 of the first web 21 is broken, the intermittently formed “cuts” are connected to each other to form a long “cut”, and as a result, the granular material that has absorbed the body fluid. 3 or body fluid is allowed to overflow from between the two webs 21 and 22 to the upper surface of the first web 21.
  • the top sheet 6 covering the entire surface of the first web 21 is provided on the skin surface side of the first web 21, and the swollen granular material 3 overflowing from the notch is worn by the wearer 100. Does not stick to the skin.
  • a diffusion layer for diffusing body fluid in the plane direction of the core 23 (along the surface) or a liquid holding layer for temporarily holding body fluid may be provided between the top sheet 6 and the first web 21. Good.
  • the carrier web 1 serving as the second web 22 (FIG. 2) is introduced into the transport drum 4 by the first introduction roller 71, and the first surface 11 of the carrier web 1 is transported to the transport surface 41 of the transport drum 4.
  • the carrier web 1 is transported along a predetermined transport path, that is, along the transport surface 41 of the transport drum 4 while being sucked and held in step (1).
  • the granular material 3 may be intermittently supplied for each absorbent main body 200 (FIG. 1).
  • the center in the axial direction of the conveyance drum 4 may be thicker than both ends.
  • the thickness of the layer of the granular material 3 may be thin at the periphery of one absorbent main body 200 (FIG. 1), and may be thick at the center or in the vicinity thereof.
  • the easily breakable portion 10 (FIG. 2) is formed in advance on the cover web 2 to be the first web 21 (FIG. 2) before being introduced into the transport drum 4. That is, a perforated cut is formed in the cover web 2 between the cutter roll 90 and the anvil roll 91 disposed upstream of the second introduction roller 72.
  • the sandwich structure 20 continues to be transported by the transport surface 41 and reaches the ultrasonic horn 81 of FIG. 4.
  • the carrier web 1, the cover web 2, Is ultrasonically welded.
  • each aggregate group 30 of the granular material 3 is partitioned from each other by the ultrasonically welded carrier web 1 and the cover web 2, and a predetermined pattern of the granular material 3 is held.
  • the granular material 3 (aggregate group 30) of each arrangement area D arranged in the predetermined pattern moves from one arrangement area D to another arrangement area D of the plurality of arrangement areas D.
  • the carrier web 1 and the cover web 2 are joined at a portion to be the joint W.
  • the sandwich structure 20 is cut into individual worn article units, that is, individual absorbent body 200 units shown in FIG. 3A.
  • each absorbent main body 200 is sandwiched between the liquid-permeable top sheet 6 and the liquid-impermeable back sheet 24.
  • the top sheet 6 and the back sheet 24 may be bonded or welded to each other at the peripheral joint W1 (FIG. 1B). Further, the back sheet 24 and the absorbent main body 200 may be bonded together.
  • the present invention can be used for disposable wearing articles in which granules are arranged in a predetermined pattern.

Abstract

所定のパターンで互いに区画された複数の配置エリアごとに複数の粒状体が、パターンに従って互いに接合部において接合された２枚の透液性の不織布の間に配置された吸収性本体と、吸収性本体の非肌面に配置された不透液性のバックシートとを備え、肌面側の不織布の全面を覆う透液性のシートが配置され、少なくとも一方の不織布の配置エリアには、粒状体が体液を吸収して膨潤した際に破断する易破断部が形成されている。

Description

使い捨て着用物品およびその製造方法
　本発明は体液を吸液して膨潤する多数の粒状体（以下、単に「粒状体」という。）を有する使い捨て着用物品およびその製造方法に関するものである。
　近年、多量の粒状体を小さな多数の空間に閉じ込めた吸収性のコアが提案されている（特許文献１）。この種の吸収性物品においては２枚の基材シート間に粒状体を所定のパターンで配置し、粒状体が配置されない領域において、両基材シートを互いに接合している。
両基材シートの接合部は、粒状体が吸水して膨潤したときに、領域内において多数の粒状体が膨らむことにより生じる分離力により分離する程度の低強度で接合される。こうすることで、２枚の基材シート間に収容できる粒状体の量（volume）の増大を図ることができる。
ＪＰ０９－５０４２１０　Ａ
　しかし、前記低強度で接合した部分の接合強度を適正に維持することは困難を伴う。
また、膨潤により接合部分が分離するため、粒状体の配置パターンの初期の形状が型崩れして、２枚の基材シートの間で粒状体が片寄るだろう。
　したがって、本発明の目的は簡便な構造で多量の粒状体を収容できる使い捨て着用物品およびその製造方法を提供することである。
本発明は使い捨て着用物品であって、
　所定のパターンで互いに区画された複数の配置エリアごとに体液を吸液して膨潤する複数の粒状体が、前記パターンに従って互いに接合部において接合された２枚の透液性の不織布の間に配置された吸収性本体と、
　前記吸収性本体の非肌面に配置された不透液性のバックシートとを備え、ここにおいて、
　前記２枚の不織布のうちの肌面側の不織布の全面を覆う透液性のシートが配置され、
　前記２枚の不織布のうちの少なくとも一方の不織布における前記複数の配置エリアの少なくとも１以上の配置エリアには、前記粒状体が体液を吸収して膨潤した際に生じる力で破断する易破断部が形成されている。
本発明において、粒状体が体液を吸収して膨潤すると、２枚の不織布の間が大きく膨らみ、更に粒状体が体液を吸収して膨潤すると、膨潤した際に生じる力により、配置エリアに形成された易破断部が破断する。
この破断後、一部の粒状体は破断した易破断部を通って２枚の吸収性本体の配置エリアから押し出される。しかし、吸収性本体の非肌面側はバックシートで覆われているうえ、吸収性本体の肌面側は前記吸収性本体の不織布とは別の透液性シートで覆われている。したがって、体液を吸収した粒状体や体液が着用物品から漏れ出るおそれはない。
本発明において、「易破断部」とは、２枚の不織布の間に配置された粒状体が膨潤していない状態では粒状体が実質的に溢れ出る開口とはならず、かつ、同粒状体が吸液して膨潤するとその際に配置エリア内に生じる圧力で破断して粒状体が溢れ出る部分を意味する。
　したがって、少なくとも一方の不織布に易破断部を形成するという簡便な構造で、多量の粒状体を前記各配置エリアに収容できる。
　なお、本発明において「肌面」とは着用物品の着用時に着用者の肌に直接的または間接的に接する内側の面であり、「非肌面」とは前記肌面の反対側の面を意味する。
図１Ａは本発明の一実施例にかかる着用物品の平面図、図１Ｂは同着用物品の１Ｂ－１Ｂ線断面図である。 図２は同着用物品の吸収性本体の分解斜視図である。 図３Ａは同吸収性本体の平面図、図３Ｂは同断面図である。 図４は同吸収性本体の製造装置の概略側面図である。 図５Ａ、図５Ｂおよび図５Ｃは、それぞれ、本着用物品の製造方法を示す平面図である。
好ましくは、前記接合部は前記２枚の不織布に超音波エネルギーを付与することで形成された超音波接合部であり、前記粒状体が体液を吸収して膨潤した際に生じる力で前記接合部において前記不織布同士が互いに分離しない接合強度を有する。
超音波接合により、不織布同士が互いに分離しないように接合部において接合されている場合、前記粒状体が体液を吸収して膨潤すると、接合部は破断せず、易破断部が破断するであろう。
更に好ましくは、易破断部が不織布に線状に、かつ、断続的に形成されている。すなわち、前記易破断部はミシン目状である。
かかるミシン目状の易破断部は、吸収性本体内の膨潤した粒状体の圧力で易破断部を有する不織布が破断した際に、易破断部が連なって大きな開口となる。そのため、易破断部を通って粒状体が吸収性本体から出易い。その一方で、超音波溶着された前記不織布同士は分離せず、粒状体の配置パターンの初期の形状が型崩れし難いだろう。
更に好ましくは、前記ミシン目状の易破断部としては、前記不織布に断続的に形成された複数の孔、スリットおよび／または切り込み（ｆｉｓｓｕｅ：割れ目）を含む。
この場合、粒状体が吸液して膨潤すると、ミシン目状の複数の孔、スリットまたは切り込み同士が互いに連なって大きな開口ができ易いだろう。
本発明において、易破断部を形成するミシン目状の「切り込み」は不織布に負荷が作用していない場合は、実質的に開いておらず、そのため、製造中や使用前に粒状体が「切り込み」を通って吸収性本体の外に出にくいだろう。
「切り込み」とは、不織布にトリミング片が生じることなく生成された、繊維の連続を遮断するラインをいう。
前記易破断部としては、「切り込み」の他、小孔や、細長い長方形状のスリットや、菱形状のスリットであってもよい。
又、前記易破断部は不織布を熱によって硬化させて脆弱化させることで、強度を劣化（低下）させたものであってもよい。
更に、不織布自体が幅方向に引っ張られた際に裂け易い材料で構成されていることで、易破断部が形成されていてもよい。
また、易破断部は各配置エリアに均等に設けられてもよいし、各配置エリアの粒状体の量や吸収性本体の部位に応じて不均等に設けられてもよい。更に、吸液量が少ない一部の配置エリアには易破断部を設けなくてもよい。
前記着用物品の製造方法としては、前記２枚の不織布のうちの１枚を形成するキャリアウエブの第１面を搬送装置の搬送面で保持しながら前記キャリアウエブを所定の搬送経路に沿って搬送する工程と、
　前記搬送中のキャリアウエブの前記第１面とは反対の第２面上に前記粒状体を供給する工程と、
　前記キャリアウエブの前記第２面上の前記各配置エリアごとに前記供給された複数の粒状体の一部を保持して前記所定のパターンで配置する工程と、
　前記２枚の不織布のうちの他の１枚を形成するカバーウエブに前記易破断部が形成される工程と、
　前記粒状体を前記所定のパターンで配置する工程の後に、前記キャリアウエブの前記第２面および前記粒状体を前記易破断部を有するカバーウエブで覆ってサンドイッチ構造体を生成する工程と、
　前記所定のパターンで配置された前記各配置エリアの前記粒状体が前記複数の配置エリアのうちの１つの配置エリアから別の配置エリアへ移動するのを抑制ないし防止するために、前記接合部となる部位において前記キャリアウエブと前記カバーウエブとを接合する工程とを備える。
このように、サンドイッチ構造体となる前の不織布に易破断部が形成されることで、易破断部の形成が容易になる。
　好ましくは、前記接合された前記キャリアウエブと前記カバーウエブの流れ方向に沿うように、前記易破断部が形成される工程において、線状の前記易破断部が断続的または連続的に形成される。
　この場合、キャリアウエブおよびカバーウエブの流れ方向には搬送のための所定の張力が生じるが、前記流れ方向に沿って延びる易破断部は前記張力により拡開しないだろう。したがって、サンドイッチ構造体の搬送中に粒状体が前記易破断部から漏れ出るおそれがない。
本発明は、添付の図面を参考にした好適な実施例の説明からより明瞭に理解されるであろう。しかしながら、実施例および図面は単なる図示および説明のためのものであり、本発明の範囲を定めるために利用されるべきものではない。本発明の範囲は請求の範囲によってのみ定まる。添付図面において、複数の図面における同一の部品番号は、同一または相当部分を示す。
　以下、本発明の一実施例が図面にしたがって説明される。
　着用物品１００：
　図１Ａに示すように、本実施例の着用物品１００は、吸収性本体（オムツ本体）２００、前胴回り部３０１および後胴回り部３０２を備えている。前記吸収性本体２００は、着用者の前胴を覆うフロント部２０１、着用者の後胴を覆うバック部２０２、ならびに、前記フロント部２０１とバック部２０２との間の股間を覆う股部２０３を有している。
　前記股部２０３はフロント部２０１およびバック部２０２に連なり胴回り方向Ｘに直交する縦方向Ｙに延びる。前胴回り部３０１と後胴回り部３０２とは着用時に互いに接合されてもよいし、あるいは、着用前に予め接合されていてもよい。　　
　吸収性本体２００には立体ギャザー（図示せず）が設けられてもよい。
　また、吸収性本体２００には、着用者の脚部に沿って括れた脚回り部を形成してもよい。
　さらに、吸収性本体２００の脚回りとなる部分などには、着用物品１００を着用者にフィットさせるための弾性部材が設けられていてもよい。この弾性部材としては、たとえば、複数の糸ゴムや平ゴム、フィルムまたは熱可塑性樹脂を含む材料などを採用することができる。また、これらの材料は着用物品１００を着用者にフィットさせるための弾性部材としてフロント部２０１およびバック部２０２や前胴回り部３０１および後胴回り部３０２に設けられてもよい。
　図２に示すように、前記吸収性本体２００は、着用者の肌面に接する第１ウエブ２１と前記肌面に接しない第２ウエブ２２および吸収性のコア２３を備える。コア２３は第１ウエブ２１と第２ウエブ２２との間に挟まれる。
図３Ｂの第１ウエブ２１と第２ウエブ２２とは図３Ａのように例えば縦横に延びる例えば格子状の溶着ラインＬ、Ｌに沿って互いに溶着されて、その間にコア２３を挟んだサンドイッチ構造を形成する。すなわち、図３Ｂに示すように、コア２３は前記溶着ラインＬ，Ｌに沿って互いに溶着された第１ウエブ２１および第２ウエブ２２に囲まれている。
前記各溶着ラインＬは、第１ウエブ２１と第２ウエブ２２とが連続的又は断続的に溶着された接合部Ｗで形成される。前記接合部Ｗは前記２枚の不織布２１，２２に超音波エネルギーを付与することで形成された超音波接合部であってもよい。前記接合部Ｗは前記粒状体３が体液を吸収して膨潤した際に生じる力で前記接合部Ｗにおいて前記不織布２１，２２同士が互いに分離しない接合強度を有していてもよい。
なお、各図において溶着された接合部Ｗはｘｘで示される。
　図３Ｂの前記第１ウエブ２１および第２ウエブ２２は、互いに溶着が可能な熱可塑性樹脂を含み、いずれも液透過性で、かつ、通気性を有する不織布で形成されている。図１Ｂにおいて前記第２ウエブ２２の非肌面には液不透過性のバックシート２４が付着されて吸収性本体２００がバックシート２４に覆われている。一方、前記第１ウエブ２１の肌面には第１ウエブ２１の全面を覆う透液性のトップシート６が配置されている。
なお、不織布としては、ポリプロピレン，ポリエチレン，ポリエステル等の熱可塑性樹脂製不織布が挙げられ、また、綿やレーヨン等の熱可塑性を示さない繊維等を前記熱可塑性樹脂製繊維に混紡した不織布であってもよい。
　前記コア２３は多数の吸収性の粒状体３からなる。かかる粒状体３は周知の吸収性の高分子ポリマーからなり、一般に、水分を吸水する前の状態で平均粒径が１０μｍ～１，０００μｍ程度で、吸水後に膨潤し数倍ないし数百倍の体積となる。
　なお、各図において粒状体３は多数の微細なドットで示される。また、図１Ａおよび図５Ａ～図５Ｃについては、易破断部１０を分りやすくするために粒状体３は図示していない。
　図３Ａの前記コア２３は前記粒状体３が多数集まった各集合グループ３０が各々、多数の配置エリアＤに配置されて形成されている。前記各集合グループ３０、３０は前記縦横に延びる格子状の溶着ラインＬ、Ｌによって区画された前記配置エリアＤ，Ｄに分かれて配列されている。すなわち、前記各集合グループ３０，３０が配置されている各配置エリアＤ，Ｄは前記溶着ラインＬ，Ｌによって区画されている。
　換言すれば、前記各集合グループ３０は多数の粒状体３の集まりからなり、図３Ａに示すように、前記集合グループ３０のうちの１つのグループと別のグループとが前記溶着ラインＬ，Ｌを挟んで縦横方向に並んでいる。図３Ａに示すように、前記各集合グループは縦横方向に多数（３つ以上）並んでいる。
また、各溶着ラインＬは完全に連なっている必要はなく、各集合グループ３０の粒状体３が他の集合グループ３０に移動しにくい程度に溶着部位が断続的に形成されていてもよい。
つまり、所定のパターンで配置された前記各集合グループ３０における粒状体３が前記複数のグループのうちの１つのグループから別のグループへ移動するのを抑制できる程度に溶着ラインＬ，Ｌが形成されていてもよい。
前記集合グループ３０の配置は所定の定まったパターンであればよく、規則正しく縦横方向に並んでいる必要はない。また、各集合グループ３０に包含される粒状体３の数（量）は互いに同程度である必要はなく、各集合グループ３０について排泄される体液の量に応じた数（量）であってもよい。
図３Ａに示すように、集合グループ３０は矩形や丸形であってもよく、その一辺の長さや直径は数ｍｍ～１０ｍｍ程度であってもよい。また、集合グループ同士３０、３０の配置のピッチは１０ｍｍ程度ないし十数ｍｍ程度であってもよい。
　つぎに、本発明の要部について説明する。
　図１Ａ～図２に示すように、第１ウエブ２１の各配置エリアＤには、例えば、断続的に形成された「切り込み」を含むミシン目状の易破断部１０が形成されている。
　この易破断部１０は、前記２枚の不織布２１，２２のうちの少なくとも一方の不織布に設けられていればよく、前記粒状体３が体液を吸収して膨潤した際に生じる力で破断する。すなわち、本実施例の場合、第１ウエブ２１の易破断部１０が破断すると断続的に形成された「切り込み」同士が互いに連なって長い「切り込み」となり、その結果、前記体液を吸収した粒状体３や体液が２枚のウエブ２１，２２の間から第１ウエブ２１の上面に溢れ出るのを許容する。
　したがって、使用前には各配置エリアＤに多量の粒状体３を収容することができる。その一方で、前記第１ウエブ２１の肌面側には第１ウエブ２１の全面を覆うトップシート６が設けられており、切り込みから溢れ出した膨潤状態の粒状体３が着用物品１００の着用者の肌に付着することがない。
　なお、トップシート６と第１ウエブ２１との間には、体液をコア２３の面方向に（面に沿って）拡散させる拡散層や体液を一時的に保持する液保持層が設けられてもよい。
つぎに、サンドイッチ構造体２０の製造方法の概要が説明される。
図４に示すように、第１導入ローラ７１により第２ウエブ２２（図２）となるキャリアウエブ１が搬送ドラム４に導入され、キャリアウエブ１の第１面１１を搬送ドラム４の搬送面４１で吸着保持しながら、前記キャリアウエブ１が所定の搬送経路つまり前記搬送ドラム４の搬送面４１に沿って搬送される。
前記第１導入ロール７１と第２導入ロール７２との間において、前記供給装置５から前記搬送中のキャリアウエブ１の第１面１１とは反対の第２面１２上に多数の粒状体３が供給される。供給された粒状体３は前記第２面１２上において層を形成する。
前記搬送ドラム４に形成された吸引孔（図示せず）に向かってエアが吸引されることで前記供給された粒状体３は前記キャリアウエブ１上の前記第２面１２の前記配置エリアＤにおいて集合グループ３０ごとに吸着保持される。
なお、前記エアの少なくとも一部にキャリアウエブ１の前記第２面１２に沿う方向の流れの成分を付与する気流偏向体がキャリアウエブ１の第２面１２に対向して設けられてもよい。（ＰＣＴ／ＪＰ２０１２／５２３７１）
前記粒状体３は吸収性本体２００（図１）ごとに断続的に供給されてもよい。
粒状体３の層の厚さは搬送ドラム４の軸方向において中央が両端よりも厚くてもよい。また、粒状体３の層の厚さは、１つの吸収性本体２００（図１）の周縁において薄く、かつ、中央やその近傍において厚くてもよい。
一方、第１ウエブ２１（図２）となるカバーウエブ２は前記搬送ドラム４に導入される前に予め易破断部１０（図２）が形成される。すなわち、第２導入ローラ７２の上流に配置されたカッタロール９０とアンビルロール９１との間でミシン目状の切り込みがカバーウエブ２に形成される。
図３Ａに示すように、前記供給装置５から供給された前記粒状体３が所定のパターンでキャリアウエブ１上に配置された後に（配置エリアＤごとに配置された後に）、前記キャリアウエブ１の粒状体３が配置されていない図４の第２面１２とキャリアウエブ１上に配置された前記粒状体３とが前記第２導入ローラ７２により導入されたカバーウエブ２で覆われて、サンドイッチ構造体２０が生成される。
その後、前記サンドイッチ構造体２０は搬送面４１により搬送され続け、図４の超音波ホーン８１に到達すると、図２の粒状体３が配置されていない部位において前記キャリアウエブ１と前記カバーウエブ２とが超音波溶着される。これにより、粒状体３の各集合グループ３０は超音波溶着されたキャリアウエブ１およびカバーウエブ２により互いに区画され、前記粒状体３の所定のパターンが保持される。
すなわち、前記所定のパターンで配置された前記各配置エリアＤの前記粒状体３（集合グループ３０）が前記複数の配置エリアＤのうちの１つの配置エリアＤから別の配置エリアＤへ移動するのを抑制ないし防止するために、前記接合部Ｗとなる部位において前記キャリアウエブ１と前記カバーウエブ２とが接合される。
その後、前記サンドイッチ構造体２０は個々の着用物品の単位、つまり、図３Ａに示す個々の吸収性本体２００の単位に切り分けられる。
その後、図５Ａ～図５Ｃに示すように、前記各吸収性本体２００は前記透液性であるトップシート６と前記不透液性のバックシート２４との間に挟まれる。なお、前記トップシート６とバックシート２４とは周縁の接合部Ｗ１（図１Ｂ）において互いに接着ないし溶着されてもよい。また、バックシート２４と吸収性本体２００との間も接着されてもよい。
つぎに、本物品の使用方法について説明する。
図１Ａの前記易破断部１０を有する第１ウエブ２１および該第１ウエブ２１を覆うトップシート６を有する吸収性本体２００に体液が吸収されると、体液により図１Ｂの粒状体３が膨潤し、第１ウエブ２１（不織布）と第２ウエブ２２（不織布）との間が膨らむ。この粒状体３の膨らみにより、前記第１ウエブ２１に加わる負荷が大きくなりすぎると、図１Ａの前記易破断部１０において第１ウエブ２１が裂け、前記第１ウエブ２１の易破断部１０の切り込み同士が連なって、配置エリアＤ内において、第１ウエブ２１の一部が破断する。
一方、接合部Ｗにおいて互いに超音波溶着されている第１ウエブ２１と第２ウエブ２２は粒状体３の膨潤によっても互いに分離しない。
破断した第１ウエブ２１の易破断部１０から体液を吸収した粒状体３や体液が溢れ出るが、図１Ｂのトップシート６が吸収性本体２００の上面を覆っており、膨潤した粒状体３や体液が図１Ａの着用物品１００の着用者の肌に付着して着用感を低下させるおそれがない。
以上のとおり、図面を参照しながら好適な実施例を説明したが、当業者であれば本明細書を見て、自明な範囲で種々の変更および修正を容易に想定するであろう。
たとえば、搬送装置としてドラムではなくコンベヤを採用してもよい。
また、キャリアウエブ１とカバーウエブ２との接合方法として、超音波溶着の他に、たとえばヒートシールなどの熱溶着による接合方法や接着剤を用いた接着による接合方法を用いてもよい。
また、本発明において、各配置エリアＤには粒状体の集合体のみが配置されている場合の他に、複数の粒状体に他の粒状の材料やパルプ等の繊維材料が混合されていてもよい。
したがって、そのような変更および修正は、請求の範囲から定まる本発明の範囲内のものと解釈される。
本発明は吸収性本体以外に、粒状体を所定のパターンで配置した使い捨て着用物品に利用できる。
１：キャリアウエブ（不織布）、１０：易破断部、１１：第１面 、１２：第２面
２：カバーウエブ（不織布）、２０：サンドイッチ構造体、２１：第１ウエブ 、２２：第２ウエブ、２３：コア、２４：バックシート 
３：粒状体、３０：集合グループ、Ｄ：配置エリア
４：搬送ドラム、４１：搬送面
５：供給装置
６：トップシート 
７１：第１導入ローラ、７２：第２導入ローラ
８１：超音波ホーン
１００：着用物品、２００：吸収性本体（オムツ本体）、２０１：フロント部、２０２：バック部、２０３：股部、３０１：前胴回り部、３０２：後胴回り部
Ｌ：溶着ライン
Ｘ：胴回り方向、Ｙ：縦方向
Ｗ：接合部
Ｗ１：接合部
 

Claims (7)

  1. 　使い捨て着用物品であって、
    　所定のパターンで互いに区画された複数の配置エリアごとに体液を吸液して膨潤する複数の粒状体が、前記パターンに従って互いに接合部において接合された２枚の透液性の不織布の間に配置された吸収性本体と、
    　前記吸収性本体の非肌面に配置された不透液性のバックシートとを備え、ここにおいて、
    　前記２枚の不織布のうちの肌面側の不織布の全面を覆う透液性のシートが配置され、
    　前記２枚の不織布のうちの少なくとも一方の不織布における前記複数の配置エリアの少なくとも１以上の配置エリアには、前記粒状体が体液を吸収して膨潤した際に生じる力で破断する易破断部が形成されている。
  2. 　請求項１の物品において、前記接合部は前記２枚の不織布に超音波エネルギーを付与することで形成された超音波接合部であり、前記粒状体が体液を吸収して膨潤した際に生じる力で前記接合部において前記不織布同士が互いに分離しない接合強度を有する。
  3. 　請求項２の物品において、前記易破断部が前記不織布に線状に、かつ、断続的に形成されている。
  4. 　請求項３の物品において、前記易破断部は、前記不織布に断続的に形成された複数の孔、スリットおよび／または切り込みを含む。
  5. 　請求項１の物品を製造する方法であって、
    　前記２枚の不織布のうちの１枚を形成するキャリアウエブの第１面を搬送装置の搬送面で保持しながら前記キャリアウエブを所定の搬送経路に沿って搬送する工程と、
    　前記搬送中のキャリアウエブの前記第１面とは反対の第２面上に前記粒状体を供給する工程と、
    　前記キャリアウエブの前記第２面上の前記各配置エリアごとに前記供給された複数の粒状体の一部を保持して前記所定のパターンで配置する工程と、
    　前記２枚の不織布のうちの他の１枚を形成するカバーウエブに前記易破断部が形成される工程と、
    　前記粒状体を前記所定のパターンで配置する工程の後に、前記キャリアウエブの前記第２面および前記粒状体を前記易破断部を有するカバーウエブで覆ってサンドイッチ構造体を生成する工程と、
    　前記所定のパターンで配置された前記各配置エリアの前記粒状体が前記複数の配置エリアのうちの１つの配置エリアから別の配置エリアへ移動するのを抑制ないし防止するために、前記接合部となる部位において前記キャリアウエブと前記カバーウエブとを接合する工程とを備える。
  6. 　請求項５の方法において、前記サンドイッチ構造体を各吸収性本体の単位ごとに切り分ける工程と、
    　前記各吸収性本体を前記透液性シートと前記バックシートとの間に挟む工程とを更に備える。
  7. 　請求項６の方法において、前記接合された前記キャリアウエブと前記カバーウエブの流れ方向に沿うように、前記易破断部が形成される工程において、線状の前記易破断部が断続的または連続的に形成される。
     
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