WO2016098867A1 - 吸収体、吸収体の製造方法及び吸収体の製造装置 - Google Patents
吸収体、吸収体の製造方法及び吸収体の製造装置 Download PDFInfo
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- WO2016098867A1 WO2016098867A1 PCT/JP2015/085407 JP2015085407W WO2016098867A1 WO 2016098867 A1 WO2016098867 A1 WO 2016098867A1 JP 2015085407 W JP2015085407 W JP 2015085407W WO 2016098867 A1 WO2016098867 A1 WO 2016098867A1
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- WIPO (PCT)
- Prior art keywords
- fiber material
- basis weight
- absorbent body
- absorber
- duct
- Prior art date
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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
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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
- A61F13/45—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 shape
- A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
Definitions
- the present invention relates to an absorber, an absorber manufacturing method, and an absorber manufacturing apparatus.
- a rotating drum having a concave portion for accumulation is provided on the outer peripheral surface, and the outer peripheral surface absorbs pulp and the like while rotating the rotating drum
- the body material is supplied in a scattered state, and the absorber material is deposited in the accumulation recess by suction from the bottom surface of the accumulation recess composed of a porous member in which a large number of suction holes are formed.
- Absorber manufacturing apparatuses are known in which a deposit formed into a predetermined shape is released from the inside to obtain an absorber.
- the absorbent body is used as an absorbent body of an absorbent article as it is or after being coated with a cover sheet such as paper or a breathable nonwoven fabric.
- a first suction region having a high opening area ratio and a second suction region having a lower opening area ratio than the first suction area are provided on the bottom surface of the concave portion for accumulation, thereby absorbing capacity.
- An apparatus for manufacturing an absorbent body having a portion designed to be partially high has also been proposed (see Patent Document 1).
- a fiber material is supplied in a scattered state to a rotating drum having an accumulation recess formed on the outer peripheral surface, and the fiber material is deposited in the accumulation recess by suction to obtain an absorber having a predetermined shape.
- a method for manufacturing an absorbent body which has a portion in which the basis weight of the fiber material is relatively high and a portion in which the basis weight of the fiber material is relatively low by changing a supply amount of the fiber material per unit time
- the manufacturing method of an absorber which obtains an absorber is provided.
- this invention provides the absorber of the novel structure which can be manufactured with the manufacturing method or manufacturing apparatus of the absorber of this invention.
- the present invention provides an absorbent body including a fiber material and a water-absorbing polymer, which satisfies the following conditions A to C.
- Condition A The basis weight of the fiber material and the basis weight of the water-absorbing polymer are changed in the longitudinal direction of the absorbent body.
- Condition B In the longitudinal direction of the absorbent body, the portion having the highest basis weight of the fiber material and the portion having the highest basis weight of the water-absorbing polymer coincide with each other.
- Condition C The uneven distribution ratio which is the basis weight ratio between the portion with the highest basis weight and the portion with the lowest basis weight is different between the fiber material and the water-absorbing polymer.
- the present invention also relates to a rotating drum having a plurality of accumulation recesses formed at predetermined intervals on the outer peripheral surface, and a duct for supplying fiber material as an absorbent material in a scattered state toward the outer peripheral surface of the rotating drum.
- a fiber material supply unit that supplies the fiber material into the duct, and a mold release unit that releases the deposit generated by the deposition of the fiber material in the accumulation recess as an absorber from the accumulation recess.
- the manufacturing apparatus of the absorber provided with this is provided.
- the absorbent body manufacturing apparatus of the present invention by changing the supply amount per unit time of the fiber material to the duct, a portion having a relatively high basis weight of the fiber material in each absorber and the fiber material An absorber having a portion having a relatively low basis weight is manufactured. Moreover, the manufacturing apparatus of the absorber of the present invention measures the uneven distribution state of the fiber material in the absorber or the deposit, and based on the measured uneven distribution state, supplies the fiber material to the duct by the fiber material supply unit. A supply amount control unit to be changed is provided.
- FIG. 1 is a schematic diagram showing an absorbent body production apparatus preferably used for carrying out an embodiment of the absorbent body production method of the present invention.
- FIG. 2 is an exploded perspective view showing the structure of the concave portion for accumulation in the manufacturing apparatus shown in FIG.
- FIG. 3A is a graph showing how to change the supply amount of the fiber material in the preferred embodiment
- FIG. 3B shows the change in the amount of fiber material that reaches the drum outer peripheral surface in the preferred embodiment.
- FIG. 3C is an explanatory diagram of the length of the duct opening in the drum circumferential direction and the like.
- FIG. 4 is a perspective view showing an example of an absorbent body obtained by the present invention.
- FIG. 4 is a perspective view showing an example of an absorbent body obtained by the present invention.
- FIG. 5 is an explanatory diagram of a method for measuring the basis weight of the portion having the lowest basis weight of the fiber material and the portion having the highest basis weight of the fiber material.
- 6 (a) to 6 (c) are side views showing ducts of other shapes used in the examples and comparative examples.
- FIG. 7 is a graph showing the uneven distribution state of the fiber material of each absorber manufactured in Examples 2 to 5.
- FIG. 8 is a graph showing the frequency every 5% of the basis weight change rate of the fiber material of each absorbent body manufactured in Examples 2 to 5.
- FIG. 9 is a graph showing the uneven distribution states of the fiber material and the water-absorbing polymer of each absorber manufactured in Examples 6 and 7.
- FIG. 10 is a graph showing the frequency every 5% of the basis weight change rate of the fiber material and the water-absorbent polymer of each absorbent body manufactured in Examples 6 and 7.
- FIG. 11 is a schematic view showing an embodiment of the absorbent body manufacturing apparatus of the present invention.
- FIG. 12 (a) is a graph showing how to change the supply amount of the fiber material in the preferred embodiment
- FIG. 12 (b) is a graph showing the period of the concave portion for accumulation corresponding to FIG. 12 (a).
- FIG. 12C is an explanatory diagram of the length of the duct opening in the drum circumferential direction and the like.
- FIG. 13 (a) to 13 (c) are graphs showing the displacement of the height position of the upper surface of the absorbent body used for determining the suitability of the uneven distribution state of the fiber material.
- FIG. 14 is a diagram corresponding to FIG. 12A illustrating an example in which the phase of the supply amount is changed in accordance with the pattern of the uneven distribution state of the absorber.
- Fig.15 (a) and FIG.15 (b) are side views which show the other example of the absorber obtained by this invention.
- the absorber manufacturing apparatus described in Patent Document 1 is capable of partially adjusting the accumulation amount of the absorber material in the concave portion for accumulation and manufacturing an absorber in which the basis weight of the absorber material is partially different.
- the specifications such as the area ratio of the areas having different basis weights, it was necessary to modify the accumulation recesses themselves, which required a lot of labor.
- This invention relates to providing the manufacturing method and manufacturing apparatus of an absorber which can solve the solution subject which a prior art has. Moreover, this invention relates to providing the absorber of a novel structure.
- An absorbent body manufacturing apparatus 1 shown in FIG. 1 is an absorbent body manufacturing apparatus preferably used in an embodiment of the absorbent body manufacturing method of the present invention, and the absorbent body manufacturing apparatus 1A shown in FIG. It is an absorber manufacturing apparatus which is one Embodiment of the manufacturing apparatus of this absorber. As shown in FIG. 1, an absorbent body manufacturing apparatus 1 shown in FIG.
- manufacturing apparatus 1 includes a rotating drum 2 having a plurality of accumulation recesses 22 formed at predetermined intervals on an outer peripheral surface.
- the duct 4 that supplies the fiber material 31 and the water-absorbing polymer 32 as the absorber material in a scattered state toward the outer peripheral surface 2f of the rotary drum 2 and the fiber material supply unit that supplies the fiber material 31 into the duct 4 5, a release air blow device 6 for releasing the deposit generated by depositing the fiber material 31 and the water-absorbing polymer 32 in the accumulation recess 22 as the absorber 3 from the accumulation recess 22, and rotation And a vacuum conveyor 7 as a conveying means disposed below the drum 2.
- FIG. 11 an absorbent body manufacturing apparatus 1A shown in FIG.
- the manufacturing apparatus 1A includes a rotating drum 2 having a plurality of concave portions 22 formed on the outer peripheral surface at predetermined intervals.
- the duct 4 that supplies the fiber material 31 as the absorber material in a scattered state toward the outer peripheral surface 2f of the rotary drum 2, the fiber material supply unit 5 that supplies the fiber material 31 into the duct 4, and the accumulation A release air blow device 6 is provided as a release means for releasing the deposit generated by the deposition of the fiber material 31 and the water-absorbing polymer 32 in the recess 22 from the accumulation recess 22 as the absorber 3.
- a vacuum conveyor 7 as a conveying means disposed below the rotary drum 2 and a supply amount control unit 8A for controlling the amount of the fiber material 31 supplied from the fiber material supply unit 5 into the duct 4 are provided. ing.
- the rotating drum 2 of the manufacturing apparatuses 1 and 1A includes a cylindrical drum main body 20 made of a metal rigid body, and an outer peripheral member that is arranged so as to overlap the outer peripheral portion of the drum main body 20 and forms the outer peripheral surface 2f of the rotary drum 2. 21.
- the outer peripheral member 21 receives power from a motor (not shown) such as a motor and rotates around the horizontal axis in the direction of arrow R, while the drum body 20 is fixed and does not rotate.
- the outer peripheral member 21 has a porous plate 27 (porous member) and a pattern forming plate 28 that is fixed on the outer surface 27 a side of the porous plate 27, as shown in FIG. 2. .
- the bottom surface of the accumulation recess 22 is formed from a porous plate 27.
- the pattern forming plate 28 has an outer surface 28a that forms the outer peripheral surface 2f of the rotating drum 2 and an inner surface 28b that faces the rotating shaft side of the rotating drum 2, and an accumulation recess is provided between the outer surface 28a and the inner surface 28b.
- 22 has a space portion 280 having a shape corresponding to the three-dimensional shape in 22. The outline 22L of the space 280 coincides with the outline of the accumulation recess 22.
- the porous plate 27 transmits the air flow generated by the suction from the drum body 20 side to the outside of the rotating drum 2, holds the absorber material carried on the air flow without passing it, and the air It is a breathable plate that only allows it to pass through.
- the porous plate 27 is formed with a plurality of (multiple) suction holes (pores) penetrating the plate 27 in the thickness direction with a uniform distribution over the entire plate 27, and the accumulation recess 22 is a rotating drum. While passing through the space A maintained at a negative pressure in 2, the suction hole functions as an airflow vent.
- the porous plate 27 in the present manufacturing apparatus 1 has a constant aperture ratio over the entire region, and no suction force control plate or the like that partially varies the suction force is disposed below the porous plate 27. . That is, the accumulation recess 22 in the manufacturing apparatus 1 generates a uniform suction force on the entire bottom surface.
- the porous plate 27 for example, a metal or resin mesh plate, or a metal or resin plate formed with a plurality of (many) pores by etching or punching can be used.
- the drum body 20 includes a plurality of mutually independent spaces A and B partitioned by a partition plate 20 p provided from the central axis side of the rotating drum 2 toward the outer peripheral surface 2 f side. , C, D.
- An intake fan (not shown) is connected to the central shaft portion 222 of the drum body 20.
- the pressure in the partitioned spaces A to D in the rotary drum 2 can be adjusted by driving the intake fan.
- a shutter valve or the like that can adjust the opening area is provided between the central shaft portion 222 and each space, and the rotary drum 2 is partitioned by increasing or decreasing the opening area of the shutter. The pressure in each of the spaces A to D can be adjusted.
- the suction force in the region of the space A located in the region where the outer peripheral surface 2f is covered with the duct 4 is stronger than the suction force in the regions of the spaces BD. Since the spaces C and D are regions including the transfer position of the absorber 3 in the accumulation recess 22 and the front and back thereof, zero pressure or positive pressure is preferable.
- the duct 4 of the manufacturing apparatus 1, 1 ⁇ / b> A extends from the fiber material supply unit 5 to the rotating drum 2, and the opening on the downstream side of the duct 4 is maintained at a negative pressure.
- the outer peripheral surface 2f located on the space A in the rotating drum 2 is covered.
- the fiber material supply unit 5 includes a pulverizer 51 as a defibrator, and a raw material sheet 31A of a fiber material such as a wood pulp sheet is introduced into the pulverizer 51 by a raw material supply roller 52 and is defibrated by the pulverizer 51.
- the fiber material 31 generated in this way is configured to be supplied into the duct 4.
- a spray pipe 55 that supplies the duct 4 with a water-absorbing polymer 32, which is another kind of absorber material, is provided.
- the holding belt 24 of the absorber manufacturing apparatuses 1 and 1A is an endless breathable or non-breathable belt, and is stretched over a roll 25, a roll 26, and another roll (not shown) to rotate the rotating drum 2. It is supposed to be accompanied with.
- the pressing belt 24 is a breathable belt, it is preferable that the absorbent material (the fiber material 31 and the water-absorbing polymer 32) in the accumulation concave portion 22 is not allowed to pass therethrough. Even if the pressure in the space B is set to atmospheric pressure, the presser belt 24 can hold the deposit in the stacking recess 22 in the stacking recess 22 until it is transferred onto the vacuum conveyor 7.
- the vacuum conveyor 7 (conveying means) of the manufacturing apparatus 1, 1 ⁇ / b> A is disposed below the rotary drum 2, and is located in a space C set at a weak positive pressure or zero pressure (atmospheric pressure) of the rotary drum 2. It is arranged close to the outer peripheral surface 2f.
- the vacuum conveyor 7 includes an endless breathable belt 73 and a vacuum box 74 disposed at a position facing the outer peripheral surface 2f of the rotary drum 2 with the breathable belt 73 interposed therebetween.
- a breathable coating sheet 35 made of thin paper (tissue paper) or non-woven fabric is introduced. This air-permeable covering sheet 35 is also a liquid-permeable covering sheet.
- the mold release air blow device 6 of the manufacturing apparatus 1, 1 ⁇ / b> A allows the deposit obtained by depositing the absorbent material (the fiber material 31 and the water-absorbing polymer 32) to the accumulation recess 22 from the accumulation recess 22. It functions as a releasing means for releasing.
- the release air blow device 6 is disposed inside the outer peripheral member 21 in the space C, and is an inner surface of a porous member such as a porous plate that forms the bottom surface of the accumulation recess 22 in which the absorber material is deposited. Air can be blown from the side toward the outer surface 27a side, and release of the deposit from the accumulation recess 22 is promoted by the air.
- the manufacturing apparatus 1 is provided with the supply amount control part 8 which controls the quantity of the fiber material 31 supplied in the duct 4 from the fiber material supply part 5, as shown in FIG.
- the manufacturing apparatus 1A includes a supply amount control unit 8A that controls the amount of the fiber material 31 supplied from the fiber material supply unit 5 into the duct 4 as shown in FIG.
- the supply amount control units 8 and 8A are composed of a computer having a display unit, an interface for electrically connecting the computer and other devices, and a predetermined program incorporated in the computer. Has been.
- the manufacturing apparatus 1A includes a surface displacement measuring instrument 82, and a signal from the surface displacement measuring instrument 82 is input to the computer of the supply amount control unit 8A, and the absorber 3 conveyed on the conveying means 7A.
- a change in the height position of the upper surface of the absorber 3 along the flow direction X is recorded in a storage device such as an HDD, a RAM, or an SSD and displayed on the display unit.
- the computer of the supply amount control units 8 and 8A outputs a control signal to the drive motor 53 to control the rotation of the drive motor 53, thereby controlling the supply amount of the raw material sheet 31A to the pulverizer 51,
- the supply amount of the fiber material 31 into the duct 4 can be controlled.
- a programmable logic controller PLC
- PLC programmable logic controller
- the drive motor 53 rotates the pair of supply rollers 52 and 52 that feed the raw material sheet 31 ⁇ / b> A of the fiber material 31 to the crusher 51.
- the supply amount of the raw material sheet 31A to the pulverizer 51 is increased, and the supply amount of fiber material such as pulp fibers to the duct 4 per unit time is increased.
- the supply amount of the raw material sheet 31A to the pulverizer 51 is reduced, and the supply amount of fiber material such as pulp fiber per unit time to the duct 4 is reduced.
- the absorber manufacturing apparatus 1 or 1A includes a mechanism for covering the upper and lower surfaces of the absorber 3 released from the accumulation recess 22 with the covering sheets 35 and 36 to obtain the absorber continuous body 30A.
- the covering sheet 36 covering the surface opposite to the covering sheet 35 supplied on the vacuum conveyor 7 in the absorbent body 3 is placed after the absorbent body 3 is placed at the center in the width direction on one side of the covering sheet 35. Further, both sides of the covering sheet 35 folded back to the other side may be used, or a covering sheet 36 different from the covering sheet 35 supplied onto the vacuum conveyor 7 may be used.
- a thin paper tissue paper
- a non-woven fabric, or the like can be used similarly to the covering sheet 35, and preferably has air permeability.
- This air-permeable covering sheet 36 is also a liquid-permeable covering sheet.
- the manufacturing apparatus 1 or 1A of the absorbent body has an absorbent body 30 having a length (hereinafter, also referred to as a length of one absorbent article) in which the absorbent body continuous body 30A is used for each absorbent article.
- a cutting device 9 for cutting is provided.
- various known cutting means used for manufacturing absorbent articles and absorbent bodies can be used. For example, as shown in FIGS. 1 and 11, a cutter roll 91 having a cutting blade 92 and its roll It has an anvil roll 93 which receives a blade, and can cut
- a method for continuously producing the absorbent body 3 using the above-described absorbent body production apparatus 1, that is, an embodiment of the absorbent body production method of the present invention will be described.
- this embodiment is also referred to as a first embodiment.
- the rotary drum 2 is rotated and the intake fan is operated to make the space A have a negative pressure.
- the release air blow device 6, the vacuum conveyor 7, the belt conveyor 7 ⁇ / b> A disposed adjacent to the vacuum conveyor 7, and the cutting device 9 are operated.
- the intake fan By the operation of the intake fan, a uniform suction force is generated over the entire bottom surface of the accumulation recess 22 located on the space A, and the air flowing in the duct 4 toward the outer peripheral surface of the rotary drum 2. A flow occurs.
- the fiber material 31 generated by defibration by the pulverizer 51 is supplied into the duct 4. Is done.
- the fiber material 31 supplied into the duct 4 is in a scattered state, is carried on the air flow flowing through the duct 4, and is supplied toward the outer peripheral surface of the rotary drum 2.
- the supply amount per unit time of the fiber material supplied in a scattered state to the rotating drum 2 is periodically changed. Specifically, the supply amount per unit time of the fiber material 31 supplied into the duct 4 is periodically changed. More specifically, the rotational speed of the supply roller 52 for supplying the raw material is periodically changed by a computer included in the supply amount control unit 8, and the raw material sheet 31A of the fiber material is supplied to the pulverizer 51 as a defibrator. The supply rate per unit time of the fiber material 31 supplied into the duct 4 is periodically changed by periodically changing the speed to be performed. A program for causing such a change is installed in the computer of the supply amount control unit 8. The rotational speed of the supply roller 52 may be periodically changed using a programmable computer.
- the mass of the fiber material 31 supplied to the duct 4 by the supply amount control unit 8 is periodically changed in the pattern shown in FIG.
- the mass of the fiber material 31 reaching the outer peripheral surface is periodically changed in the pattern shown in FIG.
- the fiber material 31 is obtained by defibrating the raw material sheet 31A with the pulverizer 51.
- the pulp sheet is defibrated until the pulp fibers are in an independent state. It is difficult, and the form of the fiber material 31 is a cotton-like form in which pulp fibers are entangled in a rough state. For this reason, the fiber material 31 has a smaller apparent density than the particulate water-absorbing polymer 32 and is easily affected by the air flow.
- FIG. 3A and FIG. 3B do not match, and the change amount of the fiber material reaching the drum outer peripheral surface with respect to the change amount of the fiber material supplied to the duct 4. Becomes smaller. That is, the difference between FIG. 3A and FIG. 3B is that when the fiber material 31 passes through the duct 4, the fiber material distribution becomes uniform due to the diffusion effect caused by the air flow. It is difficult to accurately predict the diffusion effect, and when it is made completely uniform, the intended distribution of the fiber material cannot be obtained in the manufactured absorber. In order to maintain the state of FIG.
- the pattern shown in FIG. 3A is a pattern in which the step of supplying a relatively small amount of fiber material 31 to the duct 4 and the step of supplying a relatively large amount of fiber material 31 to the duct 4 are repeated alternately.
- the fiber material 31 is continuously supplied by changing the supply amount.
- the fiber material 31 may be supplied to the duct 4 in a pattern in which the step of not supplying the fiber material 31 to the duct 4 and the step of supplying the fiber material 31 to the duct 4 are alternately repeated.
- the supply rollers 52 in the manufacturing apparatuses 1 and 1 ⁇ / b> A are connected and interlocked with each other through, for example, gears and the like, and rotate in opposite directions at the same peripheral speed by one drive motor 53.
- a servo motor is preferably used.
- an input / output interface, a servo amplifier, etc. are arranged between the drive motor 53 and the supply amount control units 8, 8A.
- the drive motor 53 and the connection motor 52 are used for connection in order to ensure the responsiveness of the supply roller 52. It is preferable that the gear ratio of the gears is set to performance and setting with excellent responsiveness.
- the vertical axis in the graph of FIG. 3A is the supply amount (mass a) of the fiber material 31 supplied to the duct 4 per unit time, and the vertical axis in the graph of FIG. This is the amount (mass b) of the fiber material 31 that reaches the surface.
- the length T shown in FIGS. 3A and 3B is the interval between the accumulation recesses 22 that pass through the portion covered with the duct 4 as the rotary drum 2 rotates. This shows the length of one cycle of the rotational movement period of the accumulation recess 22. Specifically, as shown in FIG.
- the specific position P1 of one accumulation recess 22a for example, the front end in the rotational direction R passes through the specific position P2 in the direction along the circumferential direction of the rotating drum 2 of the duct 4.
- the specific position P1 common to the next accumulation recess 22b corresponds to the time until it passes the specific position P2.
- the supply amount per unit time of the fiber material 31 supplied into the duct 4 is periodically changed according to the rotational movement cycle of the accumulation recess 22.
- the deposition amount of the fiber material 31 is added to the deposit deposited in the accumulation recess 22 by periodically changing the supply amount of the fiber material 31 supplied into the duct 4 per unit time.
- a portion having a relatively low basis weight of the fiber material is formed.
- the same absorbent body 3 can be obtained by appropriately adjusting the period and the supply amount of the fiber material 31 supplied into the duct 4. Can be obtained.
- FIG. 4 is a perspective view showing an example of the absorbent body 3 manufactured by the method of the first embodiment.
- a high basis weight portion 33 having a relatively high basis weight of the fiber material is formed on the one end 3 a side corresponding to the rotation direction front end f of the accumulation recess 22, and the accumulation recess 22.
- a low basis weight portion 34 having a relatively low basis weight of the fiber material is formed on the other end 3b side corresponding to the rear end r in the rotation direction.
- the absorber 3 has a longitudinal direction 3X corresponding to the circumferential direction of the rotary drum 2 and a width direction 3Y orthogonal to the longitudinal direction.
- the longitudinal direction 3X is along the transport direction X, and one end 3a having a high basis weight portion 33.
- the side is directed downstream in the transport direction.
- the absorbent body 3 thus obtained is coated with the covering sheets 35 and 36 to form an absorbent body continuous body 30 ⁇ / b> A, and then cut into a predetermined length by the cutting device 9.
- the absorbent body 30 covered with the covering sheet is incorporated into an absorbent article such as a disposable diaper.
- the absorbent body 30 or the absorbent body 30 whose core portion is composed of the absorbent body 3 is preferably used as an absorbent body of an absorbent article.
- the absorbent article is mainly used to absorb and retain body fluids excreted from the body such as urine and menstrual blood.
- Absorbent articles include, for example, disposable diapers, sanitary napkins, incontinence pads, panty liners, etc., but are not limited to these, and widely include articles used to absorb liquid discharged from the human body. To do.
- the absorber 3 in which the absorbent body 3 or the core portion is composed of the absorbent body 3 is composed of the high basis weight portion 33 having a relatively high basis weight and the low basis weight portion 34 having a relatively low basis weight.
- the deposit amount of the absorber material is partially different. Therefore, in particular, as an absorbent body used for a disposable diaper, it is incorporated into an absorbent article so that the high basis weight portion 33 is on the ventral side (front side) and the low basis weight portion 34 is on the back side (rear side). It is preferable that the performance of the absorber is maximized.
- the absorber 3 can also be used as an absorber of an absorbent article, without coat
- the length of the duct opening in the drum circumferential direction is The ratio of the accumulation recess 22 to the length in the drum circumferential direction is preferably 2.0 or less, more preferably 1.5 or less. Further, from the viewpoint of the magnitude relationship between the deposition rate of the fiber material and the pneumatic transport rate of the same material in the duct 4, the ratio is preferably more than 0, and more preferably 0.1 or more. As shown in FIGS.
- the length of the duct opening in the drum circumferential direction is the both ends of the opening 4e on the rotating drum side of the duct 4 in the direction along the circumferential direction of the rotating drum.
- the length between 4f and 4r is measured along the outer peripheral surface of the rotating drum.
- the length of the accumulation recess 22 in the drum circumferential direction is the length between both ends f and r of the accumulation recess 22 in the direction along the circumferential direction of the rotating drum, and is measured along the outer peripheral surface of the rotation drum.
- a portion having a high fiber material concentration and a concentration are present on the outer peripheral surface of the rotary drum 2. It is preferable that the lower portion reaches in a wavy manner. Further, on the outer peripheral surface of the rotary drum 2, a portion having a relatively high basis weight of the fiber material (high basis weight portion) and a portion having a relatively low basis weight of the fiber material (low basis weight portion) are wavy. Preferably it is formed.
- the ratio of the basis weight of the portion with the highest basis weight of the fiber material to the basis weight of the portion with the lowest basis weight of the fiber material is preferably 1.5 or more, more preferably 2 or more, preferably 30 or less.
- the basis weight of the lowest basis weight of the fiber material is preferably 100 g / m 2 or more and 3000 g / m 2 or less from the viewpoint of the absorber strength.
- the content (mass) of the fiber material contained in each absorbent body is determined by the application of the absorbent article.
- the content of the fiber material contained in each absorbent body and the basis weight of the portion with the lowest basis weight of the fiber material From the amount and the preferred basis weight ratio, the basis weight of the portion with the highest basis weight of the fiber material is determined.
- the basis weight of the portion with the highest basis weight of the fiber material and the portion with the lowest basis weight of the fiber material is obtained as follows. That is, as shown in FIG. 5, a straight line C along the width direction 3Y is drawn at an interval of 30 mm from one end 3a in the longitudinal direction 3X of the absorbent body 3, and the absorbent body 3 is divided into a plurality of portions 3A to 3F with the straight line C as a boundary. And the area and the mass of the fiber material contained are determined for each of the divided portions. Then, the basis weight is calculated from the calculated mass and area, the basis weight of the divided portion with the highest calculated basis weight is set as the basis weight of the portion with the highest basis weight of the fiber material, and the calculated basis weight is the lowest division.
- the basic weight of a part be the basic weight of the part with the lowest basic weight of a fiber material.
- the portion 3G is not divided on the straight line Ce.
- the basis weight of the part 3F is calculated.
- the one end 3a in the longitudinal direction 3X of the absorbent body 3 is the one end closer to the abdomen side (front side) of the wearer in the front-rear direction when the absorbent article is an absorbent body.
- the end corresponding to the front end f in the rotational direction of the concave portion 22 for accumulation is used, and when it is also unknown, one end in the longitudinal direction is set as the one end 3a.
- the water-absorbing polymer 32 is supplied from, for example, the spray tube 55 described above, and supplied into the air stream that conveys the fiber material 31. Even if the water-absorbing polymer 32 is continuously supplied at a constant supply amount, the water-absorbing polymer 32 is compared with a portion where the concentration of the fiber material in the air flow conveying the fiber material 31 is high and a portion where the concentration is low. A relatively large amount. This is because the fiber material 31 functions as a transport medium for the water-absorbing polymer 32 when the concentration of the fiber material is high.
- an absorbent body having more water-absorbing polymer in a portion where the basis weight of the fiber material is relatively high than in a portion where the basis weight of the fiber material is relatively low is obtained.
- an absorbent body in which water-absorbing polymers are unevenly distributed can be obtained without providing means for changing the supply amount in the water-absorbing polymer 32 supply device.
- an absorbent body in which the water-absorbing polymer is unevenly distributed can be obtained without providing a means for changing the supply amount in the water-absorbing polymer 32 supply device, and the fiber material and the water-absorbing polymer can be obtained.
- the phase of uneven distribution of the polymer is in agreement.
- the basis weight change of the water-absorbing polymer depends on the change in the amount of the fiber material as shown in FIG. 3B, there is an absorber in which the basis weight of the fiber material and the water-absorbing polymer changes continuously and gently. can get.
- both the fiber material and the water-absorbing polymer are unevenly distributed, and the phase of uneven distribution is in agreement (see FIG. 9).
- a basis weight distribution that is continuous and gently changes can be obtained. Therefore, when it is incorporated into an absorbent article and used, there is no sense of incongruity even when the amount of absorption is large. Moreover, even if it is a case where a water absorptive polymer is not supplied, an absorptive article without a feeling of discomfort similarly is obtained similarly.
- the absorbent body includes a fiber material and a water-absorbing polymer, and the basis weight of the fiber material and the basis weight of the water-absorbent polymer are respectively the absorption.
- the portion having the highest basis weight of the fiber material and the portion having the highest basis weight of the water-absorbing polymer coincide with each other in the longitudinal direction of the absorber.
- Absorbent bodies in which the uneven distribution ratio, which is the basis weight ratio between the highest part and the lowest basis weight, are different between the fiber material and the water-absorbing polymer are obtained.
- the uneven distribution ratio of the fiber material is higher than the uneven distribution ratio of the water-absorbing polymer.
- the uneven distribution ratio of the fiber material is the ratio of the basis weight of the fiber material in the portion with the highest basis weight of the fiber material to the basis weight of the fiber material in the portion with the lowest basis weight of the fiber material.
- the uneven distribution ratio is a ratio of the basis weight of the water-absorbing polymer in the portion having the highest basis weight of the water-absorbing polymer to the basis weight of the water-absorbing polymer in the portion having the lowest basis weight of the water-absorbing polymer.
- the ratio of the uneven distribution ratio of the fiber material to the uneven distribution ratio of the water-absorbing polymer is preferably 1.05 or more, more preferably 1.1 or more, and preferably 10 or less, and more preferably 5 or less.
- the absorber 3 shown in FIG. 4 similar to the first embodiment described above can be obtained.
- the rotary drum 2 is rotated and the intake fan is operated to make the space A have a negative pressure.
- the release air blow device 6, the vacuum conveyor 7, the belt conveyor 7 ⁇ / b> A disposed adjacent to the vacuum conveyor 7, and the cutting device 9 are operated.
- the supply amount control unit 8A periodically changes the supply amount per unit time of the fiber material supplied to the rotating drum 2 in a scattered state. Specifically, the supply amount per unit time of the fiber material 31 supplied into the duct 4 is periodically changed. More specifically, the raw material sheet 31A of the fiber material is pulverized as a defibrating machine by periodically changing the rotation speed of the supply rollers 52, 52 for supplying the raw material by a computer included in the supply amount control unit 8A. The speed supplied to the machine 51 is periodically changed, whereby the supply amount per unit time of the fiber material 31 supplied into the duct 4 is periodically changed. A program for causing such a change is installed in the computer of the supply amount control unit 8A. The rotation speed of the supply rollers 52 and 52 may be periodically changed using a programmable logic controller.
- the supply amount control unit 8A periodically changes the rotation speed of the supply rollers 52, 52 for supplying raw materials in the pattern shown in FIG. 12A, thereby supplying the supply amount control unit 8A.
- the pattern shown in FIG. 12A is a pattern in which the step of supplying a relatively small amount of fiber material 31 to the duct 4 and the step of supplying a relatively large amount of fiber material 31 to the duct 4 are repeated alternately.
- the fiber material 31 is continuously supplied by changing the supply amount.
- the fiber material 31 may be supplied to the duct 4 in a pattern in which the step of not supplying the fiber material 31 to the duct 4 and the step of supplying the fiber material 31 to the duct 4 are alternately repeated.
- the vertical axis in the graph of FIG. 12A is the speed at which the raw material sheet 31A of the fiber material 31 is introduced into the pulverizer 51 by the supply rollers 52, 52, and per unit time of the fiber material 31 supplied to the duct 4.
- the supply amount (mass a) also changes.
- the graph of FIG. 12B shows the period of the accumulation recess 22 that passes through the portion covered with the duct 4, and one period is, for example, as shown in FIGS. 3C and 12C.
- the supply amount control unit 8A As shown in FIG. 12 (a) and FIG. 12 (b), a cycle for changing the speed at which the raw material sheet 3A of fiber material is supplied to the pulverizer 51; The period when the accumulation recess 22 passes through the portion covered with the duct 4 is matched.
- FIG. 4 is a perspective view showing an example of the absorber 3 manufactured by the apparatus 1 of the present embodiment. In the absorbent body 3 shown in FIG.
- a high basis weight portion 33 having a relatively high basis weight of the fiber material is formed on the one end 3 a side corresponding to the rotation direction front end f of the accumulation recess 22, and the accumulation recess 22.
- a low basis weight portion 34 having a relatively low basis weight of the fiber material is formed on the other end 3b side corresponding to the rear end r in the rotation direction.
- the absorber 3 has a longitudinal direction 3X corresponding to the circumferential direction of the rotary drum 2 and a width direction 3Y orthogonal to the longitudinal direction. When the absorbent body 3 is transported by a vacuum conveyor 7 or a belt conveyor 7A as transport means, as shown in FIG. 11, the longitudinal direction 3X is along the transport direction X, and one end 3a having a high basis weight portion 33.
- the absorbent body 3 thus obtained is coated with the covering sheets 35 and 36 to form an absorbent body continuous body 30 ⁇ / b> A, and then cut into a predetermined length by the cutting device 9.
- the absorbent body 30 covered with the covering sheet is incorporated into an absorbent article such as a disposable diaper.
- the supply amount control unit 8A records the displacement of the height of the upper surface of the absorber 3 being conveyed by the conveying means, based on the signal input from the surface displacement measuring device 82.
- FIG. 13A is a graph showing the displacement of the height position of the upper surface of the absorber 3 recorded in the storage unit of the supply amount control unit 8A.
- the horizontal axis 0 to 360 in FIG. 13 (a) indicates the time length of one cycle of the cutting cycle by the cutter roll 91 or one cycle of the above-described concave portion for accumulation, divided into 360 equal parts, Each 0 point on the horizontal axis is a point in time when a detection signal is input from a detector that detects a reference position provided on the cutter roll or the rotary drum.
- the rotary encoder 83 is attached to the shaft portion of the cutter roll 91 of the cutting device, and the length of the pulse corresponding to one rotation of the cutter roll 91 output from the rotary encoder 83 is set to 0 to 360 on the horizontal axis. It can also be the length.
- a preferable range of the height position of the upper surface at a plurality of positions in the length from 0 to 360 on the horizontal axis is recorded in advance according to the target absorber to be manufactured. Depending on whether or not each value of the absorber actually measured at the time of manufacturing the absorber 3 satisfies these values, the manufactured absorber 3 has the form of the target absorber 3. Can be determined.
- the surface displacement meter 82 a laser displacement meter or the like can be used.
- the absorber 3 to be manufactured has the form shown in FIG. 13A, the form of the absorber 3 determined by the input value from the surface displacement measuring device 82 is the same as that shown in FIG. ),
- the phase of the supply amount is changed in accordance with the unevenly distributed pattern of the absorber.
- the phase moving direction is a direction in which the uneven distribution state of the fiber material in the manufactured absorbent body approaches the uneven distribution state of the target absorbent body.
- an absorption in which a large amount of absorbent material is unevenly distributed at a desired site in one absorbent body by simply changing the supply amount of the fiber material per unit time.
- a body can be manufactured, and the uneven distribution state of the manufactured absorber 3 is monitored using the surface displacement meter 82 and the like, and the fiber material supply unit supplies the fiber material to the duct based on the uneven distribution state.
- the absorbent body in which the fiber material is unevenly distributed in a desired state can be stably produced continuously.
- the absorbent body 30 or the absorbent body 30 whose core portion is composed of the absorbent body 3 is preferably used as an absorbent body of an absorbent article. Further, the absorbent body 3 manufactured by the manufacturing apparatus 1A or the absorbent body 30 in which the core portion is composed of the absorbent body 3 is also configured such that the absorbent body 3 has a relatively high basis weight portion 33 and a relatively low basis weight portion 33. The amount of low basis weight 34 and the amount of deposited absorbent material is partially different.
- the absorbent body 3 can also be used as an absorbent body for absorbent articles without being covered with the covering sheets 35 and 36.
- the absorber 3 to be manufactured may have the form shown in FIG. 13B or 13C. Moreover, the thing of the form shown to Fig.15 (a) or FIG.15 (b) may be sufficient.
- the absorbent body shown in FIG. 13 (b) has a high basis weight portion 33 having the highest basis weight of the fiber material at the center in the longitudinal direction 3X corresponding to the circumferential direction of the rotating drum 2, and has a high height in the longitudinal direction 3X.
- the basis weight portion 33 has a low basis weight portion 34 having the lowest basis weight of the fiber material.
- 13A has a high basis weight portion 33 having the highest basis weight of the fiber material at the center in the longitudinal direction 3X corresponding to the circumferential direction of the rotary drum 2, and one end in the longitudinal direction 3X.
- the basis weight of the fiber material is the lowest on the side, and the basis weight of the fiber material is less than the high basis weight portion 33 and higher than the low basis weight portion 34 on the other end side in the longitudinal direction 3X.
- An intermediate basis weight portion 38 is provided.
- a plurality of high basis weight portions 33 are formed in a state of being separated from each other in the longitudinal direction 3X corresponding to the circumferential direction of the rotary drum 2.
- the three portions other than the two high basis weight portions 33 are all the low basis weight portions 34 in which the basis weight of the fiber material is the lowest. Or two places can also be made into the intermediate
- the absorbent article produced by the production method or production apparatus of the present invention or the absorbent article in the case of incorporating the absorbent body of the present invention into an absorbent article is typically disposed between the top sheet, the back sheet, and both sheets.
- the upper and lower surfaces of the absorber may be covered with one or a plurality of covering sheets.
- the back sheet may or may not have water vapor permeability.
- the absorbent article may further include various members according to specific uses of the absorbent article. Such members are known to those skilled in the art. For example, when the absorbent article is applied to a disposable diaper or a sanitary napkin, a pair or two or more pairs of three-dimensional guards can be arranged on the outer side of both sides of the absorbent body.
- the fiber material and the water-absorbing polymer used in the present invention various materials conventionally used for absorbent bodies of absorbent articles such as sanitary napkins, panty liners, and disposable diapers can be used without particular limitation.
- short fibers of cellulosic fibers such as pulp fibers, rayon fibers, and cotton fibers
- short fibers of synthetic fibers such as polyethylene are used. These fibers can be used alone or in combination of two or more.
- the fiber material is preferably entirely or partly pulp fiber, and the ratio of the pulp fiber in the fiber material is preferably 50 to 100% by mass, more preferably 80 to 100% by mass, More preferably, it is 100 mass%.
- a deodorant or an antibacterial agent may be supplied into the duct as necessary.
- the water-absorbing polymer may or may not be supplied.
- water-absorbing polymers examples include sodium polyacrylate, (acrylic acid-vinyl alcohol) copolymer, cross-linked sodium polyacrylate, (starch-acrylic acid) graft copolymer, and (isobutylene-maleic anhydride) copolymer.
- water-absorbing polymers include sodium polyacrylate, (acrylic acid-vinyl alcohol) copolymer, cross-linked sodium polyacrylate, (starch-acrylic acid) graft copolymer, and (isobutylene-maleic anhydride) copolymer.
- examples thereof include a polymer and a saponified product thereof, and polyaspartic acid.
- a fiber and a water absorbing polymer can be used individually by 1 type or in combination of 2 or more types.
- the manufacturing method of the absorber of the present invention, the absorber, and the manufacturing apparatus of the absorber are not limited to the above-described embodiments, and can be changed as appropriate.
- the method of changing the amount of the fiber material 31 supplied to the duct 4 by the supply amount control unit 8 is different from the pattern shown in FIG. Absorbers with different parts of the amount can also be produced.
- the supply amount of the fiber material 31 to the duct 4 can be periodically changed by another method.
- a supply amount of the fiber material 31 to the duct 4 can be periodically changed by providing a shutter immediately after the pulverizer 51 and performing an opening / closing operation.
- a plurality of stacking recesses forming an absorbent body for one absorbent article are formed at intervals in the circumferential direction of the rotating drum.
- the rotating drum used in the manufacturing apparatus of the absorbent body of the present invention or the manufacturing method of the absorbent body of the present invention has a concave portion for accumulation continuous in the circumferential direction, and a continuous absorbent body in which absorbent bodies for a plurality of absorbent articles are connected. May be formed. It can also be combined with the method described in Patent Document 1.
- a first suction region having a high opening area ratio and a second suction region having a lower opening area ratio than the first suction area may be provided on the bottom surface of the accumulation recess 22, and the fiber material may be deposited on both the suction regions. . Moreover, you may manufacture the absorber which does not contain a water absorbing polymer, without supplying a water absorbing polymer, while supplying a fiber material to a duct.
- the surface displacement measuring instrument is used for measuring the uneven distribution state of the fiber material in the absorbent body.
- image processing or a capacitance sensor may be used. it can.
- the basis weight amount of the fiber material can be determined based on the density of the absorber in the image captured by the imaging unit.
- the electrostatic capacity sensor is preferable because it is suitable for measuring insulators such as cellulose fibers such as pulp fibers, rayon fibers, and cotton fibers used as a material for absorbent articles, and synthetic fibers such as polyethylene.
- the present invention further discloses the following additional notes (absorber manufacturing method, absorber, absorber manufacturing apparatus, etc.) with respect to the above-described embodiment.
- ⁇ 1> Manufacture of an absorbent body in which a fiber material is supplied in a scattered state to a rotating drum having an accumulation recess formed on the outer peripheral surface, and the fiber material is deposited in the accumulation recess by suction to obtain an absorber having a predetermined shape
- a method By periodically changing the supply amount of the fiber material per unit time in accordance with the rotational movement period of the concave portion for accumulation, the portion where the basis weight of the fiber material is relatively high and the basis weight of the fiber material are relatively The manufacturing method of an absorber which obtains the absorber which has a low part.
- stacking is a manufacturing method of the absorber as described in ⁇ 1> which produces a uniform suction
- the fiber material supplied in a scattered state to the rotating drum is generated by supplying a raw material sheet of the fiber material to a defibrator and changing the supply amount per unit time of the raw material sheet to the defibrator.
- the manufacturing method of the absorber as described in said ⁇ 1> or ⁇ 2> which changes the supply amount per unit time of the fiber material supplied in a scattered state to a drum periodically.
- ⁇ 4> Supplying the fiber material per unit time supplied into the duct by periodically changing the rotation speed of the supply roller for supplying the raw material and periodically changing the speed at which the fiber material sheet is supplied to the defibrating machine
- ⁇ 5> The step of supplying a relatively small amount of fiber material to the duct and the step of supplying a relatively large amount of fiber material to the duct alternately alternate the mass of the fiber material supplied to the duct by the supply amount control unit. In the repeated pattern, the fiber material is continuously supplied by changing periodically, changing the supply amount, and the mass of the fiber material reaching the outer peripheral surface of the rotating drum is periodically changed.
- the manufacturing method of the absorber as described in any one of ⁇ 4>.
- ⁇ 6> A pattern in which the step of not supplying the fiber material to the duct and the step of supplying the fiber material to the duct are alternately repeated, and the mass of the fiber material that reaches the outer peripheral surface of the rotating drum is changed periodically.
- ⁇ 7> The method for producing an absorbent body according to any one of ⁇ 1> to ⁇ 6>, wherein a servo motor is used as a drive motor for the supply roller.
- ⁇ 8> The absorbent material obtained by releasing from the concave portion for accumulation by forming a portion having a small amount of accumulated fiber material and a portion having a large amount of accumulated fiber material in the deposit deposited in the concave portion for accumulation,
- a high basis weight portion having a relatively high basis weight of the fiber material is formed on one end side corresponding to the rotation direction front end of the accumulation recess, and relative to the other end side corresponding to the rotation direction rear end of the accumulation recess.
- ⁇ 10> ⁇ 1> to ⁇ 9 wherein when the absorbent body is conveyed by a vacuum conveyor or a belt conveyor as a conveying means, the longitudinal direction is along the conveying direction, and one end having the high basis weight portion is directed downstream in the conveying direction.
- ⁇ 11> The production of an absorbent body according to any one of ⁇ 1> to ⁇ 10>, wherein the absorbent body includes a high basis weight part having a relatively high basis weight and a low basis weight part having a relatively low basis weight.
- Method. ⁇ 12> The length of the duct opening in the drum circumferential direction is such that the ratio of the accumulation recess to the drum circumferential length is preferably 2.0 or less, more preferably 1.5 or less, and preferably more than 0.
- a portion having a relatively high basis weight of the fiber material (high basis weight portion) and a portion having a relatively low basis weight of the fiber material (low basis weight portion) are formed in a wave shape on the outer peripheral surface of the rotating drum.
- the ratio of the basis weight of the portion with the highest basis weight of the fiber material to the basis weight of the portion with the lowest basis weight of the fiber material is preferably 1.5 or more, more preferably 2 or more.
- the absorbent body has a basis weight of a portion having the highest basis weight of the fiber material, preferably 100 g / m 2 or more, and preferably 3000 g / m 2 or less.
- the manufacturing method of the absorber of 1. ⁇ 16> The whole or part of the fiber material is preferably pulp fiber, and the proportion of the pulp fiber in the fiber material is preferably 50 to 100% by mass, more preferably 80 to 100% by mass, and still more preferably.
- ⁇ 17> The method for producing an absorbent body according to any one of ⁇ 1> to ⁇ 16>, wherein a water-absorbing polymer is supplied into an air stream carrying the fiber material to obtain an absorbent body having the water-absorbing polymer.
- the water-absorbing polymer is supplied at a constant supply rate per unit time, and as the absorber, the basis weight of the fiber material is placed in a portion where the basis weight of the fiber material is relatively high.
- Water-absorbing polymers include sodium polyacrylate, (acrylic acid-vinyl alcohol) copolymer, cross-linked sodium polyacrylate, (starch-acrylic acid) graft copolymer, (isobutylene-maleic anhydride) copolymer
- ⁇ 20> The method for producing an absorbent body according to any one of ⁇ 1> to ⁇ 19>, wherein a shutter is provided immediately after the pulverizer and the supply amount of the fiber material to the duct is periodically changed by opening and closing the pulverizer.
- a first suction region having a high opening area ratio and a second suction region having a lower opening area ratio than the first suction region are provided on a bottom surface of the concave portion for accumulation, and the fiber material is deposited on both the suction regions;
- ⁇ 22> The absorbent according to any one of ⁇ 1> to ⁇ 21>, wherein the absorbent is used as an absorbent of an absorbent article, and the absorbent article is an article used to absorb liquid discharged from a human body. Body manufacturing method.
- ⁇ 23> The method for producing an absorbent body according to any one of ⁇ 1> to ⁇ 22>, wherein the absorbent article is any one of a disposable diaper, a sanitary napkin, an incontinence pad, and a panty liner.
- the absorbent used for the disposable diaper is incorporated in an absorbent article so that the high basis weight portion is on the ventral side (front side) and the low basis weight portion is on the back side (rear side).
- the manufacturing method of the absorber as described in any one of ⁇ 23>.
- An absorbent comprising a fibrous material and a water-absorbing polymer,
- the basis weight of the fiber material and the basis weight of the water-absorbing polymer are each changed in the longitudinal direction of the absorber, In the longitudinal direction of the absorbent body, the portion having the highest basis weight of the fiber material and the portion having the highest basis weight of the water-absorbing polymer coincide with each other.
- ⁇ 27> The absorbent body according to ⁇ 25> or ⁇ 26>, wherein a basis weight of the fiber material is gently changed in a longitudinal direction of the absorbent body.
- a rotating drum having a plurality of accumulation recesses formed at predetermined intervals on the outer peripheral surface; a duct for supplying fiber material as an absorbent material in a scattered state toward the outer peripheral surface of the rotating drum;
- the duct includes a fiber material supply section for supplying the fiber material to the stack, and mold release means for releasing the deposit generated by depositing the fiber material in the stacking recess as an absorber from the stacking recess.
- An absorber manufacturing apparatus for manufacturing an absorber, An absorbent body comprising a supply amount control unit that measures the uneven distribution state of the fiber material in the absorber or the deposit and changes the supply amount of the fiber material to the duct by the fiber material supply unit based on the measured uneven distribution state. Manufacturing equipment.
- the absorber according to any one of ⁇ 28> to ⁇ 30>, wherein a surface displacement measuring instrument, an image processing, or a capacitance sensor is used for measuring the uneven distribution state of the fiber material in the absorber or the deposit.
- Manufacturing equipment ⁇ 32>
- the rotating drum includes a cylindrical drum main body and an outer peripheral member that is arranged on the outer peripheral portion of the drum main body and forms an outer peripheral surface of the rotating drum.
- a porous plate and a pattern forming plate fixed to be overlapped on the outer surface side of the porous plate, and the bottom surface of the concave portion for accumulation is formed from the porous plate.
- the manufacturing apparatus for an absorbent body according to any one of> to ⁇ 31>.
- the porous plate transmits an air flow generated by suction from the drum body side to the outside of the rotating drum, holds the absorber material carried on the air flow without passing through, and only air
- the duct extends from the fiber material supply unit to the rotating drum,
- the fiber material supply unit includes a pulverizer as a defibrator, a fiber material raw material sheet is introduced into the pulverizer by a raw material supply roller, and the fiber material generated by defibration by the pulverizer is placed in the duct.
- the said fiber material supply part is a manufacturing apparatus of the absorber as described in said ⁇ 34> provided with a pair of supply roller which sends the said raw material sheet
- ⁇ 36> By increasing the rotation speed of the drive motor, the supply amount of the fiber material per unit time to the duct is increased, and by decreasing the rotation speed of the drive motor, the supply amount of the fiber material per unit time to the duct is increased.
- the manufacturing apparatus of the absorber as described in ⁇ 35> in which decreases.
- the supply amount control unit includes a computer having a display unit and an input unit, an interface for electrically connecting the computer and other devices, and a predetermined program incorporated in the computer.
- a computer that outputs a control signal to the drive motor to control the rotation of the drive motor, thereby controlling the supply amount of the raw material sheet to the pulverizer and into the duct.
- the absorbent body manufacturing apparatus according to any one of ⁇ 34> to ⁇ 37>, wherein the supply amount of the fiber material is controlled.
- a mechanism for obtaining a continuous absorbent body by coating the upper and lower surfaces of the absorbent body released from the accumulation recess with a covering sheet, and absorbing the length of the absorbent continuous body used for individual absorbent articles.
- a spray pipe for supplying a water-absorbing polymer, which is another kind of absorbent material, to the duct is provided. 40> The manufacturing apparatus of the absorber as described in any one of 40>.
- Example 1 The absorber was manufactured using the apparatus shown in FIG. As the raw material sheet 31A, a wood pulp sheet is used, and its supply amount is changed as shown in FIG. 3 (a) so that the absorption as shown in FIG. Body 3 was produced. During the manufacture of the absorber 3, a uniform suction force was generated over the entire area of the bottom surface of the concave portion for accumulation. Further, the water-absorbing polymer 32 was not supplied. [Examples 2 to 5, Comparative Examples 1 to 3] The shape of the duct 4 in the vicinity of the rotating drum 2 is changed to that shown in “Duct shape” in Table 1, and the length in the drum longitudinal direction of the accumulation recess is changed as shown in Table 1. The absorber was manufactured in the same manner as in Example 1.
- Shapes 1 to 4 which are ducts shown in the column of “duct shape” in Table 1 are as follows. Shape 1: Shape shown in FIG. 1, length of duct opening 940 mm Shape 2: Shape shown in FIG. 6A, duct opening length 520 mm Shape 3: Shape shown in FIG. 6B, length of duct opening 346 mm Shape 4: Shape shown in FIG.
- Example 6C duct opening length 173 mm
- the production rates of Examples 1 to 4 and Comparative Examples 1 to 3 were 10 m / min. Only Example 5 was performed at production speeds of 10, 50, 100, and 150 m / min, and the evaluation results in Table 1 showed the average values under the four speed conditions.
- the production speed is the peripheral speed of the rotating drum or the conveying speed of the conveyors 7 and 7A.
- the absorbent bodies obtained in Examples 1 to 5, which are embodiments of the present invention, have an uneven distribution ratio of 1.5 or more, a portion having the highest basis weight of the fiber material and a portion having the lowest basis weight of the fiber material, Is formed.
- the absorbers obtained in Comparative Examples 1 to 3 had an uneven magnification of 1.2 or less.
- FIG. 7 corresponds to FIG. 3 (b)
- the results for a plurality of absorbers are shown as continuous measurement results, assuming that the divided parts are continuous next to each other.
- the measurement was performed for 3 to 4 sheets when the length per absorber was 333 mm.
- the length of the last divided portion on the rear side in the transport direction (the portion corresponding to the portion of the absorbent body 3 shown in FIG. 5 where the portion 3F and the portion 3G are combined) was 33 mm.
- a range indicated by an arrow in FIG. 7 is a range corresponding to one absorber.
- the basis weight change rate at intervals of 30 mm was obtained, and the frequency distribution is shown in FIG.
- the basis weight change rate was calculated
- the basis weight change rate of the fiber material is examined at intervals of 30 mm along the longitudinal direction of the absorbent body, when the maximum basis weight change rate is 35% / 30 mm or less, the absorbent body has its longitudinal direction (one Direction), “the basis weight of the fiber material is changing gently”.
- the numerical value on the horizontal axis of the graph shown in FIG. 8 means that the range in which the numerical value is written is a range that is larger than the numerical value 5 percentage points lower than the numerical value and equal to or smaller than the numerical value.
- the basis weight change rate is a range where the basis weight change rate is more than 30% and 35% or less, and the basis weight change rate is measured within the range. It means that there is one place in the section.
- Example 6 and 7 An absorbent body was produced in the same manner as in Example 3 or 4 except that the water-absorbing polymer 32 was continuously supplied from the spray pipe 55 during the production of the absorbent body. (Evaluation 1) About each absorber obtained in Examples 6 and 7, the basis weight of the polymer between the basis weight of the polymer with the highest basis weight of the fiber material and the basis weight of the polymer with the lowest basis weight of the fiber material The ratio (hereinafter, also referred to as polymer second uneven distribution ratio) was measured, and the results are shown in Table 2.
- the total basis weight of the fiber material and the water absorbent polymer was determined without distinguishing between the fiber material and the water absorbent polymer. Thereafter, a gray-scale image of the water-absorbing polymer was obtained with a soft X-ray imaging apparatus (Softex EMT-J). The basis weight of the water-absorbing polymer was determined from a calibration curve between the degree of shading of the density image and the separately measured water-absorbing polymer basis weight. The basis weight of the fiber material was determined by subtracting the basis weight of the water absorbent polymer from the total basis weight of the fiber material and the water absorbent polymer.
- both the basis weight and water absorption of the fiber material are within the range corresponding to one absorbent body having a length of 333 mm.
- the basis weight of the polymer varies in the longitudinal direction of the absorber.
- the portion with the highest basis weight of the fiber material is a portion having a distance from the reference position of 0 mm to 450 to 480 mm, and the basis weight of the water-absorbing polymer.
- the portion with the highest amount is a portion whose distance from the reference position 0 is 390 to 420 mm, and the position difference (absolute value) is 60 obtained by subtracting 420 from 480, which is 1/4 or less of the length of the absorber 333 mm. It is. Further, in Example 7, within the range corresponding to one absorbent body, the portion having the highest basis weight of the fiber material is a portion having a distance of 480 to 510 mm from the reference position 0 mm, and the basis weight of the water-absorbing polymer.
- the portion with the highest amount is a portion whose distance from the reference position 0 mm is 420 to 450 mm, and the position difference (absolute value) is 60 obtained by subtracting 450 from 510, and is less than 1/4 of the length of the absorber 333 mm. It is.
- the difference (absolute value) of the position of the portion with the highest basis weight of the fiber material and the portion with the highest basis weight of the water-absorbing polymer is 1/4 or less of the length in the longitudinal direction of the absorbent body, In the longitudinal direction of the absorbent body, it is assumed that the portion with the highest basis weight of the fiber material and the portion with the highest basis weight of the water-absorbing polymer coincide.
- the portion having the highest basis weight of the fiber material and the basis weight of the water-absorbing polymer are the most.
- the high part is the same part, adjacent parts, or two parts sandwiching one or two parts between them, and is the same part or adjacent parts. It is more preferable that the two parts sandwich one part between them.
- the absorber manufactured by this invention and the absorber of this invention are the basis weight (maximum basis weight) of the part with the highest basis weight, and the basis weight of the part with the lowest basis weight about each of a fiber material and a water absorbing polymer.
- the uneven distribution ratio is different between the fiber material and the water-absorbent polymer when calculating the uneven distribution ratio that is the basis weight ratio (maximum basis weight / minimum basis weight) with the amount (minimum basis weight)
- Example 11 The absorber was manufactured using the apparatus shown in FIG. As the raw material sheet 31A, a wood pulp sheet is used, and the supply amount to the pulverizer 51 is changed as shown in FIG. 12 (a), so that the basis weight of the fiber material is high and low in FIG.
- the absorber 3 of the form shown was manufactured. During the manufacture of the absorber 3, a uniform suction force was generated over the entire area of the bottom surface of the concave portion for accumulation. Further, the water-absorbing polymer 32 was not supplied. Moreover, when the uneven distribution state of the fiber material of the absorber 3 was monitored using the surface displacement measuring device during manufacture, the uneven distribution state of the fiber material was always stable.
- Shape 1 Shape shown in FIG. 11, duct opening length 940 mm
- Shape 2 Shape shown in FIG. 6A, duct opening length 520 mm
- Shape 3 Shape shown in FIG. 6B, length of duct opening 346 mm
- Shape 4 Shape shown in FIG. 6C, duct opening length 173 mm
- the absorbent bodies obtained in Examples 11 to 15, which are embodiments of the present invention, have an uneven distribution ratio of 1.5 or more, a portion having the highest basis weight of the fiber material, and a portion having the lowest basis weight of the fiber material, Is formed.
- the absorbents obtained in Comparative Examples 11 to 13 have an uneven distribution ratio of 1.2 or less, and the basis weight is almost constant.
- the basis weight of the fiber material can be relatively easily increased with respect to the portion having a relatively high basis weight of the fiber material only by changing the supply amount of the fiber material per unit time.
- An absorber with a lower part can be produced.
- the absorber manufacturing apparatus of the present invention it is possible to manufacture an absorber in which a large amount of absorber material is unevenly distributed at a desired site, and it is possible to stably produce the absorber continuously.
Abstract
Description
また本発明は、本発明の吸収体の製造方法又は製造装置により製造可能な新規な構成の吸収体を提供するものである。即ち、本発明は、繊維材料及び吸水性ポリマーを含む吸収体であって、下記の条件A~Cを満たすものを提供するものである。
条件A:前記繊維材料の坪量及び前記吸水性ポリマーの坪量が、それぞれ、吸収体の長手方向において変化している。条件B:前記吸収体の長手方向において、前記繊維材料の坪量が最も高い部分と前記吸水性ポリマーの坪量が最も高い部分とが一致している。条件C:坪量が最も高い部分と坪量が最も低い部分との坪量比である偏在倍率が、前記繊維材料と前記吸水性ポリマーとで異なる。
先ず、本発明の吸収体の製造方法の一実施態様に好ましく用いられる吸収体の製造装置、及び本発明の吸収体の製造装置の一実施形態である吸収体の製造装置について説明する。
図1に示す吸収体の製造装置1は、本発明の吸収体の製造方法の一実施態様に好ましく用いられる吸収体の製造装置であり、図11に示す吸収体の製造装置1Aは、本発明の吸収体の製造装置の一実施形態である吸収体の製造装置である。
図1に示す吸収体の製造装置1(以下「製造装置1」ともいう)は、図1に示すように、外周面に複数の集積用凹部22が所定の間隔で形成された回転ドラム2と、回転ドラム2の外周面2fに向けて、吸収体材料としての繊維材料31及び吸水性ポリマー32を飛散状態にて供給するダクト4と、ダクト4内に繊維材料31を供給する繊維材料供給部5と、集積用凹部22内に、繊維材料31及び吸水性ポリマー32が堆積して生じた堆積物を、吸収体3として該集積用凹部22から離型させる離型用エアブロー装置6と、回転ドラム2の下方に配された搬送手段としてのバキュームコンベア7とを備えている。
図11に示す吸収体の製造装置1A(以下「製造装置1A」ともいう)は、図11に示すように、外周面に複数の集積用凹部22が所定の間隔で形成された回転ドラム2と、回転ドラム2の外周面2fに向けて、吸収体材料としての繊維材料31を飛散状態にて供給するダクト4と、ダクト4内に繊維材料31を供給する繊維材料供給部5と、集積用凹部22内に、繊維材料31及び吸水性ポリマー32が堆積して生じた堆積物を、吸収体3として該集積用凹部22から離型させる離型手段としての離型用エアブロー装置6とを備え、更に、回転ドラム2の下方に配された搬送手段としてのバキュームコンベア7と、繊維材料供給部5からダクト4内に供給される繊維材料31の量を制御する供給量制御部8Aとを備えている。
外周部材21は、その外周部に、図2に示すように、多孔性プレート27(多孔性部材)と、該多孔性プレート27の外面27a側に重ねて固定されたパターン形成プレート28とを有する。集積用凹部22の底面は、多孔性プレート27から形成されている。
多孔性プレート27としては、例えば、金属又は樹脂製のメッシュプレート、あるいは金属又は樹脂製の板にエッチング、パンチングで複数(多数)の細孔を形成したもの等を用いることができる。
製造装置1、1Aのいずれにおいても、外周面2fがダクト4で覆われた領域に位置する空間Aの領域の吸引力が、空間B~Dの領域の吸引力よりも強い。なお、空間C及びDは、集積用凹部22内の吸収体3の転写位置及びその前後を含む領域であるので、圧力ゼロ又は陽圧が好ましい。
ダクト4における回転ドラム2と繊維材料供給部5との間には、吸収体材料の他の一種である吸水性ポリマー32をダクト4に供給する散布管55が設けられている。回転ドラム2の吸気ファン(図示せず)の作動により、ダクト4内の空間には、回転ドラム2の外周面2fに向けて吸収体材料(繊維材料31及び吸水性ポリマー32)を流す空気流が生じるようになっている。
また製造装置1Aは、表面変位計測器82を備えており、供給量制御部8Aのコンピュータには、表面変位計測器82からの信号が入力され、搬送手段7A上を搬送される吸収体3の流れ方向Xに沿う、吸収体3の上面の高さ位置の変化が、HDDやRAM、SSD等の記憶装置に記録されると共に表示部に表示される。
また供給量制御部8,8Aのコンピュータは、駆動モーター53に対して制御信号を出力して駆動モーター53の回転を制御することにより、原料シート31Aの粉砕機51への供給量を制御し、ダクト4内への繊維材料31の供給量を制御することができる。コンピュータに代えて、プログラマブルロジックコントローラ(PLC)を用いることもできる。
また、吸収体の製造装置1,1Aは、その吸収体連続体30Aを、個々の吸収性物品に使用される長さ(以下、吸収性物品一枚分の長さともいう)の吸収体30に切断する切断装置9を備えている。切断装置9としては、吸収性物品や吸収体の製造に用いられる各種公知の切断手段を用いることができ、例えば、図1及び図11に示すように、切断刃92を有するカッターロール91とその刃を受けるアンビルロール93とを有しており、両ロールの回転により一定の周期で、吸収体連続体30Aを順次切断するものを用いることができる。
上述した製造装置1を用いて吸収体3を製造するためには、回転ドラム2を回転させると共に、上記吸気ファンを作動させて空間Aを負圧とする。また離型用エアブロー装置6、バキュームコンベア7、バキュームコンベア7に隣接して配置したベルトコンベア7A、及び切断装置9を作動させる。
吸気ファンの作動により、空間A上に位置する集積用凹部22の底面に、底面の全域に亘って均一な吸引力が生じると共に、ダクト4内に、回転ドラム2の外周面に向けて流れる空気流が生じる。
原料シート31Aを粉砕機51により解繊することによって繊維材料31を得るが、原料シート31Aとしてパルプシートを用いた場合、そのパルプシートをパルプ繊維が個々に独立した状態となるまで解繊することは難しく、繊維材料31の形態は、パルプ繊維が粗な状態で絡み合った綿状の形態となっている。そのため、繊維材料31は、粒子状である吸水性ポリマー32に比較して、見掛けの密度が小さく、空気流の影響を受けやすい。結果として、図3(a)と図3(b)の波形、及び、振幅は一致せず、ダクト4に供給する繊維材料の変化量に対して、ドラム外周面に到達する繊維材料の変化量は小さくなる。即ち、図3(a)と図3(b)の差異は、繊維材料31がダクト4内を通過する際に、空気流による拡散効果によって繊維材料分布が一様化するためである。拡散効果を正確に予測することは困難であり、完全に一様化した場合は、製造する吸収体に、目的とする繊維材料の分布を得ることができない。図3(b)の状態を保持し、繊維材料が偏在した吸収体を製造するためには、ダクト4に供給する繊維材料の変化量を十分に大きくし、且つ、ダクト4での拡散効果を低減することが好ましい。
図3(a)に示すパターンは、ダクト4に相対的に少ない量の繊維材料31を供給するステップとダクト4に相対的に多い量の繊維材料31を供給するステップとが交互に繰り返されるパターンであり、供給量を変えて繊維材料31を連続して供給している。これに代えて、ダクト4に繊維材料31を供給しないステップと、ダクト4に繊維材料31を供給するステップとが交互に繰り返されるパターンで、繊維材料31をダクト4に供給しても良い。
粉砕機51への原料シート31Aの供給量を、図3(a)に示すようなパターンで変化させるにあたり、供給ローラ52の応答性を担保するために、駆動モーター53、及び、連結に使用しているギアのギア比は応答性に優れた性能、設定であることが好ましい。
第1実施態様においては、ダクト4内に供給される繊維材料31の単位時間当たりの供給量を周期的に変化させることによって、集積用凹部22に堆積させる堆積物に、繊維材料31の堆積量が少ない部位と繊維材料31の堆積量が多い部位とを形成することができ、集積用凹部22から離型して得た吸収体3には、繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とが形成される。
また、第1実施態様においては、吸収体3の生産速度が変化する際においても、適切に周期とダクト4内に供給される繊維材料31の供給量を調整することにより、同様の吸収体3を得ることができる。
図4に示す吸収体3においては、集積用凹部22の回転方向前端fに対応する一端3a側に、相対的に繊維材料の坪量が高い高坪量部33が形成され、集積用凹部22の回転方向後端rに対応する他端3b側に、相対的に繊維材料の坪量が低い低坪量部34が形成されている。吸収体3は、回転ドラム2の周方向に対応する長手方向3X及び該長手方向に直交する幅方向3Yを有している。吸収体3は、搬送手段としてのバキュームコンベア7やベルトコンベア7Aにより搬送される際には、図1に示すように、長手方向3Xが搬送方向Xに沿い、高坪量部33を有する一端3a側が、搬送方向の下流側に向けられている。
このようにして得られた吸収体3は、図1に示すように、被覆シート35,36で被覆されて吸収体連続体30Aとされた後、切断装置9により所定長さに切断されて、被覆シートで被覆された吸収体30として、使い捨ておむつ等の吸収性物品に組み込まれる。
また、吸収体3内に繊維材料の坪量が異なる高坪量部及び低坪量部を有することは、例えば、必要な部分に高い吸収容量を確保し易い一方、必要性に劣る部分の吸収容量を減らして、全体としての原料の使用量を軽減する観点からも好ましい。なお、吸収体3は、被覆シート35,36で被覆することなく、吸収性物品の吸収体として用いることもできる。
ダクト開口部のドラム周方向の長さは、図3(c)及び図12(c)に示すように、ダクト4の回転ドラム側の開口部4eの、回転ドラムの周方向に沿う方向の両端4f,4r間の長さであり、回転ドラムの外周面に沿って測定する。集積用凹部22のドラム周方向の長さは、集積用凹部22の、回転ドラムの周方向に沿う方向の両端f,r間の長さであり、回転ドラムの外周面に沿って測定する。
個々の吸収体に含まれる繊維材料の含有量(質量)は、吸収性物品の用途によって決まり、個々の吸収体に含まれる繊維材料の含有量と、繊維材料の坪量が最も低い部分の坪量と、好ましい坪量比から、繊維材料の坪量が最も高い部分の坪量が決まる。
吸水性ポリマー32を一定の供給量で連続的に供給しても、吸水性ポリマー32は、繊維材料31を搬送する空気流のなかの繊維材料の濃度が高い部分に濃度の低い部分に比して相対的に多い量が含まれる。これは、繊維材料の濃度が高い場合、繊維材料31が吸水性ポリマー32の輸送媒体として機能するためである。そのため、吸収体3として、繊維材料の坪量が相対的に高い部分に、繊維材料の坪量が相対的に低い部分より多くの吸水性ポリマーを有する吸収体が得られる。
このように、本実施形態の方法によれば、吸水性ポリマー32の供給装置に供給量を変化させる手段を設けなくても、吸水性ポリマーが偏在した吸収体が得られる。
また、吸水性ポリマーの坪量変化は、図3(b)のような繊維材料量の変化に依存するため、繊維材料と吸水性ポリマーの坪量が、連続的且つなだらかに変化する吸収体が得られる。
そのため、吸収性物品に組み込まれて使用された場合、吸収量が多い場合であっても装着感に違和感がない。また、吸水性ポリマーを供給しない場合であっても、同様に装着感に違和感のない吸収性物品が得られる。
繊維材料の偏在倍率は、繊維材料の坪量が最も低い部分の該繊維材料の坪量に対する、繊維材料の坪量が最も高い部分の該繊維材料の坪量の比であり、吸水性ポリマーの偏在倍率は、吸水性ポリマーの坪量が最も低い部分の該吸水性ポリマーの坪量に対する、吸水性ポリマーの坪量が最も高い部分の該吸水性ポリマーの坪量の比である。吸水性ポリマーの偏在倍率に対する繊維材料の偏在倍率の比は、1.05以上が好ましく、1.1以上が更に好ましく、また10以下が好ましく、5以下が更に好ましい。
上述した製造装置1Aを用いて吸収体3を製造するためには、回転ドラム2を回転させると共に、上記吸気ファンを作動させて空間Aを負圧とする。また離型用エアブロー装置6、バキュームコンベア7、バキュームコンベア7に隣接して配置したベルトコンベア7A、及び切断装置9を作動させる。吸気ファンの作動により、空間A上に位置する集積用凹部22の底面に、底面の全域に亘って均一な吸引力が生じると共に、ダクト4内に、回転ドラム2の外周面に向けて流れる空気流が生じる。そして、繊維材料供給部5の供給ローラ52,52を作動させて、繊維材料31の原料シート31Aを粉砕機51に導入すると、粉砕機51により解繊されて生じた繊維材料31がダクト4内に供給される。ダクト4内に供給された繊維材料31は、飛散状態となって、ダクト4内を流れる空気流に載って、回転ドラム2の外周面に向けて供給される。
図12(a)に示すパターンは、ダクト4に相対的に少ない量の繊維材料31を供給するステップとダクト4に相対的に多い量の繊維材料31を供給するステップとが交互に繰り返されるパターンであり、供給量を変えて繊維材料31を連続して供給している。これに代えて、ダクト4に繊維材料31を供給しないステップと、ダクト4に繊維材料31を供給するステップとが交互に繰り返されるパターンで、繊維材料31をダクト4に供給しても良い。
製造装置1Aの運転時には、供給量制御部8Aによって、図12(a)及び図12(b)に示すように、繊維材料の原料シート3Aを粉砕機51に供給する速度を変化させる周期と、集積用凹部22が、ダクト4に覆われた部分を通過する周期とを一致させる。
図4に示す吸収体3においては、集積用凹部22の回転方向前端fに対応する一端3a側に、相対的に繊維材料の坪量が高い高坪量部33が形成され、集積用凹部22の回転方向後端rに対応する他端3b側に、相対的に繊維材料の坪量が低い低坪量部34が形成されている。吸収体3は、回転ドラム2の周方向に対応する長手方向3X及び該長手方向に直交する幅方向3Yを有している。吸収体3は、搬送手段としてのバキュームコンベア7やベルトコンベア7Aにより搬送される際には、図11に示すように、長手方向3Xが搬送方向Xに沿い、高坪量部33を有する一端3a側が、搬送方向の下流側に向けられている。
このようにして得られた吸収体3は、図11に示すように、被覆シート35,36で被覆されて吸収体連続体30Aとされた後、切断装置9により所定長さに切断されて、被覆シートで被覆された吸収体30として、使い捨ておむつ等の吸収性物品に組み込まれる。
供給量制御部8Aの記憶部には、製造すべき目的の吸収体に応じて、横軸の0から360の長さのうちの、複数個所における上面の高さ位置の好ましい範囲が予め記録されており、吸収体3の製造時に実際に計測された吸収体についての各値が、それらの値を満たすか否かによって、製造された吸収体3が、目的とする吸収体3の形態を有しているかを判別することができる。表面変位計測計82としては、レーザー変位計等を用いることができる。
そして、例えば、製造すべき吸収体3が、図13(a)に示す形態であるにもかかわらず、表面変位計測器82からの入力値により判別した吸収体3の形態が、図13(b)に示す形態であった場合には、図14に示すように、吸収体の偏在状態のパターンに合わせて供給量の位相を変化させる。位相の移動方向は、製造される吸収体における繊維材料の偏在状態が、目的とする吸収体の同偏在状態に近づく方向とする。
図13(b)に示す吸収体は、回転ドラム2の周方向に対応する長手方向3Xの中央部に、繊維材料の坪量が最も高い高坪量部33を有し、長手方向3Xにおける高坪量部33に、繊維材料の坪量が最も低い低坪量部34を有している。
図13(a)に示す吸収体は、回転ドラム2の周方向に対応する長手方向3Xの中央部に、繊維材料の坪量が最も高い高坪量部33を有し、長手方向3Xの一端側に、繊維材料の坪量が最も低い低坪量部34を有し、長手方向3Xの他端側に、繊維材料の坪量が、高坪量部33より少なく低坪量部34より多い中間坪量部38を有している。
図15(b)に示す吸収体は、回転ドラム2の周方向に対応する長手方向3Xに、相互に離間した状態に複数の高坪量部33が形成されている。図15(b)に示す吸収体は、2つの高坪量部33以外の3箇所が何れも繊維材料の坪量が最も低い低坪量部34となっているが、3箇所のうちの1又は2箇所を、繊維材料の坪量が高坪量部33より少なく低坪量部34より高い中間坪量部38とすることもできる
例えば、供給量制御部8によりダクト4へと供給する繊維材料31の量の変化のさせ方を、図3(a)に示すパターンとは異なるパターンとして、図4に示す吸収体とは高坪量部の部位が異なる吸収体を製造することもできる。また、原料シート31Aの粉砕機51への供給量を変化させるのに代えて、他の方法により、ダクト4への繊維材料31の供給量を周期的に変化させることもできる。例えば、粉砕機51の直後にシャッターを設け、開閉操作することによりダクト4への繊維材料31の供給量を周期的に変化させることができる。
図1に示す吸収体の製造装置の回転ドラムにおいては、吸収性物品1個分の吸収体を形成する集積用凹部が、回転ドラムの周方向に間隔を開けて複数形成されていたが、本発明の吸収体の製造装置又は本発明の吸収体の製造方法に使用する回転ドラムは、周方向に連続する集積用凹部を有し、吸収性物品複数個分の吸収体が連なった連続吸収体を形成するものであっても良い。
また、特許文献1に記載の方法と組み合わせることも出来る。集積用凹部22の底面に、開口面積率の高い第1吸引領域と第1吸引領域よりも開口面積率の低い第2吸引領域を設け、これら両吸引領域に前記繊維材料を堆積させることもできる。
また、ダクトに、繊維材料を供給する一方、吸水性ポリマーを供給せずに、吸水性ポリマーを含まない吸収体を製造しても良い。
画像処理は、例えば、撮像手段により撮影した画像中の吸収体の濃淡により、繊維材料の坪量の量を判定することができる。静電容量センサーは、吸収性物品の材料として用いられるパルプ繊維、レーヨン繊維、コットン繊維等のセルロース系繊維や、ポリエチレン等の合成繊維など絶縁体の測定に適している点から好ましい。
<1>
外周面に集積用凹部が形成された回転ドラムに、繊維材料を飛散状態にて供給し、該繊維材料を前記集積用凹部内に吸引により堆積させて所定形状の吸収体を得る吸収体の製造方法であって、
繊維材料の単位時間当たりの供給量を、集積用凹部の回転移動周期に合わせて周期的に変化させることによって、繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とを有する吸収体を得る、吸収体の製造方法。
前記集積用凹部は、底面全体に均一な吸引力を生じるものである、<1>に記載の吸収体の製造方法。
<3>
前記回転ドラムに飛散状態で供給する繊維材料を、繊維材料の原料シートを解繊機に供給して生じさせるとともに、該原料シートの解繊機に対する単位時間当たりの供給量を変化させることによって、前記回転ドラムに飛散状態で供給する繊維材料の単位時間当たりの供給量を周期的に変化させる、前記<1>又は<2>に記載の吸収体の製造方法。
<4>
原料供給用の供給ローラの回転速度を周期的に変化させ、繊維材料の原料シートを解繊機に供給する速度を周期的に変化させることによって、ダクト内に供給する繊維材料の単位時間当たりの供給量を周期的に変化させる、前記<1>~<3>の何れか1に記載の吸収体の製造方法。
<5>
供給量制御部によりダクトへと供給される繊維材料の質量を、ダクトに相対的に少ない量の繊維材料を供給するステップとダクトに相対的に多い量の繊維材料を供給するステップとが交互に繰り返されるパターンで、周期的に変化させ、供給量を変えて繊維材料を連続して供給し、回転ドラムの外周面に到達する繊維材料の質量を、周期的に変化させる、前記<1>~<4>の何れか1に記載の吸収体の製造方法。
ダクトに繊維材料を供給しないステップとダクトに繊維材料を供給するステップとが交互に繰り返されるパターンで、周期的に変化させ、回転ドラムの外周面に到達する繊維材料の質量を、周期的に変化させる、前記<1>~<5>の何れか1に記載の吸収体の製造方法。
<7>
供給ローラの駆動モーターとして、サーボモーターを用いる、前記<1>~<6>の何れか1に記載の吸収体の製造方法。
<8>
集積用凹部に堆積させる堆積物に、繊維材料の堆積量が少ない部位と繊維材料の堆積量が多い部位とを形成することにより、集積用凹部から離型して得た吸収体に、繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とを形成する、前記<1>~<7>の何れか1に記載の吸収体の製造方法。
<9>
集積用凹部の回転方向前端に対応する一端側に、相対的に繊維材料の坪量が高い高坪量部が形成され、集積用凹部の回転方向後端に対応する他端側に、相対的に繊維材料の坪量が低い低坪量部を形成する、前記<1>~<8>の何れか1に記載の吸収体の製造方法。
<10>
吸収体を、搬送手段としてバキュームコンベアやベルトコンベアにより搬送する際に、長手方向が搬送方向に沿い、高坪量部を有する一端が、搬送方向の下流側に向ける、前記<1>~<9>の何れか1に記載の吸収体の製造方法。
吸収体が、相対的に高坪量の高坪量部と相対的に低坪量の低坪量部とを含む、前記<1>~<10>の何れか1に記載の吸収体の製造方法。
<12>
ダクト開口部のドラム周方向の長さは、集積用凹部のドラム周方向の長さに対する比が、好ましくは2.0以下、更に好ましくは1.5以下であり、また、好ましくは0超、更に好ましくは0.1以上である、前記<1>~<11>の何れか1に記載の吸収体の製造方法。
前記回転ドラムの外周面に、繊維材料の坪量が相対的に高い部分(高坪量部)と繊維材料の坪量が相対的に低い部分(低坪量部)とが波状的に形成される、前記<1>~<12>の何れか1に記載の吸収体の製造方法。
<14>
吸収体は、繊維材料の坪量が最も低い部分の坪量に対する、繊維材料の坪量が最も高い部分の坪量の比が、好ましくは1.5以上、更に好ましくは2以上であり、また好ましくは30以下である、前記<1>~<13>の何れか1に記載の吸収体の製造方法。
<15>
吸収体は、繊維材料の坪量が最も高い部分の坪量は、好ましくは100g/m2以上であり、また好ましくは3000g/m2以下である、前記<1>~<14>の何れか1に記載の吸収体の製造方法。
<16>
繊維材料は、全体又は一部がパルプ繊維であることが好ましく、繊維材料中のパルプ繊維の割合は50~100質量%であることが好ましく、より好ましくは80~100質量%であり、更に好ましくは100質量%である、前記<1>~<15>の何れか1に記載の吸収体の製造方法。
<17>
前記繊維材料を搬送する空気流中に吸水性ポリマーを供給し、吸水性ポリマーを有する吸収体を得る、前記<1>~<16>の何れか1に記載の吸収体の製造方法。
<18>
前記繊維材料を搬送する空気流中に、吸水性ポリマーを単位時間当たりの供給量を一定として供給し、前記吸収体として、繊維材料の坪量が相対的に高い部分に、繊維材料の坪量が相対的に低い部分より多くの吸水性ポリマーを有する吸収体を得る、前記<1>~<17>の何れか1に記載の吸収体の製造方法。
吸水性ポリマーとしては、ポリアクリル酸ナトリウム、(アクリル酸-ビニルアルコール)共重合体、ポリアクリル酸ナトリウム架橋体、(でんぷん-アクリル酸)グラフト共重合体、(イソブチレン-無水マレイン酸)共重合体及びそのケン化物、ポリアスパラギン酸から選ばれる1種又は2種以上を組み合わせて用いる、前記<1>~<18>の何れか1に記載の吸収体の製造方法。
<20>
粉砕機の直後にシャッターを設け、開閉操作することによりダクトへの繊維材料の供給量を周期的に変化させる、前記<1>~<19>の何れか1に記載の吸収体の製造方法。
<21>
前記集積用凹部の底面に、開口面積率の高い第1吸引領域と第1吸引領域よりも開口面積率の低い第2吸引領域を設け、これら両吸引領域に前記繊維材料を堆積させる、前記<1>~<20>の何れか1に記載の吸収体の製造方法。
<22>
吸収体は、吸収性物品の吸収体として用いられ、吸収性物品は、人体から排出される液の吸収に用いられる物品である、前記<1>~<21>の何れか1に記載の吸収体の製造方法。
<23>
吸収性物品が、使い捨ておむつ、生理用ナプキン、失禁パッド、パンティライナーの何れか1である、前記<1>~<22>の何れか1に記載の吸収体の製造方法。
<24>
使い捨ておむつに用いられる吸収体として、高坪量部が腹側(前側)、低坪量部が背側(後側)となるように吸収性物品に組み込まれて使用する、前記<1>~<23>の何れか1に記載の吸収体の製造方法。
<25>
繊維材料及び吸水性ポリマーを含む吸収体であって、
前記繊維材料の坪量及び前記吸水性ポリマーの坪量が、それぞれ、吸収体の長手方向において変化しており、
前記吸収体の長手方向において、前記繊維材料の坪量が最も高い部分と前記吸水性ポリマーの坪量が最も高い部分とが一致しており、
坪量が最も高い部分と坪量が最も低い部分との坪量比である偏在倍率が、前記繊維材料と前記吸水性ポリマーとで異なる、吸収体。
<26>
前記繊維材料の前記偏在倍率が、前記吸水性ポリマーの前記偏在倍率より高い、前記<25>に記載の吸収体。
<27>
前記吸収体の長手方向において、前記繊維材料の坪量がなだらかに変化している、前記<25>又は<26>に記載の吸収体。
外周面に複数の集積用凹部が所定の間隔で形成された回転ドラムと、該回転ドラムの外周面に向けて、吸収体材料としての繊維材料を飛散状態にて供給するダクトと、該ダクト内に繊維材料を供給する繊維材料供給部と、集積用凹部内に、繊維材料が堆積して生じた堆積物を、吸収体として該集積用凹部から離型させる離型手段とを備え、前記ダクトへの前記繊維材料の単位時間当たりの供給量を変化させることによって、個々の吸収体中に繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とを有する吸収体を製造する吸収体の製造装置であって、
前記吸収体又は前記堆積物における繊維材料の偏在状態を計測し、計測した偏在状態に基づき、繊維材料供給部によるダクトへの繊維材料の供給量を変化させる供給量制御部を備える、吸収体の製造装置。
回転ドラム側に開口するダクト開口部のドラム周方向の長さの、前記集積用凹部のドラム周方向の長さに対する比が2.0以下である、前記<28>に記載の吸収体の製造装置。
<30>
前記供給量制御部は、予め記憶部に登録されている繊維材料の偏在状態に合致する偏在状態の吸収体を製造するように、繊維材料の供給量を変化させる、前記<28>又は<29>に記載の吸収体の製造装置。
<31>
前記吸収体又は前記堆積物における繊維材料の偏在状態の計測に、表面変位計測器、画像処理又は静電容量センサーが用いられる、前記<28>~<30>の何れか1に記載の吸収体の製造装置。
<32>
前記回転ドラムは、円筒状のドラム本体と、該ドラム本体の外周部に重ねて配され、回転ドラムの外周面を形成する外周部材とを含んで構成されており、前記外周部材は、その外周部に、多孔性プレートと、該多孔性プレートの外面側に重ねて固定されたパターン形成プレートとを有し、前記集積用凹部の底面が、該多孔性プレートから形成されている、前記<1>~<31>の何れか1に記載の吸収体の製造装置。
前記多孔性プレートは、前記ドラム本体側からの吸引によって生じた空気流を回転ドラムの外方に伝え、該空気流に乗って運ばれてくる吸収体材料を透過させずに保持し、空気のみを透過させる通気性のプレートである、前記<32>に記載の吸収体の製造装置。
<34>
前記ダクトは、前記繊維材料供給部から前記回転ドラムに亘って延びており、
前記繊維材料供給部は、解繊機として粉砕機を備えており、繊維材料の原料シートが、原料供給ローラにより粉砕機に導入され、粉砕機により解繊されて生じた繊維材料が前記ダクト内に供給される、前記<28>~<33>の何れか1に記載の吸収体の製造装置。
<35>
前記繊維材料供給部は、前記原料シートを前記粉砕機に送り込む一対の供給ローラと、該供給ローラを回転駆動させる駆動モーターとを備えている、前記<34>に記載の吸収体の製造装置。
<36>
前記駆動モーターの回転数を上げることで、前記ダクトに対する繊維材料の単位時間当たりの供給量が増加し、該駆動モーターの回転数を下げることで、前記ダクトに対する繊維材料の単位時間当たりの供給量が減少する、前記<35>に記載の吸収体の製造装置。
<37>
前記供給量制御部は、表示部及び入力部を備えたコンピュータ、該コンピュータと他の装置等とを電気的に接続するインターフェース、及び該コンピュータに組み込まれた所定のプログラム等から構成されている、前記<28>~<36>の何れか1に記載の吸収体の製造装置。
コンピュータを備え、該コンピュータは、前記駆動モーターに対して制御信号を出力して駆動モーターの回転を制御することにより、前記原料シートの前記粉砕機への供給量を制御して、前記ダクト内への前記繊維材料の供給量を制御する、前記<34>~<37>の何れか1に記載の吸収体の製造装置。
<39>
前記集積用凹部から離型された吸収体の上下面を被覆シートで被覆して吸収体連続体を得る機構、及びその吸収体連続体を、個々の吸収性物品に使用される長さの吸収体に切断する切断装置を備えている、前記<28>~<38>の何れか1に記載の吸収体の製造装置。
<40>
前記供給量制御部によって、前記原料シートを前記粉砕機に供給する速度を変化させる周期と、前記集積用凹部が、前記ダクトに覆われた部分を通過する周期とを一致させる、前記<34>~<39>の何れか1に記載の吸収体の製造装置。
<41>
前記ダクトにおける前記回転ドラムと前記繊維材料供給部との間には、吸収体材料の他の一種である吸水性ポリマーを該ダクトに供給する散布管が設けられている、前記<28>~<40>の何れか1に記載の吸収体の製造装置。
図1に示す装置を用いて吸収体を製造した。原料シート31Aとしては、木材パルプシートを用い、その供給量を図3(a)に示すように変化させて、繊維材料の坪量が高い部分と低い部分とを有する図4に示すような吸収体3を製造した。吸収体3の製造中には、集積用凹部の底面には全域に亘って均一な吸引力を生じさせた。また、吸水性ポリマー32の供給は行わなかった。
〔実施例2~5、比較例1~3〕
ダクト4の回転ドラム2付近の形態を、表1中の「ダクト形状」に示すものに変更するとともに、集積用凹部のドラム長手方向の長さを、表1中に示す通りに変更する以外は、実施例1と同様にして吸収体を製造した。集積用凹部のドラム長手方向の長さは、製造した吸収体の長手方向の長さに一致する。比較例1~3は、木材パルプシートを一定の速度で粉砕機に導入し、ダクトに対する供給量を変化させなかった。
表1中の「ダクト形状」の欄に示すダクトである形状1~4は、下記の通りである。
形状1:図1に示す形状,ダクト開口部の長さ940mm
形状2:図6(a)に示す形状,ダクト開口部の長さ520mm
形状3:図6(b)に示す形状,ダクト開口部の長さ346mm
形状4:図6(c)に示す形状,ダクト開口部の長さ173mm
なお、実施例1~4、比較例1~3の製造速度は10m/minにて行った。実施例5のみ、製造速度10、50、100、150m/minにて行い、表1の評価結果は速度4条件の平均値を示した。製造速度は、回転ドラムの周速度やコンベア7,7Aの搬送速度である。
実施例1~5及び比較例1~3において得られた各吸収体について、繊維材料の坪量が最も高い部分と繊維材料の坪量が最も低い部分との坪量比(以下、偏在倍率ともいう)を前述した方法により測定して表1に示した。
吸収体の長手方向に沿って、30mm間隔で繊維材料の坪量変化率を調べたときに、最大の坪量変化率が35%/30mm以下である場合、吸収体は、その長手方向(一方向)において、「繊維材料の坪量がなだらかに変化している」とする。なお、図8に示すグラフの横軸の数値は、当該数値が記載された範囲が、当該数値より5パーセントポイント低い数値より大きく、当該数値以下である範囲であることを意味する。例えば、実施例5のグラフの横軸上に示された数値が35の範囲は、坪量変化率が30%超35%以下の範囲であり、坪量変化率が当該範囲内の部分が測定した区間内に1箇所存在することを意味する。
吸収体の製造中に、散布管55から連続して吸水性ポリマー32を供給する以外は、実施例3又は4と同様にして吸収体を製造した。
(評価1)
実施例6,7において得られた各吸収体について、繊維材料の坪量が最も高い部分のポリマーの坪量と繊維材料の坪量が最も低い部分のポリマーの坪量とのポリマー同士の坪量比(以下、ポリマー第2偏在倍率ともいう)を測定して、その結果を表2に示した。
また実施例6,7において得られた各吸収体について、製造時の搬送方向に対応する吸収体の長手方向に沿って30mm間隔で繊維材料及び吸水性ポリマーの坪量を測定した。その結果を図9に示した。繊維材料及び吸水性ポリマーの坪量変化率を、上述した繊維材料の坪量変化率の測定方法と同様の手法により測定し、図10に、繊維材料及び吸水性ポリマーのそれぞれについて坪量変化率及びその頻度を示した。
30mm間隔に分割した部分毎の繊維材料及び吸水性ポリマーの坪量は、以下のようにして測定した。
まず、繊維材料と吸水性ポリマーとを区別せずに、繊維材料及び吸水性ポリマーの合計坪量を求めた。その後、軟エックス線撮影装置(ソフテックス社EMT-J)により、吸水性ポリマーの濃淡画像を得た。濃淡画像の濃淡度合いと、別途測定した吸水性ポリマー坪量との検量線から吸水性ポリマーの坪量を求めた。繊維材料と吸水性ポリマーの合計坪量から、吸水性ポリマーの坪量を引くことによって、繊維材料の坪量を求めた。
そして、実施例6については、一つの吸収体に対応する範囲内において、繊維材料の坪量が最も高い部分は、基準位置0mmからの距離が450~480mmの部分であり、吸水性ポリマーの坪量が最も高い部分は、基準位置0からの距離が390~420mmの部分であり、位置の差(絶対値)は480から420を減算した60で、吸収体の長さ333mmの1/4以下である。また、実施例7については、一つの吸収体に対応する範囲内において、繊維材料の坪量が最も高い部分は、基準位置0mmからの距離が480~510mmの部分であり、吸水性ポリマーの坪量が最も高い部分は、基準位置0mmからの距離が420~450mmの部分であり、位置の差(絶対値)は510から450を減算した60で、吸収体の長さ333mmの1/4以下である。
このように、繊維材料の坪量が最も高い部分と吸水性ポリマーの坪量が最も高い部分の位置の差(絶対値)が、吸収体の長手方向の長さの1/4以下の場合、吸収体の長手方向において、繊維材料の坪量が最も高い部分と吸水性ポリマーの坪量が最も高い部分とが一致しているものとする。本発明で製造する吸収体及び本発明の吸収体は、吸収体を長手方向の一端から30mm間隔で順次分割したときに、繊維材料の坪量が最も高い部分と吸水性ポリマーの坪量が最も高い部分とが、同一の部分であるか、隣り合う部分であるか、間に一つ若しくは二つの部分を挟む2つの部分であることが好ましく、同一の部分であるか、隣り合う部分であるか、間に一つの部分を挟む2つの部分であることが更に好ましい。
図11に示す装置を用いて吸収体を製造した。原料シート31Aとしては、木材パルプシートを用い、その粉砕機51に対する供給量を図12(a)に示すように変化させて、繊維材料の坪量が高い部分と低い部分とを有する図4に示す形態の吸収体3を製造した。吸収体3の製造中には、集積用凹部の底面には全域に亘って均一な吸引力を生じさせた。また、吸水性ポリマー32の供給は行わなかった。また、製造中には、吸収体3の繊維材料の偏在状態を、表面変位計測器を用いて監視したところ、その繊維材料の偏在状態は常時安定していた。
〔実施例12~15、比較例11~13〕
ダクト4の回転ドラム2付近の形態を、表3中の「ダクト形状」に示すものに変更するとともに、集積用凹部のドラム長手方向の長さを、表3中に示す通りに変更する以外は、実施例11と同様にして吸収体を製造した。集積用凹部のドラム長手方向の長さは、製造した吸収体の長手方向の長さに一致する。比較例11~13については、木材パルプシートを粉砕機51に対して常時一定の速度で供給した。表3中の「パルプ供給量制御」の欄の「有」は、木材パルプシートの供給量を周期的に変化させたことを意味する。
表3中の「ダクト形状」の欄に示すダクトである形状1~4は、下記の通りである。
形状1:図11に示す形状,ダクト開口部の長さ940mm
形状2:図6(a)に示す形状,ダクト開口部の長さ520mm
形状3:図6(b)に示す形状,ダクト開口部の長さ346mm
形状4:図6(c)に示す形状,ダクト開口部の長さ173mm
ダクト4の回転ドラム2付近の形態を、表4中の「ダクト形状」に示すものに変更するとともに、集積用凹部のドラム長手方向の長さを、表4中に示す通りに変更する以外は、実施例11と同様にして吸収体を製造した。参考例11~14については、パルプ供給量の制御を行ったが、回転ドラム側に開口するダクト開口部のドラム周方向の長さaの、前記集積用凹部のドラム周方向の長さbに対する比が3.0超であった。
実施例11~15、比較例11~13及び参考例11~14において得られた各吸収体について、繊維材料の坪量が最も高い部分と繊維材料の坪量が最も低い部分との坪量比(以下、偏在倍率ともいう)を前述した方法により測定して表3及び表4に示した。
Claims (38)
- 外周面に集積用凹部が形成された回転ドラムに、繊維材料を飛散状態にて供給し、該繊維材料を前記集積用凹部内に吸引により堆積させて所定形状の吸収体を得る吸収体の製造方法であって、
繊維材料の単位時間当たりの供給量を、集積用凹部の回転移動周期に合わせて周期的に変化させることによって、繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とを有する吸収体を得る、吸収体の製造方法。 - 前記集積用凹部は、底面全体に均一な吸引力を生じるものである、請求項1に記載の吸収体の製造方法。
- 前記回転ドラムに飛散状態で供給する繊維材料を、繊維材料の原料シートを解繊機に供給して生じさせるとともに、該原料シートの解繊機に対する単位時間当たりの供給量を変化させることによって、前記回転ドラムに飛散状態で供給する繊維材料の単位時間当たりの供給量を周期的に変化させる、請求項1又は2に記載の吸収体の製造方法。
- 原料供給用の供給ローラの回転速度を周期的に変化させ、繊維材料の原料シートを解繊機に供給する速度を周期的に変化させることによって、ダクト内に供給する繊維材料の単位時間当たりの供給量を周期的に変化させる、請求項1~3の何れか1項に記載の吸収体の製造方法。
- 供給量制御部によりダクトへと供給される繊維材料の質量を、ダクトに相対的に少ない量の繊維材料を供給するステップとダクトに相対的に多い量の繊維材料を供給するステップとが交互に繰り返されるパターンで、周期的に変化させ、供給量を変えて繊維材料を連続して供給し、回転ドラムの外周面に到達する繊維材料の質量を、周期的に変化させる、請求項1~4の何れか1項に記載の吸収体の製造方法。
- ダクトに繊維材料を供給しないステップとダクトに繊維材料を供給するステップとが交互に繰り返されるパターンで、周期的に変化させ、回転ドラムの外周面に到達する繊維材料の質量を、周期的に変化させる、請求項1~5の何れか1項に記載の吸収体の製造方法。
- 原料供給用の供給ローラの駆動モーターとして、サーボモーターを用いる、請求項1~6の何れか1項に記載の吸収体の製造方法。
- 集積用凹部の回転方向前端に対応する一端側に、相対的に繊維材料の坪量が高い高坪量部が形成され、集積用凹部の回転方向後端に対応する他端側に、相対的に繊維材料の坪量が低い低坪量部を形成する、請求項1~7の何れか1項に記載の吸収体の製造方法。
- 吸収体を、搬送手段としてバキュームコンベアやベルトコンベアにより搬送する際に、長手方向が搬送方向に沿い、高坪量部を有する一端が、搬送方向の下流側に向ける、請求項1~8の何れか1項に記載の吸収体の製造方法。
- ダクト開口部のドラム周方向の長さは、集積用凹部のドラム周方向の長さに対する比が、0超2.0以下である、請求項1~9の何れか1項に記載の吸収体の製造方法。
- 回転ドラムの外周面に、繊維材料の坪量が相対的に高い部分(高坪量部)と繊維材料の坪量が相対的に低い部分(低坪量部)とが波状的に形成される、請求項1~10の何れか1項に記載の吸収体の製造方法。
- 吸収体は、繊維材料の坪量が最も低い部分の坪量に対する、繊維材料の坪量が最も高い部分の坪量の比が、1.5以上30以下である、請求項1~11の何れか1項に記載の吸収体の製造方法。
- 吸収体は、繊維材料の坪量が最も高い部分の坪量は、100g/m2以上3000g/m2以下である、請求項1~12の何れか1項に記載の吸収体の製造方法。
- 繊維材料は、全体又は一部がパルプ繊維であり、繊維材料中のパルプ繊維の割合は50質量%以上100質量%以下である、請求項1~13の何れか1項に記載の吸収体の製造方法。
- 前記繊維材料を搬送する空気流中に吸水性ポリマーを供給し、吸水性ポリマーを有する吸収体を得る、請求項1~14の何れか1項に記載の吸収体の製造方法。
- 前記繊維材料を搬送する空気流中に、吸水性ポリマーを単位時間当たりの供給量を一定として供給し、前記吸収体として、繊維材料の坪量が相対的に高い部分に、繊維材料の坪量が相対的に低い部分より多くの吸水性ポリマーを有する吸収体を得る、請求項1~15の何れか1項に記載の吸収体の製造方法。
- 粉砕機の直後にシャッターを設け、開閉操作することによりダクトへの繊維材料の供給量を周期的に変化させる、請求項1~16の何れか1項に記載の吸収体の製造方法。
- 前記集積用凹部の底面に、開口面積率の高い第1吸引領域と第1吸引領域よりも開口面積率の低い第2吸引領域を設け、これら両吸引領域に前記繊維材料を堆積させる、請求項1~17の何れか1項に記載の吸収体の製造方法。
- 吸収体は、吸収性物品の吸収体として用いられ、吸収性物品は、人体から排出される液の吸収に用いられる物品である、請求項1~18の何れか1項に記載の吸収体の製造方法。
- 吸収性物品が、使い捨ておむつ、生理用ナプキン、失禁パッド、パンティライナーの何れか1である、請求項1~19の何れか1項に記載の吸収体の製造方法。
- 前記吸収体は、使い捨ておむつに用いられる吸収体として、高坪量部が腹側(前側)、低坪量部が背側(後側)となるように吸収性物品に組み込まれて使用されるものである、請求項1~20の何れか1項に記載の吸収体の製造方法。
- 繊維材料及び吸水性ポリマーを含む吸収体であって、
前記繊維材料の坪量及び前記吸水性ポリマーの坪量が、それぞれ、吸収体の長手方向において変化しており、
前記吸収体の長手方向において、前記繊維材料の坪量が最も高い部分と前記吸水性ポリマーの坪量が最も高い部分とが一致しており、
坪量が最も高い部分と坪量が最も低い部分との坪量比である偏在倍率が、前記繊維材料と前記吸水性ポリマーとで異なる、吸収体。 - 前記繊維材料の前記偏在倍率が、前記吸水性ポリマーの前記偏在倍率より高い、請求項22に記載の吸収体。
- 前記吸収体の長手方向において、前記繊維材料の坪量がなだらかに変化している、請求項22又は23に記載の吸収体。
- 外周面に複数の集積用凹部が所定の間隔で形成された回転ドラムと、該回転ドラムの外周面に向けて、吸収体材料としての繊維材料を飛散状態にて供給するダクトと、該ダクト内に繊維材料を供給する繊維材料供給部と、集積用凹部内に、繊維材料が堆積して生じた堆積物を、吸収体として該集積用凹部から離型させる離型手段とを備え、前記ダクトへの前記繊維材料の単位時間当たりの供給量を変化させることによって、個々の吸収体中に繊維材料の坪量が相対的に高い部分と繊維材料の坪量が相対的に低い部分とを有する吸収体を製造する吸収体の製造装置であって、
前記吸収体又は前記堆積物における繊維材料の偏在状態を計測し、計測した偏在状態に基づき、繊維材料供給部によるダクトへの繊維材料の供給量を変化させる供給量制御部を備える、吸収体の製造装置。 - 回転ドラム側に開口するダクト開口部のドラム周方向の長さの、前記集積用凹部のドラム周方向の長さに対する比が2.0以下である、請求項25に記載の吸収体の製造装置。
- 前記供給量制御部は、予め記憶部に登録されている繊維材料の偏在状態に合致する偏在状態の吸収体を製造するように、繊維材料の供給量を変化させる、請求項25又は26に記載の吸収体の製造装置。
- 前記吸収体又は前記堆積物における繊維材料の偏在状態の計測に、表面変位計測器、画像処理又は静電容量センサーが用いられる、請求項25~27の何れか1項に記載の吸収体の製造装置。
- 前記回転ドラムは、円筒状のドラム本体と、該ドラム本体の外周部に重ねて配され、回転ドラムの外周面を形成する外周部材とを含んで構成されており、前記外周部材は、その外周部に、多孔性プレートと、該多孔性プレートの外面側に重ねて固定されたパターン形成プレートとを有し、前記集積用凹部の底面が、該多孔性プレートから形成されている、請求項25~28の何れか1項に記載の吸収体の製造装置。
- 前記多孔性プレートは、前記ドラム本体側からの吸引によって生じた空気流を回転ドラムの外方に伝え、該空気流に乗って運ばれてくる吸収体材料を透過させずに保持し、空気のみを透過させる通気性のプレートである、請求項29に記載の吸収体の製造装置。
- 前記ダクトは、前記繊維材料供給部から前記回転ドラムに亘って延びており、
前記繊維材料供給部は、解繊機として粉砕機を備えており、繊維材料の原料シートが、原料供給ローラにより粉砕機に導入され、粉砕機により解繊されて生じた繊維材料が前記ダクト内に供給される、請求項25~30の何れか1項に記載の吸収体の製造装置。 - 前記繊維材料供給部は、前記原料シートを前記粉砕機に送り込む一対の供給ローラと、該供給ローラを回転駆動させる駆動モーターとを備えている、請求項31に記載の吸収体の製造装置。
- 前記駆動モーターの回転数を上げることで、前記ダクトに対する繊維材料の単位時間当たりの供給量が増加し、該駆動モーターの回転数を下げることで、前記ダクトに対する繊維材料の単位時間当たりの供給量が減少する、請求項32に記載の吸収体の製造装置。
- 前記供給量制御部は、表示部及び入力部を備えたコンピュータ、該コンピュータと他の装置等とを電気的に接続するインターフェース、及び該コンピュータに組み込まれた所定のプログラム等から構成されている、請求項25~33の何れか1項に記載の吸収体の製造装置。
- コンピュータを備え、該コンピュータは、前記駆動モーターに対して制御信号を出力して駆動モーターの回転を制御することにより、前記原料シートの前記粉砕機への供給量を制御して、前記ダクト内への前記繊維材料の供給量を制御する、請求項31~34の何れか1項に記載の吸収体の製造装置。
- 前記集積用凹部から離型された吸収体の上下面を被覆シートで被覆して吸収体連続体を得る機構、及びその吸収体連続体を、個々の吸収性物品に使用される長さの吸収体に切断する切断装置を備えている、請求項25~35の何れか1項に記載の吸収体の製造装置。
- 前記供給量制御部によって、前記原料シートを前記粉砕機に供給する速度を変化させる周期と、前記集積用凹部が、前記ダクトに覆われた部分を通過する周期とを一致させる、請求項31~36の何れか1項に記載の吸収体の製造装置。
- 前記ダクトにおける前記回転ドラムと前記繊維材料供給部との間には、吸収体材料の他の一種である吸水性ポリマーを該ダクトに供給する散布管が設けられている、請求項25~37の何れか1項に記載の吸収体の製造装置。
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CN107522159A (zh) * | 2017-09-30 | 2017-12-29 | 安徽珂力智能电气有限公司 | 多供料高克重高速床垫成型机 |
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WO2023112760A1 (ja) * | 2021-12-16 | 2023-06-22 | ユニ・チャーム株式会社 | 吸収性物品 |
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BR112017013115A2 (pt) | 2018-01-02 |
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