WO2018116996A1

WO2018116996A1 - Composite sheet manufacturing method and manufacturing apparatus

Info

Publication number: WO2018116996A1
Application number: PCT/JP2017/045200
Authority: WO
Inventors: 圭介黒田; 松永　竜二; 進之介森田; 数馬齊藤
Original assignee: 花王株式会社
Priority date: 2016-12-19
Filing date: 2017-12-15
Publication date: 2018-06-28
Also published as: TWI742214B; TW201827233A

Abstract

A composite sheet manufacturing method is provided with: a step of introducing a first sheet (1) into a meshing part (33) and deforming the first sheet (1) into a concavo-convex shape while rotating a first roll (31) and a second roll (32) having meshing concavities and convexities on peripheral surface parts thereof; a step of conveying the first sheet (1), deformed into the concavo-convex shape, while carrying the same on the first roll (31), and overlapping a second sheet (2) with the first sheet (1) being conveyed; and a step of sandwiching the overlapped sheets (1 and 2) between a convex part (35) of the first roll (31) and an ultrasonic horn (42) of a ultrasonic welding machine, and applying ultrasonic vibrations. During the application of the ultrasonic vibrations in the ultrasonic treatment step, a welded part (4) having a through-hole (14) is formed.

Description

Composite sheet manufacturing method and manufacturing apparatus

The present invention relates to a method and an apparatus for manufacturing a composite sheet.

As a surface sheet of an absorbent article such as a disposable diaper or a sanitary napkin, there is known one having irregularities formed on a surface that comes into contact with a wearer's skin.
For example, the present applicant has a large number of fused portions in which the first and second sheets are fused, and a portion other than the fused portions in the first sheet protrudes on the side opposite to the second sheet side. The composite sheet which forms the part is proposed. Since such a composite sheet has irregularities formed on the surface, it is excellent in the touch and the liquid diffusion preventing property.
In addition, it is also known that through holes are formed in the fused portion of such a composite sheet to improve liquid drawing-in properties (see Patent Documents 1 and 2). In Patent Document 2, in order to form a fused part having a through hole, a small convex part for forming an opening having a step between the peripheral shoulder part is provided at the tip part of the convex part of the uneven roll. It is also described that two sheets are sandwiched between the small convex part and the anvil roll and heated to form a fused part having an opening.

JP 2006-175688 A JP 2006-175688 A

The present invention has a large number of fused portions in which the first sheet and the second sheet are fused, and at least a portion of the first sheet other than the fused portion is opposite to the second sheet side. It is the manufacturing method of the composite sheet which forms the convex part which protruded in the side. While rotating the first roll and the second roll having unevenness meshing with each other on the peripheral surface part, the first sheet was introduced into the meshing part of both rolls and deformed into an uneven shape, and deformed into an uneven shape. The first sheet is transported while being held on the first roll, the superimposing step of superimposing the second sheet on the first sheet being transported, and both the superposed sheets are disposed on the first roll. And an ultrasonic treatment step of applying ultrasonic vibration sandwiched between the convex portion and the ultrasonic horn of the ultrasonic fusion machine. In the ultrasonic treatment step, the fusion part having a through hole is formed when the ultrasonic vibration is applied.

Further, the present invention has a large number of fused portions in which the first sheet and the second sheet are fused, and at least a part of the first sheet other than the fused portion is defined as the second sheet side. It is the manufacturing apparatus of the composite sheet which forms the convex part which protruded on the opposite side. An unevenness shaping portion that has a first roll and a second roll having unevenness meshing with each other on a peripheral surface portion, and deforms the first sheet introduced into the meshing portion of both rolls into an uneven shape, and an ultrasonic fusion machine. And after superposing the second sheet on the first sheet in a state of being deformed into a concavo-convex shape, the two sheets are connected to the convex portion of the first roll and the ultrasonic horn of the ultrasonic fusion machine. And an ultrasonic processing unit that partially applies ultrasonic vibration to form the fused part having a through hole.

FIG. 1 is a perspective view of a main part showing an example of a composite sheet manufactured by the composite sheet manufacturing method and apparatus of the present invention. FIG. 2 is an enlarged plan view of the composite sheet shown in FIG. 1 viewed from the first sheet side. FIG. 3 is a schematic view showing a first embodiment of a method for manufacturing a composite sheet of the present invention and a first embodiment of a composite sheet manufacturing apparatus of the present invention. FIG. 4 is an enlarged perspective view showing a main part of the first roll shown in FIG. FIG. 5 is a view showing a main part of the ultrasonic welder shown in FIG. 3, and is a view showing a state viewed from the left side in FIG. FIG. 6 is a diagram showing a main part of a second embodiment of the method for manufacturing a composite sheet of the present invention and a second embodiment of the apparatus for manufacturing a composite sheet of the present invention. FIG. 7 is a diagram showing a main part of a third embodiment of the method for manufacturing a composite sheet of the present invention and a third embodiment of the apparatus for manufacturing a composite sheet of the present invention. FIG. 8A is a view showing another example of an ultrasonic horn provided with a heat-synthetic synthetic resin layer at the tip, and FIG. 8B is an ultrasonic horn made of a metal such as a titanium alloy. It is a figure which shows the state which formed only the connection layer by the thermal spraying in the front end surface of the main-body part.

Detailed Description of the Invention

When manufacturing the composite sheet, if the fusion part and the through hole are formed in different steps, a positional deviation may occur between the position of the fusion part and the position of the through hole. The method of providing the small convex portion at the tip of the convex portion described in Patent Document 2 has room for improvement in that the small convex portion is easily worn and the maintenance burden is large.

Therefore, the present invention relates to a composite sheet manufacturing method and a manufacturing apparatus that can solve the problems of the prior art.

The present invention will be described below based on preferred embodiments with reference to the drawings.
First, the composite sheet manufactured by the manufacturing method or manufacturing apparatus of the composite sheet of this invention is demonstrated, referring FIG.
A composite sheet 10 shown in FIG. 1 is an example of a composite sheet manufactured by the composite sheet manufacturing method or manufacturing apparatus of the present invention. As shown in FIG. 1, the first sheet 1 and the second sheet 2 are fused. In the first sheet 1, at least a part of the portion other than the fusion part 4 forms a convex part 5 that protrudes on the side opposite to the second sheet 2 side.
The composite sheet 10 is preferably used as a surface sheet of an absorbent article. When used as a top sheet of an absorbent article, the first sheet 1 forms a surface directed to the wearer's skin (hereinafter also referred to as a skin-facing surface), and the second sheet 2 faces the absorber when worn. A surface to be directed (hereinafter also referred to as a non-skin facing surface) is formed.

The convex portions 5 and the fused portions 4 are arranged alternately and in a line in the X direction in FIG. 1, which is one direction parallel to the surface of the composite sheet 10. It is formed in multiple rows in the Y direction in FIG. 1, which is a direction parallel to the surface of the sheet 10 and perpendicular to the one direction. The convex portions 5 and the fused portions 4 in the rows adjacent to each other are each shifted in the X direction, and more specifically, are shifted by a half pitch.
In the composite sheet 10, the Y direction coincides with the flow direction (MD, machine direction) at the time of manufacture, and the X direction coincides with a direction (CD) orthogonal to the flow direction at the time of manufacture.

The first sheet 1 and the second sheet 2 are made of sheet material. As the sheet material, for example, a fiber sheet such as a nonwoven fabric, a woven fabric, and a knitted fabric, a film, and the like can be used. From the viewpoint of touch and the like, it is preferable to use a fiber sheet, and it is particularly preferable to use a nonwoven fabric. The kind of sheet material which comprises the 1st sheet | seat 1 and the 2nd sheet | seat 2 may be the same, or may differ.

As a nonwoven fabric in the case of using a nonwoven fabric as the sheet material constituting the first sheet 1 and the second sheet 2, for example, an air-through nonwoven fabric, a spunbond nonwoven fabric, a spunlace nonwoven fabric, a meltblown nonwoven fabric, a resin bond nonwoven fabric, a needle punched nonwoven fabric, etc. It is done. A laminate obtained by combining two or more of these nonwoven fabrics, or a laminate obtained by combining these nonwoven fabrics and a film can also be used. The basis weight of the nonwoven fabric used as the sheet material constituting the first sheet 1 and the second sheet 2 is preferably 10 g / m ² or more, more preferably 15 g / m ² or more, and preferably 40 g / m ² or less. More preferably, it is 35 g / m ² or less. The basis weight of the nonwoven fabric is preferably 10 g / m ² or more and 40 g / m ² or less, and more preferably 15 g / m ² or more and 35 g / m ² or less.

As the fibers constituting the nonwoven fabric, fibers made of various thermoplastic resins can be used. As the sheet material other than the nonwoven fabric, those in which the constituent fibers and the constituent resins are made of various thermoplastic resins are preferably used.
Examples of thermoplastic resins include polyolefins such as polyethylene, polypropylene and polybutene, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyamides such as nylon 6 and nylon 66, polyacrylic acid, polymethacrylic acid alkyl ester, polyvinyl chloride, and polychlorinated. Examples include vinylidene. These resins can be used alone or as a blend of two or more. Further, it can be used in the form of a composite fiber such as a core-sheath type or a side-by-side type.

As shown in FIG. 1, the composite sheet 10 has a large number of concave portions 3 sandwiched between convex portions 5 in both the X direction and the Y direction on the surface on the first sheet 1 side. 3 is formed with a fused portion 4 having a through-hole 14. When viewed as a whole, the composite sheet 10 has a large uneven surface composed of the concave portion 3 and the convex portion 5 on the surface on the first sheet 1 side, and the surface on the second sheet 2 side is flat. Or a substantially flat surface with relatively small undulations relative to the surface on the first sheet 1 side.

As shown in FIG. 2, each fused portion 4 in the composite sheet 10 has a substantially rectangular plan view shape that is long in the Y direction, and the plan view shape is substantially rectangular inside each. Through-holes 14 are formed. In other words, each fusion part 4 is formed in an annular shape surrounding the through hole 14. It is preferable that only one through hole 14 is formed in one fusion part 4, and it is preferable that the through hole 14 is formed in a specific position that is predetermined in relation to the position of the fusion part 4. In addition, the through hole 14 may have a shape in plan view that is similar to or not similar to the shape in plan view of the outer peripheral edge of the fused portion 4, but is preferably similar.
In the fusion | melting part 4, the 1st sheet | seat 1 and the 2nd sheet | seat 2 are couple | bonded by the heat-fusible resin which comprises at least one of the 1st sheet | seat 1 and the 2nd sheet | seat 2 being melted and solidified. . When the 1st sheet 1 and the 2nd sheet 2 are comprised from fiber sheets, such as a nonwoven fabric, in the melt | fusion part 4, the constituent fibers of the 1st sheet 1 and the 2nd sheet 2 are melted or melted resin It is preferable that the fiber-like form cannot be observed by visual inspection, that is, it is in a film state in appearance.

Next, the 1st embodiment of the manufacturing method of the composite sheet of this invention is demonstrated.
In the first embodiment, the composite sheet 10 described above is manufactured using the composite sheet manufacturing apparatus 20 of the first embodiment shown in FIG.

The composite sheet manufacturing apparatus 20 shown in FIG. 3 will be described. The composite sheet manufacturing apparatus 20 is configured to control the unevenness shaping section 30, the ultrasonic processing section 40, and a predetermined sheet in which the sheet before applying ultrasonic vibration is controlled. Preheating means 6 for preheating to temperature is provided.
As shown in FIG. 3, the concavo-convex shaping portion 30 includes first and

second rolls

31 and 32 having concavo-convex meshing with each other on the peripheral surface portion, and while rotating both the

rolls

31 and 32, By introducing the first sheet 1 into the meshing portion 33 of 32, the first sheet 1 is deformed into an uneven shape along the uneven shape of the peripheral surface portion of the first roll 31.

FIG. 4 is an enlarged perspective view showing a main part of the first roll 31. FIG. 4 shows a part of the peripheral surface portion of the first roll 31.
The first roll 31 is formed in a roll shape by combining a plurality of

spur gears

31a, 31b,... Having a predetermined tooth width. The teeth of each gear form a concavo-convex convex portion 35 in the peripheral surface portion of the first roll 31, and the tip surface 35 c of the convex portion 35 of the ultrasonic horn 42 of the ultrasonic fusion machine 41 described later is provided. It is a pressing surface that pressurizes the first and

second sheets

1 and 2 to be fused with the front end surface 42t.
The tooth width of each gear (the axial length of the gear) determines the dimension in the X direction of the convex portion 5 of the composite sheet 10, and the tooth thickness of each gear (the length in the rotational direction of the gear) is: The dimension of the Y direction in the convex part 5 of the composite sheet 10 is determined. Adjacent gears are combined such that the pitch of their teeth is shifted by half a pitch. As a result, as for the 1st roll 31, the peripheral surface part is uneven | corrugated shape. In this embodiment, the front end surface 35c of each convex portion 35 has a rectangular shape in which the rotation direction of the first roll 31 is a long side and the axial direction is a short side. If the distal end surface 35c has a longer shape in the rotational direction, the contact time with the distal end surface 42t of the ultrasonic horn 42 in one convex portion 35 of the first roll 31 can be lengthened to make it easier to raise the temperature. Therefore, it is preferable.

The tooth groove portion of each gear in the first roll 31 forms an uneven recess in the peripheral surface of the first roll 31. A suction hole 34 is formed at the bottom of the tooth groove portion of each gear. The suction hole 34 communicates with a suction source (not shown) such as a blower or a vacuum pump, and from a meshing portion 33 between the first roll 31 and the second roll 32, a joining portion between the first sheet 1 and the second sheet 2. It is controlled so that suction is performed in the interval. Therefore, the first sheet 1 deformed into the uneven shape by the engagement of the first roll 31 and the second roll 32 is deformed into a shape along the unevenness of the first roll 31 by the suction force by the suction hole 34. In a maintained state, the first sheet 1 and the second sheet 2 are conveyed to a joining portion and an ultrasonic vibration applying unit 36 by an ultrasonic fusion machine.
In this case, as shown in FIG. 4, if a predetermined gap G is provided between adjacent gears, an excessive stretching force is applied to the first sheet 1, or the meshing portion 33 of both

rolls

31, 32 It is preferable to cut the one sheet 1, and the first sheet 1 can be deformed into a shape along the peripheral surface of the first roll 31.

The second roll 32 has a concavo-convex shape that engages with the concavo-convex of the peripheral surface portion of the first roll 31 on the peripheral surface portion. The second roll 32 has the same configuration as the first roll 31 except that it does not have the suction hole 34. Then, while rotating the first and

second rolls

31 and 32 having unevenness that mesh with each other, the first sheet 1 is introduced into the meshing portion 33 of both the

rolls

31 and 32 to make the first sheet 1 uneven. Can be deformed. In the meshing portion 33, a plurality of locations of the first sheet 1 are pushed into the concave portion of the peripheral surface portion of the first roll 31 by the convex portion of the second roll 32, and the pushed portion of the composite sheet 10 to be manufactured. Protrusions 5 are formed. A plurality of convex portions to be inserted into the concave portions of the first roll 31 are formed on the peripheral surface portion of the second roll 32, but the convex portions corresponding to all of the concave portions of the first roll 31 are formed on the second roll 32. It is not essential that is formed.

As illustrated in FIG. 3, the ultrasonic processing unit 40 includes an ultrasonic fusion machine 41 including an ultrasonic horn 42, and the second sheet 2 is formed on the first sheet 1 that is deformed into an uneven shape. The two sheets are sandwiched between the convex portion of the first roll 31 and the ultrasonic horn 42, and ultrasonic vibration is partially applied to form the fused portion 4 having the through hole 14. To do.

As shown in FIGS. 3 and 5, the ultrasonic fusion machine 41 includes an ultrasonic oscillator (not shown), a converter 43, a booster 44, and an ultrasonic horn 42. The ultrasonic oscillator (not shown) is electrically connected to the converter 43, and a high-voltage electric signal having a wavelength of about 15 kHz to 50 kHz generated by the ultrasonic oscillator is input to the converter 43. An ultrasonic oscillator (not shown) is installed on the movable table 45 or outside the movable table 45.
The converter 43 includes a piezoelectric element such as a piezoelectric element, and converts an electric signal input from the ultrasonic oscillator into mechanical vibration by the piezoelectric element. The booster 44 adjusts the amplitude of the mechanical vibration emitted from the converter 43, preferably amplifies it, and transmits it to the ultrasonic horn 42. The ultrasonic horn 42 is made of a lump of metal such as an aluminum alloy or a titanium alloy, and is designed to resonate correctly at the frequency used. The ultrasonic vibration transmitted from the booster 44 to the ultrasonic horn 42 is also amplified or attenuated in the ultrasonic horn 42 and applied to the first and

second sheets

1 and 2 to be fused. As such an ultrasonic fusion machine 41, a commercially available ultrasonic horn, converter, booster, and ultrasonic oscillator can be used in combination.

The ultrasonic fusion machine 41 is fixed on the movable table 45, and the front surface of the ultrasonic horn 42 is moved by moving the position of the movable table 45 toward and away from the circumferential surface of the first roll 31. The clearance between 42t and the front end surface 35c of the convex portion 35 of the first roll 31 and the pressure applied to the stacked first and

second sheets

1 and 2 can be adjusted.
The first and second objects to be fused are pressed while being sandwiched between the tip surface 35 c of the convex portion 35 of the first roll 31 and the tip surface 42 t of the ultrasonic horn 42 of the ultrasonic fusion machine 41. By applying ultrasonic vibration to the

sheets

1 and 2, each of the portions of the first sheet 1 located on the front end surface 35 c of the convex portion 35 is fused to the second sheet 2, and the fused portion 4 is While being formed, the through hole 14 penetrating both

sheets

1 and 2 is formed in a state surrounded by the melted portion.

In the preferred embodiment, the composite sheet manufacturing apparatus 20 includes preheating means 6 having a heater 61 disposed in the first roll 31. More specifically, a heating unit such as a heater 61 disposed in the first roll 31, a temperature measuring unit (not shown) capable of measuring the temperature of the sheet before applying ultrasonic vibration, and a temperature measuring unit Is provided with a temperature control unit (not shown) for controlling the temperature of the heater 61 based on the measured value. By controlling the heating temperature of the peripheral surface portion of the first roll 31 by the heater 61 based on the measured value by the temperature measuring means, the temperature of the first sheet 1 immediately before the ultrasonic vibration is applied is increased to a desired temperature. The accuracy can be controlled.
In a preferred embodiment, the heater 61 is embedded in the first roll 31 along the axial direction thereof. A plurality of heaters 61 are arranged in the vicinity of the outer peripheral portion around the rotation axis of the first roll 31 with an interval in the circumferential direction. The heating temperature of the peripheral surface portion of the first roll 31 by the heater 61 is controlled by a temperature control unit (not shown), and the first sheet introduced into the ultrasonic vibration applying unit 36 during the operation of the composite sheet manufacturing apparatus 20. The temperature of 1 can be maintained within a predetermined range of temperatures.

It is preferable that the preheating means 6 includes a heating means for heating the object to be heated by applying heat energy from the outside. Examples of the heating means include a cartridge heater using a heating wire, but are not limited thereto, and various known heating means can be used without particular limitation.
The ultrasonic fusion machine applies ultrasonic vibration to a fusion target object, thereby fusing and melting the fusion target object, and is not included in the heating means here.

In the manufacturing method of the first embodiment of the present invention, as shown in FIG. 3, the first sheet 1 fed out from a raw roll (not shown) is rotated while rotating the first and

second rolls

31 and 32. Then, the

rolls

31 and 32 are introduced into the meshing portion 33 and deformed into an uneven shape (shaping step). And the 1st sheet | seat 1 deform | transformed into the uneven | corrugated shape is conveyed, hold | maintaining on the 1st roll 31, and the original fabric roll (not shown) different from the 1st sheet | seat 1 is conveyed to the 1st sheet | seat 1 being conveyed. The second sheet 2 fed out from (1) is superposed (superimposing step). And the ultrasonic vibration is applied by sandwiching the two

sheets

1 and 2 overlapped between the convex portion 35 of the first roll 31 and the ultrasonic horn 42 of the ultrasonic fusion machine (ultrasonic processing step). . In the ultrasonic processing step, the fused portion 4 having the through hole 14 is formed when ultrasonic vibration is applied.

In the manufacturing method of the first embodiment, prior to the application of the ultrasonic vibration, at least one of the first sheet 1 and the second sheet 2 is heated to a temperature lower than the melting point of the sheet and at a temperature 50 ° C. lower than the melting point. It is preferable to keep it. That is, it is preferable to perform one or both of the following (1) and (2) prior to application of ultrasonic vibration.
(1) The first sheet 1 is heated to a temperature below the melting point of the first sheet and at a temperature lower by 50 ° C. than the melting point.
(2) The second sheet 2 is heated to a temperature lower than the melting point of the second sheet and 50 ° C. lower than the melting point.
Preferably, the first sheet 1 is heated to a temperature lower than the melting point of the first sheet and 50 ° C. lower than the melting point, and the second sheet 2 is heated to a temperature lower than the melting point of the second sheet and 50 higher than the melting point. Heat to a temperature lower than ℃.

As a method of setting the first sheet 1 to a temperature lower than the melting point of the first sheet 1 and 50 ° C. lower than the melting point, for example, the temperature of the first sheet 1 on the first roll 31 is set to the first and second rolls. The first roll 31 is measured so that the measurement value is within the specific range described above, and is measured between the meshing portion 33 of 31 and 32 and the ultrasonic vibration applying unit 36 by the ultrasonic fusion machine. Control the temperature of the peripheral surface. As a method of preheating the first sheet 1 to a specific range of temperatures, the temperature of the peripheral surface portion of the first roll 31 is set in the first roll 31 so that the first sheet 1 has a specific range of temperatures. Various methods can be used in place of the method of controlling with the heater arranged. For example, a heater, a hot air outlet, and a far-infrared irradiation device are provided in the vicinity of the peripheral surface portion of the first roll 31, and thereby the temperature of the peripheral surface portion of the first roll 31 before or after the first sheet 1 is aligned. A method of controlling the temperature, a method of heating the second roll 32 in contact with the first sheet 1 at the meshing portion 33, and controlling the temperature of the first sheet 1 by controlling the temperature of the peripheral surface portion thereof, and before the alignment with the first roll 31 Examples of the first sheet 1 include a method in which the first sheet 1 is brought into contact with a heated roller, passed through a space maintained at a high temperature, and hot air is blown.
On the other hand, as a method of setting the second sheet 2 to a temperature lower than the melting point of the second sheet and 50 ° C. lower than the melting point, the temperature of the second sheet before joining the first sheet 1 is adjusted by conveying the second sheet. Measured by a temperature measuring means arranged in the path, and a second sheet heating means (not shown) arranged in the second sheet conveyance path so that the measured value is within the specific range described above. It is preferable to control the temperature. The heating means of the second sheet may be a contact method such as contacting a heated roller or the like, or a non-contact type such as passing through a space maintained at a high temperature, blowing hot air, penetrating, or irradiating infrared rays. But you can.

The melting points of the first sheet 1 and the second sheet 2 are measured by the following method.
For example, a differential scanning calorimeter (DSC) PYRIS manufactured by Perkin-Elmer
Measure using a Diamond DSC. Calculate the melting point from the peak value of the measurement data. When the first sheet 1 or the second sheet 2 is a fiber sheet such as a nonwoven fabric, and the constituent fiber is a composite fiber composed of a plurality of components such as a core-sheath type and a side-by-side type, the melting point of the sheet The melting point of the lowest temperature among the melting points measured by DSC is the melting point of the composite fiber sheet.

In the composite sheet manufacturing method according to the first embodiment, the first and

second sheets

1 and 2 that are overlapped in this way are formed with a convex portion of the first roll 31 and an ultrasonic horn 42 of an ultrasonic fusion machine. Ultrasonic vibration is applied between them to form the fused portion 4 having the through hole 14. In the composite sheet manufacturing method according to the first embodiment, at least one of the first and

second sheets

1 and 2 is preheated to a temperature in the specific range described above in which the sheet does not melt, Alternatively, it is preferable to apply ultrasonic vibration to both

sheets

1 and 2 in a state where both are preheated. At this time, conditions for applying the ultrasonic vibration, for example, the wavelength and intensity of the ultrasonic vibration to be applied, the pressure for pressurizing both

sheets

1 and 2 are adjusted, and both

sheets

1 and 2 are adjusted by ultrasonic vibration. Is melted to form the fused portion 4, and the through hole 14 penetrating both the

sheets

1 and 2 is formed in a state surrounded by the melted portion.

According to the method of manufacturing the composite sheet of the first embodiment, at least one of the first sheet 1 and the second sheet 2, preferably both, is heated to such a high temperature that the sheet is not melted by heating means such as a heater. Heating in advance, and then applying ultrasonic vibration while applying pressure between the convex portion 35 of the first roll 31 and the ultrasonic horn 42 of the ultrasonic fusing machine, and fusing having the through hole 14 By forming the portion 4, it is possible to more reliably form the fused portion 4 having the through-holes 14 than when both the

sheets

1 and 2 are not preheated, and both the

sheets

1 and 2 exceed the melting point. Inconveniences that are likely to occur when the temperature is preheated, for example, inconveniences such as adhesion of the molten resin to the conveying means and wrapping of the sheet around the conveying rolls are less likely to occur, so the maintenance burden on the apparatus is small.
Further, by simultaneously forming the fusion part 4 and the through-hole 14 between the convex part 35 of the first roll 31 and the ultrasonic horn 42 of the ultrasonic fusion machine, the position of the fusion part 4 is determined. There is no misalignment between the position of the through hole 14 and the through hole 14.

Since the composite sheet 10 obtained by the method for manufacturing a composite sheet according to the first embodiment has unevenness and has a fused portion 4 having a through hole 14 at the bottom of the concave portion, it prevents touch and the diffusion of liquid in the planar direction. In addition, it has excellent breathability and liquid draw-in.
The composite sheet 10 is preferably used as a surface sheet of an absorbent article taking advantage of such characteristics, but the application of the composite sheet 10 is not limited thereto.

From the viewpoint of ensuring that the above-described one or more effects are more reliably exhibited, the manufacturing method and the manufacturing apparatus of the present invention preferably have the following configuration.
(1) The first sheet 1 is preferably preheated to a temperature that is 50 ° C. lower than the melting point of the first sheet 1 and lower than the melting point, and is 20 ° C. lower than the melting point of the

first sheet

1 and 5 ° C. higher than the melting point. It is more preferable to preheat to a lower temperature or lower.
(2) The second sheet 2 is preferably preheated to a temperature of 50 ° C. lower than the melting point of the second sheet 2 or lower and lower than the melting point of the second sheet 2. It is more preferable to preheat to a temperature below a low temperature.

The preheating temperature of each of the first sheet 1 and the second sheet 2 is preferably 100 ° C. or higher, more preferably 130 ° C. or higher, from the viewpoint of easy formation of the through holes 14, and prevention of adhesion to the conveying means. Or from the viewpoint of preventing winding around the transport roll, it is preferably 150 ° C. or lower, more preferably 145 ° C. or lower.

Further, from the viewpoint of ease of forming the fusion part 4 and the through-hole 14, the first and first sandwiches between the front end surface 35 c of the convex portion 35 of the first roll 31 and the front end surface 42 t of the ultrasonic horn 42. The pressure applied to the two

sheets

1 and 2 is preferably 10 N / mm or more, more preferably 15 N / mm or more, preferably 150 N / mm or less, more preferably 120 N / mm or less, and preferably 10 N. / Mm to 150 N / mm, more preferably 15 N / mm to 120 N / mm.
The applied pressure here is a so-called linear pressure, and the total tooth width (X direction) of the convex portion 35 that touches the applied pressure (N) of the ultrasonic horn 42 with the ultrasonic horn 42 (the concave portion of the first roll 31 is It is indicated by the value (pressure per unit length) divided by the length of (not including).

Further, from the viewpoint of easy formation of the fused portion 4 and the through-hole 14, the frequency of the ultrasonic vibration to be applied is preferably 15 kHz or more, more preferably 20 kHz or more, and preferably 50 kHz or less, more preferably. Is 40 kHz or less, preferably 15 kHz or more and 50 kHz or less, more preferably 20 kHz or more and 40 kHz or less.
[Frequency measurement method]
Measure the displacement of the horn tip with a laser displacement meter. The frequency is measured by setting the sampling rate to 200 kHz or more and the accuracy to 1 μm or more.

In addition, from the viewpoint of ease of forming the fusion part and the through hole, the amplitude of the ultrasonic vibration to be applied is preferably 20 μm or more, more preferably 25 μm or more, and preferably 50 μm or less, more preferably 40 μm. Or less, preferably 20 μm or more and 50 μm or less, more preferably 25 μm or more and 40 μm or less.
[Amplitude measurement method]
Measure the displacement of the horn tip with a laser displacement meter. The amplitude is measured by setting the sampling rate to 200 kHz or more and the accuracy to 1 μm or more.

Next, the 2nd and 3rd embodiment of the manufacturing method of the composite sheet of this invention is demonstrated.
In the second embodiment, the above-described composite sheet 10 is manufactured using the composite sheet manufacturing apparatus of the second embodiment whose main part is shown in FIG.
The composite sheet manufacturing apparatus of the second embodiment is only provided with means for heating the ultrasonic horn 42 of the ultrasonic fusion machine 41 in place of the heater 61 (preheating means) arranged in the first roll 31. This is different from the composite sheet manufacturing apparatus 20 described above. More specifically, the composite sheet manufacturing apparatus of the second embodiment includes a heater 62 attached to the ultrasonic horn 42 as means for heating the ultrasonic horn 42.
In the method of manufacturing the composite sheet according to the second embodiment, the temperature of the second sheet 2 immediately before the ultrasonic vibration is applied is controlled by controlling the temperature of the ultrasonic horn 42 heated by the heater 62. It is heated to a temperature lower than the melting point of 2 and 50 ° C. lower than the melting point, and in this state, sandwiched between the convex portion 35 of the first roll 31 and the ultrasonic horn 42 of the ultrasonic fusion machine, Ultrasonic vibration is applied to the first and

second sheets

1 and 2.

When the ultrasonic horn 42 is heated by heating means such as the heater 62, the first and

second sheets

1 and 2 generate heat and are heated by the preheating means in a state where ultrasonic vibration is applied by the ultrasonic fusion machine. The temperature of the finished sheet is difficult to measure. Therefore, when one or both of the first and

second sheets

1 and 2 are preheated via the heated ultrasonic horn 42, the ultrasonic horn is only heated for 30 minutes without causing ultrasonic vibration. The temperature of the tip surface 42t is measured, and the measured value is taken as the temperature of the sheet heated by the preheating means.
The points that are not particularly described in the second embodiment are the same as those in the first embodiment, and the description of the first embodiment is appropriately applied.

In the third embodiment, the above-described composite sheet 10 is manufactured using the composite sheet manufacturing apparatus of the third embodiment whose main part is shown in FIG.
The composite sheet manufacturing apparatus of the third embodiment has no preheating means for heating at least one of the first sheet and the second sheet to a predetermined temperature prior to application of ultrasonic vibration, while the tip of the ultrasonic horn 42 is not provided. The member 7 (hereinafter also referred to as “heat storage material”) having heat storage properties is arranged in the section.

In the manufacturing method of the third embodiment, the first sheet 1 is introduced into the meshing portion 33 of the first and

second rolls

31 and 32 in the same manner as the manufacturing method of the first embodiment, and is deformed into an uneven shape. Then, the first sheet 1 deformed into the concavo-convex shape is conveyed toward the ultrasonic vibration applying unit 36 while being held on the first roll 31, and the second sheet 2 is transferred to the first sheet 1 being conveyed. After the two

sheets

1 and 2 are superposed, the ultrasonic vibration applying unit 36 applies the convex portion 35 of the first roll 31 and the front end face 42t of the ultrasonic horn 42 of the ultrasonic fusion machine to the

superposed sheets

1 and 2. And apply ultrasonic vibration.
In the manufacturing method of the third embodiment, the application of the ultrasonic vibration is performed in a state where the heat storage material 7 is arranged at the tip of the ultrasonic horn 42 as shown in FIG.

According to the manufacturing method of the third embodiment, immediately after the start of operation of the composite sheet manufacturing apparatus, the temperature of the tip of the ultrasonic horn 42 made of the heat storage material 7 is the melting point of the first and

second sheets

1 and 2. When the operation is continued, the heat of the first and

second sheets

1 and 2 generated by the ultrasonic vibration is stored in the heat storage material 7, and the temperature of the heat storage material 7 is increased to increase the first sheet 1 and The melting point of the second sheet 2 is exceeded. In the state where the temperature of the heat storage material 7 is equal to or higher than the melting points of the first sheet 1 and the second sheet 2, conditions for applying ultrasonic vibration, for example, the wavelength, intensity, and both of ultrasonic vibration When the ultrasonic vibration is applied by adjusting the pressure or the like for pressurizing the

sheets

1 and 2, both the

sheets

1 and 2 are melted, and the through hole 14 that penetrates both the

sheets

1 and 2 is surrounded by the melted portion. If it forms in a state, while being able to form the fusion | fusion part 4 which has the through-hole 14 reliably, adhesion to the conveyance means of the molten resin which a sheet fuse | melts, and the winding to the conveyance roll of a sheet | seat Thus, the maintenance burden on the apparatus is small.

Further, by simultaneously forming the fusion part 4 and the through-hole 14 between the convex part 35 of the first roll 31 and the ultrasonic horn 42 of the ultrasonic fusion machine, the position of the fusion part 4 is determined. There is no misalignment between the position of the through hole 14 and the through hole 14.

The heat storage material 7 has a lower thermal conductivity than at least the metal constituting the ultrasonic horn 42.
The heat storage material 7 preferably has a thermal conductivity of 2.0 W / mK or less measured by the following method. The thermal conductivity of the heat storage material is preferably 2.0 W / mK or less, more preferably 1.0 W / mK or less from the viewpoint of making it difficult to dissipate heat to the ultrasonic horn or the atmosphere, and the sheet is efficiently heated. In view of the above, it is preferably 0.1 W / mK or more, more preferably 0.5 W / mK or more, and preferably 0.1 W / mK or more and 2.0 W / mK or less, more preferably 0.5 W / mK or more. 1.0 W / mK or less.

[Measurement method of thermal conductivity]
The thermal conductivity of the heat storage material 7 is measured using a thermal conductivity measuring device.

As the heat storage material 7, a heat-resistant material is preferably used. The heat-resistant temperature of the heat storage material 7 is preferably 150 ° C. or higher, more preferably 200 ° C. or higher, and further preferably 250 ° C. or higher. Although there is no upper limit of the heat-resistant temperature, it is 1500 ° C. or less, for example.

As the heat storage material 7, it is also possible to use a main body portion having heat storage properties and an adhesive layer for adhering the main body to the ultrasonic horn, and the thermal conductivity in that case is excluding the adhesive portion. taking measurement. As such a heat storage material, for example, commercially available products such as “glass cloth adhesive tape” manufactured by Nitto Denko and “polyimide adhesive tape for heat-resistant insulation” manufactured by Nitto Denko can also be used.
Examples of the material of the main part of the heat storage material 7 having heat storage properties include glass and polyimide, and polyimide and the like are preferable from the viewpoint of appropriate heat storage properties and high heat resistance. The heat storage material 7 may be a sheet having a single layer structure, or may be a laminate of two or more sheets made of the same or different materials.

Further, the heat storage material 7 preferably has a shape that is long in the same direction with respect to the tip surface of the ultrasonic horn 42 that is long in the axial length direction of the first roll 31. Further, from the viewpoint of preventing catching at the time of applying ultrasonic waves, the heat storage material 7 is a sheet on the tip surface 42t of the ultrasonic horn 42 in addition to the portion covering the tip surface of the ultrasonic horn 42 as shown in FIG. It is preferable to have a portion covering the corner portion 42a on the upstream side in the flow direction (left side in FIG. 7), and the corner portion 42b on the downstream side in the sheet flow direction (right side in FIG. 7) of the tip surface 42t of the ultrasonic horn 42. It is preferable to have a portion for coating.

Polyimide used for the main body portion of the heat storage material 7 is preferable in that it is excellent in wear resistance and heat resistance, and is a synthetic resin and has the ability to generate heat upon receiving ultrasonic vibration.
From the same point of view, the main portion of the heat storage material 7 and the synthetic resin layer 42h provided on the ultrasonic horn 42 shown in FIG. 8A are polyimide, polybenzimidazole, polyether ethyl ketone, polyphenylene sulfite, polyether. It is preferably made of a synthetic resin having a Rockwell hardness of R120 or more and R140 or less, such as imide or polyamideimide, and a heat resistant temperature of 150 ° C or more and 500 ° C or less, and a Rockwell hardness such as polyimide or polybenzimidazole is R125 or more and R140 or less. More preferably, it is made of a synthetic resin having a heat resistant temperature of 280 ° C. or higher and 400 ° C. or lower.
Here, the Rockwell hardness is a value measured according to ASTM D785, and the heat-resistant temperature is a value measured according to ASTM D648.

The synthetic resin layer provided at the tip of the ultrasonic horn 42 has a heat resistant temperature of preferably 150 ° C. or higher, more preferably 280 ° C. or higher, preferably 500 ° C. or lower, more preferably 400 ° C. or lower. Preferably they are 150 degreeC or more and 500 degrees C or less, More preferably, they are 280 degreeC or more and 400 degrees C or less.
The synthetic resin layer provided at the tip of the ultrasonic horn 42 has a Rockwell hardness of preferably R120 or more, more preferably R125 or more, preferably R140 or less, and preferably R120 or more and R140 or less, more preferably R125 or more and R140 or less.

FIG. 8A is a diagram illustrating another example of the ultrasonic horn 42 in which the heat storage material 7 is provided at the tip. In FIG. 8A, a circle C2 portion is an enlarged cross-sectional view of the circle C1 portion.
In the ultrasonic horn 42 shown in FIG. 8A, as shown in FIG. 8B, the tip surface 42t of the main body portion 42c of the ultrasonic horn 42 made of a metal such as an aluminum alloy or a titanium alloy is sprayed. After forming the connection layer 42f having the gap 42e extending from the one surface 42d to the inside, as shown in FIG. 8A, on the one surface 42d side of the connection layer 42f, the synthetic resin layer 42h as a member having heat storage property Is fixed. Thermal spraying is a surface treatment method in which particles of a thermal spraying material such as metal or ceramics that are melted or close to the state by heating are accelerated and collided with the base material surface at a high speed to form a coating on the base material surface. It is. A synthetic resin layer 42h having a heat storage property is provided on the tip surface 42t of the main body portion 42c of the ultrasonic horn 42 made of a metal such as a titanium alloy via a connection layer 42f formed by thermal spraying, thereby providing a heat storage synthesis. As a material for the resin layer 42h, it is excellent in wear resistance, heat resistance and the like, but has sufficient fixing strength even when using a synthetic resin such as polyimide which is difficult to obtain sufficient fixing strength when directly fixed. Can be easily obtained. If the fixing strength is insufficient, problems such as peeling of the synthetic resin layer 42h are likely to occur during the manufacture of the composite sheet 10.

As the thermal spray material for forming the connection layer 42f, a thermal sprayable material that can contribute to improvement of the fixing strength of the synthetic resin layer 42h having heat storage properties can be used without particular limitation, but a metal such as a titanium alloy can be used. From the viewpoint of excellent bonding strength to the main body portion 42c of the ultrasonic horn 42 made of, and excellent wear resistance and heat resistance, ceramics such as tungsten carbide, zirconia, and chromium carbide, alloys such as aluminum magnesium and zinc aluminum, aluminum, A metal such as stainless steel, titanium, or molybdenum, or a cermet that is a composite material of metal and ceramic is preferably used, and ceramic is more preferable from the viewpoint of forming the void 42e that increases the fixing strength of the synthetic resin layer 42h, and tungsten carbide is used. More preferably.
Further, the material for forming the connection layer 42f has a higher melting point than the synthetic resin constituting the synthetic resin layer 42h having heat storage properties, and maintains the shape of the gap 42e when the synthetic resin 42h is formed. From the viewpoint of increasing the fixing strength of the synthetic resin layer 42h.

As a method of fixing the synthetic resin layer 42h having heat storage property to the connection layer 42f, a method of immersing the connection layer 42f in a synthetic resin melted by heating, or a method of applying the synthetic resin melted by heating to the connection layer 42f. Examples thereof include a method and a method of pressing a softened synthetic resin plate to the connection layer 42f.

The thickness Tf [see FIG. 8A] of the connection layer 42f is not particularly limited, but for example, it is preferably 10 μm or more, more preferably 20 μm or more, and preferably 100 μm or less, more preferably 50 μm or less. It is preferably 10 μm or more and 100 μm or less, more preferably 20 μm or more and 50 μm or less.
The thickness Th [see FIG. 8 (a)] of the synthetic resin layer 42h having heat storage properties is not particularly limited. However, for example, it is preferably 5 μm or more, more preferably 10 μm or more, and preferably 100 μm or less. More preferably, it is 50 μm or less, preferably 5 μm or more and 100 μm or less, more preferably 10 μm or more and 50 μm or less.
Further, the thickness Tf of the connection layer 42f is preferably from the viewpoint that the ratio of the thickness Tf and the thickness Th of the synthetic resin layer 42h to the total thickness Tt does not inhibit ultrasonic vibration and heat generation while maintaining the fixing strength of the synthetic resin. Is 30% or more, more preferably 50% or more, preferably 85% or less, more preferably 75% or less, and preferably 30% or more and 85% or less, more preferably 50% or more and 75% or less. is there.

Even if it is a composite sheet manufacturing apparatus including the heat storage material 7 as in the third embodiment, the preheating means 6 included in the composite sheet manufacturing apparatus of the first embodiment and the composite sheet manufacturing apparatus of the second embodiment are included. A means for heating the ultrasonic horn 42 may be provided.

The composite sheet 10 manufactured in each embodiment described above preferably has the following configuration.
The height H (see FIG. 1) of the convex portion 5 is preferably 1 to 10 mm, particularly preferably 3 to 6 mm. The number of convex portions 5 per unit area (1 cm ² ) of the composite sheet 10 is preferably 1 to 20, particularly 6 to 15. The bottom dimension A (see FIG. 1) of the convex portion 5 in the X direction is preferably 0.5 to 5.0 mm, particularly preferably 1.0 to 4.0 mm. The bottom dimension B (see FIG. 1) of the convex portion 5 in the Y direction is preferably 1.0 to 10 mm, particularly preferably 2.0 to 7.0 mm.
The ratio of the bottom dimension A in the X direction to the bottom dimension B in the Y direction (bottom dimension A: bottom dimension B) is preferably 1: 1 to 1:10, particularly 1: 2 to 2: 5. The bottom area (bottom dimension A × bottom dimension B) of the convex portion 5 is preferably 0.5 to 50 mm ² , particularly preferably 2 to 20 mm ² .

The fusion part 4 preferably has a dimension C in the X direction (see FIG. 1) of 0.5 to 2 mm, particularly 0.8 to 1.5 mm, and a dimension D in the Y direction (see FIG. 1) of 1. It is preferably 0 to 5.0 mm, particularly preferably 1.2 to 3.0 mm. The ratio of the dimension C in the X direction to the dimension D in the Y direction (dimension C: dimension D) is preferably 1: 1 to 1: 3, particularly 2: 3 to 2: 5.

The area inside the outer peripheral edge of the fused part 4 is preferably 0.5 mm ² or more, more preferably 1.0 mm ² or more, and preferably 5.0 mm ² or less, more preferably 4.0 mm ² or less. It is preferably 0.5 mm ² or more and 5.0 mm ² or less, more preferably 1.0 mm ² or more and 4.0 mm ² or less. The area inside the outer peripheral edge of the fused part 4 includes the area of the through hole 14.
The opening area of the through hole 14 is preferably 50% or more, more preferably 80% or more, and preferably less than 100%, more preferably 95, with respect to the area inside the outer peripheral edge of the fused portion 4. % Or less, preferably 50% or more and less than 100%, more preferably 80% or more and 95% or less.

The composite sheet 10 described above is suitably used as a top sheet for absorbent articles such as disposable diapers, sanitary napkins, panty liners, incontinence pads, and the like.

Moreover, it can also be used for uses other than the surface sheet of an absorbent article.
For example, as a sheet for absorbent articles, it can be used as a sheet disposed between a top sheet and an absorbent body, a sheet for forming a three-dimensional gather (leakage barrier) (particularly a sheet for forming the inner wall of a gather), and the like. Moreover, as an application other than the absorbent article, it can be used as a cleaning sheet, particularly a cleaning sheet mainly for liquid absorption, a personal use decorative sheet, and the like. When using it for a cleaning sheet, in a convex part, since followability to a to-be-cleaned surface which is not smooth is good, it is preferred to use the 1st nonwoven fabric side toward a to-be-cleaned surface. When used as a decorative sheet, it can follow the skin of the subject at the convex part, express a massage effect, and can absorb excess cosmetic (used separately) and sweat, so the first nonwoven fabric side can be It is preferable to use it toward the side.

The manufacturing method and manufacturing apparatus of the composite sheet of this invention are not restrict | limited to said embodiment at all, and can be changed suitably.
For example, in the composite sheet 10 described above, one fusion part is formed in each recess, but the composite sheet manufactured in the present invention includes a plurality of fusion parts in one recess. Also good. Moreover, although the convex part 5 of the composite sheet 10 was a quadrangular frustum shape, a hemispherical thing etc. may be sufficient. Further, the degree to which the convex portions 5 and the fused portions 4 in the rows adjacent to each other are displaced in the X direction may be 1/3 pitch, 1/4 pitch, or the like, instead of 1/2 pitch, Furthermore, it does not need to be shifted in the X direction.
Moreover, the planar view shape of a fusion | melting part and a through-hole can be made into the polygon (square, a rectangle, a triangle, a rhombus etc.) etc. which rounded the ellipse, the circle | round | yen, and the corner | angular part.

Further, the composite sheet 10 to be manufactured may have a convex portion and a fused portion formed in the form shown in FIG. 4 or FIG. 5 of Japanese Patent Application Laid-Open No. 2016-116582. The convex part and the fusion | melting part may be formed in the aspect shown in FIG. Further, instead of using all of the fused parts existing in the composite sheet as fused parts having through holes, a part of the fused parts existing in the composite sheet may be used as fused parts having through holes. it can. For example, one or both of the first and second sheets in the central region in the width direction of the band-shaped composite sheet is preheated to form a fusion part having a through hole, while the first and second in the side region sandwiching the central region Both the second sheets can be formed with a fused portion having no through hole without preheating.

In relation to the above-described embodiment (aspect) of the present invention, the following composite sheet manufacturing method and composite sheet manufacturing apparatus are disclosed.
<1>
The first sheet and the second sheet have a large number of fused portions, and at least a part of the first sheet other than the fused portion protrudes on the side opposite to the second sheet side. A method of manufacturing a composite sheet forming a convex part,
While rotating the first roll and the second roll having unevenness meshing with each other on the peripheral surface part, the first sheet was introduced into the meshing part of both rolls and deformed into an uneven shape, and deformed into an uneven shape. The first sheet is transported while being held on the first roll, the superimposing step of superimposing the second sheet on the first sheet being transported, and both the superposed sheets are disposed on the first roll. An ultrasonic treatment process of applying ultrasonic vibration sandwiched between the convex part of the ultrasonic fusion machine and the ultrasonic horn of the ultrasonic fusion machine,
The method for producing a composite sheet, wherein, in the ultrasonic treatment step, the fusion part having a through hole is formed when the ultrasonic vibration is applied.

<2>
The ultrasonic horn is heated to a predetermined temperature, and in the ultrasonic treatment step, at least one of the first sheet and the second sheet is heated together with the application of the ultrasonic vibration, according to <1>. A method for producing a composite sheet.
<3>
The first roll is heated to a predetermined temperature, and at least one of the first sheet and the second sheet is heated prior to application of the ultrasonic vibration, according to <1> or <2>. A method for producing a composite sheet.
<4>
The composite sheet according to any one of <1> to <3>, wherein at least one of the first sheet and the second sheet is directly heated to a predetermined temperature prior to application of the ultrasonic vibration. Production method.
<5>
The composite sheet according to any one of <2> to <4>, wherein the predetermined temperature is less than a melting point of the first sheet or the second sheet to be heated and is equal to or higher than a temperature lower by 50 ° C. than the melting point. Method.
<6>
In the ultrasonic treatment step, the ultrasonic vibration is applied in a state in which a member having heat storage properties is arranged at a tip portion of the ultrasonic horn, and the melt having a through hole is applied when the ultrasonic vibration is applied. The method for producing a composite sheet according to any one of the above items <1> to <5>, wherein a landing portion is formed.

<7>
The member having heat storage properties is a method for producing a composite sheet according to <6>, wherein the thermal conductivity is lower than that of a material constituting the ultrasonic horn.
<8>
The heat storage member has a thermal conductivity of 2.0 W / mK or less, preferably 1.0 W / mK or less, 0.1 W / mK or more, preferably 0.5 W / mK or more. The method for producing a composite sheet according to <6> or <7>, which is 0.1 W / mK or more and 2.0 W / mK or less, preferably 0.5 W / mK or more and 1.0 W / mK or less.
<9>
The member having the heat storage property has heat resistance,
The heat resistant temperature of the member having heat storage property is 150 ° C. or higher, preferably 200 ° C. or higher, more preferably 250 ° C. or higher, and the upper limit of the heat resistant temperature of the member having heat storage property is 1500 ° C. or lower, The method for producing a composite sheet according to any one of <6> to <8>.
<10>
The method for producing a composite sheet according to any one of <6> to <9>, wherein the material for the heat storage member is glass or polyimide.
<11>
The member having heat storage property has a portion covering the corner of the tip end surface of the ultrasonic horn on the upstream side in the sheet flow direction in addition to the portion covering the tip end surface of the ultrasonic horn. The method for producing a composite sheet according to any one of> to <10>.
<12>
The method for producing a composite sheet according to <11>, wherein the member having heat storage properties further includes a portion that covers a corner of the tip surface of the ultrasonic horn on the downstream side in the sheet flow direction.

<13>
The pressure applied to the first sheet and the second sheet is 10 N / mm or more, preferably 15 N / mm, sandwiched between the front end surface of the convex portion of the first roll and the front end surface of the ultrasonic horn. The above <1> to <12>, which are 150 N / mm or less, preferably 120 N / mm or less, and 10 N / mm or more and 150 N / mm or less, preferably 15 N / mm or more and 120 N / mm or less. A method for producing a composite sheet according to any one of the above.
<14>
<1> The frequency of the ultrasonic vibration to be applied is 15 kHz or more, preferably 20 kHz or more, 50 kHz or less, preferably 40 kHz or less, and 15 kHz to 50 kHz, preferably 20 kHz to 40 kHz. A method for producing a composite sheet according to any one of <13>.
<15>
<1> The amplitude of the ultrasonic vibration to be applied is 20 μm or more, preferably 25 μm or more, 50 μm or less, preferably 40 μm or less, and 20 μm or more and 50 μm or less, preferably 25 μm or more and 40 μm or less. The method for producing a composite sheet according to any one of <14>.
<16>
The method for producing a composite sheet according to any one of <1> to <15>, wherein the composite sheet is used as a surface sheet of an absorbent article such as a disposable diaper, a sanitary napkin, a panty liner, or an incontinence pad.

<17>
The first sheet and the second sheet have a large number of fused portions, and at least a part of the first sheet other than the fused portion protrudes on the side opposite to the second sheet side. An apparatus for producing a composite sheet forming a convex part,
An unevenness shaping portion that has a first roll and a second roll having unevenness meshing with each other on a peripheral surface portion, and deforms the first sheet introduced into the meshing portion of both rolls into an uneven shape, and an ultrasonic fusion machine. And after superposing the second sheet on the first sheet in a state of being deformed into a concavo-convex shape, the two sheets are connected to the convex portion of the first roll and the ultrasonic horn of the ultrasonic fusion machine. An apparatus for manufacturing a composite sheet, comprising: an ultrasonic processing unit that partially applies ultrasonic vibrations between the two and forms the fused portion having a through hole.

<18>
The apparatus for producing a composite sheet according to <17>, comprising means for heating the ultrasonic horn.
<19>
The composite sheet manufacturing apparatus according to <17> or <18>, further comprising preheating means for preheating at least one of the first sheet and the second sheet before applying the ultrasonic vibration to a predetermined temperature.
<20>
The apparatus for producing a composite sheet according to <19>, wherein the preheating means is a heater disposed in the first roll.
<21>
The apparatus for producing a composite sheet according to <19> or <20>, wherein the preheating means heats the first sheet to a temperature lower than the melting point of the sheet and lower than the melting point by 50 ° C.
<22>
The apparatus for producing a composite sheet according to any one of <19> to <21>, wherein the preheating means preheats to a temperature that is 20 ° C. lower than the melting point of the first sheet and 5 ° C. lower than the melting point. .
<23>
The apparatus for producing a composite sheet according to any one of <17> to <22>, wherein a member having heat storage properties is disposed at a tip portion of the ultrasonic horn.

<24>
The member having heat storage property is a composite sheet manufacturing apparatus according to <23>, wherein the thermal conductivity is lower than that of a material constituting the ultrasonic horn.
<25>
The heat storage member has a thermal conductivity of 2.0 W / mK or less, preferably 1.0 W / mK or less, 0.1 W / mK or more, preferably 0.5 W / mK or more. The apparatus for producing a composite sheet according to <23> or <24>, which is 0.1 W / mK or more and 2.0 W / mK or less, preferably 0.5 W / mK or more and 1.0 W / mK or less.
<26>
The member having the heat storage property has heat resistance,
The heat resistant temperature of the member having heat storage property is 150 ° C. or higher, preferably 200 ° C. or higher, more preferably 250 ° C. or higher, and the upper limit of the heat resistant temperature of the member having heat storage property is 1500 ° C. or lower, <23>-<25> The composite sheet manufacturing apparatus according to any one of <25>.

<27>
The heat storage member has a portion that covers a corner portion on the upstream side in the sheet flow direction of the tip surface of the ultrasonic horn in addition to a portion that covers the tip surface of the ultrasonic horn. <23 The composite sheet manufacturing apparatus according to any one of> to <26>.
<28>
The apparatus for producing a composite sheet according to <27>, wherein the member having heat storage properties further includes a portion that covers a corner of the tip surface of the ultrasonic horn on the downstream side in the sheet flow direction.
<29>
The composite sheet manufacturing apparatus according to any one of <23> to <28>, wherein a material of the heat storage member is glass or polyimide.

<30>
The composite sheet manufacturing apparatus according to any one of <23> to <29>, wherein the ultrasonic horn is provided with a heat-resistant synthetic resin layer as a heat-storing member at a tip portion thereof.
<31>
The heat resistance temperature of the synthetic resin layer is 150 ° C. or higher, preferably 280 ° C. or higher, and 500 ° C. or lower, preferably 400 ° C. or lower, and 150 ° C. or higher and 500 ° C. or lower, preferably 280 ° C. or higher and 400 ° C. or lower. The apparatus for producing a composite sheet according to <30>, wherein
<32>
The composite sheet manufacturing apparatus according to any one of the above <23> to <31>, wherein a synthetic resin layer having wear resistance is provided as a heat storage member at a tip portion of the ultrasonic horn. .
<33>
The Rockwell hardness of the synthetic resin layer is R120 or more, preferably R125 or more, R140 or less, and R120 or more and R140 or less, preferably R125 or more and R140 or less. Manufacturing equipment.
<34>
The synthetic resin layer is fixed to the tip surface of the main body portion made of metal of the ultrasonic horn via a connection layer formed by thermal spraying, according to any one of the above <30> to <33>. Composite sheet manufacturing equipment.

<35>
The pressure applied to the first sheet and the second sheet sandwiched between the convex portion of the first roll and the ultrasonic horn is 10 N / mm or more, preferably 15 N / mm or more, and 150 N <17> to <34>, which is not more than 10 mm / mm, preferably not more than 120 N / mm, and not less than 10 N / mm and not more than 150 N / mm, preferably not less than 15 N / mm and not more than 120 N / mm. Composite sheet manufacturing equipment.
<36>
The frequency of the ultrasonic vibration to be applied is 15 kHz or more, preferably 20 kHz or more, 50 kHz or less, preferably 40 kHz or less, and 15 kHz to 50 kHz, preferably 20 kHz to 40 kHz, <17> The apparatus for producing a composite sheet according to any one of <35>.
<37>
<17> The amplitude of the ultrasonic vibration to be applied is 20 μm or more, preferably 25 μm or more, 50 μm or less, preferably 40 μm or less, and 20 μm or more and 50 μm or less, preferably 25 μm or more and 40 μm or less. The apparatus for producing a composite sheet according to any one of <36>.
<38>
The composite sheet manufacturing apparatus according to any one of <17> to <37>, wherein the composite sheet is used as a surface sheet of an absorbent article such as a disposable diaper, a sanitary napkin, a panty liner, or an incontinence pad.

According to the method for producing a composite sheet of the present invention, a fusion part having a through hole can be easily formed, and a positional deviation is hardly generated between the position of the fusion part and the position of the through hole, and the maintenance burden of the apparatus is also increased. small.
According to the composite sheet manufacturing apparatus of the present invention, a fusion part having a through hole can be easily formed, and a positional deviation is hardly generated between the position of the fusion part and the position of the through hole, and the maintenance burden is small.

Claims

The first sheet and the second sheet have a large number of fused portions, and at least a part of the first sheet other than the fused portion protrudes on the side opposite to the second sheet side. A method of manufacturing a composite sheet forming a convex part,
While rotating the first roll and the second roll having unevenness meshing with each other on the peripheral surface part, the first sheet was introduced into the meshing part of both rolls and deformed into an uneven shape, and deformed into an uneven shape. The first sheet is transported while being held on the first roll, the superimposing step of superimposing the second sheet on the first sheet being transported, and both the superposed sheets are disposed on the first roll. An ultrasonic treatment process of applying ultrasonic vibration sandwiched between the convex part of the ultrasonic fusion machine and the ultrasonic horn of the ultrasonic fusion machine,
The method for producing a composite sheet, wherein, in the ultrasonic treatment step, the fusion part having a through hole is formed when the ultrasonic vibration is applied.
The composite according to claim 1, wherein the ultrasonic horn is heated to a predetermined temperature, and in the ultrasonic treatment step, at least one of the first sheet and the second sheet is heated together with the application of the ultrasonic vibration. Sheet manufacturing method.
The composite sheet according to claim 1 or 2, wherein the first roll is heated to a predetermined temperature, and at least one of the first sheet and the second sheet is heated prior to application of the ultrasonic vibration. Production method.
The method for producing a composite sheet according to any one of claims 1 to 3, wherein at least one of the first sheet and the second sheet is directly heated to a predetermined temperature prior to application of the ultrasonic vibration. .
The method for producing a composite sheet according to any one of claims 2 to 4, wherein the predetermined temperature is lower than the melting point of the first sheet or the second sheet to be heated and is equal to or higher than a temperature lower by 50 ° C than the melting point.
In the ultrasonic treatment step, the ultrasonic vibration is applied in a state in which a member having heat storage properties is arranged at a tip portion of the ultrasonic horn, and the melt having a through hole is applied when the ultrasonic vibration is applied. The manufacturing method of the composite sheet of any one of Claims 1 thru | or 5 which forms a landing part.
The method for producing a composite sheet according to claim 6, wherein the member having heat storage property has a lower thermal conductivity than a material constituting the ultrasonic horn.
The method for producing a composite sheet according to claim 6 or 7, wherein the heat storage member has a thermal conductivity of 0.1 W / mK or more and 2.0 W / mK or less.
The member having the heat storage property has heat resistance,
The method for producing a composite sheet according to any one of claims 6 to 8, wherein the heat-resistant temperature of the member having heat storage properties is 150 ° C or higher and 1500 ° C or lower.
The method for producing a composite sheet according to any one of claims 6 to 9, wherein a material of the heat storage member is glass or polyimide.
The member having heat storage properties includes a portion covering a corner portion on the upstream side in the sheet flow direction of the tip surface of the ultrasonic horn in addition to a portion covering the tip surface of the ultrasonic horn. The manufacturing method of the composite sheet of any one of thru | or 10.
The method for producing a composite sheet according to claim 11, wherein the member having heat storage properties further has a portion covering a corner of the tip surface of the ultrasonic horn on the downstream side in the sheet flow direction.
The pressure applied to the first sheet and the second sheet sandwiched between the front end surface of the convex portion of the first roll and the front end surface of the ultrasonic horn is 10 N / mm or more and 150 N / mm or less. The manufacturing method of the composite sheet of any one of Claims 1 thru | or 12.
The method of manufacturing a composite sheet according to any one of claims 1 to 13, wherein a frequency of the ultrasonic vibration to be applied is 15 kHz or more and 50 kHz or less.
The method of manufacturing a composite sheet according to any one of claims 1 to 14, wherein an amplitude of the ultrasonic vibration to be applied is 20 µm or more and 50 µm or less.
The method for producing a composite sheet according to any one of claims 1 to 15, wherein the composite sheet is used as a surface sheet of an absorbent article such as a disposable diaper, a sanitary napkin, a panty liner, or an incontinence pad.
The first sheet and the second sheet have a large number of fused portions, and at least a part of the first sheet other than the fused portion protrudes on the side opposite to the second sheet side. An apparatus for producing a composite sheet forming a convex part,
An unevenness shaping portion that has a first roll and a second roll having unevenness meshing with each other on a peripheral surface portion, and deforms the first sheet introduced into the meshing portion of both rolls into an uneven shape, and an ultrasonic fusion machine. And after superposing the second sheet on the first sheet in a state of being deformed into a concavo-convex shape, the two sheets are connected to the convex portion of the first roll and the ultrasonic horn of the ultrasonic fusion machine. An apparatus for manufacturing a composite sheet, comprising: an ultrasonic processing unit that partially applies ultrasonic vibrations between the two and forms the fused portion having a through hole.
The composite sheet manufacturing apparatus according to claim 17, comprising means for heating the ultrasonic horn.
The composite sheet manufacturing apparatus according to claim 17 or 18, comprising preheating means for preheating at least one of the first sheet and the second sheet before applying the ultrasonic vibration to a predetermined temperature.
The composite sheet manufacturing apparatus according to claim 19, wherein the preheating means is a heater disposed in the first roll.
21. The composite sheet manufacturing apparatus according to claim 19 or 20, wherein the preheating means heats the first sheet to a temperature lower than the melting point of the sheet and 50 ° C. lower than the melting point.
The composite sheet manufacturing apparatus according to any one of claims 19 to 21, wherein the preheating means preheats the steel sheet to a temperature not lower than 20 ° C lower than the melting point of the first sheet and not higher than 5 ° C lower than the melting point.
The composite sheet manufacturing apparatus according to any one of claims 17 to 22, wherein a member having a heat storage property is disposed at a tip portion of the ultrasonic horn.
The composite sheet manufacturing apparatus according to claim 23, wherein the heat storage member has a lower thermal conductivity than a material constituting the ultrasonic horn.
The composite sheet manufacturing apparatus according to claim 23 or 24, wherein the member having heat storage property has a thermal conductivity of 0.1 W / mK or more and 2.0 W / mK or less.
The member having the heat storage property has heat resistance,
The composite sheet manufacturing apparatus according to any one of claims 23 to 25, wherein a heat resistant temperature of the member having heat storage property is 150 ° C or higher and 1500 ° C or lower.
24. The member having heat storage properties includes a portion covering a corner portion on the upstream side in the sheet flow direction of the tip surface of the ultrasonic horn in addition to a portion covering the tip surface of the ultrasonic horn. The manufacturing apparatus of the composite sheet of any one of thru | or 26.
28. The composite sheet manufacturing apparatus according to claim 27, wherein the member having heat storage properties further includes a portion that covers a corner of the tip surface of the ultrasonic horn on the downstream side in the sheet flow direction.
The composite sheet manufacturing apparatus according to any one of claims 23 to 28, wherein a material of the heat storage member is glass or polyimide.
The composite sheet manufacturing apparatus according to any one of claims 23 to 28, wherein a synthetic resin layer having heat resistance is provided at a tip portion of the ultrasonic horn as a member having heat storage properties.
31. The composite sheet manufacturing apparatus according to claim 30, wherein the heat-resistant temperature of the synthetic resin layer is 150 ° C. or higher and 500 ° C. or lower.
The composite sheet manufacturing apparatus according to any one of claims 23 to 31, wherein a synthetic resin layer having wear resistance is provided as a member having heat storage property at a tip portion of the ultrasonic horn.
The composite sheet manufacturing apparatus according to claim 32, wherein the Rockwell hardness of the synthetic resin layer is R120 or more and R140 or less.
The composite resin according to any one of claims 30 to 33, wherein the synthetic resin layer is fixed to a distal end surface of a main body portion made of metal of the ultrasonic horn via a connection layer formed by thermal spraying. Sheet manufacturing equipment.
35. The pressing force applied to the first sheet and the second sheet sandwiched between the convex portion of the first roll and the ultrasonic horn is 10 N / mm or more and 150 N / mm or less. The composite sheet manufacturing apparatus according to any one of the above.
36. The composite sheet manufacturing apparatus according to any one of claims 17 to 35, wherein a frequency of the ultrasonic vibration to be applied is 15 kHz or more and 50 kHz or less.
37. The composite sheet manufacturing apparatus according to any one of claims 17 to 36, wherein an amplitude of the ultrasonic vibration to be applied is 20 μm or more and 50 μm or less.
The composite sheet manufacturing apparatus according to any one of claims 17 to 37, wherein the composite sheet is used as a surface sheet of an absorbent article such as a disposable diaper, a sanitary napkin, a panty liner, or an incontinence pad.