Apparatus and method for manufacturing a laminate

Abstract

The present invention is a manufacturing device for a laminate in which a pair of sheets sandwich elastic threads therebetween, in which a pair of nip rollers are provided, the axes of which are arranged parallel to each other, and sandwich elastic threads between the pair of sheets being conveyed in a conveying direction; a needle is arranged on the upstream side of the conveying direction of the nip rollers, feeds out the elastic threads through a through hole through which the elastic threads are fed, and guides and arranges the elastic threads between the pair of sheets; a needle body holds the needle; a reciprocating movement section is installed with the needle body, and reciprocates in a width direction that intersects the conveying direction; and a stabilizer stabilizes the reciprocating movement of the reciprocating movement section, the stabilizer being a non-contact guide.

Description

Technical Field

[0001] The present invention relates to an apparatus and a method for manufacturing a laminate as part of a disposable wearable article. Background Technology

[0002] Around the leg holes of disposable underwear, diapers, etc., there are often elastic threads known as rubber threads.

[0003] use Figure 7 and Figure 8 One of the previous examples of such a device and method will be described.

[0004] Figure 7 This is a conceptual diagram illustrating a method for manufacturing disposable underwear from a laminated body W in which elastic threads F are sandwiched between a pair of sheets S. Figure 8 This is a three-dimensional view of the manufacturing apparatus for the laminate W.

[0005] like Figure 8 As shown, a conventional manufacturing apparatus includes a pair of nip rolls 2, a pair of needles 1, a pair of needle bodies 11, and a pair of conveyor belts 3. For the pair of nip rolls 2, their axes 2s are arranged parallel to each other.

[0006] A pair of needles 1 are positioned upstream of the sheet S in the conveying direction X of the clamping roller 2. They deliver the elastic thread F through the through-hole 10 through which the elastic thread F passes, and guide and position the elastic thread F. Figure 7 Between a pair of sheets S. Figure 8 A pair of needles 1 are held in a needle body 11, which is mounted on a conveyor belt 3. The needle body 11 moves back and forth by the reciprocating rotation of the conveyor belt 3.

[0007] Towards Figure 8 The clamping part 20 of a pair of clamping rollers 2 supplies Figure 7 A pair of sheets S are provided, and multiple elastic threads F are supplied between these sheets while being bent in a wavy shape. After these supplies, a laminate W is formed in which the elastic threads F are sandwiched between the pair of sheets S.

[0008] Then, after forming leg holes H on the laminated body W, the laminated body W is folded into two parts, sealed at the side seal SS, and then cut into individual wearable items N. In this way, wearable items N with elastic lines F arranged along the leg holes H are generated.

[0009] The apparatus and method for configuring such an elastic line F are known in the past (Patent Document 1).

[0010] Prior art literature

[0011] Patent documents

[0012] Patent Document 1: WO2015 / 053088 ( Figures 1-5 A) Summary of the Invention

[0013] Figure 8 Each conveyor belt 3 is alternately pulled by a pair of pulleys 3P in the rotational direction during reciprocating movement, thus causing the tension to change periodically. This periodic tension change causes the conveyor belt 3 to vibrate in a direction orthogonal to the surface 3a of the conveyor belt 3, resulting in vibration at the tip of the needle 1. Therefore, conventionally, mechanical guiding members such as linear guides are provided to prevent the conveyor belt 3 and even the needle body 11 from swaying due to this vibration.

[0014] However, since the needle body 11 and the conveyor belt 3 operate at high speeds, mechanical guiding components such as the aforementioned linear guide may be damaged due to friction. Therefore, there are naturally limits to the speed of operation.

[0015] Therefore, the object of the present invention is to provide an apparatus and method for manufacturing laminates that can operate at higher speeds than ever before.

[0016] The manufacturing apparatus of the present invention is an apparatus for manufacturing a laminate of a pair of sheets S sandwiched between each other by an elastic thread F, wherein,

[0017] The apparatus for manufacturing the laminate includes:

[0018] A pair of clamping rollers 2, whose axes 2s are arranged parallel to each other, clamp the elastic line F between the pair of sheets S being conveyed along the conveying direction X;

[0019] Needle 1, which is disposed on the upstream side of the conveying direction X of the clamping roller 2, feeds out the elastic line F through the through hole 10 through which the elastic line F passes and guides and arranges the elastic line F between the pair of sheets S;

[0020] Needle body 11, which holds the needle 1;

[0021] A reciprocating moving part, on which the needle body 11 is mounted, reciprocates in a width direction Y intersecting the conveying direction X; and

[0022] A stabilizer, which stabilizes the reciprocating movement of the reciprocating moving part.

[0023] The stabilizer is a non-contact guide 4.

[0024] On the other hand, the manufacturing method of the present invention is a method for manufacturing a laminate (W) in which a pair of sheets (S) are sandwiched between each other with an elastic thread (F), wherein,

[0025] The method for manufacturing the laminated body uses an apparatus for manufacturing laminated bodies (W).

[0026] The apparatus for manufacturing the laminate W includes:

[0027] A pair of clamping rollers (2), whose axes (2s) are arranged parallel to each other, clamp the elastic thread (F) between the pair of sheets (S) being conveyed along the conveying direction (X);

[0028] A needle (1), which is disposed on the upstream side of the conveying direction (X) of the clamping roller (2), delivers the elastic wire (F) through the through hole (10) through which the elastic wire (F) passes and guides and arranges the elastic wire (F) between the pair of sheets (S);

[0029] Needle body (11) which holds the needle (1);

[0030] A reciprocating moving part, on which the needle body (11) is mounted, reciprocates in a width direction (Y) intersecting the conveying direction (X); and

[0031] A stabilizer that stabilizes the reciprocating movement of the reciprocating moving part.

[0032] The method for manufacturing the laminate includes:

[0033] The process of continuously feeding a pair of sheets (S) to the clamping portion (20) of the pair of clamping rollers (2);

[0034] The process of continuously feeding and supplying the elastic thread (F) from the through hole (10) of the needle (1) to a pair of sheets (S) before they are to be supplied to the clamping part (20) of the pair of clamping rollers (2);

[0035] The process of reciprocating the reciprocating moving part in the width direction (Y), and reciprocating the position of the needle (1) in the width direction (Y) to arrange the elastic thread (F) in a wavy shape between the pair of sheets (S); and

[0036] During the reciprocating movement of the needle (1), the stabilizer stabilizes the reciprocating movement by blowing air or by magnetic force.

[0037] According to the present invention, the reciprocating movement of the needle 1 is stabilized by a stabilizer, and since it is non-contact, no friction is generated. Therefore, higher speed operation is possible than before.

[0038] In this invention, the elastic line F refers to the so-called rubber line, but as long as it has the property of stretching, the raw material does not need to be rubber, as long as it is a linear continuous elastomer.

[0039] In this invention, the sheet S is continuous in the conveying direction, and the sheet S is generally a sheet-like material (non-woven fabric).

[0040] In addition, the so-called "needle" does not refer to a pointer-shaped needle, but rather to a component that delivers the elastic line F out through the through hole 10 that passes through the elastic line F. Attached Figure Description

[0041] Figure 1 This is a side view showing one embodiment of the manufacturing apparatus for the laminate of the present invention.

[0042] Figure 2 It is a planar (bottom) diagram of a pair of configuration units (Unit) U.

[0043] Figure 3 This is a side view of a partial cross-section of the configuration unit.

[0044] Figure 4A It is a top view showing a portion of the conveyor belt and a portion of the stabilizer, etc. Figure 4B This is a front view showing the needle and its body. Figure 4C This is the front view showing the blow-out surface of the stabilizer.

[0045] Figure 5 It is the main view representing a part of the configuration unit.

[0046] Figure 6 This is a top view showing a portion of the configuration unit.

[0047] Figure 7 This is a conceptual diagram illustrating an example of a manufacturing method for a typical garment.

[0048] Figure 8 It is a three-dimensional diagram showing a known manufacturing device by partially cutting it out. Detailed Implementation

[0049] The present invention will be more clearly understood from the following description of preferred embodiments with reference to the accompanying drawings. However, the embodiments and drawings are for illustration and description only and are not intended to define the scope of the invention. The scope of the invention is shown by the technical solutions. In the drawings, the same part numbers in multiple figures indicate the same or equivalent parts.

[0050] It should be noted that, for some of the katakana symbols in this instruction manual, the English words are also included in parentheses to make their meaning clearer.

[0051] The embodiments of the present invention will be described below.

[0052] Figures 1-6 This illustrates one embodiment of the present invention.

[0053] exist Figure 1 In this process, sheets S are supplied to a pair of clamping rollers 2, 2 respectively, and an elastic thread F is supplied between the sheets S, S. The sheets S and the elastic thread F are stacked on top of each other at the clamping part 20. It should be noted that in Figure 1 In the middle, a pair of clamping rollers 2 and configuration units U are provided, and the pair of configuration units U are arranged symmetrically to each other. In addition, the pair of clamping rollers 2, 2 are in contact with each other at the clamping part 20, separated by a pair of sheets S and elastic threads F.

[0054] like Figure 4B As shown, multiple through holes 10 for the elastic thread F to pass through can also be provided on the needle 1. Figure 1 As shown, needle 1 is held in the needle body 11.

[0055] Figure 1 The needle body 11 is mounted on the conveyor belt 3. This conveyor belt 3 is configured to intersect the conveying direction X of the sheet S. Figure 2 A reciprocating moving part that moves back and forth in the width direction Y. Needle 1 and conveyor belt 3 constitute part of the configuration unit U of the elastic line F.

[0056] Next, a summary of the configuration unit U will be provided.

[0057] like Figure 6 As shown, each conveyor belt 3 is circular and is erected on... Figure 2 A pair of pulleys (Pulley) 3P.

[0058] Figure 5 The conveyor belt 3, indicated by the double-dotted line, is driven by the motor 31 and passes through the pulley 3P ( Figure 2 It rotates back and forth. This is achieved through a cylinder 32, a rod 33, a motor 31, and a pulley 3P. Figure 2 The cylinder 32 and rod 33 are used to prevent the conveyor belt 3 from slackening, forming a pressing mechanism that applies tension to the conveyor belt 3 in a manner that brings the needle body 11 close to the guide 4.

[0059] like Figure 1 As shown, the conveyor belt 3 is sandwiched between the plate-shaped needle body 11 and the mounting plate 12, and the needle body 11 is mounted on the surface 3a of the conveyor belt 3. A guide 4 is disposed close to the needle body 11 and the conveyor belt 3. Figure 4A As shown, the straight portion of the guide 4 relative to the conveyor belt 3 extends along the surface 3a of the conveyor belt 3.

[0060] Figure 3 The guide 4 includes: an air tank 41 that forms an air flow path 44 and is longer along the conveyor belt 3, and an air plate 43 that covers an opening 42 formed on one side of the air tank 41 and has a plurality of blowout holes 40. Figure 4C The blow-out holes 40 are intermittently arranged along the length direction 4L of the guide 4 and are used to blow out air. That is, Figure 4A The guide 4 is configured to push the conveyor belt 3, on which the needle body 11 is mounted, in a direction Z orthogonal to the surface 3a of the conveyor belt 3 by blowing out air.

[0061] like Figure 4B As shown, in this example, the needle body 11 has a pair of wings 13, 13 protruding in the direction along the guide 4. Figure 4A As shown, a gap Δ corresponding to the thickness of the needle body 11 is provided between the conveyor belt 3 and the guide 4. On the other hand, a tiny gap is created between the needle body 11 and the guide 4 to allow air flowing from the blow-out hole 40 to pass through. This gap is so narrow that it cannot be shown in the figure, and forms an air layer. That is, Figure 4A The needle body 11 has a flat plate portion 11P that engages with the surface 3a of the conveyor belt 3. The flat plate portion 11P faces the guide member 4, and an air layer formed by air blown out from the blow hole 40 is formed between the flat plate portion 11P and the guide member 4.

[0062] like Figure 4C As shown, the multiple air outlets 40 can also be arranged in multiple rows (e.g., two rows) that are separated from each other in the width direction 4D of the conveyor belt 3. In this case, air from the upper row of air outlets 40 is discharged upwards, and air from the lower row of air outlets 40 is discharged downwards, maintaining... Figure 4A The accuracy of the tiny gap between the flat plate portion 11P of the needle body 11 and the guide 4 is improved.

[0063] Next, regarding Figure 1 The manufacturing method of the laminate W is described.

[0064] like Figure 1 As shown, a pair of sheets S are continuously supplied to the clamping portions 20 of a pair of clamping rollers 2, and an elastic thread F is continuously supplied between the pair of sheets S through the through hole 10 of the needle 1. At this time, each needle 1 passes through together with the needle body 11. Figure 2 The conveyor belt 3 is driven to reciprocate in the width direction Y, as shown in the figure, and the elastic line F is configured in a wave shape.

[0065] During the reciprocating movement of needle 1, from Figure 3 Air is constantly being blown out of the blow-out hole 40 of the guide member 4. On the other hand, tension acts on the conveyor belt 3 as described above, and the air blown out from the blow-out hole 40 will... Figure 4A The needle body 11 and the conveyor belt 3 are pushed in a direction Z orthogonal to the surface 3a of the conveyor belt 3. As a result, the conveyor belt 3 and the needle 1 will not swing in the orthogonal direction Z, but will move in the width direction Y.

[0066] On the other hand, since the needle body 11 and the conveyor belt 3 are not in contact with the guide 4, wear on these components can be prevented. Therefore, high-speed operation of the conveyor belt 3 is possible, and the productivity of the laminate W is improved.

[0067] Other components and methods are the same as those described above. Figure 7 and Figure 8 As in previous cases, detailed explanations are omitted. Additionally, as... Figure 1 The configuration unit U is described in WO2015 / 053088 and JP2003-38565A, and its entire description is incorporated herein by reference.

[0068] The present invention, as understood from the above embodiments, includes the following preferred embodiments.

[0069] In the preferred manufacturing apparatus, the guide 4 can be a magnetic guide in addition to an air guide. In the case of a magnetic guide, the repulsive force (rebound) of magnetism can also be utilized.

[0070] In the case of these guides, an air layer is formed between the guide 4 and the needle body 11.

[0071] That is, the guide only needs to form an air layer between the guide and the needle body to prevent them from contacting each other.

[0072] In a preferred manufacturing apparatus, the reciprocating moving part is a conveyor belt 3.

[0073] The needle body 11 is mounted on the surface 3a of the conveyor belt 3.

[0074] The guide 4 is configured to extend along the surface 3a of the conveyor belt 3 and push the conveyor belt 3, on which the needle body 11 is mounted, in a direction Z orthogonal to the surface 3a of the conveyor belt 3 by air blowing or magnetic force.

[0075] In this case, since the conveyor belt 3 is pushed in a direction Z that is orthogonal to the conveying direction X of the conveyor belt 3, the conveyor belt 3 is not prone to slack.

[0076] In a preferred manufacturing apparatus, the guide 4 has a plurality of blowout holes 40 intermittently arranged in the longitudinal direction 4L of the guide 4 for blowing out the air.

[0077] In this case, since multiple air outlets 40 are provided in the length direction 4L, the force of the air blowing on the conveyor belt 3 is stable in the length direction 4L.

[0078] More preferably, the blow-out holes 40 of the guide member 4 are arranged in multiple rows, which are separated from each other in the width direction 4D, which is orthogonal to the length direction 4L of the guide member.

[0079] In this case, the air blown out from the multiple rows of blowout holes 40 diffuses in the width direction 4D, forming a stable air layer.

[0080] More preferably, the needle body 11 has a flat plate portion 11P that engages with the surface 3a of the conveyor belt 3, the flat plate portion 11P facing the guide member 4, and an air layer formed by air blown out from the blow-out hole 40 is formed between the flat plate portion 11P and the guide member 4.

[0081] In this case, by forming an air layer between the guide 4 and the plate portion 11P, the tiny gap between the plate portion 11P and the guide 4 is kept constant, thereby improving the accuracy of obtaining the anti-wear effect.

[0082] Preferably, the guide 4 has an air canister 41 that extends along the conveyor belt 3, and an air plate 43 that covers an opening 42 formed on the side of the air canister 41 facing the surface of the conveyor belt 3 and has the blowout hole 40 formed thereon.

[0083] In this case, the cost of the guide 4, which is longer along the conveyor belt 3, is reduced.

[0084] Preferably, a pressing mechanism for applying tension to the conveyor belt 3 is provided such that the flat plate portion 11P is close to the guide member 4.

[0085] In this case, due to the tension of the conveyor belt 3, the flat plate 11P becomes close to the guide 4, maintaining a thin air layer between the guide 4 and the flat plate 11P.

[0086] It should be noted that, more preferably, the flat plate portion 11P contacts the guide member 4 in a non-operating state where no air is blown out.

[0087] In a preferred manufacturing method of the present invention, the stabilizer is a guide 4 extending along the surface 3a of the conveyor belt 3.

[0088] In the stable process, the guide 4 uses air blowing or magnetic force to push the conveyor belt 3 on which the needle body 11 is mounted in a direction Z orthogonal to the surface 3a of the conveyor belt 3, thereby suppressing the swaying of the conveyor belt 3 in the orthogonal direction Z.

[0089] This prevents deterioration caused by wear of the guide components and enables high-speed operation.

[0090] Features described and / or illustrated in connection with one or more embodiments or preferred embodiments may be used in the same or similar form and / or in combination with or in place of other embodiments in one or more other embodiments.

[0091] As described above, preferred embodiments have been explained with reference to the accompanying drawings. Those skilled in the art should readily conceive of various modifications and alterations upon reading this specification.

[0092] For example, only one configuration unit may be set up. The guide may also be a magnetic guide that utilizes magnetic repulsion rather than air pressure.

[0093] Therefore, such changes and modifications are to be interpreted as being included within the scope of the invention as defined by the technical solution.

[0094] Industrial availability

[0095] This invention can be used as an apparatus and method for manufacturing laminated bodies such as disposable wearable items.

[0096] Explanation of reference numerals in the attached figures:

[0097] 1: Needle; 10: Through hole; 11: Needle body; 11P: Flat plate section;

[0098] 12: Mounting plate; 13: Wing;

[0099] 2: Clamping roller; 20: Clamping part; 2s: Axis;

[0100] 3: Conveyor belt (reciprocating moving part); 3a: Surface; 3P: Pulley;

[0101] 31: Motor; 32: Cylinder (pressing mechanism); 33: Rod;

[0102] 4: Guide component; 40: Blowout hole; 41: Air canister; 42: Opening; 43: Air plate; 44: Flow path;

[0103] 44: Pathway; 4D: Width direction; 4L: Length direction;

[0104] F: Elastic line;

[0105] S: Sheet; H: Leg opening; N: Clothing item; W: Laminated body;

[0106] X: Conveying direction; Y: Width direction; Z: Orthogonal direction;

[0107] U: Configuration Unit;

[0108] Δ: gap.

Claims

1. An apparatus for manufacturing a laminate, comprising a laminate (W) of a pair of sheets (S) sandwiched between each other by an elastic thread (F), wherein, The apparatus for manufacturing the laminate includes: A pair of clamping rollers (2), whose axes (2s) are arranged parallel to each other, clamp the elastic wire (F) between the pair of sheets (S) being conveyed along the conveying direction (X). A needle (1), which is positioned upstream of the clamping roller (2) in the conveying direction (X), delivers the elastic wire (F) through a through hole (10) through which the elastic wire (F) passes and guides and positions the elastic wire (F) between the pair of sheets (S). Needle body (11) which holds the needle (1); The conveyor belt (3), which serves as a reciprocating moving part, has a flat plate (11P) on which the needle body (11) is mounted, and reciprocates in the width direction (Y) intersecting the conveying direction (X); and A stabilizer that stabilizes the reciprocating movement of the reciprocating moving part. The stabilizer is a non-contact guide (4). The flat portion (11P) of the needle body (11) has a pair of wings (13, 13) protruding in directions opposite to each other along the direction of the guide (4). The guide (4) is an air guide or a magnetic guide. The flat plate portion (11P) of the needle body (11) is engaged with the surface (3a) of the conveyor belt (3). The guide (4) is configured to extend along the surface (3a) of the conveyor belt (3) and, by means of air blowing or magnetic force, push the conveyor belt (3) in a direction (Z) orthogonal to the surface (3a) of the conveyor belt (3).

2. The apparatus for manufacturing a laminate according to claim 1, wherein, The guide (4) has a plurality of blow holes (40) intermittently arranged in the length direction (4L) of the guide (4) for blowing out the air.

3. The apparatus for manufacturing a laminate according to claim 2, wherein, The blow holes (40) of the guide (4) are arranged in multiple rows in a width direction (4D) that is orthogonal to the length direction (4L) of the guide (4).

4. The apparatus for manufacturing a laminate according to claim 2 or 3, wherein, The flat plate (11P) faces the guide (4), and an air layer formed by air blown out from the blow-out hole (40) is formed between the flat plate (11P) and the guide (4).

5. The apparatus for manufacturing a laminate according to claim 4, wherein, A pressing mechanism for applying tension to the conveyor belt (3) is provided such that the flat plate (11P) is close to the guide (4).

6. The apparatus for manufacturing a laminate according to claim 2 or 3, wherein, The guide (4) has an air canister (41) along the length of the conveyor belt (3) and an air plate (43) with an opening (42) formed on the side of the air canister (41) facing the surface of the conveyor belt (3) and having the blow-out hole (40) formed thereon.

7. A method for manufacturing a laminate, comprising manufacturing a laminate (W) of a pair of sheets (S) sandwiched between each other by an elastic thread (F), wherein, The method for manufacturing the laminated body uses an apparatus for manufacturing laminated bodies (W). The apparatus for manufacturing the laminate (W) includes: A pair of clamping rollers (2), whose axes (2s) are arranged parallel to each other, clamp the elastic wire (F) between the pair of sheets (S) being conveyed along the conveying direction (X). A needle (1), which is positioned upstream of the clamping roller (2) in the conveying direction (X), delivers the elastic wire (F) through a through hole (10) through which the elastic wire (F) passes and guides and positions the elastic wire (F) between the pair of sheets (S). Needle body (11) which holds the needle (1); The conveyor belt (3), which serves as a reciprocating moving part, has a flat plate (11P) on which the needle body (11) is mounted, and reciprocates in the width direction (Y) intersecting the conveying direction (X); and A stabilizer that stabilizes the reciprocating movement of the reciprocating moving part. The stabilizer is a non-contact guide (4). The flat portion (11P) of the needle body (11) has a pair of wings (13, 13) protruding in directions opposite to each other along the direction of the guide (4). The guide (4) is an air guide or a magnetic guide. The flat plate portion (11P) of the needle body (11) is engaged with the surface (3a) of the conveyor belt (3). The guide (4) extends along the surface (3a) of the conveyor belt (3). The manufacturing method of the laminate includes the following steps: A pair of sheets (S) are continuously fed to the clamping portion (20) of the pair of clamping rollers (2). The elastic wire (F) is continuously fed from the through hole (10) of the needle (1) to a pair of sheets (S) before being fed to the clamping part (20) of the pair of clamping rollers (2). The reciprocating moving part is moved back and forth in the width direction (Y), and the position of the needle (1) is moved back and forth in the width direction (Y), thereby arranging the elastic line (F) in a wavy shape between the pair of sheets (S); as well as During the reciprocating movement of the needle (1), the guide (4) non-contactly guides the conveyor belt (3) by means of air blowing or magnetic force, using the flat plate portion (11P) of the needle body (11) to push the conveyor belt (3) in a direction (Z) orthogonal to the surface (3a) of the conveyor belt (3), thereby suppressing the swaying of the conveyor belt (3).

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