Stretch laminated sheet, disposable wearing article, method for manufacturing stretch laminated sheet, and manufacturing apparatus

Abstract

The present stretch laminated sheet has: a plurality of joint portions formed by mutually heat-fusing a pair of nonwoven fabrics and a film, each of the plurality of joint portions including at least one fusion region in which the pair of nonwoven fabrics and the film are mutually heat-fused; at least one boundary line defining the fusion region; a first air-permeable portion defined by a first aperture of the film occurring in an elongated state of the film and exhibiting air permeability on the boundary line; and a second air-permeable portion adjacent to the fusion region, divided by the boundary line, and defined by a second aperture of the film in which a portion is defective, exhibiting air permeability in both the elongated state and a non-elongated state.

Description

TECHNICAL FIELD

[0001] The present application relates to a stretch laminated sheet, a disposable wearing article, a manufacturing method of a stretch laminated sheet, and a manufacturing apparatus. BACKGROUND

[0002] A stretch laminated sheet in which a stretchable film is sandwiched between a pair of nonwoven fabrics is known (Patent Literature 1). Figures 11A-11D An example of a structure of the sheet is shown.

[0003] Figure 11A is an enlarged plan view showing a shape of a joint 1 formed in the stretch laminated sheet S, Figure 11B is an enlarged plan view showing an opening H formed in the film F of the stretch laminated sheet S, Figure 11C is a sectional view showing a cross section of the stretch laminated sheet S in a non-elongated state, Figure 11D is a sectional view showing a cross section of the stretch laminated sheet S in an elongated state.

[0004] In Figures 11A-11D , the pair of nonwoven fabrics NW constituting a part of the stretch laminated sheet S contain thermoplastic fibers and have air permeability. On the other hand, the film F constituting another part of the stretch laminated sheet S has thermoplasticity and stretchability.

[0005] The pair of nonwoven fabrics NW and the film F are heat-fused to each other at the joint 1 colored in gray. The periphery of the joint 1 of the film F is broken at the time of heat-fusion or at the time of re-elongation at the time of wearing, and an opening H shown by a broken line appears in the Figure 11B and Figure 11D the elongated state of the film F of Figure 11B . Thus, in the elongated state, the stretch laminated sheet S exhibits air permeability. If such a stretch laminated sheet S is used as a waist portion of a wearing article, stuffiness at the time of wearing can be suppressed.

[0006] PRIOR ART DOCUMENT

[0007] PATENT LITERATURE

[0008] Patent Literature 1: JP 2016-189826 A (Fig. 3) SUMMARY

[0009] However, in the non-elongated state in which the stretch laminated sheet S is contracted, the aforementioned opening H is closed as shown in Figure 11A and Figure 11C . Thus, the air permeability of the stretch laminated sheet S is significantly reduced. Therefore, in the case of a wearer or the like in which the degree of elongation of the stretch laminated sheet S in a wearing article is small, it becomes a cause of generating stuffiness due to the reduction in air permeability.

[0010] Accordingly, an object of the present application is to provide a stretch laminated sheet having good air permeability, and a disposable wearing article, and to provide a method and an apparatus for manufacturing the stretch laminated sheet.

[0011] The stretch laminated sheet of the present application is a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated on at least one nonwoven fabric NW having thermoplastic fibers and air permeability, wherein

[0012] The stretch laminated sheet of the present application is a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated on at least one nonwoven fabric NW having thermoplastic fibers and air permeability, wherein

[0013] a plurality of joint portions 1 formed by heat fusion of the nonwoven fabric NW and the film F, each joint portion 1 of the plurality of joint portions 1 including at least one fusion region a in which the nonwoven fabric NW and the film F are heat fused to each other;

[0014] at least one boundary line 10 defining the fusion region a;

[0015] a first air permeable portion 11 defined by first apertures H1 of the film F occurring in an elongated state of the film F and exhibiting air permeability on the boundary line 10; and

[0016] a second air permeable portion 12 adjacent to the fusion region a, defined by second apertures H2 of the film F divided by the boundary line 10 and by a portion of the film F being defective, and exhibiting air permeability in both the elongated state and a non-elongated state.

[0017] The stretch laminated sheet of the present application is a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated on at least one nonwoven fabric NW having thermoplastic fibers and air permeability, wherein

[0018] The stretch laminated sheet of the present application is a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated on at least one nonwoven fabric NW having thermoplastic fibers and air permeability, wherein

[0019] a plurality of joint portions 1 formed by heat fusion of the nonwoven fabric NW and the film F, each joint portion 1 of the plurality of joint portions 1 including at least one fusion region a in which the nonwoven fabric NW and the film F are heat fused to each other;

[0020] at least one boundary line 10 defining the fusion region a;

[0021] a first air permeable portion 11 defined by first apertures H1 of the film F occurring in an elongated state of the film F and exhibiting air permeability on the boundary line 10; and

[0022] a second air permeable portion 12 adjacent to the fusion region a, defined by second apertures H2 of the film F divided by the boundary line 10 and by a portion of the film F being defective, and exhibiting air permeability in both the elongated state and a non-elongated state.

[0023] The disposable wearing article of the present application is a disposable wearing article including the stretch laminated sheet,

[0024] The disposable wearing article has a waist portion formed of the stretch laminated sheet and configured to extend along a waistline direction of a wearer and cover a waist of the wearer, and an absorbent main body configured to cover a crotch of the wearer.

[0025] In these sheets or articles, the first opening H1 occurs in the elongated state, and thus the first air permeable portion 11 exhibits air permeability through the pair of nonwoven fabrics NW.

[0026] On the other hand, in the elongated state and the non-elongated state (contracted state), the second air permeable portion 12 exhibits air permeability through the second opening H2 in which a portion of the film F is defective and the pair of nonwoven fabrics NW.

[0027] Thus, in either of the elongated state and the non-elongated state, the air permeability is improved compared to the past.

[0028] The manufacturing method of the present application is a manufacturing method of a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated on at least one nonwoven fabric NW having air permeability and containing a thermoplastic fiber, wherein

[0029] The manufacturing method of the stretch laminated sheet includes:

[0030] a first conveying step of conveying the nonwoven fabric NW while being tensioned;

[0031] a second conveying step of conveying the film F in an elongated state;

[0032] a step of overlapping the nonwoven fabric NW and the film F with each other while the conveying steps are performed;

[0033] a step of heat-fusing the overlapped nonwoven fabric NW and film F to each other at a plurality of joint portions 1, each joint portion 1 of the plurality of joint portions 1 including at least one fusion region a in which the nonwoven fabric NW and the film F are heat-fused to each other;

[0034] a step of forming a first opening H1 that becomes a first air permeable portion 11 exhibiting air permeability in the elongated state, by breaking a portion of the film F in the elongated state through the heat-fusion on at least one boundary line 10 defining the fusion region a; and

[0035] a step of generating a second opening H2 that becomes a second air permeable portion 12 exhibiting air permeability in both the elongated state and the non-elongated state, by a portion of the film F divided by the boundary line 10 being defective due to the heat-fusion adjacent to the fusion region a.

[0036] In a case where the nonwoven fabric is a pair, the manufacturing method of the present application is a manufacturing method of a stretch laminated sheet in which a film F having thermoplasticity and stretchability is sandwiched between a pair of nonwoven fabrics NW having air permeability and containing thermoplastic fibers, wherein

[0037] The manufacturing method of the stretch laminated sheet includes:

[0038] a conveying step of conveying the pair of nonwoven fabrics NW while being tensioned;

[0039] a conveying step of conveying the film F in an elongated state;

[0040] a step of overlapping the pair of nonwoven fabrics NW and the film F with each other in a manner of sandwiching the film F between the pair of nonwoven fabrics NW while the conveying steps are performed;

[0041] a step of heat-fusing the pair of nonwoven fabrics NW and the film F to each other at a plurality of joint portions 1, each of the plurality of joint portions 1 including at least one fusion region a in which the pair of nonwoven fabrics NW and the film F are heat-fused to each other;

[0042] a step of forming a first opening H1 that becomes a first air permeation portion 11 that functions to allow air to permeate in the elongated state, by breaking a part of the film F in the elongated state by the heat-fusion at at least one boundary line 10 that defines the fusion region a; and

[0043] a step of forming a second opening H2 that becomes a second air permeation portion 12 that functions to allow air to permeate in both the elongated state and the non-elongated state, by the part of the film F divided by the boundary line 10 adjacent to the fusion region a being lost along with the heat-fusion.

[0044] In the present method, when the nonwoven fabric NW and the film F are heat-fused to each other in the fusion region a, a part of the film F in the elongated state is broken at the boundary line 10 by tension, and a first opening H1 is formed. The first opening H1 becomes a first air permeation portion 11 that allows air to flow through the pair of nonwoven fabrics NW in the elongated state.

[0045] Note that the "part of the film F in the elongated state being broken by the heat-fusion" refers to a case where the part is broken at the time of the heat-fusion, in addition to a case where the part is broken at the time of re-elongation after the heat-fusion.

[0046] On the other hand, a part of the film F divided by the boundary line 10 adjacent to the fusion region a is lost along with the heat-fusion or the above-mentioned breaking, and a second opening H2 is formed. The second opening H2 becomes a second air permeation portion 12 that allows air to flow through the pair of nonwoven fabrics NW in both the elongated state and the non-elongated state.

[0047] Thus, the stretch laminated sheet manufactured by the present method has improved air permeability in either of the elongated state and the non-elongated state compared to the past.

[0048] The manufacturing device of the present application is a manufacturing device of a stretch laminated sheet in which a film F having thermoplasticity and stretchability is laminated between at least one nonwoven fabric NW containing thermoplastic fibers and having air permeability, wherein

[0049] The manufacturing device of the stretch laminated sheet has:

[0050] a anvil roll R having a plurality of protruding portions 4 for heat-fusing the nonwoven fabric NW and the film F to each other at a plurality of joint portions 1; and

[0051] a fusing device 5 that cooperates with the anvil roll R to heat-fuse the nonwoven fabric NW and the film F on the protruding portions 4 to each other,

[0052] each protruding portion 4 of the plurality of protruding portions 4 has:

[0053] at least one convex surface β corresponding to a region of heat-fusion in the joint portion 1;

[0054] an edge line 40 defining the at least one convex surface β and forming a first opening H1 of the film F that occurs in the elongated state of the film F; and

[0055] a cutout portion 42 divided by the edge line 40, cutting the convex surface β, and generating a second opening H2 in which a portion of the film F is heat-fused and is defective.

[0056] In the case where the nonwoven fabric is a pair, the manufacturing device of the present application is a manufacturing device of a stretch laminated sheet in which a film F having thermoplasticity and stretchability is sandwiched between a pair of nonwoven fabrics NW containing thermoplastic fibers and having air permeability, wherein

[0057] The manufacturing device of the stretch laminated sheet has:

[0058] a anvil roll R having a plurality of protruding portions 4 for heat-fusing the pair of nonwoven fabrics NW and the film F to each other at a plurality of joint portions 1; and

[0059] a fusing device 5 that cooperates with the anvil roll R to heat-fuse the nonwoven fabric NW and the film F on the protruding portions 4 to each other,

[0060] each protruding portion 4 of the plurality of protruding portions 4 has:

[0061] at least one convex surface β corresponding to a region of heat-fusion in the joint portion 1;

[0062] an edge line 40 defining the at least one convex surface β and forming a first opening H1 of the film F that appears in an elongated state of the film F; and

[0063] a cutout portion 42 divided by the edge line 40, cutting the convex surface β to generate a second opening H2 in which a portion of the film F is thermally fused and missing.

[0064] In the present manufacturing apparatus, the fusing device 5 contacts the protrusion portion 4 with the nonwoven fabric NW and the film F interposed therebetween, and the nonwoven fabric NW and the film F on the protrusion portion 4 are heated, and the nonwoven fabric NW and the film F are thermally fused with each other at the convex surface β. At this time, the film F is maintained in the elongated state, and thus the film F is broken along the edge line 40 of the convex surface β, and the first opening H1 is formed.

[0065] On the other hand, the cutout portion 42 is provided on the convex surface β, and the film F is missing due to softening or the breaking caused by heat when the first opening H1 is formed, and the second opening H2 is formed in the film F. The second opening H2 appears also in a non-elongated state of the film F.

[0066] Therefore, as with the foregoing, the air permeability is improved compared to the past. BRIEF DESCRIPTION OF DRAWINGS

[0067] Figure 1A is a schematic perspective view showing a macrostructure of an elongated stretch laminate sheet, Figure 1B is a schematic front view showing a manufacturing apparatus of the sheet.

[0068] Figure 2A and Figure 2B are schematic plan views of a wearing article each shown in an elongated state.

[0069] Figure 3A and Figure 3B show a waist portion as an example of the sheet in a non-elongated state, Figure 3A is a plan view showing the waist portion, Figure 3B is a plan view showing a portion of the waist portion in an enlarged scale.

[0070] Figure 4 is an enlarged plan view showing a portion of the sheet in the elongated state in an enlarged scale.

[0071] Figures 5A-5D is a super-enlarged view of the sheet in an elongated state in which the sheet is elongated in a lengthwise direction, Figure 5A is a plan view of the sheet, Figure 5B 、 Figure 5C and Figure 5D are sectional views of the sheet taken along the B-B line, the C-C line, and the D-D line in Figure 5A , respectively.

[0072] Figure 6 is an enlarged plan view of a portion of the sheet in the non-elongated state.

[0073] Figures 7A-7D is an ultra-enlarged view of the sheet in the non-elongated state, Figure 7A is a plan view of the sheet, Figure 7B Figure 7C and Figure 7D are respectively Figure 7A B-B line, C-C line and D-D line sectional views of the sheet in

[0074] Figure 8A is an enlarged perspective view showing a portion of the anvil roll, Figure 8B is an enlarged perspective view showing another example of a protruding portion different from Figure 8A the protruding portion of

[0075] Figure 9A Figure 9B Figure 9C Figure 9D Figure 9E Figure 9F Figure 9G and Figure 9H are respectively ultra-enlarged plan views showing another example of the joint portion, the first air permeable portion and the second air permeable portion.

[0076] Figures 10A-10D is an ultra-enlarged view of the stretchable laminated sheet in the elongated state in which the stretchable laminated sheet with the nonwoven fabric as one sheet is elongated in the length direction, Figure 10A is a plan view of the sheet, Figure 10B Figure 10C and Figure 10D are respectively Figure 10A B-B line, C-C line and D-D line sectional views of the sheet in

[0077] Figures 11A-11D is an enlarged view showing a portion of the conventional stretchable laminated sheet, Figure 11A and Figure 11B are respectively plan views of the sheet, Figure 11C and Figure 11D are respectively sectional views of the sheet.

[0078] In Figure 3B Figure 4 Figure 5A Figure 5B Figure 5D Figure 6 Figure 7A Figure 7B Figure 7D Figures 9A-9H Figures 10A-10D and Figures 11A-11D ​​​​​​​​​​​​​​​​​​In the figure, the fusion region is colored in gray. In addition, the boundary of the second opening H2 is indicated by a shorter dotted line in Figure 5A and the like. Figure 7A In the figure, the fusion region is colored in gray. In addition, the boundary of the second opening H2 is indicated by a shorter dotted line in DETAILED DESCRIPTION

[0079] The present application can be more clearly understood from the following description of preferred embodiments with reference to the accompanying drawings. However, the embodiments and drawings are merely illustrative and are not intended to limit the scope of the present application. The scope of the present application is solely determined by the technical scope. In the drawings, the same numbers in different drawings represent the same or corresponding parts.

[0080] Hereinafter, embodiments of the present application will be described.

[0081] Figures 1A-9B Embodiment 1 of the present application is shown.

[0082] The stretch laminated sheet can be used for various purposes. Hereinafter, a case where the stretch laminated sheet is applied to a disposable diaper (an example of a wearing article) will be exemplarily described. The diaper has a waist circumference portion that covers the waist of a wearer, and a crotch portion that covers the crotch of the wearer. The stretch laminated sheet is used for the waist circumference portion.

[0083] A more detailed structure in the case where the stretch laminated sheet is used for a disposable diaper is disclosed, for example, in US2013 / 0110073A1 (WO2012 / 017817A1), all of which are incorporated herein.

[0084] As shown in Figure 1A , the stretch laminated sheet S is formed by sandwiching a film F having thermoplasticity and stretchability between a pair of nonwoven fabrics NW containing thermoplastic fibers and having air permeability.

[0085] The pair of nonwoven fabrics NW and the film F are laminated to each other by thermal fusion at a plurality of joint portions 1 shown in Figure 3A and Figure 3B The stretch laminated sheet S can be used, for example, for a flap and a waist circumference portion of a disposable diaper. In this case, the waist circumference direction X becomes a stretch direction in which the stretch laminated sheet S stretches.

[0086] Each joint portion 1 can be formed by vibration energy of an ultrasonic welding head, or can be formed by heating and warming up.

[0087] Before the stretch laminated sheet is described in detail, an example of a wearing article will be described.

[0088] Figure 2A and Figure 2B An example of a wearing article 6 is shown.

[0089] As shown in these drawings, the wearing article 6 has an absorbent main body 20 and a waist portion 30. The absorbent main body 20 is longer in a longitudinal direction Y orthogonal to a waist direction X. The wearing article can be a diaper type as shown in Figure 2A , or a brief type as shown in Figure 2B .

[0090] The absorbent main body 20 is provided with an unillustrated absorbent core. The absorbent core absorbs body fluid. The absorbent core is sandwiched between a top sheet and a bottom sheet. Each sheet and the absorbent core are layered one on another.

[0091] The top sheet is composed of a thin liquid-permeable nonwoven fabric, and covers a skin surface of the absorbent core. An unillustrated cuff can also be provided on the top sheet.

[0092] The bottom sheet covers a non-skin surface of the absorbent core, and is composed of a non-liquid-permeable resin sheet. The waist portion 30 is attached to the end portions of the absorbent main body 20 in the longitudinal direction Y. That is, the waist portion 30 has an overlapping portion 34 in which the absorbent main body 20 is overlapped.

[0093] The waist portion 30 is formed of a stretchable layered sheet S, and is configured to extend along the waist direction X of the wearer and cover the waist of the wearer. The absorbent main body 20 is configured to cover the crotch of the wearer.

[0094] Figure 3A and Figure 3B represent examples of the stretchable layered sheet S that constitutes the waist portion 30.

[0095] The transverse long engaging portions 1 are provided in multiple rows and multiple columns (in a matrix pattern) in the upper edge portion 32 of the waist portion 30. The longitudinal long engaging portions 1 are provided in multiple rows and multiple columns (in a matrix pattern) in the lower edge portion 31 and the intermediate portion 33 of the waist portion 30. Each engaging portion 1 is arranged intermittently in the waist direction X, and is arranged intermittently in the longitudinal direction Y.

[0096] The intermediate portion 33 is a portion between the lower edge portion 31 and the upper edge portion 32 other than the lower edge portion 31 and the upper edge portion 32. Generally, the upper edge portion 32 is called a waist portion, and the lower edge portion 31 and the intermediate portion 33 are called a hip portion.

[0097] Next, the details of the structure of the stretchable layered sheet S will be described taking the hip portion as an example.

[0098] As shown in Figure 5A , each engaging portion 1 of the plurality of engaging portions 1 includes, for example, two fusion regions a in which a pair of nonwoven fabrics and a film are heat-fused to each other. In these drawings, each fusion region a is colored in gray. Each fusion region a is defined by one annular boundary line 10. The boundary line 10 is depicted in a solid line.

[0099] As shown in Figure 5AAs shown in the enlarged view, the stretch laminated sheet S has a first breathable portion 11 and a second breathable portion 12. Figure 5A In the middle, these breathable parts 11 and 12 are depicted with dashed lines.

[0100] The first vent 11 is defined by the first opening H1 of the membrane F and provides air permeability. When the membrane F is stretched, the boundary line 10 opens and appears as a dashed line.

[0101] On the other hand, the second vent 12 is adjacent to the welded area α and is divided by the boundary line 10. A portion of the membrane F is defined by the defective second opening H2. Figure 5A Elongation state and Figure 7A It exhibits breathability in both its non-elongated and non-stretched states.

[0102] exist Figure 7A In this joint, a pair of welded areas α of each joint 1 are close to each other. A second vent 12 is formed between these welded areas α. The distance Δ between the two close welded areas α is preferably greater than 0 mm and less than 3 mm, and more preferably less than 2 mm.

[0103] exist Figure 2A and Figure 2B When the garment is worn, if the stretchable laminated sheet S is stretched along the waistline X, the stretchable laminated sheet S will elongate in the waistline X. At this time, as... Figure 4 and Figure 5A As shown, at the edge of the joint 1 along the boundary line 10, which is orthogonal to the waist direction X, Figure 5C and Figure 5D The stretch membrane F between a pair of nonwoven fabrics NW easily extends in the waist direction X and is easy to perforate. Therefore, as Figure 5A The large first opening H1, as shown by the dashed line, is formed in the stretch membrane F. That is, through the above stretching, the opening is not formed on the pair of nonwoven fabrics NW with high strength, but only on the stretch membrane F sandwiched between the pair of nonwoven fabrics NW.

[0104] Figure 1B This is an example of a manufacturing apparatus for the stretchable laminated sheet S.

[0105] exist Figure 1B In the process, the membrane F is held between a pair of clamping rollers R1 and R2, and supplied to the anvil roller R between them. Meanwhile, a pair of nonwoven fabrics NW are wound around the anvil roller R, clamping the membrane F. Vibrational energy is imparted from the ultrasonic welding head 50 to the three overlapping sheets NW and F. On the surface of the anvil roller R, as... Figure 8A That would form with Figure 4The protruding portions 4 in which the sheet-like materials NW, F are fused (sealed) to each other.

[0106] Figure 1B The film F is laminated to the nonwoven fabric NW in an elongated state in which tension is applied by the nip rollers R1, R2. In the case where the film F is applied with tension, the film F is contracted (shrinkage) in the width direction of the longitudinal direction Y which becomes the waistline portion. Therefore, it is preferable to apply tension to the film F before the fusion of the film is performed. Therefore, as shown in FIG. 1, it is preferable to arrange a pair of nip rollers R1, R2 upstream of the vicinity of the ultrasonic welding horn 50 and the anvil roller R. Figure 1A Figure 1B

[0107] Figure 1B The ultrasonic welding horn 50 of the present example is an output portion of the fusion device 5, and cooperates with the anvil roller R to impart vibration energy to the sheet-like materials NW, F which are overlapped by the above-mentioned three pieces, in the joint portion 1( Figure 4 ) to heat-fuse the nonwoven fabric NW and the film F to each other. That is, the fusion device 5 of the present example is an ultrasonic fusion device which performs the fusion using ultrasonic energy.

[0108] Next, the details of the protruding portions 4 of the anvil roller R will be described. Figure 8A

[0109] As shown in FIG. 2, on the anvil roller R, a plurality of protruding portions 4 are arranged intermittently in the circumferential direction of the anvil roller R and intermittently in the axial direction Rs of the anvil roller R. These plurality of protruding portions 4 are provided in a plurality corresponding to the joint portions 1( Figure 8A ) of the waistline portion 30 of the film F. Note that, for the sake of easy illustration, Figure 4 The protruding portions 4 of the present example only show the portion corresponding to the joint portions 1 of the lower edge portion 31 of the waistline portion 30 of the film F, and the portion corresponding to the upper edge portion 32 is not shown. Figure 8A Figure 3A Figure 3B Each protruding portion 4 of the present example has two convex surfaces β. The two convex surfaces β approach each other with the cutout portion 42 interposed therebetween. These each convex surface β corresponds to the fusion region a of the film F, and on the other hand, the cutout portion 42( ) corresponds to the second opening H2.

[0110] Figure 8A In the protruding portion 4 of the present example, one convex surface β is defined by being surrounded by one annular edge line 40, and forms the first opening H1 of the film F which appears in the elongated state of the film F. The mechanism of this formation will be described in the manufacturing method described later. Figure 5A Figure 8A Here,

[0111] In the protruding portion 4 of the present example, one convex surface β is defined by being surrounded by one annular edge line 40, and forms the first opening H1 of the film F which appears in the elongated state of the film F. The mechanism of this formation will be described in the manufacturing method described later. Figure 8A Figure 5A

[0112] Here, Figure 8A ​​​​​​​The edge line 40 is preferably not sharp, but has a smaller C-surface or rounded corners. A moderately sized C-surface and rounded corners can melt the membrane F without damaging the nonwoven fabric NW.

[0113] Figure 8A The cut portion 42 is defined by edge lines 40, that is, between two edge lines 40, 40, and is formed by cutting the convex surface β. This cut portion 42 is formed when there is a defect in the membrane F during the thermal fusion of the membrane F. Figure 7A The second opening H2. The formation mechanism is explained in the manufacturing method described later.

[0114] It should be noted that, Figure 7A The distance Δ and Figure 8A The width W of the cut portion 42 Figure 8A The corresponding values ​​are approximately or the same size.

[0115] Next, an example of a method for manufacturing a stretch laminated sheet will be described.

[0116] like Figure 1B As shown, a pair of continuous sheets of nonwoven fabric NW are conveyed while being tensioned, and the film F is conveyed in an elongated state. On the anvil roller R, the film F is overlapped between the pair of continuous sheets of nonwoven fabric NW in such a way that it is sandwiched between them.

[0117] At this point, as is well known, the nonwoven fabric NW is held at a tension that is not relaxed, while the membrane F is conveyed to the anvil roller R in an elongated state in a post-shrinking manner. It should be noted that the membrane F becomes a non-elongated state after shrinking, but it is preferable to apply tension to the membrane F in a manner where the permanent deformation of the membrane F is greater than 0% and less than 10%.

[0118] exist Figure 1B When a pair of nonwoven fabrics NW and membrane F pass between the ultrasonic welding head 50 and the protrusion 4 (8A) of the anvil roller R, the ultrasonic welding head 50 vibrates ultrasonically in the direction toward the anvil roller R. Thus, in Figures 5A-5D In the welding areas α of each joint 1, the nonwoven fabric NW is thermally fused together with each other through the membrane F to form a stretchable laminated sheet S. During this thermal fusion, as described below, a first opening H1 and a second opening H2 are formed in the membrane F.

[0119] During the aforementioned heat fusion, as described above, tension is applied to the membrane F, which is in an elongated state. During this heat fusion, the membrane F at the joint 1 is heated and softened, and a portion of the membrane F breaks at the boundary line 10 (shown by the solid line) due to the tension, as shown by the dashed line, resulting in a first opening H1, for example, an elliptical shape. This first opening H1 serves as a first breathable portion 11 when worn, providing breathability.

[0120] Note that a part of the first openings H1 can also be temporarily blocked after thermal fusion and appear again at the time of further elongation at the time of wearing, etc., by breaking the film F again. Note that the first openings H1 can also be made to appear by performing an extension process as shown in Japanese Patent Application Laid-Open No. 2000-513054 after the fusion process.

[0121] In addition, at the time of the above thermal fusion, the first openings H1 are formed, and second openings H2 are formed between the pair of fusion regions a and the fusion regions a. That is, at the time of the above thermal fusion, the film F is stretched in the girth direction X as described above, and on the other hand, at the time of formation of the above first openings H1, the distance between the fusion regions a and the fusion regions a is small, and thus the part of the film between the fusion regions a and the fusion regions a is damaged by the influence of heat from both sides at the time of thermal fusion. For example, it is presumed that this part of the film is stretched in the girth direction X and broken along the boundary line 10, or is damaged by necking in the longitudinal direction Y. The second openings H2 thus formed become the second air permeable portions 12 that exhibit air permeability in both the elongated state and the non-elongated state.

[0122] After the absorbent main body 20 is disposed on the stretch laminated sheet S thus produced, for example, Figure 2A a panty-type wearing article 6 such as Figure 2B is obtained. In this wearing article 6, the elongated state of the stretch laminated sheet S becomes the non-elongated state in which no tension is imparted in the girth direction X.

[0123] In this non-elongated state, Figure 5A the first openings H1 are closed as shown in Figure 5D and Figure 7A . In addition, in this non-elongated state, accompanied by contraction of the film F, gathers are formed in the nonwoven fabric NW as shown in Figure 7D and Figure 7C . Figure 7D Next, the joint portion 1 of the upper edge portion 32 of the girth portion 30 of

[0124] will be briefly described. As shown in Figure 3B and Figure 9A , this joint portion 1 is formed long in the girth direction X, that is, long in the elongation direction of the film. In this case, the first openings H1 are small, and the elongation rate of the film also becomes small. Figure 9B Note that the second openings H2 of

[0125] are slightly expanded in the elongation direction (girth direction X) in the elongated state of Figure 9A , but in order to facilitate the drawing, the width W of Figure 9B and the width W of Figure 9A are set to be the same and are illustrated. Figure 9B

[0126] ​Figures 9C-9H This represents another example of joint 1.

[0127] like Figure 9C and Figure 9D As shown, the joint 1 can also be two relatively long welded areas α, α separated from each other in the waist direction X (elongation direction).

[0128] like Figure 9E and Figure 9F As shown in the example, the welded region α can also include a necking αs that tapers in the middle, and two main portions αm that are larger than the necking αs and connected to each other through the necking αs. In this case, the second opening H2 is adjacent to the necking αs.

[0129] In this example, the joint 1 is made of Figure 8B The protrusion 4 is formed. Figure 8B In the middle, each convex surface β includes a constricted neck βs that tapers in the middle, and two main parts βm that are connected to each other through the constricted neck βs and are larger than the constricted neck βs.

[0130] In this case, the cut portion 42 is formed between the two main portions βm.

[0131] like Figure 9G and Figure 9H As shown, a joint 1 may also include four welded regions α. In this case, the welded regions α are separated from each other in the elongation direction of the film and in two directions orthogonal to it.

[0132] Next, according to Figures 10A-10D An example of a stretchable laminated sheet S consisting of a nonwoven fabric NW and a film F is described.

[0133] In this case, such as Figure 10A and Figure 10B As shown, in the upper and lower edges 100 of each joint 1, the membrane F can be connected to the nonwoven fabric NW without breaking. In this case, through this connection, it is possible to maintain... Figure 10C and Figure 10D The nonwoven fabric NW and the membrane F are stacked together in an integrated manner.

[0134] To form such a connected edge 100, consider in Figure 8A Methods such as forming a larger rounded corner on part of the edge line 40.

[0135] The invention as understood from the above embodiments includes the following preferred embodiments.

[0136] In a preferred embodiment, each of the plurality of joints 1 includes a plurality of welded regions α that are close to each other.

[0137] The plurality of fusion regions α are formed with the second gas permeable portion 12 therebetween.

[0138] In the case where the second gas permeable portion 12 is present between the fusion regions α, the second gas permeable portion 12 is easily formed.

[0139] In a more preferable embodiment, the plurality of fusion regions α in proximity to each other are at a distance of greater than 0 mm and 3 mm or less from each other.

[0140] In the case where the distance is greater than 3 mm, the film F does not soften between the fusion regions α, and it is difficult to form the second opening H2.

[0141] In a preferable embodiment, the fusion region α includes a neck portion αs that is tapered in the middle, and a plurality of main portions αm that are connected to each other through the neck portion αs and are larger than the neck portion αs,

[0142] The plurality of main portions αm are formed with the second gas permeable portion 12 therebetween.

[0143] In this case, the amount of the neck portion αs of the fusion region α can make the size of the second gas permeable portion 12 smaller compared to the case where the fusion region α is a plurality. However, the accuracy of forming the second opening H2 can be improved.

[0144] In a more preferable embodiment, the plurality of main portions αm are at a distance of greater than 0 mm and 3 mm or less from each other.

[0145] In the case where the distance is greater than 3 mm, the film F does not soften between the adjacent main portions αm, and it is difficult to form the second opening H2.

[0146] In a preferable manufacturing method, after the heat fusion process, there is further provided a process of making the stretchable laminated sheet from the elongated state to a non-elongated state,

[0147] The permanent deformation of the film F in the non-elongated state is greater than 0% and 10% or less.

[0148] If the permanent deformation is large, the second opening H2 is easily formed even if the distance between the fusion regions α is large, but if the permanent deformation is too large, the stretchability is poor. Therefore, it is preferable to make the permanent deformation 0 to 10% in this balance.

[0149] In a preferable manufacturing method, each of the protruding portions 4 includes a plurality of the convex surfaces β in proximity to each other,

[0150] The plurality of convex surfaces β are formed with the cutout portion 42 therebetween.

[0151] In this case, at the time of fusion, the film F is damaged in the cutout portion 42 due to heat or tension.

[0152] In another preferred manufacturing method, each convex surface β includes an intermediate tapered neck portion βs, and a plurality of main portions βm connected to each other by the neck portion βs and larger than the neck portion ps,

[0153] The plurality of main portions βm are formed with the cut portions 42 between each other.

[0154] In this case, at the time of welding, the film F is damaged by heat or tension between the neck portions αs.

[0155] Features described and / or illustrated in connection with one embodiment or preferred embodiment(s) can be incorporated in one or more other embodiments with or without modification and / or incorporated in combination with other embodiments.

[0156] As described above, the preferred embodiments have been described with reference to the accompanying drawings, and various changes and modifications obvious to those skilled in the art reading this specification should be readily apparent in the scope of obviousness.

[0157] For example, one or both of the nonwoven fabrics NW can not be continuous nonwoven fabrics but discontinuous nonwoven fabrics. In addition, the nonwoven fabric can be inelastic. In addition, the nonwoven fabric can be stretchable nonwoven fabric, crimped nonwoven fabric.

[0158] Therefore, such changes and modifications are interpreted to be included in the scope of the present application determined by the technical idea.

[0159] Industrial applicability

[0160] The stretchable laminated sheet of the present application can be used as a part of a member of a disposable wearing article or the like.

[0161] Explanation of reference numerals:

[0162] 1: joint; 10: boundary line;

[0163] 11: first air permeable portion; 12: second air permeable portion;

[0164] 20: absorbent main body;

[0165] 30: waist portion; 31: lower edge portion; 32: upper edge portion; 33: intermediate portion; 34: overlapping portion;

[0166] 4: protrusion portion; 40: edge line; 42: cut portion;

[0167] 5: welding device; 50: ultrasonic welding head;

[0168] 6: wearing article;

[0169] F: film;

[0170] NW: nonwoven fabric;

[0171] H: hole; H1: first hole; H2: second hole; MD: conveying direction;

[0172] R: anvil roll; R1, R2: nip roll; Rs: axial direction;

[0173] S: stretchable laminated sheet;

[0174] X: waist direction;

[0175] Y: longitudinal direction;

[0176] W: width;

[0177] α: fusion area; αm: main portion; αs: necked portion;

[0178] β: convex surface; βm: main portion; βs: necked portion;

[0179] Δ: distance.

Claims

1. A stretch laminated sheet, which is a stretch laminated sheet in which a film (F) having thermoplasticity and stretchability is laminated on at least one nonwoven fabric (NW) containing thermoplastic fibers and having air permeability, wherein the stretch laminated sheet comprises: a plurality of joint portions (1) formed by heat fusion of the nonwoven fabric (NW) and the film (F) with each other, each joint portion (1) of the plurality of joint portions (1) including at least one fusion region (a) in which the nonwoven fabric (NW) and the film (F) are heat fused with each other; at least one boundary line (10) defining the fusion region (a); a first air permeable portion (11) defined by first apertures (H1) of the film (F) occurring in an elongated state of the film (F) on the boundary line (10) and exhibiting air permeability; and a second air permeable portion (12) adjacent to the fusion region (a), divided by the boundary line (10) and defined by second apertures (H2) of a portion of the film (F) being defective, exhibiting air permeability in both the elongated state and a non-elongated state, each joint portion (1) includes a pair of the fusion regions (a) adjacent to each other, the second apertures (H2) defining the second air permeable portion (12) include a portion of the film (F) being defective extending from one of the pair of the fusion regions (a) to the other of the pair of the fusion regions (a) and being defective throughout the film (F).

2. The stretch laminated sheet according to claim 1, wherein the at least one nonwoven fabric (NW) includes a pair of nonwoven fabrics (NW), the film (F) is sandwiched between the pair of nonwoven fabrics (NW), and the nonwoven fabric (NW) and the film (F) are heat fused with each other in the fusion region (a) of each joint portion (1).

3. The stretch laminated sheet according to claim 1, wherein a distance between the pair of the fusion regions (a) is greater than 0 mm and is 3 mm or less.

4. The stretch laminated sheet according to claim 1 or 2, wherein the pair of the fusion regions (a) are connected to each other by a neck portion tapered in an intermediate portion.

5. The stretch laminated sheet according to claim 4, wherein a distance between the pair of the fusion regions (a) is greater than 0 mm and is 3 mm or less.

6. A disposable wearing article including the stretch laminated sheet according to claim 1 or 2, wherein the disposable wearing article comprises a waist portion formed of the stretch laminated sheet and configured to extend along a waistline direction of a wearer and cover a waist of the wearer, and an absorbent main body configured to cover a crotch of the wearer.

7. A method of manufacturing a stretch laminated sheet, which is a method of manufacturing a stretch laminated sheet in which a film (F) having thermoplasticity and stretchability is laminated on at least one nonwoven fabric (NW) containing thermoplastic fibers and having air permeability, wherein the method of manufacturing the stretch laminated sheet comprises: a first conveying step of conveying the nonwoven fabric (NW) while being tensioned; and a second conveying step of conveying the film (F) in an elongated state. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ a process of overlapping the nonwoven fabric (NW) and the film (F) with each other while performing the first conveying process and the second conveying process; a process of heat-fusing the nonwoven fabric (NW) and the film (F) to each other at a plurality of joint portions (1), each of the joint portions (1) including at least one fusion region (α) where the nonwoven fabric (NW) and the film (F) are heat-fused to each other; a process of forming a first opening (H1) that becomes a first gas permeation portion (11) that exhibits gas permeability in the elongated state, by breaking a part of the film (F) in the elongated state by the heat fusion on at least one boundary line (10) that defines the fusion region (α); and a process of generating a second opening (H2) that becomes a second gas permeation portion (12) that exhibits gas permeability in both the elongated state and the non-elongated state, by the part of the film (F) divided by the boundary line (10) being absent due to the heat fusion adjacent to the fusion region (α), each of the joint portions (1) includes a pair of the fusion regions (α) adjacent to each other, the second opening (H2) that defines the second gas permeation portion (12) includes a part where the film (F) is absent from one of the pair of the fusion regions (α) to the other of the pair of the fusion regions (α).

8. The method of manufacturing the stretch laminated sheet according to claim 7, wherein the at least one nonwoven fabric (NW) includes a pair of nonwoven fabrics (NW), and the film (F) is sandwiched between the pair of nonwoven fabrics (NW), in the first conveying process, the pair of nonwoven fabrics (NW) is conveyed while being tensioned, in the overlapping process, the pair of nonwoven fabrics (NW) and the film (F) are overlapped with each other while being conveyed in the first conveying process and the second conveying process, and in the heat-fusing process, the pair of nonwoven fabrics (NW) and the film (F) are heat-fused to each other at the plurality of joint portions (1), and the pair of nonwoven fabrics (NW) and the film (F) are heat-fused to each other at the fusion region (α) of the joint portion (1).

9. The method of manufacturing the stretch laminated sheet according to claim 7 or 8, wherein the method of manufacturing the stretch laminated sheet further includes a process of changing the stretch laminated sheet from the elongated state to the non-elongated state after the heat-fusing process, the film (F) in the non-elongated state has a permanent set of more than 0% and 10% or less.

10. A manufacturing apparatus of a stretch laminated sheet that is a stretch laminated sheet in which a film (F) having thermoplasticity and stretchability is laminated between at least one nonwoven fabric (NW) containing thermoplastic fibers and having gas permeability, wherein the manufacturing apparatus of the stretch laminated sheet includes: an anvil roller (R) having a plurality of protrusion portions (4) for heat-fusing the nonwoven fabric (NW) and the film (F) to each other at a plurality of joint portions (1); and the manufacturing apparatus of the stretch laminated sheet further includes: a first conveying roller (2) for conveying the nonwoven fabric (NW) and the film (F) in the first conveying process, and a second conveying roller (3) for conveying the nonwoven fabric (NW) and the film (F) in the second conveying process. a fusing device (5) that thermally fuses the nonwoven fabric (NW) and the film (F) on the protruding portions (4) to each other in cooperation with the anvil roll (R), each protruding portion (4) of the plurality of protruding portions (4) has: at least one convex surface (β) corresponding to a region of thermal fusion in the joint portion (1); an edge line (40) defining the at least one convex surface (β) and forming a first opening (H1) of the film (F) that occurs in an elongated state of the film (F); and a cutout portion (42) that is divided by the edge line (40), cuts the convex surface (β), and generates a second opening (H2) in which a portion of the film (F) is thermally fused and is defective.

11. The manufacturing device of the stretchable laminated sheet according to claim 10, wherein: the at least one nonwoven fabric (NW) is a pair of nonwoven fabrics (NW), and the film (F) is sandwiched between the pair of nonwoven fabrics (NW), the anvil roll (R) is an anvil roll (R) having a plurality of protruding portions (4) for thermally fusing the pair of nonwoven fabrics (NW) and the film (F) to each other in a plurality of joint portions (1).

12. The manufacturing device of the stretchable laminated sheet according to claim 10 or 11, wherein: each protruding portion (4) includes a plurality of the convex surfaces (β) that are close to each other, the cutout portion (42) is formed between the plurality of convex surfaces (β).

13. The manufacturing device of the stretchable laminated sheet according to claim 10 or 11, wherein: each convex surface (β) includes a neck portion (βs) that is tapered in the middle, and a plurality of main portions (βm) that are connected to each other through the neck portion (βs) and are larger than the neck portion (βs), the cutout portion (42) is formed between the plurality of main portions (βm). ​

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