Apparatus for manufacturing absorbent articles

Abstract

Provided is a manufacturing apparatus of an absorbent article that facilitates discovery of a defect of a coating apparatus. The manufacturing apparatus of an absorbent article (100) of an embodiment includes a non-contact coating apparatus (120) that coats a liquid material (20) by ejecting the liquid material from a nozzle (122) toward a constituent member (10) of the absorbent article being conveyed in a conveyance direction (MD), and an illumination apparatus (140) that uses an LED to at least irradiate between the nozzle and the constituent member.

Description

Technical Field

[0001] This utility model relates to an apparatus for manufacturing absorbent articles, including a non-contact coating device that applies liquid material from a nozzle to constituent components of an absorbent article. Background Technology

[0002] Conventionally, there are known apparatuses for manufacturing absorbent articles that include a non-contact coating device for coating liquid materials (e.g., adhesives) onto constituent components of absorbent articles during transport (e.g., see Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2013-66867 Utility Model Content

[0006] Problems to be solved by utility models

[0007] Due to continuous use of the coating apparatus, the cured liquid material sometimes becomes clogged in the nozzles. The liquid material does not eject from the clogged nozzles, thus sometimes failing to coat the liquid material properly. For example, even if the coating apparatus has multiple nozzles, sometimes the liquid material is only ejected from a portion of the nozzles, resulting in inadequate coating.

[0008] Operators can detect malfunctions in such coating devices by checking whether the liquid material is being applied properly to the constituent components.

[0009] However, it is extremely difficult for operators to verify the liquid material applied to the components while conveying (especially at high speeds) the components. Therefore, it is often difficult to confirm whether the liquid material has been applied to the manufactured absorbent articles. Consequently, there is a significant delay between the discovery of malfunctions in the coating equipment and the application of the liquid material; by the time the malfunction is discovered, a large quantity of absorbent articles has already been manufactured. As a result, sometimes a large number of absorbent articles must be discarded.

[0010] Therefore, this invention was made in view of the following problem, and its object is to provide an apparatus for manufacturing absorbent articles in which defects in the coating device are easily detected.

[0011] Solution for solving the problem

[0012] An apparatus for manufacturing an absorbent article includes: a non-contact coating device that coats a component of the absorbent article conveyed in a conveying direction with a liquid material ejected from a nozzle; and an illumination device that uses an LED to illuminate at least the area between the nozzle and the component.

[0013] According to this solution, the liquid material is illuminated by an illumination device until it is ejected from the nozzle and applied to the constituent component. This allows for easy visual observation of the liquid material's path from the nozzle to the constituent component. Furthermore, unlike incandescent bulbs which reach the end of their lifespan abruptly, LEDs gradually dim, preventing situations where the liquid material is no longer illuminated during the manufacturing process of the absorbent article. Consequently, defects in the coating apparatus cannot be missed. Additionally, LEDs do not generate heat compared to incandescent bulbs, thus preventing heat from affecting the quality of the liquid material. Therefore, the quality of the absorbent article is not degraded. Moreover, defects in the coating apparatus can be detected not after the absorbent article is manufactured, but during the manufacturing process itself, thus shortening the delay between the discovery of defects and the application of the liquid material, and reducing the amount of waste absorbent article.

[0014] According to a preferred embodiment, the LED is a white LED. According to this embodiment, by using a white LED capable of emitting light encompassing various wavelengths within the visible light wavelength range for illumination, the visual visibility of the liquid material ejected from the nozzle is improved compared to illumination using a conventional fluorescent lamp. As a result, the operator can accurately confirm whether the liquid material has been properly applied to the constituent components and easily detect malfunctions in the coating apparatus.

[0015] One embodiment of an apparatus for manufacturing absorbent articles includes: a non-contact coating device that coats a component of the absorbent article conveyed in a conveying direction with a liquid material containing a fluorescent material that emits visible light upon receiving ultraviolet light; and an illumination device that illuminates at least the area between the nozzle and the component using the ultraviolet light. According to this embodiment, the liquid material is irradiated with ultraviolet light by the illumination device until it is ejected from the nozzle and coated onto the component. Thus, the fluorescent material contained in the liquid material ejected from the nozzle emits visible light upon receiving ultraviolet light, making it easy to visually confirm the path of the liquid material from the nozzle to the component even in the dark. Furthermore, defects in the coating device can be detected not after the absorbent article is manufactured, but during the manufacturing process, thus shortening the delay between the discovery of defects in the coating device and the application of the liquid material, and reducing the amount of discarded absorbent articles.

[0016] According to a preferred embodiment, the system further includes: an imaging device that captures images of the area between the nozzle and the constituent member illuminated by the illumination device; and a control device that, upon detecting a change in the trajectory of the liquid material between the nozzle and the constituent member based on the image captured by the imaging device, performs the following control: stopping the delivery of the constituent member, or discarding the constituent member at least at the position where the liquid material was applied at the moment the change was detected. According to this embodiment, the operator can detect a defect in the coating apparatus by stopping the delivery of the constituent member. Furthermore, stopping the delivery of the constituent member can suppress the continued production of absorbent articles with defects. Additionally, if a constituent member is discarded, the operator can detect a defect in the coating apparatus by confirming the presence of a discarded constituent member. Moreover, it can prevent the shipment of absorbent articles with improperly applied liquid material.

[0017] According to a preferred embodiment, the lighting device has a light source that illuminates at least the area between the nozzle and the constituent member, wherein the distance from the light source to the nozzle's outlet is greater than the distance from the light source to the constituent member. According to this embodiment, the light source and the nozzle's outlet are separate, thus making it difficult for liquid material ejected from the outlet to adhere to the light source. The brightness of the lighting device is less likely to decrease, suppressing any reduction in the visual visibility of the liquid material ejected from the nozzle.

[0018] According to a preferred embodiment, the lighting device has a light source that illuminates at least the area between the nozzle and the constituent member, and the light source is positioned upstream of the nozzle in the conveying direction. According to this embodiment, even if liquid material adhering to the constituent member is splashed due to the conveying of the constituent member, the liquid material is unlikely to adhere to the light source positioned upstream of the nozzle. The brightness of the lighting device is less likely to decrease, and the reduction in the visual visibility of the liquid material ejected from the nozzle can be suppressed.

[0019] According to a preferred embodiment, the lighting device includes: a light source that irradiates light, which illuminates at least the area between the nozzle and the constituent member; and a sliding mechanism that slides the light source in a cross-direction intersecting the conveying direction. According to this embodiment, by sliding the light source in the cross-direction, the light source can be moved closer to the operator from the conveying path of the constituent member. This allows the operator to easily clean or replace the light source. Even if the brightness of the lighting device decreases, the operator can easily improve the brightness of the lighting device. Attached Figure Description

[0020] Figure 1This is a schematic diagram illustrating an example of an apparatus for manufacturing an absorbent article according to an embodiment.

[0021] Figure 2 This is a schematic diagram illustrating an example of an apparatus for manufacturing an absorbent article according to an embodiment. Figure 2 (A) is a schematic perspective view of a portion of an apparatus for manufacturing an absorbent article. Figure 2 (B) is a schematic side view of a portion of an apparatus for manufacturing an absorbent article.

[0022] Figure 3 This is a schematic diagram illustrating an example of a lighting device for explaining an embodiment. Figure 3 (A) indicates the state of the lighting device before it slides. Figure 3 (B) indicates the state of the lighting device after it has been slid. Detailed Implementation

[0023] Hereinafter, the apparatus 100 for manufacturing an absorbent article according to the embodiments will be described with reference to the accompanying drawings. Furthermore, in the following description of the drawings, the same or similar parts will be labeled with the same or similar reference numerals. However, the drawings are schematic diagrams, and it should be noted that the proportions of various dimensions may differ from reality. Therefore, specific dimensions should be determined by referring to the following description. Additionally, the drawings may contain parts with different dimensional relationships or proportions.

[0024] The absorbent article manufacturing apparatus 100 is an apparatus for manufacturing absorbent articles. Absorbent articles manufactured by the manufacturing apparatus 100 can be, for example, panty-style sanitary napkins, disposable diapers, menstrual pads, incontinence pads, underwear linings, etc. Figures 1-3 As shown and as Figure 2 As shown, the absorbent article manufacturing apparatus 100 of the embodiment may include, for example, a conveying device 110, a coating device 120, a lighting device 140, a photographing device 150, and a control device 160.

[0025] The conveying device 110 conveys the constituent components 10 of the absorbent article in the conveying direction MD. The conveying device 110 may include, for example, a conveyor roller, a drive source for driving the conveyor roller, and a conveyor belt stretched over the conveyor roller. Furthermore, the constituent components 10 of the absorbent article may be, for example, a fiber web as a sheet-like component. The constituent components 10 may be, for example, components constituting a liquid-permeable top sheet, a liquid-impermeable back sheet, etc. The constituent components 10 may be, for example, composed of nonwoven fabric, membrane, etc.

[0026] The coating apparatus 120 is a non-contact coating device that coats a component 10 of an absorbent article conveyed in the transport direction MD by ejecting liquid material 20 from a nozzle 122. The coating apparatus 120 has a nozzle 122 for ejecting the liquid material 20. The liquid material is ejected from an outlet 122p of the nozzle 122. Because the coating apparatus 120 is non-contact, the distance from the outlet 122p to the component 10 can be separated in the vertical direction TD. Furthermore, the vertical direction TD can be a direction perpendicular to the transport direction MD.

[0027] Here, the liquid material 20 may be, for example, a hot melt adhesive, or a pharmaceutical agent containing fragrances, deodorants, antibacterial agents, etc., as active ingredients. The liquid material 20 may also be a material containing a fluorescent material that emits visible light upon receiving ultraviolet light.

[0028] Here, it is very difficult for the operator to confirm the liquid material 20 applied to (especially at high speed) the constituent component 10. Furthermore, since the liquid material 20 is essentially transparent, it is even more difficult for the operator to confirm whether the transparent liquid material has been applied to the absorbent article. Therefore, in the conventional manufacture of absorbent articles, confirmation of whether the liquid material has been applied to the manufactured absorbent article is usually done by applying powder to the manufactured absorbent article and confirming by observing the adhesion of the powder. Consequently, there is a significant delay between the discovery of a malfunction in the coating apparatus and the discovery of the liquid material application; by the time the malfunction is discovered, a large number of absorbent articles have already been manufactured.

[0029] In contrast, the lighting device 140 uses an LED (Light Emitting Diode) to illuminate at least the area between the nozzle and the constituent member 10. This illumination of the liquid material 20 ejected from the nozzle 122 makes it easy to visually confirm the path of the liquid material 20 from the nozzle 122 to the constituent member 10. Furthermore, defects in the coating apparatus 120 can be detected not after the absorbent article is manufactured, but during the manufacturing process itself. This shortens the time between detecting defects in the coating apparatus 120 and the application of the liquid material 20, thus reducing the likelihood of large quantities of waste absorbent articles.

[0030] Furthermore, unlike incandescent bulbs, LEDs do not reach the end of their lifespan abruptly; their brightness gradually diminishes. This prevents situations where the liquid material is no longer irradiated during the manufacturing process of the absorbent article. Consequently, it prevents the failure to detect defects in the coating apparatus 120. Additionally, LEDs do not generate heat compared to incandescent bulbs, thus preventing heat from affecting the quality of the liquid material 20. Therefore, the quality of the absorbent article is not degraded.

[0031] The LED can be a white LED. By using a white LED capable of emitting light encompassing various wavelengths within the visible light wavelength range for illumination, the visual visibility of the liquid material 20 ejected from nozzle 122 is improved compared to illumination using a conventional fluorescent lamp. The operator can accurately confirm whether the liquid material 20 has been properly applied to the component 10, and easily detect malfunctions in the coating apparatus 120. Furthermore, the light emission mode of the white LED is not particularly limited.

[0032] Alternatively, the lighting device 140 can also use ultraviolet light to illuminate at least the area between the nozzle 122 and the component 10. The liquid material is irradiated with ultraviolet light by the lighting device until it exits the nozzle 122 and is applied to the component. As a result, the fluorescent material contained in the liquid material exiting the nozzle receives ultraviolet light and emits visible light, making it easy to visually confirm the path of the liquid material from the nozzle to the component even in the dark. Consequently, the operator can accurately confirm whether the liquid material has been properly applied to the component and easily detect malfunctions in the coating device. Furthermore, the lighting device 140 does not necessarily require the use of LEDs when irradiating with ultraviolet light. In this case, the liquid material 20 uses a material containing a fluorescent material that receives ultraviolet light and emits visible light.

[0033] The lighting device 140 may have a light source 142 that illuminates at least the area between the nozzle 122 and the constituent member 10. The light source 142 may be composed of a white LED. When the purpose is to illuminate with ultraviolet light, the light source 142 may be composed of either an LED or not. Furthermore, the light source 142 may refer to either simply an LED serving as a light source, or it may refer to a lighting device equipped with a light source.

[0034] The area illuminated by the light source 142 may not be the entire area between the nozzle 122 and the component 10, but may be a portion of that area. The area illuminated may include not only the area between the nozzle 122 and the component 10, but also other areas. Therefore, the illumination device 140 can illuminate, for example, both the outlet 122p of the nozzle 122 and the component 10. The illumination device 140 can illuminate the component 10 before and after the application of the liquid material 20.

[0035] like Figure 2As shown in (B), the distance L1 from the light source 142 to the nozzle 122 outlet 122p can be greater than the distance L2 from the light source 142 to the constituent member 10. Since the light source 142 is separated from the nozzle 122 outlet 122p, the liquid material 20 ejected from the outlet 122p is less likely to adhere to the light source 142. The brightness of the illumination device 140 is less likely to decrease, and the reduction in visual recognition of the liquid material 20 ejected from the nozzle 122 can be suppressed.

[0036] The light source 142 can be positioned downstream of the nozzle 122 in the conveying direction MD. Alternatively, the light source 142 can be positioned upstream of the nozzle 122 in the conveying direction MD. Even if the liquid material 20 adhering to the constituent member 10 is scattered due to the conveying of the constituent member 10, the liquid material 20 is unlikely to adhere to the light source 142 positioned upstream of the nozzle 122. As a result, the brightness of the illumination device 140 is unlikely to decrease, and the reduction in visual visibility of the liquid material 20 ejected from the nozzle 122 can be suppressed.

[0037] In addition, such as Figure 2 As shown in (B), the distance L2 from the light source 142 to the constituent member 10 can be greater than the distance L3 from the outlet 122p of the nozzle 122 to the constituent member 10. Since the light source 142 of the lighting device 140 is separate from the constituent member, the liquid material ejected from the nozzle 122 is less likely to adhere to the light source 142. Therefore, the brightness of the lighting device 140 is less likely to decrease, and the reduction in visual recognition of the liquid material 20 ejected from the nozzle 122 can be suppressed.

[0038] like Figure 3 As shown, the lighting device 140 may have a fixing part 144 for fixing the light source part 142 and a support part 146 for supporting the light source part 142 (by means of the fixing part 144). The fixing part 144 may be configured to allow the fixed light source part 142 to be detached. The fixing part 144 may, for example, include a substrate for mounting a lighting device that serves as the light source part 142 and a mechanism (e.g., bolts and nuts) for fixing the light source part 142. The fixing part 144 may also, for example, include a socket for mounting an LED that serves as the light source part 142.

[0039] Furthermore, the fixing part 144 may include a magnetic member for fixing the light source part 142 using magnetic force. This allows the operator to easily disassemble the lighting device 140 and perform maintenance on it. By magnetically attracting the magnetic member included in the fixing part 144 to the magnetic member included in the lighting equipment constituting the light source part 142, the light source part 142 can be fixed to the fixing part 144. Additionally, as... Figure 3As shown, the support portion 146 may extend in a cross direction CD that intersects the conveying direction MD. One end of the support portion 146 in the cross direction CD may be fixed to a wall surface, for example.

[0040] like Figure 3 As shown, the fixing part 144 and the support part 146 can form a sliding mechanism that allows the light source part 142 to slide in the intersecting direction CD. By sliding the light source part 142 in the intersecting direction CD, the light source part 142 can be moved closer to the operator from the transport path of the constituent member 10. As a result, the operator can easily clean or replace the light source part 142. Even if the brightness of the lighting device 140 decreases, the operator can easily improve the brightness of the lighting device 140.

[0041] like Figure 3 As shown in (A), the lighting device 140 can be positioned above and facing the component 10 on the transport path before sliding. Figure 3 As shown in (B), the fixing part 144 can slide relative to the support part 146 in the intersecting direction CD. Therefore, the light source part 142 can slide in the intersecting direction CD by means of the fixing part 144. In the slidable state, the light source part 142 may not face the constitutive member 10.

[0042] Additionally, the lighting device 140 may have an arm that connects the light source unit 142 and the fixing unit 144 and allows for changing the position of the light source unit 142. This allows the position of the light source unit 142 to be changed to a position that facilitates irradiation of the liquid material 20 ejected from the nozzle 122. The path from the nozzle 122 to the liquid material 20 constituting the member 10 can be easily confirmed (visually). The arm may be, for example, a member movable by bending or extending. By moving the arm, the position of the light source unit 142 can be changed (adjusted) in any of the following directions: the delivery direction MD, the cross direction CD, and the vertical direction TD. Furthermore, by moving the arm, the angle of the light source unit 142 can be changed. Therefore, the position and / or angle of the light source unit 142 can be adjusted.

[0043] The imaging device 150 can capture images of the area between the nozzle 122 and the constituent member 10 illuminated by the lighting device. The imaging device 150 can be, for example, a camera. The images captured by the imaging device 150 can be either still images or moving images. Furthermore, the area captured can include not only the area between the nozzle 122 and the constituent member 10, but also other areas. Therefore, the imaging device 150 can capture images of, for example, the outlet 122p of the nozzle 122, as well as the constituent member 10. The imaging device 150 can be connected to the control device 160. The imaging device 150 can send the captured images to the control device 160.

[0044] The control device 160 can detect changes in the trajectory of the liquid material 20 between the nozzle 122 and the constituent member 10 based on images captured by the imaging device 150. For example, the control device 160 can determine that the trajectory of the liquid material 20 has not changed if the liquid material is present at a predetermined position within the image. Conversely, the control device 160 can also determine that the trajectory of the liquid material 20 has changed if the liquid material is not present at a predetermined position within the image. The control device 160 can detect changes in the trajectory of the liquid material 20 based on this determination.

[0045] The control device 160 can perform any of the following controls, for example, upon detecting a change in the trajectory of the liquid material 20: The control device 160 can stop the conveying of the component 10. The control device 160 can stop the conveying of the component 10 by controlling the conveying device 110. The control device 160 can discard the component 10 at least at the moment the change is detected, at the position where the liquid material 20 is applied. The operator can understand that a defect has occurred in the coating device 120 by stopping the conveying of the component 10. Furthermore, stopping the conveying of the component 10 can prevent the continued production of absorbent articles with defects. Additionally, the operator can understand that a defect has occurred in the coating device 120 by confirming the existence of discarded component 10 when the component 10 is discarded. Moreover, it can prevent the shipment of absorbent articles with improperly applied liquid material 20.

[0046] Specifically, the control device 160 can control the discarding of the component 10 corresponding to the area below the injection outlet 122p of the nozzle 122 (hereinafter referred to as the coating failure area), at least at the moment a change is detected. The control device 160 can discard not only the component 10 corresponding to the coating failure area, but also the component 10 corresponding to the area upstream of the coating failure area, and the component 10 corresponding to the area downstream of the coating failure area. Here, the control device 160 can also control the feeding of the component 10 corresponding to the coating failure area along a different route than other component 10 after the component 10 is cut off. Furthermore, the control device 160 can also control the feeding of the absorbent article containing the component 10 corresponding to the coating failure area along a different route than the absorbent article containing the component 10 with the appropriately coated liquid material after processing the component 10. Thus, the component 10 corresponding to the coating failure area can also be discarded.

[0047] Subsequently, the absorbent article manufacturing apparatus 100 can manufacture absorbent articles by processing the component 10 coated with liquid material and combining it with other component components.

[0048] The present invention has been described in detail above using the embodiments described above. However, it will be apparent to those skilled in the art that the present invention is not limited to the embodiments described in this specification. The present invention can be implemented with modifications and variations without departing from the spirit and scope of the present invention as defined by the claims. Therefore, the purpose of this specification is illustrative and it does not have any limiting meaning for the present invention.

Claims

1. An apparatus for manufacturing an absorbent article, characterized in that, The apparatus for manufacturing the absorbent article includes: A non-contact coating apparatus that coats a constituent component of the absorbent article conveyed in a conveying direction with a liquid material ejected from a nozzle; and A lighting device that uses LEDs to illuminate at least the area between the nozzle and the constituent components.

2. The apparatus for manufacturing absorbent articles according to claim 1, characterized in that, The LED is a white LED.

3. An apparatus for manufacturing an absorbent article, characterized in that, The apparatus for manufacturing the absorbent article includes: A non-contact coating apparatus that coats a constituent component of the absorbent article conveyed in a conveying direction with a liquid material comprising a fluorescent material that emits visible light upon receiving ultraviolet light; and A lighting device that uses the ultraviolet light to illuminate at least the area between the nozzle and the constituent components.

4. The apparatus for manufacturing an absorbent article according to claim 1 or 3, characterized in that, The apparatus for manufacturing the absorbent article also includes: A photographing device that photographs the area between the nozzle and the constituent member illuminated by the lighting device; and A control device that, upon detecting a change in the trajectory of the liquid material between the nozzle and the constituent member based on an image captured by the imaging device, performs the following control: stops the delivery of the constituent member, or discards the constituent member at least at the position through which the liquid material is applied at the moment the change is detected.

5. The apparatus for manufacturing an absorbent article according to claim 1 or 3, characterized in that, The lighting device has a light source that illuminates at least the area between the nozzle and the constituent components. The distance from the light source to the nozzle outlet is greater than the distance from the light source to the constituent member.

6. The apparatus for manufacturing an absorbent article according to claim 1 or 3, characterized in that, The lighting device has a light source that illuminates at least the area between the nozzle and the constituent components. The light source is positioned upstream of the nozzle in the conveying direction.

7. The apparatus for manufacturing absorbent articles according to claim 1 or 3, characterized in that, The lighting device has: A light source that irradiates light, the light irradiating at least the area between the nozzle and the constituent member; and A sliding mechanism that causes the light source to slide in an intersecting direction that intersects the conveying direction.

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