Packaged item and its production process

Abstract

A packaged element (1) includes a bag (20) and a sheet laminate (10) packaged in the bag. The sheet laminate includes a first fibrous sheet comprising a first fiber comprising a PET resin having a melting point above 230 °C, and a second sheet comprising a thermoplastic resin having a melting point of 230 °C or less. The sheet laminate includes an assembled portion (30) in which the first fibrous sheet and the second sheet are joined adjacent to each other. In the assembled portion, a resin constituting the first fibrous sheet is incorporated into the thermoplastic resin constituting the second sheet. The present invention also provides a method for producing the packaged element.

Description

Title of the invention: Packaged element and method for producing it

[0001] Technical field The present invention relates to a packaged element and a method for producing it.

[0002] Prior art A sheet laminate in which a plurality of sheet materials are laminated is used in various applications. Patent literature 1 discloses a laminated sheet in which sheets of synthetic fibers with different melting points are intermittently melt-bonded and integrated. Furthermore, patent literature 2 discloses a laminated sheet in which a layer of nonwoven fabric having a resin penetration rate of 40% or less and a layer of thermoplastic resin are laminated, and an adhesion strength of 10 g / 25 mm or more.

[0003] Patent literature 3 discloses a laminated sheet comprising a sheet-forming element in which nonwoven fabrics made of polyethylene terephthalate fibers are laminated onto the two surfaces of a breathable, waterproof sheet, and a fusion-bonding film containing a low-melting-point substance. Furthermore, patent literature 4 discloses an ultrasonic sealing device for producing a flooring material by assembling a plurality of objects to be welded, which are formed from different types of materials, by ultrasonic vibration.

[0004] List of documents cited Patent literature Patent Literature 1: JPH05-287682A Patent Literature 2: JPH11-151785A Patent Literature 3: JP2016-203580A Patent Literature 4: WO2019-509921A

[0005] Summary of the invention However, in the laminated sheets described in patent literature 1 to 3, the bonding strength is insufficient when a specific resin is used as the constituent material. Furthermore, when the laminated sheet described in each patent literature is offered in the form of a packaged item in which the laminated sheet is packaged; nothing is considered regarding the volume of the laminated sheet after opening. The art described in patent literature 4 relates to the flooring material, and nothing is envisaged concerning the laminated sheet containing fibers.

[0006] The present invention relates to a packaged element having a sheet laminate having sufficient assembly strength, with a volume easily restored after opening.

[0007] The present invention relates to a packaged element comprising a bag, and a sheet laminate packaged in the bag. In one embodiment, the sheet laminate includes a first fibrous sheet including a first fiber including a constituent resin which contains a polyethylene terephthalate resin having a melting point above 230 °C; and a second sheet including a thermoplastic resin having a melting point of 230 °C or less. In one embodiment, the sheet laminate preferably includes an assembled part in which the first fibrous sheet and the second sheet are assembled adjacent to each other. In one embodiment, in the assembled part, the resin constituting the first fibrous sheet is preferably incorporated into the thermoplastic resin constituting the second sheet.

[0008] The present invention further relates to a method of producing a packaged element in which a sheet laminate is packaged in a bag. In one embodiment, a first fibrous sheet including a fiber comprising a polyethylene terephthalate resin having a melting point above 230 °C, and a second sheet including a thermoplastic resin having a melting point of 230 °C or less are preferably superimposed on each other so as to form an adjacent site where the first fibrous sheet and the second fibrous sheet are adjacent to each other. In one embodiment, the first fiber sheet and the second fiber sheet are preferably assembled by pressing the adjacent site while heating the adjacent site, in a state in which the first fiber sheet and the second fiber sheet are superimposed on each other. The other features of the present invention will be evident from the claims and the following explanation.

[0009] Brief description of the drawings [Fig.1] Fig.1 is a perspective view schematically representing a packaged element of the present invention; [Fig. 2] [Fig. 2] is a cross-sectional view schematically representing a section of a sheet laminate included in the packaged element of the present invention; [Fig. 3] [Fig. 3] is a scanning electron microscope observation image of a section of an assembled part in one embodiment of the sheet laminate; [Fig. 4] [Fig. 4] is a scanning electron microscope observation image of a section including an assembled part and other regions than the assembled part in another embodiment of the sheet laminate; [Fig. 5] [Fig. 5] is a perspective view schematically representing one embodiment of a production device that produces a packaged item; [Fig. 6] [Fig. 6] is a cross-sectional view schematically representing one embodiment of a unit for forming an assembled part in the production device shown in [Fig. 5]; [Fig. 7] [Fig. 7] is a cross-sectional view schematically representing another embodiment of the unit for forming the assembled part in the production device shown in [Fig. 5]; and [Fig. 8] Each of figures 8(a) to 8(e) is a plan view schematically representing a plan view shape of a roller projection in an embodiment of the assembled part forming unit.

[0010] Description of embodiments When the upper limit value or the lower limit value, or the upper and lower limit values ​​of a numeric value, are defined in this document, the values ​​of the upper and lower limit values ​​themselves are also included. It should further be understood that all numeric values ​​or ranges of numeric values ​​that are less than or equal to the upper limit value, or greater than or equal to the lower limit value, or within the range of the upper and lower limit values, are described even if this is not explicitly stated. In this booklet, "a", "an" and similar are interpreted as meaning "greater than or equal to one". In light of the aforementioned disclosure and the description that follows in this document, it is understandable that various modified and altered embodiments of the present invention are possible. Consequently, it should be understood that, within the technical scope based on the description of the claims, the present invention can be implemented in ways that are not clearly described. in this fascicle. This application claims priority based on Japanese patent application No. 2020-209221 filed on December 17, 2020, and Japanese patent application No. 2021-182159 filed on November 8, 2021.

[0011] We will describe the present invention below based on preferable embodiments thereof with reference to the drawings. A packaged element of the present invention comprises a bag and a sheet laminate packaged in the bag.

[0012] An embodiment of the packaged element is shown in [Fig. 1]. A packaged item 1 shown in [Fig.1] has a sheet laminate 10, and a bag 20 for packaging the sheet laminate 10. Sheet laminate 10 is a laminate of sheet materials including at least a first fibrous sheet, and a second sheet as described later. Details of sachet 20 will be described later.

[0013] We will describe below an embodiment of a configuration of the laminate in sheet 10. The 10 sheet laminate preferably includes at least the first fibrous sheet and the second sheet. The 10 sheet laminate preferably has an assembled part where the first fibrous sheet and the second sheet are joined together. The sheet laminate 10 preferably includes a first surface constituting an external surface thereof, and a second surface constituting an external surface located on an opposite side of the first surface.

[0014] An embodiment in cross-sectional view in one direction of the thickness of the laminate sheet 10 is shown in [Fig. 2]. The sheet laminate 10 shown in [Fig. 2] is a sheet having a multi-layered structure in which a first fibrous sheet 11 and a second sheet 12 provided on one side of the surface of the first fibrous sheet 11 are integrated. In the embodiment shown in [Fig. 2], a sheet laminate has a two-layer structure in which the respective sheets 11 and 12 are arranged adjacent to each other. In the present embodiment, the first fibrous sheet 11 includes a first surface F, and the second sheet 12 includes a second surface R. The second sheet 12 can be arranged over an entire region on one side of the surface of the first fibrous sheet 11, or can be arranged over only part of the surface. In the sheet laminate 10 in the present embodiment, assembled parts 30 are formed where the first fibrous sheet 11 and the second adjacent sheet 12 are joined together. In the present embodiment, other constituent elements are not present between sheets 11 and 12, and on respective external surfaces of sheets 11 and 12, but it is not impossible that other constituent elements may be placed between sheets 11 and 12, and on the respective external surfaces of sheets 11 and 12. We will later describe the other constituent elements that can make up the sheet laminate 10.

[0015] The first fibrous sheet 11 preferably includes a first fiber comprising a polyethylene terephthalate (PET) resin. In other words, the first fibrous sheet 11 is a fiber aggregate including the first fiber. The fiber containing a PET resin usually has high rigidity, so that even when the sheet laminate 10 is compressed in one direction of the sheet thickness in a packaging and distribution process, the volume of the sheet laminate 10 is easily restored and the sheet laminate 10 is made pleasant to the touch when the bag is opened and the compressed state is released; using the first fibrous sheet 11 containing a PET resin as a constituent element of the sheet laminate 10. In order to prevent compression by other constituent elements of the sheet laminate 10, and to easily restore the volume of the sheet laminate 10 to make the sheet laminate even more pleasant to the touch, the first fibrous sheet 11 is preferably arranged to constitute an external surface of the sheet laminate 10, within the sheet laminate 10. In other words, the first fibrous sheet 11 more preferably constitutes a first surface F or a second surface R of the sheet laminate 10.

[0016] In order to make it easier to restore the volume of the sheet laminate, a melting point of the PET resin included in the first fibrous sheet 11 is preferably greater than 230 °C. For the sake of sheet handling, the melting point of the PET resin included in the first fibrous sheet 11 is preferably 300 °C or less. To increase the melting point of the PET resin above 230 °C, a polymer with a site in which ethylene and terephthalic acid are not copolymerized in a chemical structure can be used, in the form of a polymerization thereof.

[0017] The second sheet 12 preferably includes a thermoplastic resin having a predetermined melting point. Even when the PET resin is included as that constituent fibers of the first fibrous sheet 11, it is possible to assemble the sheets 11 and 12 firmly while retaining a shape of the fiber by using the second sheet 12 including the thermoplastic resin having the predetermined melting point as a constituent element of the sheet laminate 10. As a result, the assembly strength between the sheets can be improved.

[0018] With a view to successful incorporation of the resin constituting the first fiber into the resin constituting the second sheet, a melting point of the thermoplastic resin included in the second sheet 12 is preferably 230 °C or less, more preferably 200 °C or less, and even more preferably 180 °C or less. For the sake of sheet handling, the melting point of the thermoplastic resin included in the second sheet 12 is preferably 70 °C or higher, more preferably 80 °C or higher, and even more preferably 90 °C or higher.

[0019] A melting point of the resin constituting each of the sheets 11 and 12 designates an endothermic peak caused by a phase change from a solid to a liquid before the resin is thermally decomposed when the resin to be measured is heated. Specifically, the melting point of a resin is a temperature at which the melting peak is observed in a differential analysis calorimetry (DAC), and signifies a temperature exhibiting the largest endothermic peak when a plurality of peaks are observed. When the melting point cannot be clearly measured by the aforementioned process, a softening point is used instead of the melting point.

[0020] Examples of thermoplastic resins that can be included in the second sheet 12 include polyolefin resin, polyester resin, polyamide resin, vinyl resin, acrylic resin, fluororesin, and the like, provided that the melting point of the resin is 230 °C or less. Examples of polyolefin resin include polyethylene (PE), polypropylene (PP), ethylene-α-olefin copolymer, ethylene-propylene copolymer, and similar. Examples of polyester resin include PET, polybutylene terephthalate, polylactic acid resin, and similar. Examples of polylactic acid resin include polylactic acid, lactic acid-hydroxycarboxylic acid copolymer, and the like. Examples of vinyl resin include polyvinyl chloride, polyvinylidene chloride, polystyrene, and similar. Examples of acrylic resin include polyacrylic acid, polyacrylic ester, polymethacrylic acid, polymethacrylic acid ester, and the like. Examples of fluororesin include polyperfluoroethylene and similar resins. These resins can be used alone or in combination with two or more others. Among these resins, the use of a polyolefin resin makes it possible to produce a sheet laminate which is easy to process into a sheet of non-woven fabric, film or similar, and which is soft on the skin. It should be noted that the second sheet 12 may contain at least one thermoplastic resin with a melting point of 230 °C or less, and for example, it is not impossible that a PET resin with a melting point above 230 °C may also be included in the second sheet.

[0021] The laminate sheet 10 preferably has an assembled portion 30 in which the first fibrous sheet 11 and the second sheet 12 are joined adjacent to each other, as shown in [Fig. 1] and [Fig. 2]. The assembled portion 30 is formed by crimping, bonding, or fusion bonding the sheets together. In order to obtain both flexibility and strength of the sheet and to further improve ease of use, the assembled portion 30 is preferably formed by fusion bonding. In the assembled part 30, a boundary surface for each of the sheets 11 and 12 is not present, or the boundary surface is not clear. A formation site of the assembled part 30 in the sheet laminate 10 can be hollow in one direction of the thickness or can be flat.

[0022] A formation method such as a plan view shape and the number of formations of the assembled part 30 can be modified appropriately according to the use of the sheet laminate, but ordinarily, in the plan view of the sheet laminate 10, one or more of the assembled part 30 are formed according to a linear shape or according to a dotted pattern, or according to a pattern of a combination of these. When the assembled part 30 is formed in a linear shape, it can be a continuous line or a dashed line, or a straight line or a curved line. Furthermore, the line width can be uniform or vary. These shapes can be used alone or in combination with a plurality of shapes. When the assembled parts 30 are formed according to a dotted pattern, a plan view shape of the assembled part 30 can be a circular shape such as a perfect circle and an oval, a polygonal shape such as a rectangle and a hexagon, an alphabetic shape such as an X shape and a Y shape, a lattice shape, or a combination of these shapes. The embodiment shown in [Fig.1] presents a method in which the assembled parts 30 are formed according to a dotted pattern in plan view of the laminate sheet 10, for the purpose of explanation, but the method of forming the assembled parts 30 is not limited to the dotted pattern, and arbitrary shapes and a combination thereof may be adopted, as described above.

[0023] With a view to successful incorporation of the resin constituting the first fiber into the resin constituting the second sheet, the first fiber sheet 11 and the second sheet 12 are preferably assembled adjacent to each other in the assembled part 30. In other words, it is preferable that there are no other constituent elements between the first fiber sheet 11 and the second sheet 12 in the formation position of the assembled part 30. Another constituent element may be present between the first fibrous sheet 11 and the second sheet 12 to give a desired function to the sheet laminate, in a site other than the formation site of the assembled part 30. The other constituent element in this form is also preferably assembled to at least one of the first fibrous sheet 11 and the second sheet 12 in the site other than the assembled part 30.

[0024] Furthermore, on a surface of the second sheet 12 on a side where the first fiber sheet 11 is not arranged, another constituent element may be present, or another constituent element may not be present, regardless of whether it is the formation position of the assembled part 30 or not. The other constituent element in this form may be assembled to both the first fiber sheet 11 and the second sheet 12 in the formation site of the assembled part 30, and may be assembled to at least one of the first fiber sheet 11 and the second sheet 12 in the site other than the assembled part 30. On a surface of the first fiber sheet 11 on a side where the second sheet 12 is not arranged, another constituent may be present, or another constituent may not be present, regardless of whether it is the formation position of the assembled part 30 or not. When another constituent is present on the surface of the first fiber sheet 11 on the side where the second sheet 12 is not arranged, the other constituent is preferably arranged in such a way that at least a part of the first fiber sheet 11 is exposed on a surface furthest outside the sheet laminate 10.

[0025] The assembled part 30 formed in the laminate sheet 10 is preferably formed in a state in which the resin constituting the first fibrous sheet 11 is incorporated into the thermoplastic resin constituting the second sheet 12, and is more preferably formed in a state in which the constituent fibers of the first fibrous sheet 11 are incorporated into the thermoplastic resin constituting the second sheet 12 with the constituent fibers of the first fibrous sheet 11 retaining their fiber shapes. With such a configuration, it is possible to obtain the laminate in sheet 10 with a high assembly strength between the sheets by sufficiently assembling the sheets 11 and 12 in the assembled part 30, even when the fiber including a high melting point resin such as the PET resin described above is used, for example, as constituent fibers of the fibrous sheet. The assembled portion 30 of this type can be produced by a production process described later, for example. One example of such a production process is one that heats the sheets in such a way that only the second sheet, which has a lower melting point, is melted, exploiting the difference between the melting points of the first and second fiber sheets, and then presses the sheets together. By adopting this process, the fibers included in the first fiber sheet are incorporated while retaining their fiber shapes. Because the first fiber sheet is incorporated while maintaining its fiber shapes, separation of the layered interface is less likely to occur, and the bonding strength between the sheets is enhanced by an anchoring effect.On the other hand, when both the first fibrous sheet and the second sheet are melted, the two sheets are arranged in layers in the assembled part 30, and interface delamination is prone to occur.

[0026] The term "incorporated" above refers to a state in which the thermoplastic resin constituting the second sheet is present in spaces among the resin constituting the first fibrous sheet, and preferably refers to a state in which the thermoplastic resin constituting the second sheet buries the spaces among the fibers constituting the first fibrous sheet. Whether the assembled part 30 is in an incorporated state or not can be confirmed by observing the site where the assembled part 30 is formed in a cut portion of the sheet laminate 10 cut to a predetermined size using a scanning electron microscope (JCM-6000 scanning electron microscope manufactured by JEOL Ltd.) at a magnification of 50 to 500 times. Figure 3 shows an example of a cross-section of the assembled part 30 as observed by the aforementioned method. In the assembled part 30 of this embodiment, there is no boundary between the respective sheets 11 and 12, but the thermoplastic resin constituting the second sheet 12 is present in spaces between the constituent fibers 1la of the first fibrous sheet, and thus joins the sheets 11 and 12. The boundaries of the constituent fibers 1la of the first fibrous sheet and the thermoplastic resin constituting the second sheet 12 are clear. This state is illustrated by the reference mark “11(12)” on the [Fig. 3].

[0027] The second sheet 12 includes the thermoplastic resin having the predetermined melting point, and a form of the second sheet 12 is, for example, a fibrous sheet or a resin film, and is preferably a fibrous sheet. Specifically, the second sheet 12 is preferably a fibrous sheet including fibers including thermoplastic resin preferably having a melting point of 230 °C or less. By adopting a combination of an inclusion of the thermoplastic resin having a melting point of 230 °C or less and using a fibrous sheet as a second sheet 12, the constituent fibers of the first fibrous sheet 11 are easily embedded in the thermoplastic resin constituting the second sheet 12.

[0028] When the second sheet 12 is a fibrous sheet, it is also preferable that the fiber shapes of the constituent fibers of the second sheet not be retained in the assembled part 30. In other words, it is preferable that in the second sheet 12 in the assembled part 30, the constituent fibers of these are melted and that the boundaries between the fibers are not sharp, or that the boundaries disappear. With such a configuration, the resistance to delamination of the first and second sheets can be further improved.

[0029] Fig. 4 shows an example of a cross-sectional shape of the laminate in sheet 10 in a case where the second sheet 12 is a fibrous sheet. In the assembled part 30 of this embodiment, there is no delimitation between the respective sheets 11 and 12, the thermoplastic resin constituting the second sheet 12 is present between the constituent fibers of the first fibrous sheet, and thus, the assembled part 30 assembles the sheets 11 and 12. In addition, in the second sheet 12 in the assembled part 30, the delimitations between the constituent fibers disappear. In an unbound region N which is a site in which the assembled part 30 is not formed, the fiber shapes of the constituent fibers of the respective leaves 11 and 12 are respectively conserved, a boundary S between the leaves 11 and 12, and the boundaries between the constituent fibers of the respective leaves 11 and 12 are conserved, and these boundaries can be distinguished. The assembled part 30 of this kind can be produced by a production process described later using a fibrous sheet as a second sheet 12, for example.

[0030] We will describe below a ratio of the resins constituting the respective leaves 11 and 12. The first fiber constituting the first fibrous sheet 11 includes a PET resin having a melting point above 230 °C as described above. A ratio of the content of the aforementioned PET resin in the resin included in the first fiber is preferably 50% by mass or more, more preferably 80% by mass or more, and even more preferably 100% by mass, with a view to further improving the ability to recover sheet volume. In other words, with a view to further improving the ability to recover sheet volume, the first fiber is preferably a fiber formed solely from a PET resin having a melting point above 230 °C.

[0031] For the ratio of PET resin content having a melting point above 230 °C in the fiber, a quantitative analysis is performed based on one or more methods of infrared spectroscopy (JIS KOI 17: 2017), high-performance liquid chromatography (JIS K0124: 2011), and nuclear magnetic resonance spectroscopy (JIS K0138: 2018). As the sheet sample provided for the measurement, a site in which an assembled part is not formed and an adhesive is not attached is used. In order to ensure measurement accuracy, the measurement is preferably performed by the two or more methods described above.

[0032] The first fibrous sheet 11 may consist solely of the first fiber, or may further include a second fiber which is the fiber other than the first fiber, in addition to the first fiber. When the first fibrous sheet 11 includes the second fiber, the second fiber preferably includes a thermoplastic resin having a melting point of 230 °C or less, and the second fiber more preferably consists solely of the thermoplastic resin having a melting point of 230 °C or less. By further incorporating the second fiber, which includes a thermoplastic resin with a melting point of 230 °C or less, into the first fiber sheet 11, it is possible to further improve the bonding strength of the sheets in the joined section 30 using the thermoplastic resin of the second fiber, while maintaining the sheet's ability to recover its volume thanks to the first fiber. Moreover, it is possible to reduce the loosening of the constituent fiber of the first fiber sheet 11 because the second fiber has a relatively lower stiffness than the first fiber, so that, as an additional advantage, the feel, handling, and ease of use of the sheet laminate are further improved. When all the melting points of the resins contained in the second fiber are 230°C or less, this presents another advantage in that it offers both an improvement high levels of assembly strength and reduced fiber loosening can be achieved.

[0033] When the first fibrous sheet 11 includes the second fiber, as thermoplastic resin constituting the second fiber, the same thermoplastic resin as thermoplastic resin used in the aforementioned second sheet 12 may be used. In order to further improve the bonding strength of the sheets in the assembled portion 30 by enhancing the compatibility with the melting of the thermoplastic resins, it is preferable to use the same type of resin as the thermoplastic resin included in the second fiber constituting the first fibrous sheet 11, and the thermoplastic resin constituting the second sheet 12. Specifically, it is more preferable that the thermoplastic resin constituting the fibrous sheet 11 and the second sheet 12 include resins in which the repeating units of the monomers share a common portion.

[0034] The content ratio of the first fiber in the first fibrous sheet 11 is preferably 25% by mass or more, more preferably 30% by mass or more, and more preferably 45% by mass or more, in order to allow for the restoration of sheet volume. In addition, the ratio of first fiber content in first fibrous sheet 11 is 100% by mass or less.

[0035] A content ratio of the second fiber in the first fibrous sheet 11 is preferably 1% by mass or more, more preferably 10% by mass or more, and even more preferably 30% by mass or more in order to further improve the bonding strength of the sheets. In addition, the content ratio of the second fiber in the first fibrous sheet 11 is preferably 80% by mass or less, more preferably 65% ​​by mass or less, and more preferably 55% by mass or less in order to allow the recovery of the sheet volume.

[0036] A fiber content ratio in the first fibrous sheet 11 can be measured by the following methods. In detail, the fiber content ratio can be measured by one or more analytical methods including infrared spectroscopy, a nuclear magnetic resonance method, pyrolysis gas chromatography coupled with mass spectrometry, a component separation method using a difference in resin solubility in a solvent, a method combining component separation and elemental analysis, and a method combining component separation and infrared spectroscopy.

[0037] When the second sheet 12 is a fibrous sheet, the constituent fiber of the second sheet 12 may be one type of fiber, or may be a plurality of types of fiber. A fiber type consists of one type of resin or a plurality of resin types. A plurality of fiber types consists of two or more fiber types. In all cases, with a view to expressing sufficient assembly strength in the assembled part, each fiber constituting the second sheet 12 preferably includes a thermoplastic resin having a melting point of 230 °C or less, and is more preferably made up entirely of a thermoplastic resin having a melting point of 230 °C or less.

[0038] As an aggregate of fibers constituting the first fibrous sheet 11, various Fibrous sheets such as woven and non-woven fabrics can be used. Examples of a form of the second sheet 12 include a resin film including the aforementioned thermoplastic resin, various fibrous sheets such as woven and non-woven fabrics, and the like. Among these forms, at least one of the first fibrous sheet and the second sheet is preferably a non-woven fabric.

[0039] When a non-woven fabric is used for the respective sheets 11 and 12, it is possible to use various non-woven fabrics such as an air-through non-woven fabric, an air-laid non-woven fabric, a spun-bonded non-woven fabric, a hydrobonded non-woven fabric, a melt-blown non-woven fabric, a needle-punched non-woven fabric and an electrospun non-woven fabric. In order to obtain both sheet formation ability and volume recovery ability, an air-through nonwoven fabric or a needle-punched nonwoven fabric is preferably used for the first fibrous sheet 11.

[0040] The sachet 20 is usually made of a sheet material. The sheet material used for bag 20 can be modified appropriately according to the constituent elements of sheet laminate 10, their properties, and similar characteristics, but is ordinarily a resin film. A single-layer or multi-layer resin film, or a resin film obtained by laminating a thin inorganic film onto the resin film (also referred to hereafter as a film containing an inorganic substance), may be used as the resin film. Examples of resin film include resin films that include the aforementioned thermoplastic resin as a raw material. Examples of the film containing an inorganic substance include a sheet in which a thin metallic film made of aluminum or similar is laminated onto the aforementioned resin film, a sheet in which an inorganic or similar oxide such as aluminum oxide or silica is vapor-deposited onto the resin film, and similar. By using the sheet containing an inorganic substance as sachet 20, it is possible to improve a light blocking effect and air tightness when packaging the laminate in sheet 10.

[0041] The sheet laminate 10 is preferably housed in the bag 20 in a state in which a predetermined pressure is applied. In detail, the pressure applied to the sheet laminate 10 in the packaged element 1 is preferably 500 Pa or more, more preferably 1,000 Pa or more, and even more preferably 2,000 Pa or more, with a view to saving space in the packaged element 1 during storage and distribution. The pressure applied to the sheet laminate 10 is preferably 5,000 Pa or less, more preferably 4,000 Pa or less, and even more preferably 3,000 Pa or less, with a view to easily restoring the volume of the sheet laminate after opening the bag.

[0042] The pressure applied to the sheet laminate 10 in the packaged element 1 can be measured by the following methods. In detail, the pressure applied to the packaged sheet laminate is measured using a pressure sensor. Alternatively, the thickness and dimensions of the sheet laminate are calculated from the external thickness and shape of the packaged element, and the pressure applied to the sheet laminate can be measured from the reaction force exerted when the sheet laminate is compressed to these dimensions.

[0043] The shape and application of the laminate sheet 10 are not particularly limited provided it has the aforementioned configuration. Examples of the shape of the laminate sheet 10 include a cleaning sheet for cleaning hard surfaces of floors, walls, and the like, as well as sanitary and similar products.

[0044] Among these products, the laminate sheet 10 contained in the bag 20 is preferably a sanitary product. Since the laminate sheet 10, as a sanitary product, is contained in the bag 20, the cleanliness of the sanitary product can be maintained, and deterioration of the sanitary product can be prevented. A sanitary product is a product used in contact with a user's skin during use. More specifically, examples of sanitary products include items worn directly on the human body to cover or near the eyes, nose, mouth, or excretory organs such as the urethra or anus, and items that maintain a worn state while attached to a user's clothing. Specific examples of this type of sanitary product include a cleansing sheet for cleaning a user's skin, such as fingers, an article absorbent, a face mask, an eye mask, a heating device and similar, but are not limited to these examples. Examples of absorbent items include disposable diapers, sanitary napkins, urinary protection, and the like. When the sanitary product is a wearable item such as an absorbent article, face mask, eye mask or warming device, the first fibrous sheet 11 in the sheet laminate 10 preferably constitutes a skin-facing surface of the sanitary product.

[0045] The other constituent elements that may make up the sheet laminate 10 can be modified appropriately according to a target article. Examples of other constituent elements include a single-layer or multi-layer sheet material, an absorbent element including an absorbent material, a heating element including an oxidizable metal, and the like. These other constituent elements may be used alone or in combination of two or more.

[0046] When the sheet laminate 10 is an absorbent article, an example of the other constituent element includes an absorbent element that includes an absorbent material capable of retaining excreted bodily fluids. The absorbent element is ordinarily made of a laminate or a stacked fiber containing an absorbent material. The absorbent material is ordinarily an absorbent polymer or an absorbent fiber. The absorbent element is located on an external surface of the first fibrous sheet 11 or the second sheet 12, or held between the first fibrous sheet 11 and the second sheet 12 in a location other than the formation sites of the assembled parts 30.

[0047] When the sheet laminate 10 is a heating device, an example of the other constituent element includes a heating element comprising an oxidizable metal. The heating element is ordinarily made of an oxidizable metal such as iron powder, and a mixed composition including a carbonaceous material, an electrolyte, and water. The heating element is ordinarily held between the first fibrous sheet 11 and the second sheet 12 in a location other than the formation sites of the assembled parts 30.

[0048] We will describe below a process for producing the sheet laminate 10 and the packaged element 1, taking as an example the shape of the sheet laminate 10 of a two-layer structure shown in [Fig. 2]. A production device 100 which is preferably used in the production of sheet laminate 10 ordinarily includes original text rolls 110 and 120, an assembled part forming unit 130, and a packaged element forming unit 140. An example of the production device 100 of this kind is shown in [Fig. 5].

[0049] First, an original fibrous sheet which constitutes the first fibrous sheet 11 is distributed from the first original text roll 110, and is transported in a transport direction MD. Similarly, an original fiber sheet, which constitutes the second sheet 12, is dispensed from the second original text roll 120, arranged separately from the first original text roll 110, and is conveyed in the MD direction. Then, the first fiber sheet 11 and the second sheet 12 are layered to form an intermediate laminate 1S. The present embodiment presents a form in which the first fiber sheet 11 is laminated and superimposed on an upper surface of the second sheet 12. At this stage, the first fibrous sheet 11 and the second sheet 12 are preferably superimposed on each other so as to present an adjacent site in which the sheets 11 and 12 are adjacent to each other. The adjacent site configures a portion or the packaged element of the intended formation positions of the assembled parts 30. The intermediate laminate 1S in this form is a continuous laminate extending in the MD transport direction, and the respective sheets 11 and 12 are not assembled to each other.

[0050] The first fibrous sheet 11 preferably includes the fiber including a PET resin having a melting point above 230 °C. The second sheet 12 preferably includes a thermoplastic resin having a melting point of 230 °C or less. The above explanation is appropriately applied to an explanation concerning the first fibrous leaf 11 and the second leaf 12.

[0051] During the production of the sheet laminate 10, it is possible to further use a third sheet (not shown) as another constituent element, for example, in addition to the first fiber sheet 11 and the second sheet 12. In this case, the first fiber sheet 11 is laminated and superimposed on an original sheet of the second sheet 12, an original sheet of the third sheet constituting the third sheet is dispensed from a third roll of original text (not shown) and conveyed along the MD direction, and the third sheet is laminated and superimposed on a top surface of the first fiber sheet 11 or a bottom surface of the second sheet 12. Thus, the intermediate laminate 1S having a multilayer structure with three or more layers can be formed. In this case, the third original text roll is a separate body from the first original text roll 110 and the second original text roll 120. The intermediate laminate 1S in this form is a continuous laminate extending in the MD transport direction, and the respective sheets constituting the intermediate laminate 1S are not assembled to each other. In the intermediate laminate 1S in this mode, at least the first fibrous sheet 11 and the second sheet 12 are configured to be adjacent to each other.

[0052] During the production of the laminate in sheet 10, it is possible to further use an absorbing element or a heating element (not shown) as a constituent element, for example, in addition to the first fibrous sheet 11 and the second sheet 12. In this case, the other constituent element is arranged at predetermined spaces between the original sheet of the first fibrous sheet 11 which is distributed and the original sheet of the second sheet 12 which is distributed, and in this state, the first fibrous sheet 11 and the second sheet 12 are superimposed on each other so as to present the adjacent site. In this way, it is possible to obtain the intermediate laminate 1S in the state in which the other constituent element is arranged between the first fibrous sheet 11 and the second sheet 12.

[0053] Next, the intermediate laminate 1S is introduced into the part-assembly forming unit 130, and the respective sheets are joined and integrated by pressing the first fiber sheet 11 and the second sheet 12 in the direction of the sheet thickness while simultaneously heating the first fiber sheet 11 and the second sheet 12 in the adjacent area. Thus, the part-assemblies 30 are formed in the adjacent area. The part-assemblies 30 in this embodiment are formed in a dotted pattern, but the plan view shapes of the part-assemblies 30 can be modified appropriately depending on the target sheet laminate 10. The part-assemblies 30 can be formed in an entire plan view region of the adjacent areas of the first fiber sheet 11 and the second sheet 12, or they can be formed in only a portion of the plan view region of the adjacent areas.

[0054] During the formation of the assembled parts 30, it is preferable to join the adjacent sites of the first fiber sheet 11 and the second sheet 12 by introducing the intermediate laminate 1S between a pair of rollers. By adopting this method, a thrust load in the direction of the sheet thickness, generated during the joining of the sheets, is applied to a small area. Consequently, the raw material resin of the second sheet 12 melts more easily and can effectively incorporate the constituent fibers of the first fiber sheet, thus further improving the bond strength with the first fiber sheet 11 in the assembled parts 30.

[0055] Fig. 5 illustrates a mode including a pair of rollers 131 and 132 as a unit for forming an assembled part 130. The present embodiment is a mode which ensures simultaneous heating and pressurization by applying heat and pressure to the intermediate laminate 1S by means of the rollers as rotating elements. Rollers 131 and 132 shown in [Fig. 5] are arranged such that their axial directions and the direction of transport MD are mutually orthogonal. Rollers 131 and 132, respectively, shown in [Fig. 5], are arranged so that they face each other in a state where their axial directions coincide. At least one of the pair of rollers 131 and 132 is preferably driven in rotation by a drive source. In this case, the other roller can provide rounding by contact, or can be driven in rotation by a drive source. The respective rollers 131 and 132 shown in [Fig. 5] are arranged in a state in which their direction of rotation and the direction of transport MD do not coincide with each other.

[0056] The assembled part forming unit 130 preferably adopts a device capable of forming the assembled part 30 by pressing the adjacent sites of the first fibrous sheet 11 and the second sheet 12 in the direction of the thickness of the sheet while heating the adjacent sites. As such devices, for example, a heat-sealing device, an impulse sealing device, an ultrasonic sealing device and the like can be used.

[0057] In order to efficiently form the assembled parts 30 into which the first fiber is incorporated, and to further improve the bonding strength of the sheets, it is preferable to press the adjacent sites while simultaneously heating them to a temperature that is greater than or equal to the melting point of the thermoplastic resin included in the second sheet 12. To achieve this method, adjustments can be made by appropriately modifying the heat-sealing temperature or, for example, by appropriately modifying the ultrasonic wave output.

[0058] When the method including the pair of rollers 131 and 132 is adopted as the unit for forming the assembled part 130, a peripheral surface of at least one of the two rollers 131 and 132 preferably has a shape with hollows and protrusions. Since the peripheral surface of the roller has the shape with hollows and protrusions, the assembled parts 30 can be formed in desired positions of adjacent sites, and the quality of the sheet laminate 10 to be obtained is improved. When the shape with hollows and protrusions is formed on only the peripheral surface of the first roller, a peripheral surface of the other roller that does not have the shape with hollows and protrusions is flat. When the roller has the shape with hollows and protrusions on the peripheral surface of the roller, the protrusions of the roller usually correspond to the formation positions of the assembled parts 30.

[0059] When the mode including the pair of rollers 131 and 132 is adopted as the unit for forming the assembled part 130, it is preferable to use the mode in which one roller includes an ultrasonic emitter, and the other roller is an anvil roller. In other words, it is preferable to use an ultrasonic sealing device including a pair of rollers as the unit for forming the assembled part 130. It is possible to heat the constituent resin of the second sheet, made of the low-melting-point constituent resin, from the inside of the laminate by applying ultrasonic waves to efficiently melt the constituent resin.Furthermore, by applying ultrasonic waves while pressing the sheets between the two rollers, it is possible to apply the pressure force in the direction of the sheet thickness which is generated during the assembly of the sheets to a small area, and to incorporate the constituent fibers of the first fibrous sheet into the resin of the second sheet efficiently during the formation of the assembled parts 30. As a result, it is possible to further improve the assembly strength of the two sheets 11 and 12 in the assembled parts 30.

[0060] When the mode in which the pair of rollers 131 and 132 are included and the first roller includes an ultrasonic emitter is adopted as the unit of formation of the assembled part 130, the intermediate laminate 1S is preferably introduced and assembled in such a way that the peripheral surface of the first roller including the ultrasonic emitter and the second sheet 12 in the intermediate laminate 1S come abutting against each other. In other words, in the present embodiment, ultrasonic waves can preferably be applied to the intermediate laminate 1S in a state in which the second roll 132 as a unit of forming of assembled part 130 includes an ultrasonic emitter. By assembling the sheets in such an arrangement, the second sheet 12, which has a low melting point, is positioned on one side near an ultrasonic wave source. This allows the second sheet 12 to melt more efficiently and further improves the incorporation of the constituent fibers of the first fibrous sheet into the assembled parts 30 that are formed. Consequently, the bond strength of the two sheets 11 and 12 can be further enhanced.

[0061] The assembly methods of the sheets 11 and 12 in a case of adoption of the method including the ultrasonic emitter as a unit for forming the assembled part 130 are schematically represented in [Fig. 6] and [Fig. 7]. An embodiment shown in [Fig. 6] includes, as an assembly part forming unit 130, an anvil roller 131 having a shape with hollows and protrusions on a peripheral surface, and an ultrasonic emitter 139 having a flat plate shape and fixedly disposed to face the anvil roller 131. In other words, the present embodiment is a fixed ultrasonic sealing device.

[0062] In the embodiment shown in [Fig. 6], when the intermediate laminate 1S is introduced into the assembly part forming unit 130, the intermediate laminate 1S is pressed in the thickness direction by the projections 135 of the anvil roller 131. The assembly parts 30 formed in this way can achieve a sheet assembly force that can withstand actual use.

[0063] An embodiment shown in [Fig. 7] presents a configuration in which a pair of rollers 131 and 132 are included, and one of the rollers includes an ultrasonic emitter. In detail, the first roller 131 is an anvil roller having a shape with hollows and projections on a peripheral surface thereof, and the other roller 132 is a roller having a flat peripheral surface and including an ultrasonic emitter. In other words, the present embodiment is a rotary ultrasonic sealing device. Furthermore, as another embodiment, a thermal embossed roller having a flat peripheral surface, namely, a rotary heat-sealing device, can be adopted as the other roller 132. In the case of rotary ultrasonic sealing or heat sealing, heat and pressure are applied only at one contact site, where sheets 11 and 12 are in contact with the rollers. Among these rollers, the roller including the ultrasonic emitter is preferable with a view to improving the production yield of sheet laminate 10 due to the improved efficiency of forming the assembled parts.

[0064] As in the embodiment shown in [Fig. 7], by adopting the rotary sealing device, it is possible to efficiently form the assembled parts having the structure in which the fibers are incorporated by preventing the constituent resin, melted by heating from the outside, from easily diffusing in a planar direction of the sheet, preventing heat transmission or similar factors from becoming weak due to the generation of frictional and shear forces other than the pressure load in the direction of the sheet thickness. Consequently, the assembly strength can be improved. The present This embodiment is particularly advantageous in that the assembled parts, having a structure incorporating fibers, can be efficiently formed even when the transport speed of the intermediate laminate in which the assembled parts are formed is increased. Furthermore, this embodiment is also highly efficient and advantageous in the continuous production of sheet laminates with shapes such as long, continuous forms.

[0065] In a preferred embodiment of the present invention shown in [Fig. 7], when the intermediate laminate 1S is introduced into the part-assembly forming unit 130, the intermediate laminate 1S is pressed in the direction of the sheet thickness by the projections 135 of the anvil roller 131. The respective rollers 131 and 132 rotate to match the transport speed of the intermediate laminate 1S. Thus, compared to the embodiment shown in [Fig. 6], the contact area between the intermediate laminate 1S and the other roller 132 can be reduced. Consequently, even when the transport speed of the intermediate laminate 1S is increased to improve production efficiency, the frictional force generated in the direction perpendicular to the pressure direction of the anvil roller 131 can be reduced between the intermediate laminate 1S and the roller 132, which includes the ultrasonic emitter.In the formation positions of the assembled parts 30, which correspond to the projections 135 of the anvil roller 131, a deviation in the direction of transport between the first fibrous sheet 11 and the second sheet 12 can be eliminated. Furthermore, the pressure force generated between the projections 135 in the anvil roller 131 and the peripheral surface of the other roller 132 can be increased. In the assembled part 30 formed in this state, heat and pressure are applied only at the contact point where the sheets 11 and 12 are in contact with the rollers, thus increasing the pressure applied to the sheets 11 and 12 during assembly. As a result, the resin constituting the second sheet melts efficiently, and the bonding force of the sheets can be achieved to a greater extent. Furthermore, the respective rollers 131 and 132 rotate to match the transport speed of the intermediate laminate 1S, so that the dimensions of the assembled parts 30 are less prone to fluctuation, and the assembled parts 30 can assume a desired shape. Consequently, adopting the mode in which the pair of rollers 131 and 132 are included and the first roller includes an ultrasonic emitter during the assembly of the sheets is advantageous in that the dimensional accuracy of the assembled parts 30 is improved and high-quality products can be obtained, in addition to further improving the strength of the sheet assembly.

[0066] When the mode in which the peripheral surface of at least one roller has a shape with hollows and protrusions is used as the unit of formation of the assembled part 130, the assembled part 30 is preferably formed in such a way that a ratio (P2 / P1) of a maximum value P2 of linear pressure of the roller having the shape with hollows and protrusions on the peripheral surface to a minimum value PI of the linear pressure is a predetermined value or less, and PI is a value greater than 0. The linear pressure of the roller, which has a shape with hollows and protrusions on its peripheral surface, is generated at the positions of the protrusions of the roller. Consequently, the linear pressure of the roller is based on a dimension along a direction orthogonal to the direction of transport MD within the protrusions of the roller.

[0067] In order to make the strength of the respective assembled parts constant and to obtain the sheet laminate with a good appearance, the ratio P2 / P1 is preferably 4 or less, more preferably 2 or less, and even more preferably 1 or less. A P2 / P1 ratio of 1 or more is realistic. In other words, this mode also includes a case where the minimum P1 value and the maximum P2 value are identical. In particular, when the sheet laminate is a wearable item such as an absorbent item, face mask, eye mask, or warming device, an external force is applied to the sheet laminate according to the movement of a user, so the expression of force is important during actual use.

[0068] The minimum PI value is preferably 30 N / m or more, and more preferably 50 N / m or more, and is preferably 150 N / m or less, and more preferably 120 N / m or less. The maximum value P2 is preferably 50 N / m or more and more preferably 100 N / m or more, and is preferably 200 N / m or less and more preferably 150 N / m or less. The minimum value PI and the maximum value P2 can be modified by appropriately adjusting a space between the rollers, and the dimensions of the roller projections having the shape with hollows and projections.

[0069] Figures 8(a) to 8(e) illustrate plan views of the projections 135 of the roller, which has a shape with hollows and projections on the peripheral surface. In Figures 8(a) to 8(e), a direction orthogonal to the direction of transport MD is represented by the reference frame CD. In [Fig. 8](a), the shape of the projection 135 is a rectangular shape in which a direction in which a long side extends coincides with a direction CD. In this case, the minimum value PI and the maximum value P2 are identical to each other. In [Fig. 8](b), the projection 135 is in the form of a perfect circle. In this case, the minimum value PI and the maximum value P2 are identical to each other. In [Fig. 8](c), the projection 135 is in the form of a waveform. In this case, the minimum value PI and the maximum value P2 are different from each other. In [Fig. 8](d), the projection 135 is in the form of a trapezoid without an internal cavity. In this case, the minimum value PI and the maximum value P2 are different from each other. In [Fig. 8](e), the projection 135 is in the form of a trapezoid with a cavity inside. In this case, the minimum value PI is determined in the illustrated positions, and the maximum value P2 is determined in a total of the illustrated positions.

[0070] The intermediate laminate 1S of the present embodiment obtained by passing the assembled part 130 through the forming unit is a long continuous sheet 1T in which the assembled parts 30 are formed. By applying a cutting process (not shown) or similar to the long continuous sheet 1T in such a way that the sheet 1T has predetermined dimensions, it is possible to obtain the laminate in sheet form 10 in the form of a single sheet in which the assembled parts 30 are formed. In addition, depending on a target product, another component may be attached by assembly or similar before or after cutting the continuous long 1T sheet to produce the 10 sheet laminate (not shown).

[0071] Subsequently, the sheet laminate 10 obtained is housed in the bag 20 produced in a different process, and a packaged element 1 in which the sheet laminate 10 is packaged in the bag 20 is obtained (see [Fig. 5]). In detail, the laminate sheet 10 in the form of a single sheet is transported in the direction SM by means of a transport device 150 such as a conveyor belt, and the laminate sheet 10 is housed in the bag 20. At this stage, the bag 20 preferably has an opening so as to be able to house the laminate sheet 10. Subsequently, the opening of the bag 20 in which the sheet laminate 10 is housed is assembled using a known assembly process such as heat sealing to package the sheet laminate 10.

[0072] When the sheet laminate 10 is packed with the bag 20, the sheet laminate 10 is preferably packed in a state in which a predetermined pressure is applied from an outside of the bag 20. In detail, the pressure applied during packaging is preferably 500 Pa or more, more preferably 1,000 Pa or more, and even more preferably 2,500 Pa or more, with a view to saving space during the storage and distribution of the packaged item 1 obtained. When the sheet laminate is a heating device including a heating element using an oxidation reaction, for example, as an embodiment of the sheet laminate, the pressure which is applied during packaging is preferably 500 Pa or more, more preferably 1,000 Pa or more, and even more preferably 2,500 Pa, with a view to preventing air from entering the bag during packaging, and improving the airtightness of the packaged item which is obtained.

[0073] In order to easily restore the volume of the sheet laminate after opening the bag, the pressure applied during packaging is preferably 5,000 Pa or less, more preferably 4,000 Pa or less, and even more preferably 3,000 Pa or less. As illustrated in [Fig. 5], it is possible to apply the aforementioned pressure by providing a pinch roller 160 which is arranged to face the transport device 150, by appropriately adjusting a space between the transport device 150 and the pinch roller 160, and by introducing the bag 20 in which the sheet laminate 10 is housed between the transport device 150 and the pinch roller 160.

[0074] By following the above process, it is possible to obtain the packaged element 1. The packaged element 1 can be stored and distributed directly or in a state where a plurality of packaged elements 1 are housed in a separate packaging material.

[0075] In each of the aforementioned embodiments, the packaged element 1 is described in the form in which the sheet laminate 10 is individually packaged in the bag 20, taken as an example, but the packaged element 1 is not limited to this form. For example, the packaged element 1 may be such that a plurality of sheet laminates 10 are housed and packaged in the single bag 20. In this case, the sheet laminates 10 are preferably housed in the state in which the aforementioned preferred pressure is applied to them. The 10-sheet laminate for packaging can be packed in a folded state.

[0076] The present invention is described on the basis of the preferred embodiments to date, but the present invention is not limited to the aforementioned embodiments.

[0077] With regard to the aforementioned embodiments, the present invention further discloses the following packaged element and the method for producing it. Packaged item comprising a bag, and a sheet laminate packaged in the bag, in which the sheet laminate comprises:

[0078] a first fibrous sheet including a first fiber including a constituent resin which contains a polyethylene terephthalate resin having a melting point above 230 °C; and a second sheet including a thermoplastic resin having a melting point of 230 °C or less, the sheet laminate includes an assembled portion in which the first fibrous sheet and the second sheet are assembled adjacent to each other, and

[0079] in the assembled portion, the constituent resin of the first fibrous sheet is incorporated into the thermoplastic resin constituting the second sheet.

[0080] <2> Item packaged according to the clause <1> , wherein in the assembled part, the constituent fibers of the first fibrous sheet are incorporated into the thermoplastic resin constituting the second sheet in a state in which the constituent fibers of the first fibrous sheet retain the fiber shapes of the constituent fibers. <3> Item packaged according to the clause <1> Or <2> , wherein a melting point of the thermoplastic resin included in the second sheet is 230 °C or less, preferably 200 °C or less, and more preferably 180 °C or less. <4> Item packaged according to any of the clauses <1> has <3> , wherein a melting point of the thermoplastic resin included in the second sheet is 70 °C or more, preferably 80 °C or more, and more preferably 90 °C or more. Item packaged according to any of the clauses <1> has <4> , wherein the thermoplastic resin which may be included in the second sheet is one or more selected from a polyolefin resin, a polyester resin, a polyamide resin, a vinyl resin, an acrylic resin and a fluororesin. <6> Item packaged according to any of the clauses <1> has <5> in which the second sheet is a fibrous sheet, and in the assembled part, the fiber forms of the constituent fibers of the second sheet are not preserved.

[0081] <7> Item packaged according to any of the clauses <1> has <6> , in which the second sheet is a fibrous sheet, and in an unassembled part in which the assembled part is not arranged, the fiber forms of the constituent fibers of the second sheet are preserved. <8> Item packaged according to any of the clauses <1> has <7> , in which, in the sheet laminate, the first fibrous sheet is arranged in such a way that the first fibrous sheet forms an external surface of the sheet laminate. <9> Item packaged according to any of the clauses <1> has <8> , wherein a content ratio of polyethylene terephthalate resin in the constituent resin included in the first fiber is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass. <10> Item packaged according to any of the clauses <1> has <9> , in which the constituent resin contained in the first fiber consists solely of a polyethylene terephthalate resin having a melting point above 230 °C. <11> Item packaged according to any of the clauses <1> has <10> , further comprising a second fiber as a constituent fiber of the first fibrous sheet, in which the second fiber includes a thermoplastic resin with a melting point of 230 °C or less.

[0082] <12> Item packaged according to the clause <11> , in which the thermoplastic resin constituting the second fiber consists solely of a thermoplastic resin having a melting point of 230 °C or less. <13> Item packaged according to the clause <11> Or <12> , in which the thermoplastic resin included in the second fiber constituting the first fibrous sheet and the thermoplastic resin constituting the second sheet include the same kind of resin as each other. <14> Item packaged according to any of the clauses <1> has <13> , wherein the sheet laminate is housed in a state in which a pressure of 500 Pa or more and 5,000 Pa or less, preferably 1,000 Pa or more, more preferably 2,000 Pa or more is applied to the sheet laminate. <15> Item packaged according to any of the clauses <1> has <14> , wherein the sheet laminate is housed in a state in which a pressure of 4,000 Pa or less, more preferably 3,000 Pa or less, is applied to the sheet laminate.

[0083] <16> Item packaged according to any of the clauses <1> has <15> in which the first fibrous sheet and / or the second sheet is a non-woven fabric. <17> Item packaged according to any of the clauses <1> has <16> in which the sachet is made of a resin film. <18> Item packaged according to any of the clauses <1> has <17> , in which another constituent element is arranged between the first fibrous sheet and the second sheet, in a site other than a formation site of the assembled part. <19> Item packaged according to the clause <18> in which the constituent element is an absorbing element including an absorbing material, or a heating element including an oxidizable metal. <20> Item packaged according to any of the clauses <1> has <19> , in which sheet laminate is a sanitary product.

[0084] <21> Item packaged according to the clause <20> , in which the sanitary product is an item that must be worn. <22> Item packaged according to the clause <20> Or <21> in which the first fibrous sheet in the sheet laminate constitutes a surface facing the skin of the sanitary product.

[0085] <23> A method for producing a packaged item in which a sheet laminate is packaged in a bag, wherein the method comprises:

[0086] the superimposition of a first fibrous sheet comprising a fiber comprising a polyethylene terephthalate resin having a melting point above 230 °C, and a second sheet comprising a thermoplastic resin having a melting point of 230 °C or less, one on top of the other so as to form an adjacent site where the first fibrous sheet and the second fibrous sheet are adjacent to each other; and in this state: the assembly of the first fibrous sheet and the second fibrous sheet by pressing the adjacent site while heating the adjacent site.

[0087] <24> Method for producing a packaged item according to clause <23> , in which the adjacent site is pressed while heating the adjacent site in such a way that the heated adjacent site has a temperature greater than or equal to the melting point of the thermoplastic resin included in the second sheet. <25> Method for producing a packaged item according to clause <23> Or <24> , in which the sheets are introduced between a pair of rollers to assemble the first fibrous sheet and the second fibrous sheet.

[0088] <26> Method for producing a packaged item according to clause <25> in which heat and pressure are applied to the first fibrous sheet and the second fibrous sheet by rollers. <27> Method for producing a packaged item according to clause <25> Or <26> in which heat and pressure are applied only at a contact site, at which the first fibrous sheet and the second fibrous sheet are in contact, with the rollers. <28> Method for producing a packaged item according to any one of the clauses <25> has <27> , in which a peripheral surface of at least one of the rollers has a shape with hollows and protrusions. <29> Method for producing a packaged item according to clause <28> , in which a ratio (P2 / P1) of a maximum value P2 of linear pressure of the roller having the shape with hollows and protrusions to a minimum value PI of the linear pressure is 4 or less, and PI is a value greater than 0.

[0089] <30> Method for producing a packaged item according to any one of the clauses <25> has <29> in which one of the rollers includes an ultrasonic emitter, and the other roller is an anvil roller. <31> Method for producing a packaged item according to clause <30> , wherein the first fibrous sheet and the second fibrous sheet are introduced in such a way that a peripheral surface of the roller including the ultrasonic emitter and the The second sheets come together against each other, to assemble the first fibrous sheet and the second fibrous sheet. <32> Method for producing a packaged item according to any one of the clauses <23> has <31> , wherein the first fibrous sheet and the second fibrous sheet assembled together are packaged with the bag in a state of application of pressure of 500 Pa or more and 5,000 Pa or less, preferably 1,000 Pa or more, and more preferably 2,500 Pa or more. <33> Method for producing a packaged item according to any one of the clauses <23> has <32> , wherein the first fibrous sheet and the second fibrous sheet assembled together are packaged with the bag in a state of application of pressure of 4,000 Pa or less, and preferably 3,000 Pa or less.

[0090] <34> Method for producing a packaged item according to any one of the clauses <23> has <33> , in which sheet laminate is produced continuously. <35> Method for producing a packaged item according to any one of the clauses <23> has <34> , in which a sanitary product which is an article to be worn is produced as sheet laminate. <36> Method for producing a packaged item according to any one of the clauses <23> has <35> , in which the sheet laminate is a sanitary product, and the first fibrous sheet in the sheet laminate is produced to constitute a skin-facing surface of the sanitary product.

[0091] Examples We will describe the present invention in detail below, based on examples. However, the scope of the present invention is not limited to these examples. In the following explanation, including the table, a PET resin with a melting point above 230°C will also be referred to as "high PET", and a PET resin with a melting point of 230°C or less will also be referred to as "low PET". In Table 1, the melting point of low-melting-point PET is 80 °C, the melting point of PP is 160 °C, and the melting point of an ethylene-propylene copolymer is 160 °C. All components containing two types of fibers have 50% by mass of each of the two fiber types. In addition, in Table 1, columns marked "-" indicate not containing or not evaluated. In addition, in Table 1, "% by mass" in the fiber explanation indicates a mass ratio of the fiber in the sheet.

[0092] [Example 1] The first fiber sheet 11 and the second sheet 12, which is a fiber sheet, have the resin compositions and basic weights indicated in Table 1 below. The first fiber sheet 11 in this example is a fiber aggregate made entirely of PET resin fiber with a melting point above 230 °C, and the second sheet is a fiber aggregate made entirely of PP fiber with a melting point of 170 °C. The first fibrous sheet 11 and the second sheet are superimposed so as to present adjacent sites. The adjacent sites are joined using an impulse sealing device (FA series, manufactured by FUJIIMPULSE® CO., LTD.), and the assembled parts 30 are formed. The formation pattern of the assembled parts 30 has the form of a plurality of continuous lines (stripe shape), which is a continuous pattern. Next, as another constituent element, the fibrous sheet including the resins indicated in Table 1 below is arranged on and assembled on the surface on the side where the second sheet is not present in the first fibrous sheet 11, and the sheet laminate 10 of a three-layer structure is obtained. Next, the laminate sheet 10 is housed in the bag 20 made of aluminum and polyethylene, and four sides of the bag undergo a sealing process to be hermetically sealed while a pressure of 1,500 Pa is applied from the external surface of the bag 20 housing the laminate sheet 10. Thus, the packaged element 1 in which the sheet laminate 10 is packaged in the bag 20 is obtained.

[0093] [Examples 2 and 3] The packaged element 1 is obtained by the same process as in Example 1, except that the assembled parts 30 are formed on the first fibrous sheet 11 indicated in Table 1 below, instead of the contents of Example 1.

[0094] [Examples 4 and 5] The packaged element 1 is obtained by the same process as in Example 1, except that the assembled parts 30 in the form shown in [Fig. 8](c) are formed on the first fibrous sheet 11 and the second sheet 12 which is a fibrous sheet, which are indicated in Table 1 below, and using the rotary ultrasonic sealing device having the configuration shown in [Fig. 5], instead of the contents of Example 1.

[0095] [Comparative example 1] The assembled parts 30 in the form shown in [Fig. 8](d) are formed on the first fibrous sheet 11 and the second sheet 12 which is a fibrous sheet, which are indicated in Table 1 below, and by means of a heat-sealing device, in place of the contents of Example 1. As the other constituent element, the fibrous sheet including the resin indicated in Table 1 below is arranged on and assembled to the surface on the side where the second sheet is not present in the first fibrous sheet 11, and the sheet laminate 10 of a three-layer structure is obtained. The packaged element 1 is obtained by the same process as in example 1, except for the preceding.

[0096] [Reference examples 1 to 13] The reference examples presented here are examples in which the laminate sheets 10 themselves are produced primarily for an evaluation of the sheet bonding strength. In each of these reference examples, the laminate sheet 10 is not packaged in bag 20.

[0097] (1) Reference example 1 The assembled part 30 in the form shown in [Fig. 8](d) is formed on the first fibrous sheet 11 and the second sheet which is a fibrous sheet, which are indicated in Table 1 below, and by means of a fixed ultrasonic sealing device which has a configuration such as shown in [Fig. 6], in place of the contents of Example 1. In the present reference example, at the time of the formation of the assembled part 30, the first fibrous sheet 11 and the second sheet 12 are introduced into the ultrasonic sealing device in such a way that the ultrasonic emitter and the second sheet 12 come into contact with each other. Next, as the other constituent element, the fibrous sheet including the resin indicated in Table 1 below is arranged on and assembled to the surface on the side where the second sheet is not present in the first fibrous sheet 11, and the sheet laminate 10 of a three-layer structure is obtained.

[0098] (2) Reference example 2 The assembled part 30 according to the shape of [Fig. 8](c) is formed on the first fibrous sheet 11 and the second sheet which is a fibrous sheet, which are indicated in Table 1 below, and by means of the rotating ultrasonic sealing device having the configuration as shown in [Fig. 7], in place of the contents of Example 1. In this reference example, the first fibrous sheet 11 and the second sheet 12 are introduced into the ultrasonic sealing device in a manner such that the peripheral surface of the roller including an ultrasonic emitter and the second sheet 12 come together against each other at the time of the formation of the assembled part 30. Next, as the other constituent element, the fibrous sheet including the resin indicated in Table 1 below is arranged on and assembled to the surface on the side where the second sheet is not present in the first fibrous sheet 11, and the sheet laminate 10 of a three-layer structure is obtained.

[0099] (3) Reference examples 3 to 11 The assembled parts 30 according to the form shown in [Fig. 8] (c) are formed on the first fibrous sheets 11 and the second sheets which are fibrous sheets indicated in Table 1 below, and by means of a rotating ultrasonic sealing device having the configuration as shown in [Fig. 7], in place of the contents of Example 1. In each of the reference examples 4, 6, 8, 9 and 11, the first fibrous sheet 11 and the second sheet are introduced into the ultrasonic sealing device in such a way that the peripheral roller surface including an ultrasonic emitter and the first fibrous sheet 11 come into contact with each other at the time of the formation of the assembled part 30. In each of the reference examples 3, 5, 7 and 10, the first fibrous sheet and the second sheet 12 are introduced into the ultrasonic sealing device in such a way that the peripheral surface of the roller including an ultrasonic emitter and the second sheet 12 come into contact with each other at the time of the formation of the assembled part 30. Next, like the other constituent elements, the fibrous sheets including the resins indicated in Table 1 below are each arranged on and assembled on the surface on the side where the second sheet is not present in the first fibrous sheet 11, and the sheet laminates 10 of a three-layer structure are obtained.

[0100] [Presence or absence of incorporation of resin constituting the first fibrous sheet] Whether or not the resin constituting the first fibrous sheet is incorporated into the resin at the formation site of the assembled part 30 is observed using the aforementioned method and evaluated according to the following criteria. The result is shown in Table 1.

[0101] <Critères d’évaluation> A: The assembled part 30 is formed in the state in which the constituent fibers are incorporated into the thermoplastic resin with the fiber shapes of the constituent fibers of the first fibrous sheet preserved. B: The assembled part 30 is formed in a state where the fiber shapes of the constituent fibers of the first fiber sheet are not distinct or disappear. C: The assembled part is not formed, or the sealing force of the first fiber sheet and the second sheet, measured using a method described later, does not reach 2 N / 50 mm.

[0102] [Evaluation of the volume recovery rate] For the packaged items 1 in the examples and comparative examples, the volume recovery rates of the sheet laminates 10 after opening are evaluated using the following method. Specifically, a thickness W1 of the sheet laminate before packaging and a thickness W2 of the sheet laminate immediately after release from the bag, following storage for 24 hours or more after packaging, are measured by applying a pressure of 3.7 gf / cm² using a constant pressure thickness gauge (PG-11 type J manufactured by Teclock Co.), and a value of (W2 / W1) x 100% is calculated as the recovery rate. Higher numerical values ​​for the recovery rate indicate earlier volume recovery upon release from the bag, and significantly improved flexibility and ease of use. The result is shown in Table 1 below.

[0103] [Seal strength evaluation] For the 10-sheet laminates in the examples, comparative examples, and reference examples, the bond strength of the first fiber sheets and the second sheets is evaluated using the following method. A higher bond strength indicates a higher bond strength. The result is shown in Table 1 below. In detail, from the sheet laminates 10, measurement samples each with a size of 50 mm long x 50 mm wide are cut so as to include the formation positions of the assembled parts 30 in such a way that the peripheries of the samples coincide with the edges of the assembled parts. Then, at one end along the length of each measurement sample, the respective sheets are attached to the respective mandrels of the dynamometer. The dynamometer used is the AUTOGRAPH AGS-X series from Shimadzu Corporation. The distance between the mandrels is set at 48 mm. The maximum force (N) is measured by separating the first fiber sheet and the second sheet at a tensile speed of 500 mm / min. The measurement is performed three times, and an arithmetic average value of the maximum force is considered the sealing force (N).

[0104] [Evaluation of tactile sensation (1): tactile sensation at the moment of contact] For packaged items 1 of the examples and comparison examples, a sensory evaluation of the sensation is performed when the sheet laminate 10, after opening, is pressed against the eyes. The evaluators are 5 or 6 women who have been engaged in the work of evaluating the sensation of the sheet laminate on the eyes for 3 years or more, and a comparative evaluation is performed on the examples using comparison example 1 as a contrast example. An average arithmetic score is calculated by dividing the total score by the number of evaluators, with 10 points added for better examples and 10 points subtracted for better comparison examples. Higher scores indicate a better sensation at the time of contact between the sheet laminate and the skin, and significantly improved usability. The results are shown in Table 1 below.

[0105] [Evaluation of touch sensation (2): touch sensation in the worn state]. For the packaged items 1 of the examples and comparison examples, the state in which the sheet laminate 10 is pressed against the eyes after opening is recorded, and a sensory evaluation of the sensation at that moment is performed. The evaluators are 5 or 6 women who have been engaged in the work of evaluating the sensation of the sheet laminate on the eyes for 3 years or more, and a comparative evaluation is performed on the examples using comparison example 1 as a contrast example. An average arithmetic score is calculated by dividing the total score by the number of evaluators, with 10 points added where the examples are better and 10 points subtracted where the comparison example is better. Higher scores indicate better sensation and significantly improved usability of the sheet laminate when used. The results are shown in Table 1 below. Comparative Example 1 Reference Example 1 Reference Example 2 Reference Example 3 Reference Example 4 Number of: sheet layers 3 3 3 3 2 Other element constituted 1 f Fiber type: Resin composition High PET PP PP PP High PET % by mass 50 100 100 100 50 Fiber type Resin composition PE - - - PE % by mass 50 - - - 50 Base weights [g / m2] 30' 37 .37 37' 30- First fiber 11th fiber 11 First fiber Resin composition PP High PET High PET High PET High PET High PET % by mass 50 50 50 50 50 Second fiber Resin composition Ethylene propylene PE PE Low PET Low PET % by mass 50 50 50 50.50' Base weight [g / m2] 80 30 30 70 70 Second sheet Ile 12 Fiber type: Resin composition PP PP PP High PET PP % by mass 100 50 50 50 100 Fiber type Resin composition■ - Ethylene propylene Ethylene propylene PE - % by mass - 50 50 50' - Base weight [g / m2] 37: ■80 80 30 37 Forming process of assembled part B Fixed ultrasonic heat Rotating ultrasonic waves Rotating ultrasonic waves Rotating ultrasonic waves Forming pattern of assembled part B Shape FIG. 8(d) Shape FIG. 8[d) Shape FIG. ■eCc) Shape FIG. 8[cl Shape FIG. 8[c) Linear pressure ratio P2 / P1 ■3.93. 3.93 1.79' T, 79 1.7-9 Presence or absence of incorporation of resin constituting first fibrous sheet BC TO A .A Evaluation Volume recovery rate [%] 58.5 - - - - Sealing force [N! 4.8 0.0 5.2' ■5.5 8.1' Sensation to touch at the time of contact [point! Comparative evaluation with examples.- - - - Sensation to touch in the worn state [point] Comparative evaluation with examples - - - - . Reference Example 5 Reference Example 6 Reference Example 7 Reference Example Reference Example 9 Number of sheet layers 3 3 3 3 2 Other element constant Fiber type: Resin composition PP High PET High PET % by mass 100 50 100 50 - Fiber type Resin composition - FE - PE - % by mass - 50 - 50 - Base weight [g / m2] 37 30 .37 30 - First fiber layer 11 First fiber Resin composition High PET High PET High PET High PET High PET % by mass 50 50 50 50 50 Second fiber Resin composition Low PET FE PE PE PE.' % by mass 50. 50- 50 50. 50' Base weight [g / m2] 11.0 80 ■35 35 30' Second sheet 12 Fiber type: Resin composition High PET PP High PET PP PP % by mass 50 100 50 100 100 Fiber type Resin composition PE' - ■PE - - % by mass 50' - :50 - - Base weight [g / m2] 30 37 :30 37 37 Forming process.of assembled part B Rotating ultrasonic waves Rotating ultrasonic waves Rotating ultrasonic waves Rotating ultrasonic waves Rotating ultrasonic waves Assembled part formation pattern B Shape FIG. ■8tcy Shape FIG. 8[c) Shape FIG. 8 [ci Shape FIG. ;8[c) Shape FIG. 8(c] Linear pressure ratio P2 / P1 1.79 1.79 1.79 T, 70 1.79 Presence or absence of incorporation of resin constituting the first fibrous sheet AAAA .A Evaluation Volume recovery rate [%] - - - - Sealing force [N] 4.9 8.8 5.2 8.7 5.6 Feeling on touch at the time of contact [point] - - - - - Feeling on touch in the worn state [point) - - - - . Example 1 Reference Example 10 Reference Example 11 Example 2 Example 3 Example 4 Example 5 Number of sheet layers 3 3 3 3 3 3 3 Other constituent element Fiber type Resin content High PET PP High PET High PET Low PET Low PET Low PET PP % by mass 50 100 50 50 50 50 100 Fiber type Resin composition PE - PE PE PE PE - % by mass 50 - 50 50 50 50 Base weight [g / m2] 30 37 30 30 30 30 30 37 First fiber layer 11 First fiber Resin composition High PET High PET High PET High PET High PET High PET High PET High PET % by mass 100 100 100 50 50 50 '50 Second fiber Resin composition - - PP PE PE PE % by mass - - - 50 50 50 50 Base weight [g / m2] 80 80 80 80 60 60 60 Second fire 11 the 12 Fiber type Resin composition PP High PET PP PP PP PP High PET % by mass 100 50 100 100 100 100 50 Fiber type Resin composition - PE - - - - PE % by mass 50 50 Base weight [g / m2] 37 30 37 37 37 37 30 Process ofAssembly part formation B Pulse sealing Rotating ultrasonic waves Rotating ultrasonic waves Pulse sealing Pulse sealing Rotating ultrasonic waves Rotating ultrasonic waves Assembly part formation pattern B Continuous linear form Shape i Shape FIG. 8(c) Shape h]Q:. 8(c) Continuous linear form I Continuous linear form I Shape FIG. 8(c) Shape FIG. 8(c) Linear pressure ratio P2 / P1 1.00 1.70 1.79 1.00 1.00 1.70 1.79 Presence or absence of incorporation of resin constituting the first fibrous sheet AAAAAAA Evaluation Volume recovery rate [%] 77.6 - - 64.2 69.6 - - Sealing force [N] - 5 3 5.7 - 7.9 6.6 Feel upon contact (point) 2.0 - 6.6 8.0 - Feel while worn (point) 2.0 - - 6.5 10.0 - -

[0106] As shown in Table 1, even when the packaged item 1 of the present invention is packaged in the state in which pressure is applied to the sheet laminate 10, the volume of the sheet laminate 10 is easily restored after opening the bag and the sheet laminate 10 is highly flexible. Furthermore, as shown in each of the examples and reference examples, even when PET fiber is used in the sheet laminate 10, the sheet assembly strength can be expressed more strongly.

[0107] Industrial applicability The present invention proposes the packaged element which presents the laminate in sheet form having sufficient assembly strength with the volume easily restored after opening.

Claims

Demands

1. Packaged item comprising a bag and a sheet laminate packaged in the bag, wherein the sheet laminate comprises: a first fibrous sheet including a first fiber including a constituent resin which contains a polyethylene terephthalate resin having a melting point above 230 °C; and a second sheet including a thermoplastic resin having a melting point of 230 °C or less, the sheet laminate includes an assembled part in which the first fibrous sheet and the second sheet are assembled adjacent to each other, characterized in that: in the assembled part, the thermoplastic resin buries the spaces among the constituent fibers of the first fibrous sheet in a state in which the constituent fibers of the first fibrous sheet retain the fiber shapes of the constituent fibers.

2. A packaged element according to claim 1, in which the second sheet is a fibrous sheet, and in the assembled part, the fiber shapes of the constituent fibers of the second sheet are not preserved.

3. Packed item according to claim 1 or 2, wherein in the sheet laminate, the first fibrous sheet is arranged in such a way that the first fibrous sheet forms an external surface of the sheet laminate.

4. A packaged item according to any one of claims 1 to 3, wherein the constituent resin contained in the first fiber consists solely of a polyethylene terephthalate resin having a melting point above 230 °C.

5. A packaged item according to any one of claims 1 to 4, further comprising a second fiber as a constituent fiber of the first fibrous sheet, wherein the second fiber includes a thermoplastic resin having a melting point of 230 °C or less.

6. Item packaged according to any one of claims 1 to 5, wherein the sheet laminate is housed in a state of application of pressure of 500 Pa or more and 5,000 Pa or less to the sheet laminate.

7. Packaged item according to any one of claims 1 to 6, wherein, in the assembled part, a boundary surface for each of the first fibrous sheet and the second sheet is not present, or the boundary surface is not sharp.

8. Item packaged according to any one of claims 1 to 7, wherein the sheet laminate is a sanitary product.

9. Packaged element according to any one of claims 1 to 8, wherein a heating element including an oxidizable metal is arranged between the first fibrous sheet and the second sheet in a site other than a formation site of the assembled part.

10. Packaged item according to any one of claims 1 to 9, wherein the second sheet is made up solely of thermoplastic resin having a melting point of 230 °C or less.

11. A method for producing a packaged item according to any one of claims 1 to 10, wherein a sheet laminate is packaged in a bag, wherein the method comprises: the superposition of a first fibrous sheet including a fiber comprising a polyethylene terephthalate resin having a melting point above 230 °C, and of a second sheet including a thermoplastic resin having a melting point of 230 °C or less, one on top of the other so as to form an adjacent site where the first fibrous sheet and the second sheet are adjacent to each other; and in this state; the assembly of the first fibrous sheet and the second sheet by pressing the adjacent site while heating the adjacent site.

12. A method for producing a packaged item according to claim 11, wherein the first fibrous sheet and the second sheet are introduced between a pair of rollers to assemble the first fibrous sheet and the second sheet, and a peripheral surface of at least one of the rollers has a shape with hollows and protrusions.

13. A method for producing a packaged item according to claim 12, wherein a ratio (P2 / P1) of a maximum value P2 of linear pressure of the roller having the shape with hollows and protrusions to a minimum value PI of the linear pressure is 4 or less, and PI is greater than 0.

14. A method for producing a packaged item according to claim 12 or 13, wherein one of the rollers includes an ultrasonic emitter and the other roller is an anvil roller.

15. A method for producing a packaged element according to claim 14, wherein the first fibrous sheet and the second sheet are introduced in such a way that a peripheral surface of the roller including the ultrasonic emitter and the second sheet come together against each other, to assemble the first fibrous sheet and the second sheet.

16. A method of producing a packaged item according to any one of claims 11 to 15, wherein the first fibrous sheet and the second sheet assembled together are packaged with the bag in a state of application of pressure of 500 Pa or more and 5,000 Pa or less to the first fibrous sheet and the second sheet.

17. A method for producing a packaged item according to any one of claims 11 to 16, wherein the second sheet is a fibrous sheet.

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