Disposable wearing article and manufacturing method thereof

Abstract

To provide a disposable wearing article that can prevent a flap member from becoming an obstacle when tearing, and to provide a manufacturing method thereof.SOLUTION: A disposable wearing article includes: a front body part 12; a back body part 14; a crotch part 16 joined to the front body part 12 and the back body part 14; a pair of first junctions 20a and 20b for joining both end parts 12a, 12b and 14a, 14b of the front body part 12 and the back body part 14 together; flap members 18a and 18b disposed on the back body part 14, and having fastening parts 19a and 19b that can be fastened to the front body part 12; second junctions 22a and 22b for joining the flap members 18a and 18b, and the back body part 14; and fracture guide lines 24a and 24b for tearing a continuous part where the front body part 12 and the back body part 14 are connected to each other by the front body part 12 or the first junctions 20a and 20b, and separating it. The continuous part torn by the fracture guide lines 24a and 24b can be connected again by fastening the fastening parts 19a and 19b of the flap members 18a and 18b onto the front body part 12.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a disposable wearing article and a manufacturing method thereof, and more particularly to a pants-type disposable wearing article which can be torn and then refastened to wear, and a manufacturing method thereof. [Background technology]

[0002] A pants-type disposable wearing article that can be torn and then refastened to be worn has been proposed in the past. Fig. 18 is an elevational view of such a disposable wearing article.

[0003] 18, in this pants-type disposable wearing article 150, both ends of a front body 152 and a back body 157 are joined to each other at a joining portion 162, and both ends of a crotch portion 160 are attached to the front body 152 and the back body 157. A pair of break guide lines 132, 134 are formed at both ends of the front body 152, extending from a waist opening 165 to leg openings 164, and a pair of flap members 166, 168 are attached so as to straddle the respective break guide lines 132, 134.

[0004] The base end 143 of the flap members 166, 168 is joined to the front body 152, and a fastening element is provided at the tip 149, so that the fastening element at the tip 149 can be attached to and detached from the fastening area 140 of the front body 152 (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] US Patent Application Publication No. 2002 / 0148557 Summary of the Invention [Problem to be solved by the invention]

[0006] Such a disposable wearing article 150 may be worn by tearing the front body 152 along the break guide lines 132, 134 before wearing, wrapping the front body 152 around the wearer's legs so that the wearer's legs pass through the leg openings 164, and refastening the flap members 166, 168. When wearing the disposable wearing article in this manner, the flap members 166, 168 get in the way when tearing the front body 152 along the break guide lines 132, 134.

[0007] In view of the above circumstances, an object of the present invention is to provide a disposable wearing article in which flap members do not get in the way when the article is torn, and a method for manufacturing the same. [Means for solving the problem]

[0008] In order to solve the above problems, the present invention provides a disposable wearing article having the following configuration.

[0009] The disposable wearing article is a pair of front bodies having (a) a front body that is placed on the stomach side of a wearer when worn, (b) a back body that is placed on the back side of a wearer when worn, (c) a crotch section connected to the front body and the rear body, (d) a pair of first joining sections that join both end portions of the front body and the rear body to each other, and (e) a first portion and a second portion, the second portions facing each other, the first portion being adjacent to one of the both end portions of the rear body, and the second portion having a fastening section configured to be releasably fastened to the one main surface of the front body. The garment comprises a wrap member, (f) a pair of second joints joining the first portion of each of the flap members and the front body, and (g) a pair of break guide lines formed so that the continuous portion connecting the front body and the back body can be torn and separated at the front body or the first joints, wherein (i) the tear strength of the break guide lines is weaker than the tear strength of the continuous portion in the portion where the break guide lines are not formed, and (ii) the continuous portion torn along the break guide lines can be reconnected by fastening the fastening portion of the second portion of the flap member to the one main surface of the front body.

[0010] According to the above-mentioned configuration, the continuous portion torn along the break guide line can be reconnected by fastening the fastening portion of the second portion of the flap member to one main surface of the front body. Since the flap member is disposed along the back body, the flap member does not get in the way when the continuous portion is torn along the break guide line.

[0011] Preferably, the second portion of the flap member is disposed along the one main surface of the rear body in a folded state so that the fastening portion is not exposed.

[0012] In this case, the fastening portion does not interfere with other articles, and the disposable wearing article can be easily handled when it is packaged or when the wearer starts wearing the article.

[0013] In a preferred embodiment, the break-inducing line is a perforation formed so that a plurality of penetrating portions penetrating between the one main surface and the other main surface of the front body are aligned between the upper edge and the lower edge of the front body.

[0014] In this case, the breakage induction wire can be easily formed.

[0015] In a preferred embodiment, the break-inducing line is the first joint, and the tear strength of the first joint is weaker than the tear strength of each of the portions of the front body and the back body where the first joint is not formed.

[0016] In this case, the configuration is simpler than when the breakage induction wire is formed separately from the first joint portion.

[0017] Preferably, the first joint portion and the second joint portion overlap each other when viewed from a direction perpendicular to the one main surface of the back body.

[0018] In this case, the first and second joining sections can be formed simultaneously, which simplifies the manufacturing process of the disposable wearing article.

[0019] Preferably, the fastening portion is a hook member of a hook and loop fastener.

[0020] In this case, the hook member can be easily attached to and detached from the front body, and the fastening remains stable even when the garment is repeatedly attached and detached.

[0021] In order to solve the above problems, the present invention provides a method for producing a disposable wearing article having the following configuration.

[0022] The method for manufacturing a disposable wearing article includes: (i) a first step of forming a main body continuum in which portions to be individual pieces, including a front body having first and second break guide lines formed therein, a back body, and a crotch portion joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuous portion to which the portions to be the front body are connected and a back body continuous portion to which the portions to be the back body are connected are separated from each other; (ii) a second step of joining a base material continuous body for forming first and second flap members and a hook continuous body for forming hook members to each other while transporting the base material continuous body and a hook continuous body for forming hook members, and cutting the base material continuous body and the hook continuous body into a predetermined shape to form a divided front flap member in which the first and second flap members, each having the hook member, are connected; and (iii) a second step of overlapping the divided front flap member with one main surface of the back body continuous portion of the main body continuum, and overlapping the front body continuous portion of the main body continuum with the other main surface of the back body continuous portion of the main body continuum. and (iv) a fourth step of cutting the joined front flap member and the main body continuum to form the individual pieces in which a pair of the first joints join both ends of the front body and the back body to each other and a pair of the second joints join the back body and the flap member to each other, wherein in the first step, the first and second break guiding wires are formed so that the tear strength of the first and second break guiding wires is weaker than the tear strength of a portion of the front body continuum where the first and second break guiding wires are not formed.

[0023] According to the above method, disposable wearing articles can be continuously and efficiently manufactured, in which the flap members do not get in the way when the articles are torn along the break guide lines formed on the front body portions.

[0024] Preferably, in the second step, the base material continuous body and the hook continuous body are transported, the hook continuous body is divided to form first and second hook continuous bodies, the first and second hook continuous bodies are cut to form pairs of hook members, the pairs of hook members are joined to the base material continuous body at intervals in the transport direction to form a first continuous body, the first continuous body is folded so that the hook members are sandwiched between the base material continuous bodies to form a second continuous body, and the second continuous body is cut between adjacent pairs of hook members to form the pre-split flap members.

[0025] In this case, the first and second hook continuous bodies and the base material continuous body of the second continuous body can be efficiently cut using separate devices, which makes it easy to improve production efficiency. In addition, wear on the cutting blades used for cutting can be suppressed, allowing for efficient operation of the production line.

[0026] In order to solve the above problems, the present invention provides another method for manufacturing a disposable wearing article, configured as follows.

[0027] The method for manufacturing a disposable wearing article includes: (i) a first step of forming a main body continuum in which portions to be individual pieces, including a front body, a back body, and a crotch portion joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuous portion to which the portions to be the front body are connected and a back body continuous portion to which the portions to be the back body are connected are separated from each other; (ii) a second step of joining a base material continuous body for forming first and second flap members and a hook continuous body for forming hook members to each other while transporting the base material continuous body and cutting the base material continuous body and the hook continuous body into a predetermined shape to form the first and second flap members, each of which has the hook member; and (iii) a second step of overlapping the first and second flap members on one main surface of the back body continuous portion of the main body continuum, and connecting the first and second flap members and the back body continuous body of the main body continuum to each other. (iv) a fourth step of overlapping the front body continuous portion of the main body continuum with the other main surface of the back body continuous portion of the main body continuum and joining the overlapped front body continuous portion and the back body continuous portion of the main body continuum to each other to form a first joint; and (v) a fifth step of cutting the main body continuum to form the individual pieces in which a pair of the first joints join both ends of the front body and the back body to each other and a pair of the second joints join the back body to the first and second flap members to each other, wherein in the fourth step, the first joints are formed so that the tear strength of the first joints is weaker than the tear strength of the portions of the front body continuous portion and the back body continuous portion where the first joints are not formed.

[0028] According to the above method, disposable wearing articles can be continuously and efficiently manufactured, in which the flap members do not get in the way when the articles are torn along the first bond portion, which is the breakage guide line.

[0029] Preferably, (a) adhesive is applied to the back body continuous portion of the main body continuum, the base material continuous portion, or the first and second flap members so that when the first and second flap members are overlapped on one main surface of the back body continuous portion of the main body continuum, an adhesive application portion is positioned between the first and second flap members and the back body continuous portion of the main body continuum, to form the adhesive application portion, and (b) in the third step, the first and second flap members are overlapped on one main surface of the back body continuous portion of the main body continuum, and the first and second flap members are temporarily fixed to the back body continuous portion of the main body continuum via the adhesive application portion, and then the second joint is formed.

[0030] In this case, by temporarily fixing the first and second flap members, the conveying speed of the production line can be made faster than when the first and second flap members are not temporarily fixed, making it easier to increase the number of products produced per unit time.

[0031] In order to solve the above problems, the present invention provides another method for manufacturing a disposable wearing article, configured as follows.

[0032] The method for manufacturing a disposable wearing article includes: (i) a first step of forming a main body continuum in which portions to be individual pieces, including a front body, a back body, and a crotch portion joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuous portion to which the portions to be the front body are connected and a back body continuous portion to which the portions to be the back body are connected are separated from each other; (ii) a second step of joining a base material continuous body for forming first and second flap members and a hook continuous body for forming hook members to each other while transporting and cutting them into a predetermined shape to form a divided front flap member in which the first and second flap members, each having the hook member, are connected; and (iii) a first step of overlapping the divided front flap member with one main surface of the back body continuous portion of the main body continuum and overlapping the front body continuous portion of the main body continuum with the other main surface of the back body continuous portion of the main body continuum, and then cutting the front body continuous portion of the main body continuum with the hook member. The method comprises: (a) a third step of joining the divided front flap member and the overlapping front body continuous portion and the back body continuous portion of the main body continuous body to each other to form a first joint portion joining the front body continuous portion and the back body continuous portion of the main body continuous body to each other and a second joint portion joining the divided front flap member and the back body continuous portion of the main body continuous body to each other; and (iv) a fourth step of cutting the divided front flap member and the main body continuous body that have been joined to each other to form the individual pieces in which a pair of the first joint portions join both ends of the front body and the back body to each other and a pair of the second joint portions join the back body and the flap member to each other, wherein in the third step, the first joint portions are formed so that the tear strength of the first joint portions is weaker than the tear strength of portions of the front body continuous portion and the back body continuous portion where the first joint portions are not formed.

[0033] According to the above method, disposable wearing articles can be continuously and efficiently manufactured, in which the flap members do not get in the way when the articles are torn along the first bond portion, which is the breakage guide line.

[0034] Preferably, (a) adhesive is applied to the rear body continuous portion of the main body continuum, the base material continuum, or the division flap member so that when the division front flap member is overlapped on the one main surface of the back body continuous portion of the main body continuum, an adhesive application portion is positioned between the division front flap member and the back body continuous portion of the main body continuum to form the adhesive application portion, and (b) in the third step, the division front flap member is overlapped on the one main surface of the back body continuous portion of the main body continuum and temporarily fixed to the back body continuous portion of the main body continuum via the adhesive application portion, and then the second joint is formed.

[0035] In this case, by temporarily fixing the pre-separation flap member, the conveying speed of the production line can be made faster than in a case where the pre-separation flap member is not temporarily fixed, and it is easy to increase the number of products produced per unit time.

[0036] Preferably, in the second step, the base material continuous body and the hook continuous body are transported, the hook continuous body is divided to form first and second hook continuous bodies, the first and second hook continuous bodies are cut to form pairs of hook members, the pairs of hook members are joined to the base material continuous body at intervals in the transport direction to form a first continuous body, the first continuous body is folded so that the hook members are sandwiched between the base material continuous bodies to form a second continuous body, and the second continuous body is cut between adjacent pairs of hook members to form the pre-split flap members.

[0037] In this case, the first and second hook continuous bodies and the base material continuous body of the second continuous body can be efficiently cut using separate devices, which makes it easy to improve production efficiency. In addition, wear on the cutting blades used for cutting can be suppressed, allowing for efficient operation of the production line. Effect of the Invention

[0038] According to the present invention, there is provided a disposable wearing article in which flap members do not get in the way when the article is torn, and a method for manufacturing the same. [Brief description of the drawings]

[0039] [Figure 1] Fig. 1(a) is a schematic rear view of a disposable wearing article, and Fig. 1(b) is a schematic front view of the disposable wearing article. [Diagram 2] Fig. 2 is a schematic cross-sectional view taken along line AA in Fig. 1(a). [Diagram 3] FIG. 3 is a perspective view of a main part of a disposable wearing article (Example 1). [Figure 4] FIG. 4 is a schematic diagram of a manufacturing process of a disposable wearing article (Example 1). [Diagram 5] Fig. 5(a) is a schematic rear view of the disposable wearing article, and Fig. 5(b) is a schematic front view. (Example 2) [Figure 6] FIG. 6 is a schematic diagram of a manufacturing process of a disposable wearing article (Example 2). [Figure 7] Fig. 7(a) is a schematic rear view of the disposable wearing article, and Fig. 7(b) is a schematic front view of the disposable wearing article. [Figure 8] FIG. 8 is a schematic diagram of a manufacturing process of a disposable wearing article (Example 4). [Figure 9] Fig. 9(p) is a schematic cross-sectional view taken along line PP in Fig. 8, Fig. 9(q) is a schematic cross-sectional view taken along line QQ in Fig. 8, and Fig. 9(r) is a schematic cross-sectional view taken along line RR in Fig. 8. (Example 4) [Figure 10] Fig. 10 is a schematic cross-sectional view taken along line SS in Fig. 8. (Example 4) [Figure 11] FIG. 11 is an enlarged schematic view of a main part of a disposable wearing article (Modification 1). [Figure 12] FIG. 12 is a schematic cross-sectional view of a disposable wearing article (modification 2). [Figure 13] FIG. 13 is a schematic cross-sectional view of a disposable wearing article (Modification 3). [Figure 14] FIG. 14 is a schematic diagram of a manufacturing process of a disposable wearing article (Modification 5). [Figure 15] Fig. 15 is a schematic cross-sectional view taken along line BB in Fig. 5(a). (Example 2) [Figure 16]Fig. 16 is a schematic cross-sectional view taken along line CC in Fig. 7(a) (Example 3). [Figure 17] FIG. 17 is a schematic diagram of a manufacturing process of a disposable wearing article (Modification 6). [Figure 18] FIG. 18 is an elevational view of a disposable wearing article (conventional example 1). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0041] Example 1 A disposable wearing article 10 of Example 1 and a method for manufacturing the same will be described with reference to Figs.

[0042] Fig. 1(a) is a schematic rear view of a disposable wearing article 10 of Example 1, and Fig. 1(b) is a schematic front view. Fig. 2 is a schematic cross-sectional view taken along line AA in Fig. 1(a). Fig. 3 is a perspective view of a main part of the wearing article 10.

[0043] As shown in Figures 1(a), 1(b), 2 and 3, in the disposable wearing article 10, both end portions 12a, 12b; 14a, 14b of a front body 12 and a back body 14 are joined to each other via a pair of first joining portions 20a, 20b, both end portions of a crotch portion 16 are joined to the front body 12 and the back body 14, and the crotch portion 16 is folded back at an intermediate position 17.

[0044] The front body 12 and the back body 14 may be made to have elasticity, for example, by using an elastic composite sheet in which an elastic member is disposed between nonwoven fabric sheets and the nonwoven fabric sheets and the elastic members are bonded to each other at appropriate locations, or may be made to have no elasticity. The disposable wearing article 10 is packaged in the state shown in Figures 1(a) and 1(b) or further folded, and is provided to a consumer.

[0045] The front body 12 is placed on the wearer's abdomen when worn, and the back body 14 is placed on the wearer's back when worn. When a space is provided between the front body 12 and the back body 14, a waist opening is formed along the upper edge 12p of the front body 12 and the upper edge 14p of the back body 14, and a pair of leg openings are formed on both sides of the crotch portion 16.

[0046] The first joints 20a, 20b are formed by intermittently heat-sealing the front body 12 and the back body 14, for example as shown in Figure 3, and multiple heat-sealed portions 20s extending diagonally relative to the upper edge 12p and lower edge 12q of the front body 12 are arranged at intervals from each other.

[0047] A pair of breakage induction wires 24a, 24b are formed on the front body 12 with a gap provided between them and the first joint portions 20a, 20b.

[0048] The pair of flap members 18a, 18b have a first portion 18p on the base end side and a second portion 18q on the tip end side, and the second portions 18q are arranged to face each other, and the first portions 18p and the back body 14 are joined to each other via second joining portions 22a, 22b. The second joining portions 22a, 22b are formed by heat sealing, ultrasonic bonding, or the like so as to extend continuously on the back body 14 between the first joining portions 20a, 20b and the breakage guide wires 24a, 24b, as shown in the perspective view of the main part from the back in Fig. 3, for example.

[0049] The second portion 18q of the flap members 18a, 18b has a fastening portion configured to be releasably fastened to one main surface 12s of the front body 12. For example, the fastening portion is hook members 19a, 19b of a hook-and-loop fastener attached to the second portion 18q of the flap members 18a, 18b so as to face one main surface 12s of the front body 12, and is configured so that the hook surfaces 19s of the hook members 19a, 19b engage with one main surface 12s of the front body 12, thereby allowing the fastening to be releasably fastened to one main surface 12s of the front body 12. The hook members 19a, 19b are preferable because they are easy to attach and detach from the front body and provide stable fastening even when repeatedly attached and detached, but the fastening portion may also be configured using an adhesive sheet, hooks, buttons, etc.

[0050] The second portions 18q of the flap members 18a, 18b are folded along the fold line 18r so that the hook members 19a, 19b are not exposed. This prevents the hook members 19a, 19b from interfering with other articles, making it easier to handle the disposable wearing article 10 when packaging it or when starting to wear it.

[0051] The pair of break induction wires 24a, 24b are configured so that the front body 12 can be torn and separated along the break induction wires 24a, 24b. In other words, the pair of break induction wires 24a, 24b are formed so that the continuous portion where the front body 12 and the back body 14 are connected in a ring-shaped or tubular shape via the first joint parts 20a, 20b can be torn and separated at the front body 12.

[0052] 3, the break induction lines 24a, 24b are perforations having multiple through portions 24s that penetrate between one main surface 12s and the other main surface 12t of the front body 12, and extend between the upper edge 12p and the lower edge 12q of the front body 12. The break induction lines 24a, 24b of the perforations can be easily formed, but the break induction lines 24a, 24b may also be formed by forming non-through slits in the front body 12, removing a portion of the material of the front body 12, or the like.

[0053] The break induction lines 24a, 24b are formed so that the tear strength of the break induction lines 24a, 24b is weaker than the tear strength of a portion of the front body 12 where the break induction lines 24a, 24b are not formed. As a result, when both sides of the break induction lines 24a, 24b of the front body 12 are pulled in opposite directions, the front body 12 is torn along the break induction lines 24a, 24b, but is not torn in the portion where the break induction lines 24a, 24b are not formed.

[0054] The break induction wires 24a, 24b and the second joints 22a, 22b are formed so that the tear strength of the break induction wires 24a, 24b is weaker than the tear strength of the second joints 22a, 22b. This ensures that when the portion of the front body 12 between the pair of break induction wires 24a, 24b and either one of the flap members 18a, 18b are pulled in directions away from each other, the front body 12 can be reliably torn along the break induction wires 24a, 24b, and the flap members 18a, 18b are not peeled off from the back body 14.

[0055] Furthermore, it is preferable that the break guiding wires 24a, 24b and the first joints 20a, 20b are formed so that the tear strength of the break guiding wires 24a, 24b is weaker than the tear strength of the first joints 20a, 20b that join the front body 12 and the back body 14. This ensures that when the portion of the front body 12 between the pair of break guiding wires 24a, 24b and the back body 14 are pulled in directions away from each other, the front body 12 can be reliably torn along the break guiding wires 24a, 24b, and the front body 12 and the back body 14 will not peel off at the first joints 20a, 20b.

[0056] In other words, the tear strength of the fracture-inducing wires 24a and 24b is F f The tear strength of the portion of the front body 12 where the breakage induction lines 24a, 24b are not formed is F 0 , the tear strength F of the first joints 20a and 20b 1、 Tear strength F of the second joints 22a and 22b 2 Then, the configuration is made so as to satisfy the following formulas 1 and 2, and preferably, the configuration is made so as to further satisfy formula 3. F f <F 0 (Formula 1) F f <F 2 (Formula 2) F f <F 1 (Formula 3)

[0057] The tear strength is measured in accordance with JIS L 1096 C method (trapezoid method).

[0058] The tear strength of the break induction wires 24a, 24b is measured by preparing a sample of the front body 12 of a specified dimension so that the break induction wires 24a, 24b are positioned in the longitudinal center of the sample, and placing the break induction wires 24a, 24b between the fixed grips and the moving grips of the testing device. A tear test is then conducted under specified conditions (specified gripping distance, specified tensile speed), and the maximum strength [Kgf (N)] shown when torn is measured, and the value is expressed as the average of three measurements.

[0059] For example, if the width of the blade forming the perforation is W (mm) and the gap dimension between adjacent perforations is D (mm), the tear strength of the breakage induction lines 24a, 24b of the perforation will be as shown in Table 1 below. [Table 1]

[0060] The tear strength of the portion of the front body 12 where the break induction wires 24a, 24b are not formed is measured by preparing a sample of the front body 12 of a specified dimension not including the break induction wires 24a, 24b, gripping the sample with the fixed grip and moving grip of the testing device, conducting a tear test under specified conditions, measuring the maximum strength shown when torn, and expressing it as the average value of three measurements.

[0061] The tear strength of the first joints 20a, 20b is measured by creating a sample of specified dimensions in which the first joints 20a, 20b are located in the longitudinal center of the sample, with the front body 12 and the back body 14 arranged on either side of it, and placing the first joints 20a, 20b between the fixed grip and moving grip of the testing equipment, with one of the fixed grip and the moving grip gripping the front body 12 of the sample and the other gripping the back body 14 of the sample, and conducting a tear test under specified conditions. The maximum strength shown when torn is measured and expressed as the average of three measurements.

[0062] The tear strength of the second joints 22a, 22b is measured by creating a sample of specified dimensions in which the second joints 22a, 22b are located in the longitudinal center of the sample, with the front body 12 and flap members 18a, 18b arranged on either side of it, and placing the second joints 22a, 22b between the fixed grip and moving grip of the testing equipment, with one of the fixed grip and the moving grip gripping the front body 12 of the sample, and the other gripping the flap members 18a, 18b of the sample. A tear test is performed under specified conditions, and the maximum strength shown when torn is measured and expressed as the average of three measurements.

[0063] For example, if the seal width of the heat-sealed portion 20s shown in FIG. 3 is W (mm), the tear strength of the first joint portions 20a and 20b will be as shown in Table 2 below. [Table 2]

[0064] The disposable wearing article 10 can be worn, for example, while standing, by tearing the front body 12 along the breakage guide lines 24a, 24b, wrapping the torn portion around the legs, pulling out the folded second portions 18q of the flap members 18a, 18b and turning them toward the front body 12, and fastening the hook members 19a, 19b to one main surface 12s of the front body 12, thereby allowing the legs to pass through the leg openings.

[0065] In the disposable wearing article 10, the flap members 18a, 18b are arranged along the back body 14 and are spaced apart from the break guide lines 24a, 24b, so that the flap members 18a, 18b do not get in the way when the disposable wearing article 10 is torn along the break guide lines 24a, 24b.

[0066] Next, a method for manufacturing the disposable wearing article 10 will be described with reference to Fig. 4. Fig. 4 is a schematic diagram of a manufacturing process for the disposable wearing article.

[0067] As shown in FIG. 4, the method for producing the disposable wearing article 10 includes the following first to fourth steps.

[0068] (i) A main body continuum 11 is formed in which a portion 11k to be an individual piece including the front body 12 on which the first and second breakage guiding wires 24a, 24b are formed, the back body 14, and the crotch section 16 joined to the front body 12 and the back body 14 is connected, and the main body continuum 11 is transported in a state in which the front body continuous portion 12k to which the portion to be the front body 12 is connected and the back body continuous portion 14k to which the portion to be the back body 14 is connected are separated from each other. This is the first process.

[0069] The main body continuum 11 can be formed by a known method, for example, by arranging a plurality of elastic members 12i, 14i between sheets of nonwoven fabric or the like, forming the front body continuous part 12k and the back body continuous part 14k using an elastic composite sheet in which the sheets of nonwoven fabric or the like and the elastic members 12i, 14i are joined together at appropriate locations, and transported in a stretched state with the elastic members 12i, 14i. The main body continuum 11 may or may not have an absorbent 18 arranged therein for absorbing and retaining liquids such as menstrual blood and / or urine.

[0070] (ii) Furthermore, the continuous base material strip 30 for forming the first and second flap members 18a, 18b and the continuous hook strips 32, 34 for forming the hook members 19a, 19b are joined to each other while being conveyed and cut into a predetermined shape to form a pre-separation flap member 31 in which the first and second flap members 18a, 18b having the hook members 19a, 19b, respectively, are connected. This is the second process.

[0071] There are various ways to form the pre-separation flap member 31. For example, the pre-separation flap member 31 is formed as follows.

[0072] First, the continuous base material strip 30 and the first and second continuous hook strips 32, 34 for forming the first and second hook members 19a, 19b of the hook-and-loop fastener are transported in the directions in which they are continuous.

[0073] Next, the first and second hook continuous bodies 32, 34 are arranged on the continuous substrate body 30 at intervals along a pair of side edges 30m, 30n of the continuous substrate body 30 and joined to each other by heat sealing, ultrasonic bonding, or the like to form the first continuous substrate body 30a. At this time, the hook faces of the first and second hook continuous bodies 32, 34 are exposed.

[0074] Next, the first continuous body 30a is cut along a pair of side edges 30m, 30n of the base material continuous body 30 to form trimming portions 30p, 30q of a predetermined shape shown by dashed lines, thereby forming a second continuous body 30b having opposing hook members 19a, 19b formed by cutting the first and second hook continuous bodies 32, 34.

[0075] Next, the second continuous body 30b has two side portions 30u and 30v, each having opposing hook members 19a and 19b, folded back as shown by arrow 30x so that the hook members 19a and 19b are on the inside, thereby forming a third continuous body 30c in which pairs of opposing hook members 19a and 19b are arranged with a gap between them.

[0076] Next, the third continuous body 30c is cut at a predetermined position 30y indicated by a dotted line to form a pre-split flap member 31 in which the first portions 18p of the portions intended to become the first and second flap members 18a, 18b are connected to each other, and then the orientation of the pre-split flap member 31 relative to the conveying direction is changed as indicated by the arrow 31u.

[0077] The orientation of the pre-division flap member 31 is changed in order to overlap the pre-division flap member 31 in the desired orientation on one main surface 14s of the back body continuous portion 14k of the main body continuum 11 in the third step described below. If the pre-division flap member 31 is formed by changing the orientation of the portion that is to become the pre-division flap member 31, it can be overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuum 11 without changing the orientation of the pre-division flap member 31.

[0078] (iii) Next, the front body continuous portion 12k of the main body continuum 11 is overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuum 11, and the front body continuous portion 12k of the main body continuum 11 is overlapped on the other main surface 14t of the back body continuous portion 14k of the main body continuum 11, and the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 are joined to each other to form first joints 20a, 20b that join the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 to each other and second joints 22a, 22b that join the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 to each other. This is the third step.

[0079] At this time, the pre-split flap member 31 is overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuum 11 so that the boundary line of the portion of the pre-split flap member 31 that is intended to become the first and second flap members 18a, 18b overlaps with the boundary line of the portion 11k that is intended to become an individual piece of the main body continuum 11.

[0080] The first sub-step of overlapping the divided front flap member 31 onto one main surface 14s of the rear body continuous portion 14k of the main body continuum 11 may be performed before the second sub-step of overlapping the front body continuous portion 12k of the main body continuum 11 onto the other main surface 14t of the rear body continuous portion 14k of the main body continuum 11, or may be performed after the second sub-step, or may be performed simultaneously with the second sub-step.

[0081] By performing the first sub-step and the second sub-step simultaneously, the first joints 20a, 20b that join the front body 12 and the back body 14 to each other, and the second joints 22a, 22b that join the flap members 18a, 18b and the back body 14 to each other can be formed simultaneously, thereby simplifying the process.

[0082] (iv) Next, the separated front flap member 31 and the continuous main body 11 joined together are cut to form the individual pieces in which the pair of first joining portions 20a, 20b join both ends 12a, 12b; 14a, 14b of the front body 12 and the back body 14 to each other, and the pair of second joining portions 22a, 22b join the back body 14 to the flap members 18a, 18b to each other. This is the fourth step.

[0083] In the first step (i) above, the first and second break induction wires 24a, 24b are formed so that the tear strength of the first and second break induction wires 24a, 24b is weaker than the tear strength of a portion of the front body continuous portion 12k where the first and second break induction wires 24a, 24b are not formed.

[0084] As a result, the break guide lines 24a, 24b are formed in the front body 12, and disposable wearing articles 10 in which the flap members 18a, 18b do not get in the way when the front body 12 is torn along the break guide lines 24a, 24b can be continuously and efficiently manufactured.

[0085] In addition, the elastic members 12i, 14i of the front body continuous portion 12k and the back body continuous portion 14k are released from their stretched state by being cut, so that the front body 12 and the back body 14 of the wearing article 10 are in a contracted state after cutting.

[0086] <Example 2> A disposable wearing article 10a of Example 2 in which the breakage guiding wires are the first bonding portions 20a, 20b and a manufacturing method thereof will be described with reference to Fig. 5, Fig. 6, and Fig. 15. Example 2 has the same structure as Example 1. In the following, the same components as in Example 1 are designated by the same reference numerals as in Example 1, and differences from Example 1 will be mainly described.

[0087] Fig. 5(a) is a schematic rear view of a disposable wearing article 10a of Example 2, and Fig. 5(b) is a schematic front view thereof Fig. 15 is a schematic cross-sectional view taken along line BB in Fig. 5(a).

[0088] As shown in Figures 5(a), 5(b) and 15, the disposable wearing article 10a of the second embodiment, like that of the first embodiment, comprises a front body section 12, a back body section 14, a crotch section 16 and a pair of flap members 18a, 18b.

[0089] Unlike Example 1, the front body 12 of the disposable wearing article 10a does not have the perforated break guide lines 24a, 24b of Example 1. In addition, the first joining portions 20a, 20b joining the front body 12 and the back body 14 to each other and the second joining portions 22a, 22b joining the flap members 18a, 18b to the back body 14 to each other are spaced apart from each other. In other words, the flap members 18a, 18b are disposed away from the first joining portions 20a, 20b and both ends 14a, 14b of the back body 14.

[0090] Furthermore, the breakage guide lines are the first joints 20a, 20b. That is, the first joints 20a, 20b are formed so that the continuous portion where the front body 12 and the back body 14 are connected can be torn and separated at the first joints 20a, 20b. In detail, the tear strength of the first joints 20a, 20b is weaker than the tear strength of the portions of the front body 12 and the back body 14 where the first joints 20a, 20b are not formed. For example, the first joints 20a, 20b are formed by intermittent heat sealing, and the joining strength is weaker than that in the case of continuous heat sealing. In addition, any joining means such as ultrasonic welding, hot melt joining, and sewing may be used as long as the tear strength of the first joints 20a, 20b can be made weaker than the tear strength of the portions of the front body 12 and the back body 14 where the first joints 20a, 20b are not formed.

[0091] When the front and back pieces 12, 14 of the wearing article 10a are pulled away from each other, they can be torn reliably along the first joining portions 20a, 20b without being torn at any other portions than the first joining portions 20a, 20b.

[0092] The flap members 18a, 18b are positioned away from the first joint portions 20a, 20b and therefore do not get in the way when tearing along the first joint portions 20a, 20b.

[0093] Preferably, the tear strength of the first joints 20a, 20b is made weaker than the tear strength of the second joints 22a, 22b. This allows the flap members 18a, 18b to be reliably torn along the first joints 20a, 20b without peeling off from the back body 14 when the front body 12 and the flap members 18a, 18b are pulled in directions away from each other.

[0094] Next, a method for manufacturing the disposable wearing article 10a will be described with reference to Fig. 6. Fig. 6 is a schematic diagram of a manufacturing process for the disposable wearing article.

[0095] As shown in FIG. 6, the method for producing the disposable wearing article 10a includes the following first to fifth steps.

[0096] (i) A continuous main body 11 is formed in which a portion 11k to be an individual piece, including a front body 12, a back body 14, and a crotch section 16 joined to the front body 12 and the back body 14, is connected, and the front body continuous portion 12k to which the portion to be the front body 12 is connected and the back body continuous portion 14k to which the portion to be the back body 14 is connected are transported in a state separated from each other. This is the first process.

[0097] (ii) Furthermore, the continuous base material strip 30 for forming the first and second flap members 18a, 18b and the continuous hook strips 32, 34 for forming the hook members 19a, 19b are joined to each other while being conveyed and cut into a predetermined shape to form the first and second flap members 18a, 18b having the hook members 19a, 19b, respectively. This is the second process.

[0098] The first and second flap members 18a, 18b can be formed in various ways. For example, the first and second flap members 18a, 18b are formed as follows.

[0099] First, the continuous base material strip 30 and the first and second continuous hook strips 32, 34 for forming the first and second hook members 19a, 19b of the hook-and-loop fastener are transported in the directions in which they are continuous.

[0100] Next, the first and second hook continuous bodies 32, 34 are joined to the continuous substrate body 30 at intervals along a pair of side edges 30m, 30n of the continuous substrate body 30 to form the first continuous substrate body 30a. At this time, the first and second hook continuous bodies 32, 34 are joined to the continuous substrate body 30 by an appropriate means such as adhesive, heat sealing, ultrasonic bonding, sewing, etc., so that the hook surfaces are exposed.

[0101] Next, the first continuous body 30a is cut along a pair of side edges 30m, 30n of the base material continuous body 30 to form trimming portions 30p, 30q of a predetermined shape shown by dashed lines, thereby forming a second continuous body 30b having hook members 19a, 19b formed by cutting the first and second hook continuous bodies 32, 34.

[0102] Next, the second continuous body 30b has two side portions 30u and 30v, each having opposing hook members 19a and 19b, folded back as shown by arrow 30x so that the hook members 19a and 19b are on the inside, thereby forming a third continuous body 30c in which pairs of opposing hook members 19a and 19b are arranged with a gap between them.

[0103] Next, the third continuous body 30c is divided between the opposing hook members 19a, 19b and the interval is widened to form a pair of fourth continuous bodies 31a, 31b having outer edges 31m, 31n formed by the division.

[0104] Next, the pair of fourth continuous bodies 31a, 31b are cut at predetermined positions 30z indicated by dashed lines to form pairs of first and second flap members 18a, 18b having hook members 19a, 19b, and then the orientation of the resulting bodies relative to the conveying direction is changed as indicated by arrow 31u.

[0105] The first and second flap members 18a, 18b can also be formed using the continuous base material body 30 and the continuous hook bodies 32, 34 so that the orientation of the first and second flap members 18a, 18b with respect to the conveyance direction does not need to be changed.

[0106] (iii) Next, the first and second flap members 18a, 18b are overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuum 11, and the first and second flap members 18a, 18b and the back body continuous portion 14k of the main body continuum 11 are joined to each other to form second joining portions 22a, 22b. This is the third step.

[0107] At this time, the pair of flap members 18a, 18b are arranged on both sides of the boundary line of the portion 11k of the main body continuous body 11 that is to become an individual piece, and second joints 22a, 22b are formed by heat sealing, ultrasonic bonding, etc.

[0108] (iv) Next, the front body continuous portion 12k of the main body continuum 11 is overlapped on the other main surface 14t of the back body continuous portion 14k of the main body continuum 11, and the overlapped front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 are joined to each other to form first joining portions 20a, 20b. This is the fourth step.

[0109] The first joints 20a, 20b are formed by heat sealing, ultrasonic bonding, or the like on both sides of the boundary line of the portion 11k that is to become an individual piece of the continuous main body 11. The first joints 20a, 20b may be connected to each other.

[0110] (v) Next, the main body continuous body 11 is cut to form the individual pieces in which the pair of first joint parts 20a, 20b join both ends 12a, 12b; 14a, 14b of the front body 12 and the back body 14 to each other, and the pair of second joint parts 22a, 22b join the back body 14 to the first and second flap members 18a, 18b to each other. This is the fifth step.

[0111] In the fourth step (iv) above, the first joints 20a, 20b are formed so that the tear strength of the first joints 20a, 20b is weaker than the tear strength of the portions of the front body continuous portion and the back body continuous portion where the first joints 20a, 20b are not formed.

[0112] In the third step (iii) above, the pair of flap members 18a, 18b may be overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuous body 11 and temporarily fixed thereto.

[0113] In this case, for example, as shown in Fig. 6, an adhesive such as hot melt is applied to appropriate locations of the fourth continuum 31a, 31b to form adhesive-applied portions 36a, 36b in the flap members 18a, 18b. An adhesive such as hot melt may also be applied to appropriate locations of the back body continuous portion 14k of the main body continuous portion 11 or the base material continuous body 30 to form the adhesive-applied portions 36a, 36b.

[0114] That is, (a) when the first and second flap members 18a, 18b are superimposed on the one main surface 14s of the back piece continuous portion 14k of the main body continuum 11, the back piece continuous portion 14k of the main body continuum 11, the base material continuous body 30, or the first and second flap members 18a, 18b are arranged such that adhesive-applied portions 36a, 36b are disposed between the first and second flap members 18a, 18b and the back piece continuous portion 14k of the main body continuum 11. b to form the adhesive-applied portions 36a, 36b, and (b) in the third step, the first and second flap members 18a, 18b are overlapped on one main surface 14s of the back piece continuous portion 14k of the main body continuum 11, and the first and second flap members 18a, 18b are temporarily fixed to the back piece continuous portion 14k of the main body continuum 11 via the adhesive-applied portions 36a, 36b, and then the second joint portions 22a, 22b are formed.

[0115] By temporarily fixing the first and second flap members 18a, 18b, the conveying speed of the production line can be made faster than when the first and second flap members 18a, 18b are not temporarily fixed, making it easier to increase the number of products produced per unit time.

[0116] As a result, disposable wearing articles 10a can be produced continuously and efficiently, without the flap members 18a, 18b getting in the way when the continuous portion connecting the front body 12 and the back body 14 is torn along the first joints 20a, 20b, which are the breakage guide lines.

[0117] In addition, without forming the adhesive application portions 36a, 36b, the flap members 18a, 18b may be overlapped on one main surface 14s of the rear body continuous portion 14k of the main body continuum 11, and the flap members 18a, 18b and the rear body continuous portion 14k of the main body continuum 11 may be joined to each other while holding the flap members 18a, 18b with an appropriate member.

[0118] Furthermore, the flap members 18a, 18b may not be temporarily fixed, but may be joined to the rear body continuous portion 14k of the main body continuum 11 to form the second joint portions 22a, 22b.

[0119] In addition, the flap members 18a, 18b may not be paired, but each may be overlapped in an appropriate order on one main surface 14s of the rear body continuous portion 14k of the main body continuum 11, and the flap members 18a, 18b and the rear body continuous portion 14k of the main body continuum 11 may be joined to each other.

[0120] Third Embodiment A disposable wearing article 10b according to a third embodiment will be described with reference to FIGS.

[0121] Fig. 7(a) is a schematic rear view of a disposable wearing article 10b of Example 3, and Fig. 7(b) is a schematic front view thereof. Fig. 16 is a schematic cross-sectional view taken along line CC in Fig. 7(a).

[0122] 7 and 16, first portions 18p of flap members 18a, 18b overlap one of both ends 14a, 14b of the back body 14, and the first portions 18p of flap members 18a, 18b are joined to the back body 14 via two second joints 22a, 22b and 23a, 23b. The breakage guiding lines are first joints 20a, 20b.

[0123] The second bonding portions 22a, 22b on one side are formed at positions spaced apart from the first bonding portions 20a, 20b, and the second bonding portions 23a, 23b on the other side are formed so as to overlap the first bonding portions 20a, 20b.

[0124] The disposable wearing article 10b of the third embodiment can be manufactured by using the pre-divided flap member 31 formed in the same manner as in the first embodiment, for example, through the following steps.

[0125] First, the pre-split flap member 31 is overlapped on one main surface 14s of the rear body continuous portion 14k of the main body continuous body 11, and the pre-split flap member 31 and the rear body continuous portion 14k of the main body continuous body 11 are joined to each other by heat sealing, ultrasonic bonding, adhesion, etc. to form one of the second joints 22a, 22b.

[0126] Next, the main body continuum 11 is folded back, and the front body continuous portion 12k of the main body continuum 11 is overlapped on the other main surface 14t of the back body continuous portion 14k of the main body continuum 11, and the divided front flap member 31 and the overlapped front body continuous portion 12k and back body continuous portion 14k of the main body continuum 11 are joined to each other by heat sealing, ultrasonic bonding, etc. to form first joints 20a, 20b and the other second joints 23a, 23b.

[0127] Next, the pre-divided flap members 31 and the continuous main body that are joined together are cut to form individual pieces.

[0128] The first bonding portions 20a, 20b and the second bonding portions 22a, 22b; 23a, 23b are formed so that the tear strength of the first bonding portions 20a, 20b is weaker than the tear strength of the second bonding portions 22a, 22b; 23a, 23b.

[0129] Example 4 A disposable wearing article 10c of Example 4 and a method for producing the same will be described with reference to FIGS.

[0130] Fig. 8 is a schematic diagram of a manufacturing process of the disposable wearing article 10c. Fig. 9(p) is a schematic cross-sectional view taken along line PP in Fig. 8. Fig. 9(q) is a schematic cross-sectional view taken along line QQ in Fig. 8. Fig. 9(r) is a schematic cross-sectional view taken along line RR in Fig. 8. FIG. 10 is a schematic cross-sectional view taken along line SS in FIG.

[0131] As shown in FIG. 8(j) and FIG. 10, in a disposable wearing article 10c, the hook members 19a, 19b of the flap members 18a, 18b are arranged to overlap both end portions 14a, 14b of the back body 14. As shown in FIG.

[0132] As shown in FIGS. 8 and 9, the method for producing the disposable wearing article 10c includes the following first to fifth steps.

[0133] (i) A continuous main body 11 is formed in which a portion 11k to be an individual piece, including a front body 12, a back body 14, and a crotch section 16 joined to the front body 12 and the back body 14, is connected, and the front body continuous portion 12k to which the portion to be the front body 12 is connected and the back body continuous portion 14k to which the portion to be the back body 14 is connected are transported in a state separated from each other. This is the first process.

[0134] (ii) Furthermore, the continuous base material strip 30 for forming the first and second flap members 18a, 18b and the continuous hook strip 33 for forming the hook members 19a, 19b are joined to each other while being conveyed and cut into a predetermined shape to form a pre-separation flap member 31a in which the first and second flap members 18a, 18b having the hook members 19a, 19b, respectively, are connected. This is the second process.

[0135] The pre-separation flap member 31a can be formed in various ways. For example, the pre-separation flap member 31a is formed as follows.

[0136] First, the continuous hook body 33 is joined to the widthwise intermediate position of the continuous substrate body 30, with a gap provided between the side edges 30m, 30n of the continuous substrate body 30, to form a first continuous body 37. At this time, the continuous hook body 33 is joined to the continuous substrate body 30 by adhesion, heat sealing, or the like, so that the hook surface is exposed.

[0137] Next, the portions of the continuous substrate body 30 adjacent to the pair of side edges 30m, 30n are folded back toward the continuous hook body 33 side.

[0138] Next, hot melt is applied to portions of the continuous substrate body 30 adjacent to the pair of side edges 30m, 30n, to form adhesive-applied portions 38a, 38b along the pair of side edges 30m, 30n of the continuous substrate body 30.

[0139] Next, the continuous body 37 is cut at a predetermined position 37x indicated by a dotted line to form a pre-split hook member 33k cut from the hook continuous body 33 and a pre-split flap member 31a having adhesive application portions 38a, 38b, and then the orientation of the pre-split flap member 31a relative to the conveying direction is changed.

[0140] (iii) Next, the front body continuous portion 12k of the main body continuum 11 is overlapped on one main surface 14s of the back body continuous portion 14k of the main body continuum 11, and the front body continuous portion 12k of the main body continuum 11 is overlapped on the other main surface 14t of the back body continuous portion 14k of the main body continuum 11, and the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 are joined to each other to form first joints 20a, 20b joining the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 to each other, and a second joint joining the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 to each other. This is the third step.

[0141] For example, the main body continuum 11 is folded back, and the front body continuous portion 12k of the main body continuum 11 is overlapped on the other main surface 14t of the back body continuous portion 14k of the main body continuum 11, and the overlapped front body continuous portion 12k and back body continuous portion 14k of the main body continuum 11 are joined to each other to form first joints 20a, 20b.

[0142] Next, the pre-separation flap member 31a is placed on one main surface 14s of the rear body continuous portion 14k of the main body continuum 11, and the pre-separation flap member 31a and the rear body continuous portion 14k of the main body continuum 11 are joined to each other via the adhesive application portions 38a, 38b to form second joint portions 22a, 22b.

[0143] (iv) Next, the joined front flap member 31a and the continuous main body 11 are cut to form the individual pieces in which the pair of first joining portions 20a, 20b join both ends 12a, 12b; 14a, 14b of the front body 12 and the back body 14 to each other, and the pair of second joining portions 22a, 22b join the back body 14 to the first and second flap members 18a, 18b to each other. This is the fourth step.

[0144] In the third step (iii) above, the first joints 20a, 20b are formed so that the tear strength of the first joints 20a, 20b is weaker than the tear strength of the portions of the front body continuous portion 12k and the back body continuous portion 14k where the first joints 20a, 20b are not formed.

[0145] In the third step, before folding back the main body continuum 11, the pre-division flap member 31a may be overlapped on one main surface 14s of the rear body continuous portion 14k of the main body continuum 11, and the pre-division flap member 31a and the rear body continuous portion 14k of the main body continuum 11 may be joined to each other to form second joints 22a, 22b, and then the main body continuum 11 may be folded back, and the front body continuous portion 12k of the main body continuum 11 may be overlapped on the other main surface 14t of the rear body continuous portion 14k of the main body continuum 11, and the overlapped front body continuous portion 12k and rear body continuous portion 14k of the main body continuum 11 may be joined to each other to form first joints 20a, 20b.

[0146] In this case, the adhesive application portions 38a, 38b may be used to temporarily fix the flap members 18a, 18b to one main surface 14s of the rear body continuous portion 14k of the main body continuous body 11, and the second joint portions 22a, 22b may be formed by heat sealing, ultrasonic bonding, etc.

[0147] Alternatively, in a third step, the main body continuum 11 is folded back and the front body continuous portion 12k and the back body continuous portion 14k of the main body continuum 11 are overlapped, at which point the front body continuous portion 12k and the back body continuous portion 14k are not joined to each other or are temporarily fixed, and then the pre-separation flap member 31a is overlapped on the back body continuous portion 14k of the main body continuum 11, and then the pre-separation flap member 31a and the main body continuum 11 are joined to each other to simultaneously form the first joints 20a, 20b and the second joints 22a, 22b.

[0148] <Modification 1> Fig. 11 is an enlarged schematic diagram of a main part of a disposable wearing article according to Modification 1. As shown in Fig. 11, a plurality of elastic members 13 such as rubber threads are arranged on the front body 12. The elastic members 13x intersecting with the through-hole portions 24s of the perforations that form the break guide lines 24a, 24b and that pass between the main surfaces 12s, 12t of the front body 12 are cut when the through-hole portions 24s are formed, but the elastic members 13a, 13b intersecting with the non-through-hole portions 24x between the adjacent through-hole portions 24s are not cut. The uncut elastic members 13a, 13b are not cut even when the front body 12 is torn along the break guide lines 24a, 24b, and therefore need to be torn off when wearing the disposable wearing article.

[0149] In order to prevent such uncut elastic members 13a, 13b from remaining, auxiliary cut lines 25 are provided in the areas adjacent to the breakage induction lines 24a, 24b.

[0150] Auxiliary cut lines 25 are formed at a pitch smaller than the perforations of break induction lines 24a, 24b so that front body 12 is torn along break induction lines 24a, 24b without being torn along auxiliary cut lines 25. For example, elastic member 13 is cut in the area near break induction lines 24a, 24b using a cutter whose blade pitch is set smaller than the perforations of break induction lines 24a, 24b, so that the nonwoven fabric of front body 12 is not substantially torn.

[0151] In order to form the auxiliary cut lines 25, the same anvil as that for forming the perforations of the breakage guide lines 24a, 24b may be used, or a separate device may be used.

[0152] The auxiliary cut lines 25 may be formed by melting the elastic member 13 or by other methods.

[0153] The auxiliary cut line 25 is used to cut at least the elastic members 13a, 13b that would not be cut when forming the break induction lines 24a, 24b in the absence of the auxiliary cut line 25, before forming the break induction lines 24a, 24b, or at the same time as forming the break induction lines 24a, 24b, or after forming the break induction lines 24a, 24b.

[0154] <Modification 2> As in a disposable wearing article 10d shown in the schematic cross-sectional view of FIG. 12, the second portions 18q of the flap members 18a, 18b may be folded so that the hook surfaces 19s of the hook members 19a, 19b face the back panel 14.

[0155] <Variation 3> As shown in the schematic cross-sectional view of FIG. 13, a disposable wearing article 10e may be configured such that the second portions 18q of the flap members 18a, 18b are not folded but are arranged along one main surface 14s of the back body 14, so that the hook surfaces 19s of the hook members 19a, 19b are exposed.

[0156] <Modification 4> The second portions 18q of the flap members 18a, 18b may be folded multiple times.

[0157] <Modification 5> The manufacturing process of a disposable wearing article according to Modification 5 will be described with reference to Fig. 14. Fig. 14 is a schematic diagram of the manufacturing process of a disposable wearing article. In Modification 5, the first and second flap members 18a, 18b are manufactured without cutting out the trimmed portions from the continuous base material body 30 and the continuous hook body 33.

[0158] As shown in FIG. 14, a continuous base material strip 30 for forming the first and second flap members 18a, 18b and a continuous hook strip 33 for forming the first and second hook members 19a, 19b are transported.

[0159] Next, the continuous hook body 33 is placed at the widthwise central position of the continuous base material body 30, and the continuous hook body 33 is fixed to the continuous base material body 30 by heat sealing, ultrasonic bonding, or the like to form a first continuous body 30c.

[0160] Next, the first continuous body 30c is cut in an appropriate sequence along the inner cutting line 39c and the outer cutting lines 39a, 39b to form first and second flap members 18a, 18b having either the first or second hook members 19a, 19b.

[0161] The inner cutting line 39c extends in a wavy manner at the widthwise middle position of the first continuum 30c, divides the first continuum 30c into a portion on one side edge 30m side and a portion on the other side edge 30n side of the base material continuum 30, and cuts the hook continuum 33 to form the hook members 19a, 19b. The outer cutting lines 39a, 39b extend between the side edges 30m, 30n of the base material continuum 30 and the inner cutting line 39c, and cut one side and the other side of the first continuum 30c cut by the inner cutting line 39c.

[0162] Although not shown, if necessary, an adhesive such as hot melt may be applied to the base material continuous body 30, the first continuous body 30c, and the first and second flap members 18a, 18b at an appropriate timing to form adhesive application portions 36a, 36b for temporarily fixing them to one main surface 12s of the front body continuous portion 12k of the main body continuous body 11.

[0163] <Modification 6> A divided front flap member 31b of modification 6 will be described with reference to Fig. 17. Fig. 17 is a schematic diagram of a process for producing a disposable wearing article using the divided front flap member 31b.

[0164] As shown in FIG. 17, a disposable wearing article is manufactured by forming a pre-divided flap member 31b.

[0165] That is, the continuous hook body 33, the continuous base material body 30, and the continuous main body body 11 are transported in the direction indicated by the arrows.

[0166] Next, a slit is formed in the widthwise middle position of the continuous hook body 33 using a slitting device 80 to form the first and second continuous hook bodies 32, 34.

[0167] Next, the first and second hook continuous bodies 32, 34 are cut to a predetermined length using a cut-and-slip device 82 to sequentially form pairs of hook members 19p, 19q, and the pairs of hook members 19p, 19q are attached to one main surface 30s of the substrate continuous body 30 with a gap between them in the conveying direction to form a first continuous body 30d. At this time, the surfaces of the hook members 19p, 19q opposite to the hook surfaces are attached to one main surface 30s of the substrate continuous body 30 along the side edges 30m, 30n of the substrate continuous body 30. Although not shown, before attaching the hook members 19p, 19q, for example, an adhesive is applied to predetermined locations of the substrate continuous body 30 and / or the hook members 19p, 19q.

[0168] Next, a pin embossing device 84 is used to strengthen the bonds between the base material continuous body 30 of the first continuous body 30d and the hook members 19p, 19q.

[0169] Next, the first continuum 30d is folded using a folding device 86 so that the hook members 19p, 19q are sandwiched between the substrate continuum 30 to form a second continuum 30e. At this time, the hook surfaces of the hook members 19p, 19q overlap one main surface 30s of the substrate continuum 30, and the side edges 30m, 30n of the substrate continuum 30 overlap a widthwise intermediate region of one main surface 30s of the substrate continuum 30.

[0170] Next, the second continuous body 30e is cut using a cut-and-turn device 88 at a predetermined position between adjacent hook members 19p, 19q in the conveying direction to form a pre-division flap member 31b, and then, while conveying the pre-division flap member 31b, it is rotated 90° relative to the conveying direction and attached to a predetermined position of the main body continuous body 11.

[0171] When the cut-and-turn device 88 transports while supporting the folding side of the second continuous body 30e, i.e., the widthwise middle region of one main surface 30s of the base material continuous body 30 and the side edge region of the other main surface of the base material continuous body 30 adjacent to the side edges 30m, 30n, the middle region of the other main surface of the pre-division flap member 31b between the hook members 19p, 19q is attached so as to overlap the intended cutting position of the main body continuous body 11, as in Figure 4 of Example 1.

[0172] When the cut-and-turn device 88 transports the second continuous body 30d while supporting the side opposite the folding side, i.e., the widthwise middle region of the other main surface of the base material continuous body 30, as in Figure 8 of Example 4, the middle region between the hook members 19p, 19q of one main surface 30s of the pre-division flap member 31b is attached so as to overlap the intended cutting position of the main body continuous body 11.

[0173] After the pre-separation flap members 31b are attached to the continuous main body 11 at predetermined positions, individual pieces of the disposable wearing article are formed according to the manufacturing process already described.

[0174] In the sixth modification, the first and second hook continuous bodies 32, 34 and the base material continuous body 30 of the second continuous body 30e can be cut using separate devices 82, 88. Therefore, the first and second hook continuous bodies 32, 34 and the base material continuous body 30 can be cut more efficiently than when both are cut simultaneously, and it is easy to increase the conveying speed and improve production efficiency. In addition, wear of the cutting blade used for cutting can be suppressed, and the production line can be operated efficiently.

[0175] As explained above, the continuous portion torn along the break guide line can be reconnected by fastening the fastening portion of the second portion of the flap member to one main surface of the front body. Since the flap member is disposed along the back body, the flap member does not get in the way when the continuous portion is torn along the break guide line.

[0176] The present invention is not limited to the above-described embodiment, but can be implemented with various modifications.

[0177] For example, the first to fourth embodiments may be configured by appropriately combining any one or more of the first to sixth modifications. [Explanation of symbols]

[0178] 10, 10a, 10b, 10c, 10d, 10e Disposable wearable items 11 Body Continuum Parts that will become 11k pieces 12 Front 12a, 12b both ends 12k Front body continuous section 12p upper edge 12q lower edge 12s,12t main surface 14 Back 14a, 14b both ends 14k back body continuous 14s,14t main surface 16 Crotch area 18a, 18b Flap members 19a, 19b, 19p, 19q Hook member, fastening part 20a, 20b First joint, breakage induction wire 22a,22b 2nd joint 23a,23b 2nd joint 24a, 24b Breaking guide wire, perforation 30 Substrate Continuum 31, 31a, 31b Pre-split flap member 32, 33, 34 Hook Continuum 36a, 36b Adhesive application section

Claims

1. A front body that is placed on the wearer's stomach when worn; A back body that is placed on the back of the wearer when worn; A crotch portion connected to the front body and the back body; A pair of first joining portions joining both ends of the front body and the back body to each other; a pair of flap members each having a first portion and a second portion, the second portions facing each other, the first portions being adjacent to either one of the two end portions of the rear body, the pair of flap members being disposed along one main surface of the rear body opposite the front body, the second portions having a fastening portion configured to be releasably fastened to the one main surface of the front body; a pair of second joining portions joining the first portion of each of the flap members to the front body; A pair of break guide wires formed so that a continuous portion connecting the front body and the back body can be torn and separated at the front body or the first joint portion; Equipped with The disposable wearing article has a tear strength of the break induction line which is weaker than a tear strength of the continuous portion where the break induction line is not formed.

2. The disposable wearing article according to claim 1 , wherein the second portion of the flap member is disposed along the one main surface of the rear body in a folded state so that the fastening portion is not exposed.

3. 3. The disposable wearing article according to claim 1 or 2, wherein the break guide line is a perforation formed so that a plurality of penetrating portions passing between the one main surface and the other main surface of the front body are aligned between an upper edge and a lower edge of the front body.

4. 3. The disposable wearing article according to claim 1, wherein the breakage guide line is the first joint portion, and a tear strength of the first joint portion is weaker than a tear strength of a portion of each of the front body portion and the back body portion where the first joint portion is not formed.

5. The disposable wearing article according to claim 1 , wherein the first joining portion and the second joining portion overlap each other when viewed from a direction perpendicular to the one main surface of the rear body.

6. 6. The disposable wearing article according to claim 1, wherein the fastening portion is a hook member of a hook-and-loop fastener.

7. a first step of forming a main body continuum in which portions intended to become individual pieces, including a front body having first and second break guide lines formed therein, a back body, and a crotch section joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuum portion to which the portion intended to become the front body is connected and a back body continuum portion to which the portion intended to become the back body is connected are separated from each other; a second step of joining a continuous base material strip for forming the first and second flap members and a continuous hook strip for forming the hook members to each other while conveying the continuous base material strip and cutting the continuous hook members into a predetermined shape to form a pre-separation flap member in which the first and second flap members each having the hook members are connected; a third step of overlapping the divided front flap member on one main surface of the rear body continuous portion of the main body continuum and overlapping the front body continuous portion of the main body continuum on the other main surface of the rear body continuous portion of the main body continuum, and joining the divided front flap member and the overlapped front body continuous portion and rear body continuous portion of the main body continuum to each other to form a first joint portion joining the front body continuous portion and the rear body continuous portion of the main body continuum to each other and a second joint portion joining the divided front flap member and the rear body continuous portion of the main body continuum to each other; a fourth step of cutting the joined separate front flap members and the continuous main body to form the individual pieces, each of which has a pair of first joints joining both ends of the front body and the back body to each other and a pair of second joints joining the back body and the flap members to each other; Equipped with In the first step, the first and second break guide lines are formed so that the tear strength of the first and second break guide lines is weaker than the tear strength of a portion of the front body continuous portion where the first and second break guide lines are not formed.

8. a first step of forming a main body continuum in which portions to become individual pieces, including a front body, a back body, and a crotch portion joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuum portion to which the portion to become the front body is connected and a back body continuum portion to which the portion to become the back body is connected are separated from each other; a second step of joining a continuous base material strip for forming the first and second flap members and a continuous hook strip for forming the hook members to each other while conveying the continuous base material strip and cutting the continuous hook members into a predetermined shape to form the first and second flap members each having the hook member; a third step of overlapping the first and second flap members on one main surface of the rear body continuous portion of the main body continuous body, and joining the first and second flap members and the rear body continuous portion of the main body continuous body to each other to form a second joining portion; a fourth step of overlapping the front body continuous portion of the main body continuous body on the other main surface of the back body continuous portion of the main body continuous body, and joining the overlapped front body continuous portion and the back body continuous portion of the main body continuous body to each other to form a first joining portion; a fifth step of cutting the continuous main body to form the individual pieces in which a pair of the first joint portions join both ends of the front body and the back body to each other and a pair of the second joint portions join the back body to the first and second flap members to each other; Equipped with In the fourth step, the first joint portion is formed so that a tear strength of the first joint portion is weaker than a tear strength of a portion of each of the front body continuation portion and the back body continuation portion where the first joint portion is not formed.

9. applying adhesive to the rear piece continuous portion of the main body continuum, the base material continuous portion, or the first and second flap members so that an adhesive-applied portion is disposed between the first and second flap members and the rear piece continuous portion of the main body continuum when the first and second flap members are overlapped on the one main surface of the rear piece continuous portion of the main body continuum; and forming the adhesive-applied portion; 9. The method for manufacturing a disposable wearing article according to claim 8, wherein in the third step, the first and second flap members are overlapped on the one main surface of the back piece continuous portion of the main body continuous body, and the first and second flap members are temporarily fixed to the back piece continuous portion of the main body continuous body via the adhesive application portion, and then the second joint portion is formed.

10. a first step of forming a main body continuum in which portions to become individual pieces, including a front body, a back body, and a crotch portion joined to the front body and the back body, are connected, and the main body continuum is transported in a state in which a front body continuum portion to which the portion to become the front body is connected and a back body continuum portion to which the portion to become the back body is connected are separated from each other; a second step of joining a continuous base material strip for forming the first and second flap members and a continuous hook strip for forming the hook members to each other while conveying the continuous base material strip and cutting the continuous hook members into a predetermined shape to form a pre-separation flap member in which the first and second flap members each having the hook members are connected; a third step of overlapping the divided front flap member on one main surface of the rear body continuous portion of the main body continuum and overlapping the front body continuous portion of the main body continuum on the other main surface of the rear body continuous portion of the main body continuum, and joining the divided front flap member and the overlapped front body continuous portion and rear body continuous portion of the main body continuum to each other to form a first joint portion joining the front body continuous portion and the rear body continuous portion of the main body continuum to each other and a second joint portion joining the divided front flap member and the rear body continuous portion of the main body continuum to each other; a fourth step of cutting the joined separate front flap members and the continuous main body to form the individual pieces, each of which has a pair of first joints joining both ends of the front body and the back body to each other and a pair of second joints joining the back body and the flap members to each other; Equipped with In the third step, the first joint portion is formed so that a tear strength of the first joint portion is weaker than a tear strength of a portion of each of the front body continuation portion and the back body continuation portion where the first joint portion is not formed.

11. applying adhesive to the rear piece continuous portion of the main body continuous body, the base material continuous body, or the division front flap member so that an adhesive-applied portion is disposed between the division front flap member and the rear piece continuous portion of the main body continuous body when the division front flap member is superimposed on the one main surface of the rear piece continuous portion of the main body continuous body, to form the adhesive-applied portion; 11. The method for manufacturing a disposable wearing article according to claim 10, wherein in the third step, the division front flap member is overlapped on the one main surface of the back piece continuous portion of the main body continuous body, and the division front flap member is temporarily fixed to the back piece continuous portion of the main body continuous body via the adhesive application portion, and then the second joint portion is formed.

12. In the second step, Transporting the continuous substrate body and the continuous hook body; Dividing the continuous hook body into first and second continuous hook bodies; cutting the first and second hook strings to form the pair of hook members; The pair of hook members are joined to the continuous base material at intervals in the conveying direction to form a first continuous body; forming a second continuous body by folding the first continuous body such that the hook members are sandwiched between the continuous bodies of base material; The method for manufacturing a disposable wearing article according to claim 7 , further comprising the step of cutting the second continuous body between adjacent pairs of the hook members to form the pre-divided flap members.

13. In the second step, Transporting the continuous substrate body and the continuous hook body; Dividing the continuous hook body into first and second continuous hook bodies; cutting the first and second hook strings to form the pair of hook members; The pair of hook members are joined to the continuous base material at intervals in the conveying direction to form a first continuous body; forming a second continuous body by folding the first continuous body such that the hook members are sandwiched between the continuous bodies of base material; The method for manufacturing a disposable wearing article according to claim 10, further comprising the step of cutting the second continuous body between adjacent pairs of the hook members to form the pre-divided flap members.

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