Manufacturing apparatus for wearable article and manufacturing method for wearable article

Abstract

To provide a manufacturing apparatus for a wearable article capable of suppressing occurrence of bonding defects caused by clamping elements clamping both an absorber and a sheet and a manufacturing method for a wearable article using the same.SOLUTION: A wearable article includes an absorber and a girth member. The girth member is constituted by a band-shaped laminate in which sheets are laminated. At least one end in a longitudinal direction of the absorber is bonded to the girth member. A manufacturing apparatus for the wearable article includes two clamping elements that clamp the laminate in a laminating direction and bond the sheets together. At least one of the two clamping elements has a recess that accommodates the absorber when the sheets are bonded together. The two clamping elements bond the sheets together in a region where the laminate and the absorber do not overlap.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a manufacturing apparatus for a worn article and a manufacturing method for a worn article. [Background technology]

[0002] Patent Document 1 (Japanese Patent Laid-Open Publication No. 4-354948) discloses a wearing article such as disposable pants having three-dimensional cuffs (pockets) that prevent leakage of body waste from a waist opening, and a method for manufacturing the same.

[0003] The wearing article disclosed in Patent Document 1 includes a back sheet, a top sheet, and an absorbent body disposed between the back sheet and the top sheet. The wearing article has three-dimensional cuffs provided inside the waist opening and extending toward the absorbent body.

[0004] The method of manufacturing a worn article disclosed in Patent Document 1 includes a step of intermittently placing an absorbent body on a web-like back sheet unwound from a winding device (absorbent body placing step), a step of overlapping a top sheet unwound from a roll on top of the back sheet and absorbent body (overlapping step), a step of placing cuff elastic members and wrapping them with both end edges of the back sheet (cuff forming step), and a step of placing waist elastic members and wrapping them again with both end edges of the back sheet (waist elastic member placing step).

[0005] In the cuff-forming step, the edges of the backsheet are joined to the surface of the backsheet to encase the cuff elastic members. Similarly, in the waist elastic member-arranging step, the surface of the backsheet is joined to the surface of the topsheet to encase the waist elastic members. In the cuff-forming step and the waist elastic member-arranging step, the backsheet and the topsheet are joined by clamping them with a clamping element (for example, an ultrasonic horn and anvil in the case of ultrasonic welding). [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 4-354948 Summary of the Invention [Problem to be solved by the invention]

[0007] The absorbent body is thicker than the backsheet and topsheet because it has an absorbent core laminated inside. Therefore, when the clamping element clamps the absorbent body together with the backsheet in the bonding process using a clamping element, the difference in thickness between the absorbent body and the backsheet causes a difference in the load (clamping pressure) acting on them, which may prevent proper bonding.

[0008] The present disclosure aims to provide a manufacturing device for a worn article that can suppress the occurrence of poor bonding caused by a clamping element clamping both an absorbent body and a sheet, and a manufacturing method for a worn article using the same. [Means for solving the problem]

[0009] The present application discloses a manufacturing apparatus for a wearing article. The wearing article includes an absorbent body and a waistband member. The waistband member is formed of a strip-shaped laminate in which sheets are stacked. At least one longitudinal end of the absorbent body is joined to the waistband member.

[0010] The manufacturing device for wearing articles includes two clamping elements that sandwich the stack in the stacking direction and bond the sheets together. At least one of the two clamping elements has a recess that accommodates the absorbent body when the sheets are bonded together. The two clamping elements bond the sheets together in an area where the stack and the absorbent body do not overlap.

[0011] The present application also discloses a method for manufacturing a wearing article, which includes a joining step in which two clamping elements sandwich a stack in the stacking direction while accommodating an absorbent body in a recess formed in at least one of the clamping elements, and the sheets are joined together in an area where the stack and the absorbent body do not overlap. [Effects of the Invention]

[0012] According to the manufacturing device of the present disclosure, the absorbent is accommodated in the recess when the sheets are joined together, thereby suppressing the occurrence of a difference in the clamping pressure acting on the absorbent and the sheet due to a difference in thickness between the absorbent and the sheet.

[0013] Therefore, according to the manufacturing apparatus and manufacturing method of the present disclosure, it is possible to suppress the occurrence of poor bonding caused by the clamping element clamping both the absorbent body and the sheet. [Brief explanation of the drawings]

[0014] [Figure 1A] FIG. 1 is a perspective view of a disposable diaper 1. [Figure 1B] FIG. 1 is a development view of a disposable diaper 1 as seen from the surface facing the wearer's skin. [Figure 1C] FIG. 2 is a development view of the disposable diaper 1 as seen from the side opposite to the side that comes into contact with the wearer's skin. [Figure 1D] FIG. 2 is a cross-sectional view of the disposable diaper 1 taken along line AA' in FIG. 1B. [Figure 2] 1 is a schematic process diagram showing a method for manufacturing a disposable diaper 1. FIG. [Figure 3] FIG. 1 is a perspective view of a manufacturing apparatus 100. [Figure 4] FIG. 1 is a perspective view of a manufacturing apparatus 100. [Figure 5A] 1A to 1C are schematic cross-sectional views showing the manufacturing apparatus 100 storing the absorbent body 4 in chronological order. [Figure 5B] 1A to 1C are schematic cross-sectional views showing the manufacturing apparatus 100 storing the absorbent body 4 in chronological order. [Figure 5C] 1A to 1C are schematic cross-sectional views showing the manufacturing apparatus 100 storing the absorbent body 4 in chronological order. [Figure 6] FIG. 5C is a schematic plan view of the manufacturing apparatus 100 shown in FIG. 5B. [Figure 7] 10 is a schematic process diagram showing a method for manufacturing a disposable diaper 1 using a manufacturing apparatus 100 according to Modification A. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0015] A method for manufacturing a disposable diaper 1 and an apparatus 100 for manufacturing the disposable diaper 1 according to an embodiment of the present disclosure will be described.

[0016] (1) Disposable diapers First, we will explain the disposable diaper 1. The disposable diaper 1 is an example of a wearing article. Fig. 1A is a perspective view of the disposable diaper 1. Fig. 1B is a developed view of the disposable diaper 1 as seen from the side that contacts the wearer's skin. Fig. 1B is a developed view of the disposable diaper 1 as seen from the side opposite to the side that contacts the wearer's skin. Fig. 1C is a cross-sectional view of the disposable diaper 1 taken along line A-A' in Fig. 1B. The disposable diaper 1 has a front abdominal portion 2, a rear portion 3, an absorbent body 4, front elastic members 5, rear elastic members 6, and pockets P1 and P2.

[0017] For convenience, the surface that contacts the wearer's skin may be referred to as the skin side, and the surface opposite to the surface that contacts the wearer's skin may be referred to as the outside.

[0018] (1-1) Anterior abdomen The front abdominal portion 2 is a strip-shaped laminate that is positioned at the front of the abdomen when the wearer puts on the disposable diaper 1. The front abdominal portion 2 is composed of a laminate formed by folding a first sheet 2a in half and laminating the first sheet 2a. The first sheet 2a is made of a nonwoven fabric. The front abdominal portion 2 is an example of a waistband member.

[0019] (1-2) Posterior part The rear portion 3 is a strip-shaped laminate that is positioned behind the buttocks when the wearer puts on the disposable diaper 1. The rear portion 3 is made of a laminate in which a second sheet 3a is folded in half and laminated. The second sheet 3a is made of a nonwoven fabric. The rear portion 3 is an example of a waistband member.

[0020] The front abdominal portion 2 and the rear dorsal portion 3 are joined at their longitudinal ends to form a waist opening W into which the wearer's torso is inserted.

[0021] (1-3) Absorbent The absorbent body 4 is a strip-shaped laminate that is positioned between the crotch of the wearer when the disposable diaper 1 is worn. The absorbent body 4 absorbs body fluids such as urine of the wearer. The absorbent body 4 has a top sheet 4a, a cover sheet 4b, and an absorbent core 4c provided between the top sheet 4a and the cover sheet 4b. The absorbent body 4 is thicker than the first sheet 2a and the second sheet 3a.

[0022] (1-3-1) Top sheet and cover sheet The top sheet 4a is a strip-shaped sheet that is provided on the skin side. The cover sheet 4b is a strip-shaped sheet that is provided on the outer side. The top sheet 4a and the cover sheet 4b have the same shape, and their edges are joined to each other.

[0023] The top sheet 4a is a liquid-permeable sheet and is formed using a nonwoven fabric or mesh sheet that allows liquid to pass through.

[0024] The cover sheet 4b is a breathable sheet and is formed using a breathable polyethylene film, a water-repellent and breathable nonwoven fabric, or a laminated sheet of these.

[0025] (1-3-2) Absorbent core The absorbent core 4c absorbs bodily fluids that have seeped in through the top sheet 4a. The planar shape of the absorbent core 4c is a strip that is slightly smaller than the top sheet 4a and the cover sheet 4b. The absorbent core 4c is contained inside the top sheet 4a and the cover sheet 4b, whose edges are joined together.

[0026] The absorbent core 4c is formed by layering fluff made by pulverizing and defibrating roll pulp. The absorbent core 4c may be formed by mixing the fluff with a superabsorbent polymer. Alternatively, the absorbent core 4c may be formed solely from nonwoven fabric without using fluff, or from nonwoven fabric carrying a superabsorbent polymer.

[0027] (1-4) Front elastic member The front elastic members 5 are thread-like elastic members that are stretchably arranged along the longitudinal direction of the front abdominal portion 2. In this embodiment, the front elastic members 5 are rubber threads. The front elastic members 5 are arranged inside the front abdominal portion 2 (in other words, between the first sheet 2a folded in half) along the longitudinal direction of the front abdominal portion 2. In this embodiment, eleven front elastic members 5 are arranged at equal intervals along the width direction of the front abdominal portion 2. The number of front elastic members 5 may be ten or less, or may be twelve or more. The front elastic members 5 are one example of an elastic member. The front elastic members 5 are formed using a material such as polyurethane, natural rubber, or thermoplastic resin.

[0028] (1-5) Rear elastic member The rear elastic members 6 are thread-like elastic members that are stretchably arranged along the longitudinal direction of the rear portion 3. In this embodiment, the rear elastic members 6 are rubber threads. The rear elastic members 6 are arranged inside the rear portion 3 (in other words, between the folded second sheet 3a) along the longitudinal direction of the rear portion 3. In this embodiment, eleven rear elastic members 6 are arranged at equal intervals along the width direction of the rear portion 3. The number of rear elastic members 6 may be ten or less, or twelve or more. The rear elastic members 6 are one example of an elastic member. The rear elastic members 6 are formed using a material such as polyurethane, natural rubber, or thermoplastic resin.

[0029] (1-6) Pocket The pockets P1 and P2 are pockets that prevent the wearer's exudates from leaking through the waist opening W. The pockets P1 and P2 are formed so as to open downward when the wearer puts on the disposable diaper 1. More specifically, the pocket P1 is formed in an area of ​​the skin-side first sheet 2a that overlaps with the absorbent body 4 in a plan view. The pocket P2 is formed in an area of ​​the skin-side second sheet 3a that overlaps with the absorbent body 4 in a plan view. The pockets P1 and P2 are areas indicated by diagonal hatching in FIG. 1B.

[0030] (1-7) Joining of each part Although a detailed description will be given later, in this embodiment, the joining of the various parts of the disposable diaper 1 described below is performed using ultrasonic welding.

[0031] (1-7-1) Junction of the anterior abdomen and posterior dorsal One longitudinal end 2b of the front portion 2 and one longitudinal end 3b of the rear portion 3 are joined together. The other longitudinal end 2c of the front portion 2 and the other longitudinal end 3c of the rear portion 3 are joined together. This connects the front portion 2 and the rear portion 3 in a circular shape, forming a waist opening W of the disposable diaper 1.

[0032] (1-7-2) Joining of absorbent body to front abdominal and back part The absorbent body 4 has one end 4ea in the longitudinal direction joined to the front abdominal portion 2 and the other end 4eb in the longitudinal direction joined to the rear portion 3.

[0033] More specifically, one end 4ea of ​​the absorbent body 4 is inserted between the folded first sheet 2a at approximately the center in the longitudinal direction of the front abdominal portion 2. The one end 4ea of ​​the absorbent body 4 inserted between the folded first sheet 2a is joined to the outer first sheet 2a.

[0034] The other end 4eb of the absorbent body 4 is inserted between the folded second sheets 3a at approximately the longitudinal center of the rear portion 3. The other end 4eb of the absorbent body 4 inserted between the folded second sheets 3a is joined to the outer second sheet 3a.

[0035] (1-7-3) Joining of the first sheet 2a and the second sheet 3a The first sheet 2a, which is folded in half and laminated, has its opposing surfaces (inner surfaces) joined together in an area where they do not overlap with one end 4ea of ​​the absorbent body 4. As a result, the area on the skin side of the first sheet 2a that overlaps with one end 4ea of ​​the absorbent body 4 in a plan view becomes a pocket P1.

[0036] The second sheet 3a, which is folded in half and stacked, is joined at a region where the inner surfaces do not overlap with the other end 4eb of the absorbent body 4. As a result, the region on the skin side of the second sheet 3a that overlaps with the other end 4eb of the absorbent body 4 in a plan view becomes a pocket P2.

[0037] (1-7-4) Joining the front abdominal part to the front elastic member and joining the back part to the back elastic member The front elastic members 5 arranged inside the front abdominal portion 2 are joined to one of the inner surfaces of the folded first sheet 2a (in other words, one of the two surfaces facing each other in the stacking direction) in a region where one end 4ea of ​​the absorbent body 4 does not overlap in a plan view, thereby fixing the front elastic members 5 to the first sheet 2a.

[0038] The rear elastic member 6 arranged inside the rear portion 3 is joined to one of the inner surfaces of the folded second sheet 3a (in other words, one of the two surfaces facing each other in the stacking direction) in a region where the other end 4eb of the absorbent body 4 does not overlap in a plan view, thereby fixing the rear elastic member 6 to the second sheet 3a.

[0039] (2) Manufacturing method of disposable diapers Next, a manufacturing method of the disposable diaper 1 will be described. The manufacturing method of the disposable diaper 1 includes a first and second sheet forming step (1), a first joining step (2), a front elastic member and a rear elastic member arranging step (3), a first folding step (4), a second joining step (5), a second folding step (6), a third joining step (7), and a cutting step (8). Figure 2 is a schematic process diagram showing the manufacturing method of the disposable diaper 1.

[0040] (2-1) First sheet and second sheet forming step In the first and second sheet forming step (1), a first sheet 2a for forming the front abdominal portion 2 and a second sheet 3a for forming the rear portion 3 are formed.

[0041] In this process, first, a roll-shaped sheet S, which is the material for the first sheet 2a and the second sheet 3a, is unrolled. The unrolled sheet S is cut into the first sheet 2a and the second sheet 3a along the longitudinal direction by a cutter (not shown) located approximately in the center of the width direction. The first sheet 2a and the second sheet 3a are fed along the longitudinal direction while being subjected to a predetermined amount of tension until the cutting process (8).

[0042] The first sheet 2a and the second sheet 3a cut from the sheet S are expanded in width outward (see arrows in FIG. 2) from a center line CL that extends along the longitudinal direction of the sheet S at the center of the width of the sheet S. Thereafter, the first sheet 2a and the second sheet 3a are fed parallel to each other along the longitudinal direction until just before the second folding step (6).

[0043] In this embodiment, the cutter forms a cut surface on the sheet S that extends in the longitudinal direction while drawing an S-shape (wave-like shape) in a plan view. In this case, phase alignment is performed so that the cut surfaces of the first sheet 2a and the second sheet 3a are symmetrical with respect to the center line CL.

[0044] (2-2) First joining process In the first joining step (2), the absorbent body 4 is joined to each of the first sheet 2a and the second sheet 3a.

[0045] In this step, first, the absorbent body 4 is arranged so that one end 4ea of ​​the absorbent body 4 overlaps the first sheet 2a and the other end 4eb of the absorbent body 4 overlaps the second sheet 3a in a plan view. Then, one end 4ea of ​​the absorbent body 4 is joined to the first sheet 2a, and the other end 4eb of the absorbent body 4 is joined to the second sheet 3a.

[0046] (2-3) Front elastic member and rear elastic member placement process In the front elastic member and back elastic member arranging step (3), the front elastic member 5 is arranged on the first sheet 2a along the longitudinal direction of the first sheet 2a. Similarly, the back elastic member 6 is arranged on the second sheet 3a along the longitudinal direction of the second sheet 3a.

[0047] (2-4) First folding process In the first folding in half step (4), the first sheet 2a and the second sheet 3a are each folded in half in the width direction so that their widthwise edges overlap in a plan view. More specifically, the first sheet 2a and the second sheet 3a are each folded in half so that the edge farther from the center line CL overlaps the edge closer to the center line CL. As a result, a laminate is formed in which the first sheet 2a is folded in half and stacked, and a laminate is formed in which the second sheet 3a is folded in half and stacked.

[0048] As a result, one end 4ea of ​​the absorbent body 4 and the front elastic member 5 are placed inside the stack of first sheets 2a folded in half, while the other end 4eb of the absorbent body 4 and the rear elastic member 6 are placed inside the stack of second sheets 3a folded in half.

[0049] (2-5) Second joining process In the second bonding step (5), using a manufacturing apparatus 100 for disposable diapers 1 described below, the first sheets 2a are bonded together, and the first sheets 2a and the front elastic members 5 are bonded together in areas where the first sheets 2a do not overlap with the absorbent body 4. Similarly, the second sheets 3a are bonded together, and the second sheets 3a and the rear elastic members 6 are bonded together in areas where the second sheets 3a do not overlap with the absorbent body 4. More specifically, the inner surfaces of the first sheets 2a that face each other are bonded together. The front elastic members 5 are bonded to one of the inner surfaces of the folded first sheet 2a. The inner surfaces of the second sheets 3a that face each other are bonded together. The rear elastic members 6 are bonded to one of the inner surfaces of the folded second sheet 3a. This forms pockets P1 and P2.

[0050] The joining of the absorbent body 4 to each of the first sheet 2a and the second sheet 3a in the first joining step (2) may be performed in the second joining step (5). Specifically, in the step following the first and second sheet forming step (1), only the placement of the absorbent body 4 on the first sheet 2a and the second sheet 3a is performed. Thereafter, in the second joining step (5), one end 4ea of ​​the absorbent body 4 is joined to the first sheet 2a, and the other end 4eb of the absorbent body 4 is joined to the second sheet 3a using the manufacturing apparatus 100. At this time, the joining of the first sheets 2a to each other, the joining of the first sheet 2a to the front elastic member 5, the joining of the second sheets 3a to each other, and the joining of the second sheet 3a to the rear elastic member 6 are also performed simultaneously.

[0051] (2-6) Second folding process In the second folding step (6), the absorbent body 4 is folded at the center in the longitudinal direction so that the first sheet 2a and the second sheet 3a overlap in a plan view.

[0052] (2-7) Third joining process In the third joining step (7), a side seal portion SS is formed in which the first sheet 2a and the second sheet 3a are joined together across the width in the center of two adjacent absorbers 4 in a plan view.

[0053] (2-8) Cutting process In the cutting step (8), the first sheet 2a and the second sheet 3a are cut at the widthwise center of the side seal portion SS formed in the side seal portion forming step (7) together with the internal front elastic members 5 and rear elastic members 6. As a result, the first sheet 2a becomes the front abdominal portion 2 and the second sheet 3a becomes the rear portion 3, and as a result, the disposable diaper 1 is formed.

[0054] (3) Disposable diaper manufacturing equipment Next, the manufacturing apparatus 100 for the disposable diaper 1 used in the second joining step (5) of the manufacturing method for the disposable diaper 1 described above will be described.

[0055] (3-1) Overview The manufacturing apparatus 100 includes an ultrasonic horn 110 and an anvil roller 120. Fig. 3 is a perspective view of the ultrasonic horn 110. Fig. 4 is a perspective view of the anvil roller 120.

[0056] Figures 5A, 5B, and 5C are schematic cross-sectional views showing in time sequence how the manufacturing apparatus 100 stores the absorbent body 4. Figure 6 is a schematic plan view of the manufacturing apparatus 100 shown in Figure 5B.

[0057] The ultrasonic horn 110 and the anvil roller 120 sandwich a laminate made of first sheets 2a in the stacking direction, and bond the first sheets 2a together, any of the inner surfaces of the first sheets 2a, and the front elastic members 5 in areas where the first sheets 2a do not overlap with the absorbent body 4. The ultrasonic horn 110 and the anvil roller 120 also sandwich a laminate made of second sheets 3a in the stacking direction, and bond the second sheets 3a together, any of the inner surfaces of the second sheets 3a, and the rear elastic members 6 in areas where the second sheets 3a do not overlap with the absorbent body 4. The ultrasonic horn 110 and the anvil roller 120 are an example of a clamping element.

[0058] In the second bonding step (5), when the absorbent body 4 is bonded to each of the first sheet 2a and the second sheet 3a, the ultrasonic horn 110 and the anvil roller 120 further bond one end 4ea of ​​the absorbent body 4 to the first sheet 2a and the other end 4eb of the absorbent body 4 to the second sheet 3a, respectively.

[0059] (3-1-1) Ultrasonic horn The ultrasonic horn 110 applies ultrasonic vibrations to the first sheet 2a, the second sheet 3a, the front elastic member 5, and the rear elastic member 6.

[0060] The ultrasonic horn 110 has a vibration surface 110a that contacts both the first sheet 2a and the second sheet 3a and vibrates ultrasonically. The vibration surface 110a is a strip-shaped surface with a predetermined width. The vibration surface 110a is arranged so that its longitudinal direction is aligned with the width direction of the first sheet 2a and the second sheet 3a. The vibration surface 110a is also formed to a length that allows it to contact both the first sheet 2a and the second sheet 3a simultaneously. In this embodiment, the vibration surface 110a is arranged so as to contact the outer sides of both the first sheet 2a and the second sheet 3a.

[0061] (3-1-2) Anvil Roller The anvil roller 120 is disposed so as to sandwich the first sheet 2a, the second sheet 3a, the front elastic member 5, and the rear elastic member 6 together with the ultrasonic horn 110. The anvil roller 120 is cylindrical and rotates around a central axis 120c by a driving force generated by a driving unit (not shown).

[0062] The anvil roller 120 is disposed such that its central axis 120c is aligned with the longitudinal direction of the vibration surface 110a and faces the vibration surface 110a across the first sheet 2a, the second sheet 3a, the front elastic member 5, and the rear elastic member 6. The radius of the anvil roller 120 is set to a size that allows the outer peripheral surface 120a of the anvil roller 120 to contact the first sheet 2a and the second sheet 3a. The length of the anvil roller 120 in the axial direction is set to a length that allows it to contact both the first sheet 2a and the second sheet 3a simultaneously. In this embodiment, the outer peripheral surface 120a of the anvil roller 120 is disposed so as to contact the skin side of each of the first sheet 2a and the second sheet 3a.

[0063] The anvil roller 120 has a recess 120b formed on its outer circumferential surface 120a, which receives the absorbent body 4 in the second joining step (5). The recess 120b is formed in a shape that can receive the absorbent body 4 in the second joining step (5), while joining the first sheets 2a to each other and the first sheets 2a and the front elastic members 5 in areas where the first sheets 2a and the absorbent body 4 do not overlap, and joining the second sheets 3a to each other and the second sheets 3a and the rear elastic members 6 in areas where the second sheets 3a and the absorbent body 4 do not overlap (see FIG. 6).

[0064] In the second joining step (5), when the absorbent body 4 is joined to each of the first sheet 2a and the second sheet 3a, the recess 120b is formed into a shape that can accommodate a portion of the absorbent body 4 in the second joining step (5) and further join one end 4ea of ​​the absorbent body 4 and the first sheet 2a to the other end 4eb of the absorbent body 4 and the second sheet 3a.

[0065] A driving unit (not shown) rotates the anvil roller 120 in conjunction with the speed at which the first sheet 2a and the second sheet 3a are fed in the manufacturing process. The driving unit also rotates the anvil roller 120 so that the recessed portion 120b accommodates at least a portion of the absorbent body 4 when the absorbent body 4 moves between the vibration surface 110a and the anvil roller 120 in the second bonding step (5) (see FIGS. 5A, 5B, 5C, and 6).

[0066] (4) Features (4-1) The manufacturing apparatus 100 is an apparatus for manufacturing a disposable diaper 1. The disposable diaper 1 has an absorbent body 3, a front abdominal section 2, and a rear section 3 (waist member). The front abdominal section 2 is composed of a strip-shaped laminate in which a first sheet 2a is folded in half and laminated. The rear section 3 is composed of a strip-shaped laminate in which a second sheet 3a is folded in half and laminated. At least one end of the absorbent body 4 in the longitudinal direction is joined to the front abdominal section 2 and the rear section 3.

[0067] The manufacturing apparatus 100 includes two clamping elements, an ultrasonic horn 110 and an anvil roller 120, which sandwich the laminate constituting the front abdominal portion 2 and the laminate constituting the rear portion 3 in the stacking direction and bond the first sheets 2a together and the second sheets 3a together, respectively. At least one of the two clamping elements (the anvil roller 120 in this embodiment) has a recess 120b formed therein that accommodates the absorbent body 4 when the first sheets 2a together and the second sheets 3a together are bonded. The two clamping elements bond the first sheets 2a together and the second sheets 3a together in areas where the laminate constituting the front abdominal portion 2 and the laminate constituting the rear portion 3 do not overlap with the absorbent body 4.

[0068] According to the manufacturing apparatus 100, when the absorbent body 4 moves between the vibration surface 110a and the anvil roller 120 in the second bonding step (5), at least a portion of the absorbent body 4 is accommodated in the recessed portion 120b. This prevents the ultrasonic horn 110 and the anvil roller 120 from clamping the absorbent body 4, thereby suppressing movement of the ultrasonic horn 110 and / or the anvil roller 120 due to the thickness of the absorbent body 4. As a result, differences in the load (clamping pressure) acting on the absorbent body 4 and the first sheet 2a and second sheet 3a due to differences in thickness between the absorbent body 4 and the first sheet 2a and second sheet 3a are suppressed.

[0069] Therefore, the manufacturing apparatus 100 can prevent poor bonding caused by the ultrasonic horn 110 and the anvil roller 120 clamping and pressing the absorber 4 and the first and second sheets 2a and 3a together.

[0070] (4-2) When joining the first sheet 2a and the second sheet 3a to one end 4ea and the other end 4eb in the longitudinal direction of the absorbent body 4, respectively, the two clamping elements may simultaneously join the first sheets 2a on the one end 4ea side in the longitudinal direction of the absorbent body 4 and join the second sheets 3a on the other end 4eb side in the longitudinal direction of the absorbent body 4.

[0071] In the second bonding step (5), in order to prevent poor bonding caused by the ultrasonic horn 110 and the anvil roller 120 clamping the absorbent body 4 and the first sheet 2a and second sheet 3a, a clamping element for bonding the first sheets 2a together and a clamping element for bonding the second sheets 3a together can be provided separately, and these can be positioned apart so as not to come into contact with the absorbent body 4. However, when the manufacturing apparatus is configured in this way, two clamping elements must be provided, which increases the manufacturing cost of the apparatus.

[0072] According to the manufacturing apparatus 100, a pair of ultrasonic horns 110 and anvil rollers 120 can be used to bond the absorbent body 4 to the first sheet 2a and the second sheet 3a, as well as to bond the first sheets 2a to each other and the second sheets 3a to each other simultaneously.

[0073] Therefore, the manufacturing apparatus 100 can suppress an increase in the manufacturing cost of the apparatus while suppressing the occurrence of poor bonding caused by the ultrasonic horn 110 and the anvil roller 120 clamping and pressing the absorber 4 and the first sheet 2a and the second sheet 3a together.

[0074] (4-3) The disposable diaper 1 further includes a front elastic member 5 and a rear elastic member 6. The front elastic member 5 is an elastic member arranged inside the front abdominal portion 2 so as to be stretchable along the longitudinal direction of the front abdominal portion 2. The rear elastic member 6 is an elastic member arranged inside the rear portion 3 so as to be stretchable along the longitudinal direction of the rear portion 3.

[0075] (4-4) The manufacturing method of the disposable diaper 1 includes a second joining step (5) in which the laminate constituting the front abdominal portion 2 and the laminate constituting the rear portion 3 are clamped in the stacking direction while the absorbent body 4 is accommodated in a recess 120b formed in at least one of the two clamping elements, the ultrasonic horn 110 and the anvil roller 120 (in this embodiment, the anvil roller 120), and the first sheets 2a and the second sheets 3a are respectively joined together in areas where the laminate constituting the front abdominal portion 2 and the laminate constituting the rear portion 3 do not overlap with the absorbent body 4.

[0076] According to this manufacturing method, when the absorber 4 moves between the vibration surface 110a and the anvil roller 120 in the second bonding step (5), at least a portion of the absorber 4 is accommodated in the recess 120b. This prevents the ultrasonic horn 110 and the anvil roller 120 from clamping the absorber 4, thereby suppressing movement of the ultrasonic horn 110 and / or the anvil roller 120 due to the thickness of the absorber 4. As a result, differences in the load (clamping pressure) acting on the absorber 4 and the first sheet 2a and second sheet 3a due to differences in thickness between the absorber 4 and the first sheet 2a and second sheet 3a are suppressed.

[0077] Therefore, according to this manufacturing method, it is possible to prevent poor bonding caused by the ultrasonic horn 110 and the anvil roller 120 clamping and pressing the absorber 4 and the first and second sheets 2a and 3a together.

[0078] (4-5) In the second joining step (5), when the two clamping elements join the first sheet 2a and the second sheet 3a to one end 4ea and the other end 4ea in the longitudinal direction of the absorbent body 4, respectively, they simultaneously join the first sheets 2a on the one end 4ea side of the longitudinal direction of the absorbent body 4 and join the second sheets 3a on the other end 4eb side of the longitudinal direction of the absorbent body 4.

[0079] According to this manufacturing method, a pair of ultrasonic horns 110 and anvil rollers 120 can be used to bond the absorbent body 4 to the first sheet 2a and the second sheet 3a, as well as to simultaneously bond the first sheets 2a to each other and the second sheets 3a to each other.

[0080] Therefore, according to this manufacturing method, it is possible to suppress an increase in manufacturing costs while suppressing the occurrence of poor bonding caused by the ultrasonic horn 110 and the anvil roller 120 clamping and pressing the absorber 4 and the first sheet 2a and the second sheet 3a together.

[0081] (4-6) The clamping elements are an ultrasonic horn 110 and an anvil roller 120 .

[0082] (5) Variations (5-1) Variation A In the above embodiment, the front portion 2 and the rear portion 3 are formed by cutting the first sheet 2a and the second sheet 3a, respectively, which are folded in half. However, the front portion 2 may be formed by stacking a plurality of first sheets 2a, 2a' and cutting them in the cutting step (8). The rear portion 3 may be formed by stacking a plurality of second sheets 3a, 3a' and cutting them in the cutting step (8).

[0083] 7 is a schematic process diagram showing a method for manufacturing a disposable diaper 1 using the manufacturing apparatus 100 according to Modification A. The following will mainly describe the differences between the method for manufacturing a disposable diaper 1 according to the above embodiment and the method for manufacturing a disposable diaper 1 using the manufacturing apparatus 100 according to Modification A. Note that the same or corresponding components will be given the same reference symbols and descriptions thereof will be omitted as appropriate.

[0084] (5-1-1) First sheet and second sheet forming step In the first and second sheet forming step (1)', first sheets 2a, 2a' for forming the front abdominal portion 2 and second sheets 3a, 3a' for forming the back portion 3 are formed.

[0085] In the first sheet and second sheet forming step (1)', two roll-shaped sheets S1 and S1' are unfolded to form first sheets 2a, 2a' and second sheets 3a, 3a'. More specifically, the first sheet 2a and second sheet 3a, which will be the outer sides, are formed from sheet S1. The first sheet 2a' and second sheet 3a', which will be the skin side, are formed from sheet S2. Note that no S-shape (wave shape) is formed in the first sheet 2a and second sheet 3a, which will be the skin side.

[0086] (5-1-2) First joining process In the first bonding step (2)', the absorbent body 4 is bonded to each of the first sheet 2a and the second sheet 3a which are to be the outer sides.

[0087] (5-1-3) Front elastic member and rear elastic member placement process In the front elastic member and back elastic member arranging step (3)', the front elastic member 5 is arranged on the outer first sheet 2a along the longitudinal direction of the first sheet 2a. Similarly, the back elastic member 6 is arranged on the outer second sheet 3a along the longitudinal direction of the second sheet 3a.

[0088] (5-1-4) Lamination process In the lamination step (4)', the first sheet 2a' and the second sheet 3a' that are to be placed against the skin are laminated on the outer first sheet 2a and the second sheet 3a so that they overlap in a plan view. As a result, one end 4ea of ​​the absorbent body 4 and the front elastic member 5 are positioned inside the two laminated first sheets 2a and 2a'. The other end 4eb of the absorbent body 4 and the rear elastic member 6 are positioned inside the two laminated second sheets 3a and 3a'.

[0089] (5-1-5) Second joining process In the second bonding step (5)', the manufacturing apparatus 100 for the disposable diaper 1 is used to bond the two stacked first sheets 2a, 2a' together with the first sheets 2a, 2a' and the front elastic member 5 in areas where the first sheets 2a, 2a' do not overlap with the absorbent 4. Similarly, the manufacturing apparatus 100 for the disposable diaper 1 is used to bond the two stacked second sheets 3a, 3a' together with the second sheets 3a, 3a' and the rear elastic member 6 in areas where the second sheets 3a, 3a' do not overlap with the absorbent 4. More specifically, the stacked first sheets 2a, 2a' are bonded at their opposing inner surfaces. The front elastic member 5 is bonded to one of the inner surfaces of the stacked first sheets 2a, 2a' (in other words, to one of the two surfaces facing each other in the stacking direction). The stacked second sheets 3a, 3a' are bonded at their opposing inner surfaces. The back elastic member 6 is bonded to one of the inner surfaces of the stacked second sheets 3a, 3a' (in other words, to one of the two surfaces facing each other in the stacking direction), thereby forming pockets P1, P2.

[0090] In the manufacturing apparatus 100 according to Modification A, the joining of the absorbent body 4 to each of the first sheet 2a and the second sheet 3a in the first joining step (2) may also be performed in the second joining step (5).

[0091] The subsequent second folding step (6), third joining step (7), and cutting step (8) are the same as those in the above embodiment, and therefore description thereof will be omitted.

[0092] The first sheets 2a and 2a' may be different types of sheets, and the second sheets 3a and 3a' may also be different types of sheets.

[0093] (5-2) Variation B In the above embodiment, the recess 120b is formed in the anvil roller 120. However, the recess for accommodating the absorber 4 may be formed in the vibration surface 110a of the ultrasonic horn 110, or in both the outer peripheral surface 120a and the vibration surface 110a.

[0094] (5-3) Variation C The anvil roller 120 may be provided with a holding vacuum that can attract the sheet S to the outer peripheral surface 120a.

[0095] (5-4) Variation D In the above embodiment, the clamping element is joined by ultrasonic welding, but the clamping element may be joined by a method other than ultrasonic welding, such as heat sealing or adhesive.

[0096] (5-5) Variation E In the above embodiment, the front elastic members 5 and the back elastic members 6 are rubber threads. However, the front elastic members 5 and the back elastic members 6 may be made of, for example, a stretchable film, as long as they are elastic members that are stretchably arranged along the longitudinal direction of the front abdominal portion 2 or the back region 3.

[0097] Furthermore, the disposable diaper 1 does not necessarily have to have the front elastic members 5 and the rear elastic members 6, as long as the front abdominal portion 2 and the rear dorsal portion 3 are stretchable along the longitudinal direction.

[0098] (5-6) Variation F In the above-described embodiment, the front elastic member 5 is fixed to the first sheet 2a by joining the front elastic member 5 to one of the inner surfaces of the first sheet 2a folded in half. However, the method of fixing the front elastic member 5 to the first sheet 2a is not limited to this. For example, the front elastic member 5 may be fixed to the first sheet 2a by forming welded portions on both sides of the front elastic member 5 in the width direction by welding the folded first sheet 2a to each other, and sandwiching the front elastic member 5 in the width direction between the welded portions.

[0099] Similarly, the rear elastic member 6 may be fixed to the second sheet 3a by forming a welded portion on both sides of the rear elastic member 6 in the width direction, where the folded second sheet 3a is welded to each other, and sandwiching the rear elastic member 6 in the width direction between the welded portions.

[0100] (6) Summary Finally, the technical concept that can be understood from the above-described embodiment will be described.

[0101] The wearing article manufactured by the manufacturing apparatus for a wearing article according to the first aspect of the present disclosure includes an absorbent body and a waistband member. The waistband member is made of a strip-shaped laminate in which sheets are stacked. At least one longitudinal end of the absorbent body is joined to the waistband member.

[0102] The manufacturing device for wearing articles includes two clamping elements that sandwich the stack in the stacking direction and bond the sheets together. At least one of the two clamping elements has a recess that accommodates the absorbent body when the sheets are bonded together. The two clamping elements bond the sheets together in an area where the stack and the absorbent body do not overlap.

[0103] According to the manufacturing apparatus of the present disclosure, when the sheets are joined together, the absorbent is accommodated in the recess. This prevents the two clamping elements from clamping the absorbent, thereby preventing the two clamping elements from moving due to the thickness of the absorbent. As a result, differences in the load (clamping pressure) acting on the absorbent and the sheet due to differences in thickness between the absorbent and the sheet are prevented.

[0104] Therefore, according to the present manufacturing apparatus, it is possible to prevent the occurrence of poor bonding caused by the clamping element clamping both the absorbent body and the sheet.

[0105] A manufacturing apparatus for a worn article according to a second aspect of the present disclosure is the manufacturing apparatus for a worn article according to the first aspect, When the two clamping elements join sheets to one end and the other end of the absorbent body in the longitudinal direction, they simultaneously join the sheets at one end side of the absorbent body in the longitudinal direction and the sheets at the other end side of the absorbent body in the longitudinal direction.

[0106] According to this manufacturing apparatus, the pair of clamping elements can be used to simultaneously bond the absorbent body and the sheet together, and also bond the sheets together at both ends of the absorbent body in the longitudinal direction.

[0107] Therefore, the present manufacturing apparatus can suppress the occurrence of poor bonding caused by the clamping element clamping both the absorbent body and the sheet, while suppressing an increase in the manufacturing cost of the apparatus.

[0108] A third aspect of the present disclosure relates to the apparatus for manufacturing a wearing article according to the first or second aspect, wherein the wearing article further includes an elastic member disposed inside the waistband member and stretchable along the longitudinal direction of the waistband member.

[0109] A fourth aspect of the present disclosure relates to an apparatus for manufacturing a wearing article, which is any one of the apparatuses for manufacturing a wearing article according to the first to third aspects, wherein the two clamping elements are an ultrasonic horn and an anvil.

[0110] A wearing part manufactured by the manufacturing method of a wearing article according to a fifth aspect of the present disclosure includes an absorbent body and a waistband member. The waistband member is made of a strip-shaped laminate in which sheets are stacked. At least one longitudinal end of the absorbent body is joined to the waistband member.

[0111] The method for manufacturing a worn article includes a joining step in which two clamping elements sandwich a laminate in the stacking direction while accommodating an absorbent body in a recess formed in at least one of the clamping elements, and the sheets are joined together in an area where the laminate and the absorbent body do not overlap.

[0112] According to the manufacturing method of the present disclosure, when the sheets are joined together, the absorbent is accommodated in the recess. Therefore, the thickness of the absorbent moving between the two clamping elements prevents the two clamping elements from moving. As a result, differences in the load (clamping pressure) acting on the absorbent and the sheet due to differences in thickness between the absorbent and the sheet are prevented. Furthermore, because the clamping elements have a relatively simple structure with recesses formed on their surfaces, increases in the manufacturing costs of manufacturing equipment equipped with clamping elements are also prevented.

[0113] Therefore, according to this manufacturing method, it is possible to suppress the occurrence of poor bonding caused by the clamping element clamping both the absorbent body and the sheet, without increasing the manufacturing cost of the manufacturing apparatus.

[0114] A manufacturing method of a worn article according to a sixth aspect of the present disclosure is the manufacturing method of a worn article according to the fifth aspect, wherein in the joining step, when joining sheets to one end and the other end of the absorbent body in the longitudinal direction, the two clamping elements simultaneously join the sheets to each other at one end of the absorbent body in the longitudinal direction and the sheets to each other at the other end of the absorbent body in the longitudinal direction.

[0115] According to this manufacturing method, the pair of clamping elements can be used to simultaneously bond the absorbent body and the sheet together, and also bond the sheets together at both ends of the absorbent body in the longitudinal direction.

[0116] Therefore, according to this manufacturing method, it is possible to suppress an increase in the manufacturing cost of the device, while suppressing the occurrence of poor bonding caused by the clamping element clamping both the absorbent body and the sheet.

[0117] A seventh aspect of the present disclosure relates to a method for manufacturing a wearing article according to the fifth or sixth aspect, wherein the wearing article further comprises an elastic member disposed inside the waistband member so as to be stretchable along the longitudinal direction of the waistband member.

[0118] A method for manufacturing a wearing article according to an eighth aspect of the present disclosure is any one of the methods for manufacturing a wearing article according to the fifth to seventh aspects, wherein the two clamping elements are an ultrasonic horn and an anvil. [Explanation of symbols]

[0119] 2: Front abdomen (waist circumference member) 2a: 1st sheet (sheet) 3: Back part (waist part) 3a: 2nd sheet (seat) 4: Absorbent 5: Front elastic member (elastic member) 6: Rear elastic member (elastic member) 100: Manufacturing equipment 110: Ultrasonic horn (clamping element) 120: Anvil roller (pressure element) 120b: recess

Claims

1. It has an absorbent body and a waistband member, the waistband member is formed of a strip-shaped laminate in which sheets are stacked, The absorbent body has at least one end in a longitudinal direction joined to the waistband member, two clamping elements that clamp the laminate in the stacking direction and join the sheets together; The two clamping elements are: a recess for accommodating the absorbent body when the sheets are joined together is formed in at least one of the sheets; The sheets are joined together in an area where the laminate and the absorbent body do not overlap. Equipment for manufacturing wearable articles.

2. The two clamping elements are: When the sheet is joined to one end and the other end in the longitudinal direction of the absorbent body, Joining the sheets together at one end side in the longitudinal direction of the absorbent body; and simultaneously joining the sheets at the other end of the absorbent body in the longitudinal direction. The apparatus for manufacturing a wearing article according to claim 1 .

3. The wearing article comprises: The waistband member further includes an elastic member arranged inside the waistband member so as to be stretchable along the longitudinal direction of the waistband member. The apparatus for manufacturing a wearing article according to claim 1 .

4. The two clamping elements are: an ultrasonic horn and anvil; The apparatus for manufacturing a wearing article according to claim 1 .

5. It has an absorbent body and a waistband member, the waistband member is formed of a strip-shaped laminate in which sheets are stacked, a method for manufacturing a wearing article, wherein at least one end of the absorbent body in a longitudinal direction is joined to the waistband member, a joining step of sandwiching the laminate in the stacking direction while accommodating the absorbent body in a recess formed in at least one of the two sandwiching elements, and joining the sheets together in an area where the laminate and the absorbent body do not overlap, A method for manufacturing a worn article.

6. In the joining step, The two clamping elements are: When the sheet is joined to one end and the other end in the longitudinal direction of the absorbent body, Joining the sheets together at one end side in the longitudinal direction of the absorbent body; and simultaneously joining the sheets at the other end of the absorbent body in the longitudinal direction. The method for manufacturing the wearing article according to claim 5 .

7. The wearing article comprises: The waistband member further includes an elastic member arranged inside the waistband member so as to be stretchable along the longitudinal direction of the waistband member. The method for manufacturing the wearing article according to claim 5 .

8. The two clamping elements are: an ultrasonic horn and anvil; A method for manufacturing the wearing article according to any one of claims 5 to 7.

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