Method for manufacturing absorbent article

Abstract

An object of the present invention is to provide a method for manufacturing an absorbent article that suppresses tearing of a water-permeable sheet.SOLUTION: A method for manufacturing an absorbent article includes a deposition step of depositing an absorbent material containing SAP particles on a forming plate on which convex portions are continuously provided, a transfer step of transferring the absorbent material deposited on the forming plate onto a first water-permeable sheet, a covering step of covering the absorbent material on a side opposite to a side on which the first water-permeable sheet is transferred in the transfer step with a second water-permeable sheet, and a pressing step of pressing a region corresponding to the convex portion and the vicinity of the region in a laminate covered with the first water-permeable sheet and the second water-permeable sheet with a pressing force lower than that of other portions of the laminate simultaneously with the other portions.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an absorbent article. [Background technology]

[0002] Absorbent articles such as disposable diapers, absorbent pads, and sanitary napkins have been developed. These absorbent articles include an absorbent body that absorbs excreted fluids such as urine. For example, Patent Document 1 discloses an absorbent article that includes an absorbent body that holds SAP particles. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-103782 Summary of the Invention [Problem to be solved by the invention]

[0004] During manufacturing, absorbent bodies that hold SAP particles may have areas with high SAP particle density. When the absorbent body is pressed to form the body, there is a risk that the water-permeable sheet corresponding to the areas with high SAP particle density may tear.

[0005] An object of the present invention is to provide a method for manufacturing an absorbent article that prevents tearing of a water-permeable sheet. [Means for solving the problem]

[0006] A method for manufacturing an absorbent article according to one aspect of the present invention includes: a depositing step of depositing an absorbent material containing SAP particles on a forming plate having a continuous series of protrusions; a transfer step of transferring the absorbent material deposited on the forming plate onto a first water-permeable sheet; a coating step of coating a second water-permeable sheet on the absorbent material on the side opposite to the side on which the first water-permeable sheet is transferred in the transfer step; and a pressing step of pressing the area of ​​the laminate covered with the first water-permeable sheet and the second water-permeable sheet corresponding to the convex portion and the vicinity of that area simultaneously with the other parts of the laminate with a pressing force lower than that of the other parts of the laminate. [Effects of the Invention]

[0007] According to the present invention, tearing of the water-permeable sheet can be suppressed. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing the appearance of a diaper manufactured by a diaper manufacturing method according to a first embodiment. [Figure 2] FIG. 2 is an exploded perspective view of a diaper manufactured by the diaper manufacturing method according to the first embodiment. [Figure 3] FIG. 3 is a plan view of a diaper manufactured by the diaper manufacturing method according to the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view of a diaper manufactured by the diaper manufacturing method according to the first embodiment. [Figure 5] FIG. 5 is a flowchart showing the method for manufacturing the diaper according to the first embodiment. [Figure 6] FIG. 6 is a diagram showing a forming drum. [Figure 7] FIG. 7 is a cross-sectional view of a protrusion provided on a forming plate. [Figure 8] FIG. 8 is a diagram showing the pressing portion. [Figure 9] FIG. 9 is a schematic view of a manufacturing apparatus for manufacturing diapers by the diaper manufacturing method according to the first embodiment. [Figure 10] FIG. 10 is a plan view of a diaper manufactured by the diaper manufacturing method according to the second embodiment. [Figure 11]FIG. 11 is a flowchart showing a method for manufacturing a diaper according to the second embodiment. [Figure 12] FIG. 12 is a view showing a pressing unit used in the method for manufacturing a diaper according to the second embodiment. [Figure 13] FIG. 13 is a flowchart showing a method for manufacturing a diaper according to the third embodiment. [Figure 14] FIG. 14 is a plan view of a diaper manufactured by the diaper manufacturing method according to the third embodiment. [Figure 15] FIG. 15 is an enlarged cross-sectional view of a groove and its vicinity in a diaper manufactured by a method for manufacturing a diaper according to a fourth embodiment. [Figure 16] FIG. 16 is a diagram showing adhesive applied to the upper layer core wrap sheet. DETAILED DESCRIPTION OF THE INVENTION

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following describes embodiments of the present invention. The embodiments described below are merely aspects of the present invention and are not intended to limit the technical scope of the present invention.

[0010] First Embodiment In the first embodiment, the longitudinal direction of a tape-type disposable diaper (an example of an "absorbent article" in the present application, hereinafter simply referred to as "diaper") is the direction connecting the front body portion, which is positioned opposite the wearer's abdomen, and the back body portion, which is positioned opposite the wearer's back. A crotch portion, which is positioned between the front body portion (one side in the longitudinal direction) and the back body portion (the other side in the longitudinal direction) (at the center in the longitudinal direction) and is positioned between the wearer's crotch (facing the crotch). When the diaper is worn by a wearer (hereinafter abbreviated as "worn state"), the side facing the wearer's skin (the inner side when worn) is the skin-facing side, and the side opposite the skin-facing side (the outer side when worn) is the non-skin-facing side. The thickness direction is the direction connecting the skin-facing side and the non-skin-facing side, and the width direction is the direction perpendicular to both the longitudinal direction and the thickness direction. A view from the thickness direction is a plan view. The left-right direction of the diaper is defined as the right side of the wearer's right hand and the left side of the wearer's left hand when the diaper is worn.

[0011] FIG. 1 is a perspective view of a diaper 1 manufactured by a manufacturing method for a diaper 1 according to a first embodiment. FIG. 2 is an exploded perspective view of the diaper 1. FIG. 3 is a plan view of the diaper 1 in a stretched state, viewed from the skin-facing side. The diaper 1 has a crotch region 1B, which corresponds to the crotch area of ​​the wearer when worn, a front body region 1F located in front of the crotch region 1B and corresponding to the wearer's front body, and a back body region 1R located behind the crotch region 1B and corresponding to the wearer's back body. Tapes 2L and 2R are attached to the left and right edges of the back body region 1R, and can be attached to front patches 2F provided on the non-wearer-facing surface of the front body region 1F. When the tapes 2L and 2R are attached to the front patches 2F with the front body region 1F positioned on the wearer's abdominal side and the back body region 1R positioned on the wearer's back side, the diaper 1 is secured to the wearer's body so as to surround the wearer's abdominal circumference and thighs. Since the diaper 1 is fixed to the wearer's body in this manner, the wearer can stand and walk around while wearing the diaper 1.

[0012] The diaper 1 has an absorbent body 6, which is capable of absorbing and retaining liquid, located mainly near the crotch region 1B. The diaper 1 also has leg gathers 3AL, 3AR provided around the wearer's legs (thighs) to prevent gaps from forming between the diaper 1 and the wearer's skin, which could serve as a liquid leakage path. Leakage barrier walls 3BL, 3BR are provided on the inside of the leg gathers 3AL, 3AR in the width direction of the diaper 1. The leg gathers 3AL, 3AR and the leakage barrier walls 3BL, 3BR are held in close contact with the wearer's skin by the elastic force of the elastic members. Therefore, liquid excreted from the wearer's genitals is absorbed by the absorbent body 6 of the diaper 1 without leaking out. The elastic members may be selected from thread-like or strip-like rubber, etc., as appropriate.

[0013] The diaper 1 has a cover sheet 4 that forms the outer surface when worn. The cover sheet 4 is a sheet-like member having a generally rectangular appearance with constrictions 4KL and 4KR in the areas corresponding to the long sides, and forms the exterior surface of the diaper 1. The constrictions 4KL and 4KR are provided in the areas where the wearer's thighs are located. The cover sheet 4 is provided to reinforce the back sheet 5 (described later) and to improve the feel. For example, to prevent leakage of excrement, a nonwoven fabric made of a liquid-impermeable thermoplastic resin can be used as the material for the cover sheet 4. Examples of liquid-impermeable thermoplastic resins include polyethylene (PE) and polypropylene (PP). The cover sheet 4 is not limited to a single-layer structure, but may also be a multi-layer structure having an inner cover sheet and an outer cover sheet.

[0014] The diaper 1 has a back sheet 5, an absorbent body 6, and a top sheet 8, which are layered in this order on the wearer-facing surface of the cover sheet 4. The top sheet 8 may consist of a single sheet, or multiple sheets may be layered together. The back sheet 5, the absorbent body 6, and the top sheet 8 are all sheet-like members having a substantially rectangular appearance, and are layered in this order on the cover sheet 4 with their longitudinal directions coinciding with the longitudinal direction of the cover sheet 4. Like the cover sheet 4, the back sheet 5 is a sheet made of a liquid-impermeable thermoplastic resin material to prevent leakage of excrement. The back sheet 5 is preferably made of a material that is also moisture-permeable to prevent stuffiness when worn.

[0015] The top sheet 8 is the portion that contacts the wearer's skin when the diaper 1 is worn. It is a water-permeable sheet made of a liquid-permeable material that allows urine and other liquids to pass through. The top sheet 8 may be made of a woven fabric, a nonwoven fabric, a porous film, or the like. The nonwoven fabric may be made of thermoplastic resin fibers such as polypropylene, polyethylene, polyester, or nylon that have been hydrophilically treated. Alternatively, air-through nonwoven fabric, point-bonded nonwoven fabric, spun-bonded nonwoven fabric, or melt-blown nonwoven fabric may be used. When the diaper 1 is worn, liquid excreted by the wearer passes through the top sheet 8, which may come into contact with the wearer's skin, into the absorbent body 6, and is absorbed therein. The longitudinal direction of the diaper 1 is the same as the longitudinal directions of the absorbent body 6 and the top sheet 8.

[0016] The back sheet 5, absorbent body 6, and top sheet 8 all extend from the front body region 1F to the back body region 1R. Therefore, when the wearer's genitals are covered with the cover sheet 4, in which the back sheet 5, absorbent body 6, and top sheet 8 are laminated, the longitudinal ends of the back sheet 5, absorbent body 6, and top sheet 8 are located on the wearer's ventral and dorsal sides. In other words, the wearer's genitals are covered by the absorbent body 6 from the wearer's ventral to dorsal sides. Therefore, whether the wearer is in a ventral or dorsal position when excreting liquid, the excreted liquid will come into contact with the absorbent body 6 via the top sheet 8.

[0017] The diaper 1 also has elastic members 4SL, 4SR for forming the leg gathers 3AL, 3AR described above, which are provided between the cover sheet 4 and the back sheet 5 so as to be stretchable in the longitudinal direction of the diaper 1. The number of elastic members 4SL, 4SR (two in this embodiment) is determined according to the elastic force (contractile force) required for the design of the diaper 1. The elastic members 4SL and 4SR do not necessarily have to be provided.

[0018] The diaper 1 also has a pair of water-impermeable side sheets 9L, 9R arranged on both skin-facing sides of the diaper 1 in the width direction and extending longitudinally. The side sheets 9L, 9R are arranged so that their longitudinal ends coincide with the longitudinal ends of the top sheet 8. Like the cover sheet 4, the side sheets 9L, 9R have constrictions 9KL, 9KR in the areas where the wearer's thighs will be located. The side sheets 9L, 9R have fixing regions 9LA, 9RA arranged on their outer widthwise sides. The fixing regions 9LA, 9RA are bonded to the top sheet 8, which is the component arranged on the non-skin-facing side, with a hot melt adhesive.

[0019] The side sheets 9L, 9R have rubber threads 9EL, 9ER arranged along their longitudinal direction to form the leak barrier walls 3BL, 3BR. When the diaper 1 is worn, i.e., when the diaper 1 is U-shaped in side view, the contractile force of the rubber threads 9EL, 9ER draws the side sheets 9L, 9R longitudinally and causes them to rise from the top sheet 8, thereby forming the leak barrier walls 3BL, 3BR that prevent the outflow of exuded liquid.

[0020] The side sheets 9L, 9R are bonded to the top sheet 8 with a hot melt adhesive. The widthwise inner edges of this hot melt adhesive form fold lines 3LL, 3LR (see FIG. 3), and the insides of the fold lines 3LL, 3LR form the upstanding leakage barrier walls 3BL, 3BR. That is, the fold lines 3LL, 3LR are the upstanding edges of the leakage barrier walls 3BL, 3BR. The widthwise inner edges of the side sheets 9L, 9R from the fold lines 3LL, 3LR are the leakage barrier walls 3BL, 3BR, and the widthwise inner edges of the side sheets 9L, 9R are the free edges 9LB, 9RB of the leakage barrier walls 3BL, 3BR. Two rubber threads 9EL, 9ER, which are thread-like elastic members, are arranged side by side in the width direction near the free edges 9LB, 9RB of the side sheets 9L, 9R. Note that only one rubber thread 9EL, 9ER may be arranged. The elastic threads 9EL, 9ER are fixed to the side sheets 9L, 9R with hot melt adhesive in a stretched state in the longitudinal direction of the diaper 1. The side sheets 9L, 9R have fixing portions 33L, 33R near their longitudinal ends. The fixing portions 33L, 33R fix the side sheets 9L, 9R to the top sheet 8, and serve as longitudinal starting points for the leakage barrier walls 3BL, 3BR when they rise. The side sheets 9L, 9R are also bonded to the top sheet 8 on their outer widthwise sides, but on the inner longitudinal sides of the fixing portions 33L, 33R, the inner widthwise sides of the fixing portions are not bonded with the hot melt adhesive, allowing them to rise toward the skin. When the elastic threads 9EL, 9ER contract and the leakage barrier walls 3BL, 3BR on the inner side of the fold lines 3LL, 3LR rise toward the skin, the free ends 9LB, 9RB become the tips on the skin-facing side. The upright leakage preventing walls 3BL, 3BR inhibit the movement of discharged liquid and loose stools outward in the width direction of the leakage preventing walls 3BL, 3BR, thereby suppressing lateral leakage of these.

[0021] 4 is a widthwise cross-sectional view of the diaper 1 taken along line AA in FIG. 3. The diaper 1 includes an absorbent body 6 that absorbs and retains excreted fluids such as urine. The absorbent body 6 is disposed on the non-skin-facing side of the top sheet 8, including the crotch region 1B, to absorb excreted fluids from the wearer. In this embodiment, the absorbent body 6 includes an absorbent core 6C and a core wrap sheet 7 that covers part or all of the absorbent core 6C. The longitudinal direction of the absorbent body 6 coincides with the longitudinal direction of the absorbent core 6C, the longitudinal direction of the core wrap sheet 7, and the longitudinal direction of the diaper 1.

[0022] In plan view, the absorbent core 6C has a generally gourd-like shape, with the front body region 1F and the back body region 1R being wider than the crotch region 1B, and the crotch region 1B being narrowed. The crotch region 1B is sandwiched between the wearer's legs, and is subjected to compressive pressure inward in the width direction. On the other hand, the front body region 1F and the back body region 1R are subjected to pressure in the thickness direction of the absorbent core 6C due to the weight of the wearer. To cope with these pressures, the crotch region 1B of the absorbent core 6C is narrowed. In the front body region 1F and the back body region 1R, the absorbent core By increasing the width of the absorbent core 6C, the area on which the body weight is applied is increased, preventing deformation in the thickness direction. For this reason, it is preferable that the absorbent core 6C be approximately gourd-shaped. However, the absorbent core 6C may also be approximately rectangular.

[0023] The absorbent core 6C has a structure in which granular absorbent resin (polymeric water-absorbing material) such as SAP (Super Absorbent Polymer), a hydrophilic polymer with a cross-linked structure that can absorb and retain water, is held in the gaps between short fibers of cellulosic fibers such as pulp, rayon, or cotton, or short fibers made from synthetic fibers such as polyethylene, polypropylene, or polyethylene terephthalate that have been hydrophilically treated. These short fibers and SAP are examples of absorbent materials.

[0024] In this embodiment, SAP particles refer to a granulated resin composition containing SAP. The term "SAP-containing resin composition" as used herein encompasses both a composition consisting solely of SAP and a composition containing SAP as the main component, with other substances added to the extent that they do not adversely affect water absorption. Examples of "other substances" include additives (such as surface modifiers added to hydrophobize the particle surface) and unreacted monomers remaining during the synthesis of SAP. SAP particles can absorb approximately 10 to 100 times their own weight in liquid. The SAP particles may be, for example, granular particles with a diameter of approximately 0.1 to 0.5 mm before absorbing liquid.

[0025] While SAP particles gel and can retain liquid, it takes a certain amount of time for the liquid to be absorbed. In diaper 1, the short fibers slow down the discharged liquid while diffusing it within the absorbent core 6C until the SAP particles have absorbed the liquid, allowing the discharged liquid to be absorbed by a wide range of SAP particles, thereby preventing the liquid from flowing back.

[0026] The absorbent core 6C has three recesses 6HA, 6HB, and 6HC extending longitudinally and spaced apart in the widthwise direction. The recesses 6HA, 6HB, and 6HC are portions in which the absorbent material composed of the above-mentioned short fibers and SAP particles is thinner than the surrounding absorbent material and is formed in a concave shape extending from the skin-facing side to the non-skin-facing side. Urine excreted by the wearer is dispersed throughout the absorbent core 6C along the recesses 6HA, 6HB, and 6HC provided on the skin-facing side of the absorbent core 6C. This allows the diaper 1 to efficiently absorb urine excreted by the wearer throughout the entire absorbent core 6C.

[0027] The absorbent core 6C may have an upper-layer absorbent mat arranged on the top sheet 8 side and a lower-layer absorbent mat arranged on the side not facing the wearer's skin.

[0028] The core wrap sheet 7 is a water-permeable sheet that sandwiches the absorbent core 6C, and more specifically, it covers the skin-facing and non-skin-facing sides of the absorbent core 6C. The core wrap sheet 7 maintains the shape of the absorbent core 6C when not in contact with excreted liquid, preventing it from losing its shape and preventing the SAP particles contained in the absorbent core 6C from escaping. Furthermore, SAP particles when not absorbing moisture are hard and sand-like, and if these SAP particles escape from the absorbent body 6 and come into direct contact with the wearer's skin, they may cause discomfort to the wearer. For this reason, the absorbent core 6C is sandwiched between the core wrap sheets 7, preventing the absorbent core 6C from losing its shape and preventing the SAP particles from escaping outside the absorbent body 6.

[0029] In the first embodiment, a pulp fiber sheet or a thin nonwoven fabric is used for the core wrap sheet 7. The core wrap sheet 7 is formed from two sheets: an upper-layer core wrap sheet 7A (an example of the "second water-permeable sheet" in this application) placed between the absorbent core 6C and the top sheet 8, and a lower-layer core wrap sheet 7B (an example of the "first water-permeable sheet" in this application) placed on the non-skin-facing side of the absorbent core 6C. The core wrap sheet 7 is The upper core wrap sheet 7A and the lower core wrap sheet 7B may be made of different materials. For example, the upper core wrap sheet 7A may be made of an air-through nonwoven fabric, and the lower core wrap sheet 7B may be made of tissue paper.

[0030] The core wrap sheet 7 may be arranged to cover the skin-facing side, non-skin-facing side, and side surfaces of the absorbent core 6C. For example, the lower-layer core wrap sheet 7B may be arranged on the non-skin-facing side of the absorbent core 6C, covering the side surfaces of the absorbent core 6C, and further covering the outer sides in the width direction of the upper-layer core wrap sheet 7A. Alternatively, the core wrap sheet 7 may be formed from a single sheet and arranged to cover the skin-facing side, non-skin-facing side, and side surfaces of the absorbent core 6C.

[0031] Next, a manufacturing method of the diaper 1 according to the first embodiment will be described with reference to FIG. 5. FIG. 5 is a flowchart illustrating the manufacturing method of the diaper 1 according to the first embodiment. First, an absorbent material containing the short fibers and SAP particles constituting the absorbent core 6C is deposited on the outer peripheral surface of a forming drum, which is a hollow cylindrical rotating body having a mold frame on its outer periphery (step S101, depositing step). In step S102 (transfer step) after step S101, the absorbent material deposited on a forming plate provided on the outer peripheral surface of the forming drum is fed to a conveying path provided below the forming drum and transferred onto a member below the absorbent core 6C in the diaper 1 traveling on the conveying path. In this embodiment, this lower member is the lower-layer core wrap sheet 7B. In step S103 (covering step) after step S102, an upper-layer core wrap sheet 7A is covered on the absorbent material on the side opposite to the side to which the lower-layer core wrap sheet 7B was transferred in the transfer step (step S102). In step S104 (pressing step) following step S103, the absorbent core 6C covered with the lower core wrap sheet 7B and the upper core wrap sheet 7A is pressed by a pressing unit provided in the diaper 1 manufacturing apparatus. At this time, the recesses 6HA, 6HB, 6HC and the vicinity of these areas are pressed with a lower pressing force than other parts of the absorbent core 6C, thereby manufacturing the absorbent body 6. In step S105 (top sheet placement step) following step S104, the manufactured absorbent body 6 is transported along a transport path, and a top sheet 8 is placed on the upper core wrap sheet 7A of the transported absorbent body 6.

[0032] FIG. 6 shows a forming drum 18D used in the deposition process and the transfer process. FIG. 6(A) is a perspective view of the forming drum 18D viewed obliquely from above. FIG. 6(B) is an exploded perspective view of the mold. The mold is formed along the entire outer periphery of the forming drum 18D and forms the absorbent core 6C. The mold has a forming plate 18F that forms the bottom of the mold and a molding plate 18S that forms the side wall of the mold and has a roughly gourd-shaped side that is the same as the outer shape of the absorbent core 6C in the width direction. The mold may be formed directly on the outer periphery of the forming drum 18D, for example, or may be formed by attaching the forming plate 18F and molding plate 18S that are configured to be detachable from a cylindrical frame.

[0033] The forming plate 18F is the bottom of the formwork formed on the forming drum 18D and is made of a porous material such as a metal mesh plate. Because the forming plate 18F is made of a porous material, the bottom of the formwork is breathable, and the negative pressure generated by the forming drum 18D can suck air outside the forming drum 18D into its interior through the formwork. For example, a suction fan can be driven to create negative pressure inside and suck in outside air.

[0034] The forming plate 18F has protrusions 18A, 18B, and 18C that protrude from the outer peripheral surface of the forming drum 18D and are spaced apart in the width direction and extend continuously in the longitudinal direction of the forming plate 18F (circumferential direction of the forming drum 18D). The protrusions 18A, 18B, and 18C make it difficult for the absorbent material to accumulate, and can form recesses 6HA, 6HB, and 6HC in which the thickness of the absorbent material is thinner than the surrounding area. Therefore, the absorbent material does not accumulate in other areas. The protrusions 18A, 18B, and 18C are often provided to form recesses 6HA, 6HB, and 6HC that are thinner than the other regions. Note that the protrusions 18A, 18B, and 18C may be provided to form slits in which no absorbent material is placed on the protrusions 18A, 18B, and 18C. In this case, the slits or recesses are formed in the regions corresponding to the protrusions 18A, 18B, and 18C.

[0035] FIG. 7 is a cross-sectional view of the protrusion 18A when cutting the forming plate 18F in the width direction. The width direction of the forming plate 18F is a direction perpendicular to the outer circumferential direction of the forming drum 18D, that is, the CD direction. Since the protrusion 18A and the protrusions 18B and 18C have the same shape, only the protrusion 18A will be described below. The protrusion 18A protrudes to the outer periphery of the forming plate 18F as shown in FIG. 7. The cross section of the protrusion 18A in this embodiment has a trapezoidal shape in which the width of the apex is shorter than the width of the bottom. The cross section of the protrusion 18A is not limited to a trapezoidal shape.

[0036] The protrusions 18A preferably have side surfaces with an inclination angle of 90 degrees or less relative to the reference plane, with the forming plate 18F being the reference plane. If the inclination angle with respect to the reference plane is greater than 90 degrees, the area of ​​the apex of the protrusions 18A will be larger than that of the forming plate 18F side. If the absorbent material is deposited in this state, there is a risk that the absorbent material will not be deposited on the forming plate 18F where the apex of the protrusions 18A overlaps. Therefore, it is preferable that the protrusions 18A have inclined surfaces with an inclination angle of 90 degrees or less relative to the reference plane. Note that it is not necessary to provide three protrusions 18A, 18B, and 18C on the forming plate 18F. The design can be adjusted depending on the location of the slits that prevent the absorbent material from being deposited or the recesses where the absorbent material is thin.

[0037] With this configuration, the absorbent material is sucked toward the forming plate 18F side of the forming drum 18D together with the air that is sucked toward the inside of the forming drum 18D. Here, although the air is sucked into the forming drum 18D through the forming plate 18F, the absorbent material cannot pass through the porous member that makes up the forming plate 18F and ends up piling up on the forming plate 18F. The accumulated absorbent material is transported by the rotation of the forming drum 18D to a position opposite the transport path 12 provided at the lower end of the forming drum 18D.

[0038] 5, the absorbent material deposited on forming plate 18F is supplied to conveying path 12 and transferred onto lower-layer core wrap sheet 7B flowing on conveying path 12. The absorbent material transferred onto lower-layer core wrap sheet 7B is inverted upside down, and the areas corresponding to protrusions 18A, 18B, 18C become recesses 6HA, 6HB, 6HC where the basis weight of the deposited absorbent material is smaller than that of the surrounding areas.

[0039] In step S103 (covering step), the upper-layer core wrap sheet 7A is covered on the absorbent material on the side opposite to the side to which the lower-layer core wrap sheet 7B was transferred in the transfer step (step S102). As a result, the absorbent core 6C becomes a laminate in which the skin-facing side and non-skin-facing side are covered with the core wrap sheet 7.

[0040] In step S104 (pressing step), a pressing unit provided in the diaper 1 manufacturing apparatus presses the recessed portions 6HA, 6HB, 6HC and the vicinity thereof with a pressing force lower than that of other portions simultaneously with the other portions, thereby manufacturing the absorbent body 6. The recessed portions 6HA, 6HB, 6HC are regions corresponding to the protruding portions 18A, 18B, 18C provided on the forming plate 18F in the deposition step (step S101). The vicinity of the recessed portions 6HA, 6HB, 6HC is a region where SAP particles slide down along the slopes of the protruding portions 18A, 18B, 18C provided on the forming plate 18F in the deposition step (step S101), and where more SAP particles are deposited than in other regions. In the first embodiment, the recessed portions 6HA, 6HB, 6 The vicinity of HC is within a range of 10 mm from the recesses 6HA, 6HB, and 6HC.

[0041] FIG. 8 is a view showing the pressing unit 11. FIG. 8(A) is an external perspective view of the pressing unit 11. FIG. 8(B) is a cross-sectional view taken in the CD direction while the pressing unit 11 is pressing the absorbent body 6. Note that, for the sake of explanation, FIG. 8(B) does not show the press roll 11B. The pressing unit 11 has a pair of press rolls (hereinafter simply referred to as "rolls") 11A and 11B, which rotate relative to each other with their cylindrical outer circumferential surfaces pressed against each other. The rolls 11A and 11B are made of, for example, metal. The pressing unit 11 presses the cylindrical outer circumferential surface of the upper roll 11A against the smooth cylindrical outer circumferential surface of the lower roll 11B with a desired pressing force. This presses the absorbent body 6 on the conveying path 12.

[0042] The roll 11A has three recesses 11AA, 11AB, and 11AC extending along the outer periphery of the roll 11A and spaced apart in the width direction perpendicular to the outer periphery of the roll 11A. The recesses 11AA, 11AB, and 11AC correspond to the recesses 6HA, 6HB, and 6HC formed in the absorbent core 6C. The roll 11A also has nearby pressing portions 11AD on both sides of the width direction adjacent to the recesses 11AA, 11AB, and 11AC, which press against areas corresponding to the vicinity of the recesses 6HA, 6HB, and 6HC formed in the absorbent core 6C. The nearby pressing portions 11AD have a shape recessed toward the interior of the roll 11A relative to the outer periphery of the roll 11A, which presses against areas other than the areas corresponding to the recesses 6HA, 6HB, and 6HC and their vicinity. Because the nearby pressing portions 11AD have a shape recessed toward the interior of the roll 11A, the pressing force on the recesses 6HA, 6HB, and 6HC of the absorbent core 6C and their vicinity can be reduced. The recesses 11AA, 11AB, and 11AC do not necessarily have to be recessed toward the inside of the roll 11A.

[0043] 8(B), the absorbent body 6 is pressed while sandwiched between the rolls 11A and 11B. Here, the recesses 6HA, 6HB, and 6HC formed in the absorbent core 6C are pressed at positions corresponding to the recesses 11AA, 11AB, and 11AC provided in the roll 11A. The nearby pressing portion 11AD presses both sides (nearby) of the recesses 6HA, 6HB, and 6HC in the CD direction.

[0044] When forming the recesses 6HA, 6HB, and 6HC by providing the protrusions 18A, 18B, and 18C on the forming plate 18F and depositing the absorbent material on the forming plate 18F, the SAP particles slide down along the slopes of the protrusions 18A, 18B, and 18C and deposit around the protrusions 18A, 18B, and 18C. When the absorbent material is transferred to the lower-layer core wrap sheet 7B in this state in the transfer step (step S102), the SAP particles deposit around the areas corresponding to the protrusions 18A, 18B, and 18C, forming areas with a high density of SAP particles. Because the staple fibers are entangled with each other, even if the upper-layer core wrap sheet 7A tears in the high-density areas of the staple fibers, the SAP particles are less likely to leak from the torn area due to the connections between the entangled staple fibers. Furthermore, it is rare for all of the entanglement between the staple fibers to tear. Because some of the staple fibers remain connected, the torn area is small and does not easily spread. On the other hand, regions with a high SAP particle density are prone to tearing because the SAP particles are not bonded to each other and are less entangled by short fibers. Compared to regions with a high short fiber density, these regions are prone to tearing, and the torn regions tend to become larger and spread more easily. Furthermore, SAP particles are more likely to leak from the torn regions. Therefore, if the regions with a high SAP particle density are pressed with the same pressing force as other regions, the upper layer core wrap sheet 7A, which is stacked in the upper layer, tears more widely than the other regions, and SAP particles are more likely to leak out. Therefore, in the first embodiment, to prevent tearing of the core wrap sheet 7 in the pressing step (step S104), the areas near the recesses 6HA, 6HB, and 6HC corresponding to the protrusions 18A, 18B, and 18C are pressed with a lower pressing force than the other areas. This prevents tearing of the core wrap sheet 7 near the recesses 6HA, 6HB, and 6HC where the SAP particles are highly dense.

[0045] The pressing force applied to the vicinity of the recesses 6HA, 6HB, 6HC in the pressing step (step S104) can be reduced by pressing the pressing roll 11A or roll 11B shallower than when pressing other regions.

[0046] In this embodiment, the depth to which the recesses 6HA, 6HB, and 6HC corresponding to the protrusions 18A, 18B, and 18C are pressed is shallower by 0.05 mm to 1 mm than the depth to which the vicinity of the recesses 6HA, 6HB, and 6HC corresponding to the protrusions 18A, 18B, and 18C are pressed, and the depth to which the vicinity of the recesses 6HA, 6HB, and 6HC corresponding to the protrusions 18A, 18B, and 18C are pressed is preferably shallower by 0.05 mm to 1 mm than the depth to which other regions are pressed. The pressing force for each region can be easily changed by changing the pressing depth for each region while applying a pressure sufficient to prevent the rolls 11A and 11B from bouncing. The pressing force may also be reduced by weakening the pressure applied to the pressing roll 11A or 11B.

[0047] In step S105 (top sheet placement step) shown in Figure 5, the manufactured absorbent body 6 is transported along the transport path 12, and a top sheet 8 is placed on the upper-layer core wrap sheet 7A of the transported absorbent body 6. By placing the top sheet 8 after the pressing step (step S104), damage to the top sheet 8 due to pressing is prevented. Furthermore, even if the upper-layer core wrap sheet 7A is torn during the pressing step (step S104), it is possible to prevent the absorbent material from leaking outward from the top sheet 8.

[0048] Next, a manufacturing apparatus for the diaper 1 according to this embodiment will be described with reference to Fig. 9. Fig. 9 is a schematic diagram showing a part of the configuration of the manufacturing apparatus for the diaper 1 according to this embodiment. The up-down direction of the manufacturing apparatus refers to the direction of gravity.

[0049] The manufacturing apparatus for diaper 1 includes a lower core wrap sheet supply section 13 that supplies a lower core wrap sheet 7B, an absorbent core manufacturing apparatus M having an absorbent core supply section 14, an upper core wrap sheet supply section 15 that supplies an upper core wrap sheet 7A, a pressing section 11 that presses the absorbent body 6, a top sheet supply section 16 that supplies a top sheet 8, and a conveying path 12 that stacks and conveys the components supplied from the supply sections for each component.

[0050] The lower core wrap sheet supply unit 13 supplies the lower core wrap sheet 7B from the lower core wrap sheet supply unit 13 to the conveying path 12 in region R1, which is the opposing region of the conveying path 12. The absorbent core manufacturing device M manufactures the absorbent core 6C and supplies the absorbent core 6C to the conveying path 12 in transfer region R2, which is the opposing region of the absorbent core supply unit 14 and the conveying path 12. The upper core wrap sheet supply unit 15 supplies the upper core wrap sheet 7A from the upper core wrap sheet supply unit 15 to the conveying path 12 in region R3, which is the opposing region of the conveying path 12. The top sheet supply unit 16 supplies the top sheet 8 from the top sheet supply unit 16 to the conveying path 12 in region R4, which is the opposing region of the conveying path 12.

[0051] The conveying path 12 is provided below the supply units for each component, and conveys the components in the direction of arrow Y1 while stacking them. In the first embodiment, the components are stacked on the conveying path 12 in the following order: lower core wrap sheet 7B, absorbent core 6C, upper core wrap sheet 7A, and top sheet 8. Therefore, the supply units for each component that supply the components to the conveying path 12 are provided in the following order from upstream: lower core wrap sheet supply unit 13, absorbent core supply unit 14, upper core wrap sheet supply unit 15, and top sheet supply unit 16. In addition, the pressing unit 11 is provided between the upper core wrap sheet supply unit 15 and the top sheet supply unit 16 to press the absorbent body 6.

[0052] The absorbent core manufacturing device M includes a forming drum 18D and an absorbent material supplying device for supplying the absorbent material containing short fibers and SAP particles that constitute the absorbent core 6C to the forming drum 18D. and an absorbent core supply section 14 that deposits the absorbent material supplied from the absorbent material supply section 17 onto a forming drum 18D and supplies the formed absorbent core 6C to the conveying path 12.

[0053] The forming drum 18D is provided so that its upper end is located below the absorbent material supply unit 17. The arc-shaped arrow Y2 in FIG. 9 indicates the rotation direction of the forming drum 18D. The forming drum 18D deposits the absorbent material supplied from the absorbent material supply unit 17 onto a forming plate 18F provided on the outer circumferential surface of the forming drum 18D. The deposited absorbent material is then sucked into the interior of the forming drum 18D. Thereafter, the rotation of the forming drum 18D transports the absorbent material to the absorbent core supply unit 14 located in the transfer region R2 opposite the conveying path 12, where the absorbent material is supplied to the conveying path 12 as an absorbent core 6C.

[0054] In the first embodiment, the pressing step (step S104) involves pressing from above the upper core wrap sheet 7A after the covering step (step S103), but pressing may also be performed from above the top sheet 8 after the top sheet placement step (step S105). When pressing is performed in the pressing step (step S104) after the top sheet 8 is placed, tearing of the top sheet 8 and upper core wrap sheet 7A in the vicinity of the areas corresponding to the convex portions 18A, 18B, and 18C can be suppressed.

[0055] <Second embodiment> A second embodiment will now be described. Fig. 10 is a plan view of a diaper 1 manufactured by a method for manufacturing a diaper 1 according to the second embodiment, showing compressed portions 20 provided in an absorbent body 6 when the diaper 1 is stretched. For ease of explanation, some components have been omitted from the illustration. The absorbent body 6 provided in a diaper 1 manufactured by a method for manufacturing a diaper 1 according to the second embodiment may have compressed portions 20 formed of a plurality of grooves, each having a groove 20A (an example of a "first extended pressing portion" as defined herein) and a groove 20B (an example of a "second extended pressing portion" as defined herein), which intersect with each other, as shown in Fig. 10.

[0056] The compressed sections 20 are formed by compressing the absorbent body 6 from the skin-facing side. The compressed sections 20 are composed of a plurality of grooves, including grooves 20A and grooves 20B that intersect with each other. As shown in FIG. 10 , the grooves 20A extend from the front right side of the diaper 1 to the rear left side, and the grooves 20B extend from the front left side of the diaper 1 to the rear right side. The grooves 20A and 20B are formed in a lattice pattern diagonal to the long or short sides of the absorbent body 6. The extending direction of the grooves 20A and 20B is not limited to the configuration example shown in FIG. 10 . For example, the grooves 20A may extend from the front to the rear of the diaper 1, and the grooves 20B may extend from the right to the left side of the diaper 1. The grooves 20A and 20B may also be formed in a lattice pattern parallel to the long or short sides of the absorbent body 6.

[0057] Air flows along the grooves 20A and 20B provided on the skin-facing side of the absorbent body 6, improving the breathability of the diaper 1. Liquids such as urine excreted by the wearer are dispersed throughout the absorbent body 6 along the grooves 20A and 20B provided on the skin-facing side of the absorbent body 6. This allows the diaper 1 to efficiently absorb urine excreted by the wearer throughout the absorbent body 6. Furthermore, providing the grooves 20A and 20B in the absorbent body 6 makes it easier to bend, thereby improving the comfort of the diaper 1 when worn by the wearer.

[0058] Next, a method for manufacturing the diaper 1 according to the second embodiment will be described with reference to Fig. 11. Fig. 11 is a flowchart showing the method for manufacturing the diaper 1 according to the second embodiment. The steps from the deposition step (step S201) to the covering step (step S203) are the same as those from the deposition step (step S101) to the covering step (step S103) in the first embodiment. Furthermore, the top sheet positioning step (step S205) is the same as the top sheet positioning step (step S105) in the first embodiment. In the second embodiment, the pressing step (step S104) in the first embodiment can be regarded as a compressed portion forming step (step S204) for forming the compressed portions 20. In the compressed portion forming step (step S204), the ranges that intersect with the areas corresponding to the protrusions 18A, 18B, 18C are pressed to form the compressed portions 20.

[0059] FIG. 12(A) is a diagram illustrating the pressing unit 11 used in the compression unit forming step (step S204). The pressing unit 11 has a pair of rolls 11A and 11B, which rotate relative to each other with their cylindrical outer surfaces pressed against each other. The rolls 11A and 11B are made of, for example, metal. The pressing unit 11 presses the protrusions 11T, which are regularly arranged on the cylindrical outer surface of the upper roll 11A, against the smooth cylindrical outer surface of the lower roll 11B with a desired pressure. This compresses the absorbent body 6 on the conveying path 12. As in the first embodiment, the roll 11A has recesses 11AA, 11AB, and 11AC corresponding to the recesses 6HA, 6HB, and 6HC, as well as a nearby pressing unit 11AD that presses the areas corresponding to the recesses 6HA, 6HB, and 6HC. For ease of explanation, the recesses 11AA, 11AB, and 11AC and the nearby pressing unit 11AD are not shown in FIG. 12.

[0060] The pressing unit 11 feeds the absorbent body 6 sandwiched between the rolls 11A and 11B in the relative rotation direction, and compresses and bonds the absorbent body 6 at a plurality of pressing points corresponding to the positions of the protrusions 11T. The protrusions 11T formed on the cylindrical outer peripheral surface of the roll 11A may be formed on the cylindrical outer peripheral surface of the roll 11B, or may be formed on the cylindrical outer peripheral surfaces of both of these rolls. Furthermore, the protrusions 11T are not limited to being convex, but may be formed in a concave shape so that, for example, a continuous rib shape is pressed against the opposing cylindrical surface to effect compression bonding.

[0061] The protrusion 11T has a first extended protrusion 11TA extending in one direction and a second extended protrusion 11TB intersecting the first extended protrusion 11TA and extending in another direction. In the second embodiment, the protrusion 11T has the first extended protrusions 11TA and the second extended protrusions 11TB intersecting each other so as to form a lattice pattern.

[0062] In the compression portion forming step (step S204) shown in FIG. 11 , grooves 20B are formed on the upper core wrap sheet 7A side of the absorbent body 6, intersecting with grooves 20A extending in one direction and extending in the other direction, corresponding to the first extended projections 11TA and second extended projections 11TB provided on the roll 11A. Intersections 6K between grooves 20A and 20B correspond to recesses 6HA, 6HB, and 6HC (protrusions 18A, 18B, and 18C). By locating intersections 6K in correspondence with recesses 6HA, 6HB, and 6HC, the compressed region is free of absorbent material or has a thinner absorbent material than the surrounding area, facilitating compression. In the second embodiment, grooves 20A are formed corresponding to the first extended projections 11TA provided on the roll 11A, and grooves 20B are formed corresponding to the second extended projections 11TB provided on the roll 11A.

[0063] As described above, in the compressed portion forming step (step S204), the range that intersects with the areas corresponding to convex portions 18A, 18B, and 18C is compressed to form compressed portions 20. The range that intersects with the areas corresponding to convex portions 18A, 18B, and 18C is the area where grooves 20A and 20B corresponding to first extended projection 11TA and second extended projection 11TB are provided, because the area that intersects with the areas corresponding to convex portions 18A, 18B, and 18C corresponds to intersection 6K. When forming compressed portions 20 in the compressed portion forming step (step S204), in the range that intersects with the areas corresponding to convex portions 18A, 18B, and 18C, the areas corresponding to convex portions 18A, 18B, and 18C and their vicinity are pressed simultaneously with the other areas with a pressing force that is lower than that of other areas. By pressing the areas corresponding to the protrusions 18A, 18B, and 18C and their vicinity with a lower pressing force than the other areas at the same time as the other areas, the absorbent body 6 can be pressed to form the grooves 20A and 20B. This can prevent the upper-layer core wrap sheet 7A from breaking. Note that the pressing step (step S104) in the first embodiment may be carried out before or after the grooves 20A and 20B are formed, and the entire absorbent body 6 may be pressed.

[0064] The pressing force of the pressing portion 11 is preferably higher near the grooves 20A and 20B other than the intersection 6K where the grooves 20A and 20B overlap than near the intersection 6K, and is highest in the area other than the areas near the grooves 20A and 20B. The intersection 6K corresponds to the protrusions 18A, 18B, and 18C, and the SAP particles accumulate near the intersection 6K due to the slopes of the protrusions 18A, 18B, and 18C. Therefore, it is preferable to apply a lower pressing force to the area near the intersection 6K than to other areas. Furthermore, since the grooves 20A and 20B correspond to the first extended projections 11TA and the second extended projections 11TB, they press the absorbent body 6 by the thickness of the first extended projections 11TA and the second extended projections 11TB, which may tear the upper-layer core wrap sheet 7A. Therefore, it is preferable to apply a lower pressing force than to areas not corresponding to the projections 11T.

[0065] In the second embodiment, the protrusions 11T are formed in a lattice pattern by the first extended projections 11TA and the second extended projections 11TB as shown in FIG. 12(B). However, the shape is not limited to a lattice pattern as long as the protrusions 11T intersect with each other. For example, as shown in FIG. 12(C), the protrusions may be arranged in a hexagonal honeycomb lattice pattern, with the protrusions extending in three directions intersecting. The regions corresponding to the convex portions 18A, 18B, and 18C correspond to the intersection points 6K where the first extended projections 11TA and the second extended projections 11TB intersect. Therefore, forming the protrusions 11T in a lattice pattern is preferable because the concave portions 6HA, 6HB, and 6HC can be formed in a straight line on the forming plate 6F.

[0066] As described above, the manufacturing method for the diaper 1 according to the second embodiment includes a compressed portion forming step (step S204) to form the compressed portions 20. At this time, by pressing the areas corresponding to the protrusions 18A, 18B, and 18C and their vicinity with a lower pressing force than other areas at the same time as the other areas, tearing of the upper core wrap sheet 7A can be suppressed even when the absorbent body 6 is pressed to form the grooves 20A and 20B. Furthermore, tearing of the upper core wrap sheet 7A can be suppressed by compressing the area near the area corresponding to the intersection 6K of the grooves 20A and 20B more shallowly than other areas.

[0067] <Third embodiment> Next, a third embodiment will be described. The method for manufacturing a diaper 1 according to the third embodiment may include, in addition to the method for manufacturing a diaper 1 according to the second embodiment, a pressing-portion-forming step of forming pressed portions by pressing in areas other than the areas corresponding to the recesses 6HA, 6HB, and 6HC and their vicinity. FIG. 13 is a flowchart showing the method for manufacturing a diaper 1 according to the third embodiment. The steps from the stacking step (step S301) to the compressed-portion-forming step (step S304) are the same as the steps from the stacking step (step S201) to the compressed-portion-forming step (step S204) in the second embodiment. The top sheet positioning step (step S306) is the same as the top sheet positioning step (step S205) in the second embodiment. The method for manufacturing a diaper 1 according to the third embodiment includes a pressing-portion-forming step (step S305) following the compressed-portion-forming step (step S304). The pressed portion forming step (step S305) may be performed between the covering step (step S303) and the top sheet arranging step (step S306), and may be performed before the squeezing step (step S304). The pressed portion forming step (step S305) forms pressed portions in areas other than the vicinity of the areas corresponding to the protrusions 18A, 18B, and 18C. The pressed portions are, for example, compressed portions formed by squeezing the absorbent body 6.

[0068] FIG. 14 is a plan view of a diaper 1 having an absorbent body 6 formed by the method for manufacturing a diaper 1 according to the third embodiment. For the sake of explanation, some components are not shown. In the absorbent body 6 manufactured by the manufacturing method of the diaper 1 according to this embodiment, in addition to the compressed portions 20, compressed portions 19 are formed in regions other than the vicinity of the regions corresponding to the protrusions 18A, 18B, and 18C by the pressing portion forming step (step S305). The regions near the regions corresponding to the protrusions 18A, 18B, and 18C have a high SAP density because SAP particles are deposited therein. When the compressed portions 19 are formed by pressing, strong pressure must be applied by the rolls 11A and 11B to the positions where the compressed portions 20 are to be formed. Here, the density of SAP particles is high near the regions corresponding to the protrusions 18A, 18B, and 18C, making the upper-layer core wrap sheet 7A prone to tearing. For this reason, the compressed portions 19 are formed in a manner that avoids the vicinity of the regions corresponding to the protrusions 18A, 18B, and 18C, thereby preventing the upper-layer core wrap sheet 7A from tearing.

[0069] In this way, in the manufacturing method of the diaper 1 of the third embodiment, when a compression portion 19 is provided in addition to the compression portion 20, tearing of the upper core wrap sheet 7A is suppressed by providing the compression portion 19 in areas other than the areas corresponding to the convex portions 18A, 18B, and 18C and their vicinity.

[0070] 14, the compression portions 19 are illustrated as being circular, but are not limited to being circular. For example, the compression portions 19 may be elliptical, rectangular, or extending in the longitudinal or transverse direction of the diaper 1.

[0071] <Fourth embodiment> Next, a fourth embodiment will be described. The diaper 1 manufactured by the manufacturing method for the diaper 1 according to the fourth embodiment may be manufactured by disengaging the upper core wrap sheet 7A from the top sheet 8 in the vicinity of the regions corresponding to the convex portions 18A, 18B, and 18C of the diaper 1 manufactured by the manufacturing method for the diaper 1 according to the second embodiment, thereby preventing tearing of the top sheet 8. That is, the upper core wrap sheet 7A and the top sheet 8 are intermittently bonded together in the top sheet positioning step (step S105). For example, the upper core wrap sheet 7A and the top sheet 8 are intermittently bonded together by partially applying an adhesive such as a hot melt to at least one of the upper core wrap sheet 7A and the top sheet 8. Therefore, the diaper 1 bonds the upper core wrap sheet 7A and the top sheet 8 and has a plurality of bonded areas (bonded regions) spaced apart from one another between the upper core wrap sheet 7A and the top sheet 8. The plurality of bonded areas are formed by adhesive that intermittently bonds the upper core wrap sheet 7A and the top sheet 8 together. The multiple bonded portions are arranged in predetermined regions including the regions of the upper core wrap sheet 7A where the compressed portions 20 are formed. The multiple bonded portions may be formed linearly, curvedly, or bent. The diaper 1 has multiple non-bonded portions (non-bonded regions) provided between the upper core wrap sheet 7A and the top sheet 8 and spaced apart from one another, where the upper core wrap sheet 7A and the top sheet 8 are not bonded. The multiple non-bonded portions are arranged near the regions of the upper core wrap sheet 7A where the compressed portions 20 are formed and in the vicinity of regions corresponding to the protrusions 18A, 18B, and 18C.

[0072] Furthermore, in the covering step (step S103), the absorbent core 6C and the core wrap sheet 7 may be intermittently bonded together. For example, by partially applying an adhesive such as hot melt to at least one of the absorbent core 6C and the core wrap sheet 7, the absorbent core 6C and the core wrap sheet 7 are intermittently bonded together. Therefore, the diaper 1 has a plurality of bonded parts (bonded regions) that bond the absorbent core 6C and the core wrap sheet 7 together and are spaced apart from each other between the absorbent core 6C and the core wrap sheet 7. The plurality of bonded parts are formed by an adhesive that intermittently bonds the absorbent core 6C and the core wrap sheet 7 together. The plurality of bonded parts are arranged in predetermined regions including the region in which the compressed parts 20 of the absorber 6 are formed. The plurality of bonded parts may be formed linearly, curvedly, or bently. The diaper 1 has a plurality of non-bonded parts (non-bonded regions) that are spaced apart from each other between the absorbent core 6C and the core wrap sheet 7 and where the absorbent core 6C and the core wrap sheet 7 are not bonded together. The non-adhesive portions are arranged in the vicinity of the region in the absorbent body 6 where the compressed portions 20 are formed and the regions corresponding to the protrusions 18A, 18B, and 18C.

[0073] Figure 15(A) is a cross-sectional view of a diaper 1 manufactured by the manufacturing method of the diaper 1 according to the fourth embodiment, taken in a direction perpendicular to the extension direction of the groove 20A, showing an enlarged cross-sectional view of the groove 20A and its vicinity. Figure 15(B) is a cross-sectional view of a diaper 1 manufactured by the manufacturing method of the diaper 1 according to the fourth embodiment, taken in a direction perpendicular to the extension direction of the groove 20B, showing an enlarged cross-sectional view of the groove 20B and its vicinity. Note that for the sake of explanation, some components are not shown in Figure 15. An adhesive 21 is intermittently provided between the upper core wrap sheet 7A and the top sheet 8, bonding the upper core wrap sheet 7A and the top sheet 8 together. By bonding the upper core wrap sheet 7A and the top sheet 8 together, the upper core wrap sheet 7A and the top sheet 8 are closely attached to each other. When the upper-layer core wrap sheet 7A and the top sheet 8 are brought into close contact with each other, the shapes of the grooves 20A and 20B formed on the skin-facing side of the absorbent body 6 are transferred to the top sheet 8, and grooves corresponding to the grooves 20A and 20B are formed in the top sheet 8. Air flows along the grooves formed in the top sheet 8, improving the breathability of the diaper 1. Urine excreted by the wearer is dispersed along the grooves formed in the top sheet 8 to the portions of the top sheet 8 that overlap with the absorbent body 6. This allows the diaper 1 to efficiently absorb urine excreted by the wearer throughout the entire absorbent body 6. An adhesive 21 that bonds the absorbent core 6C to the core wrap sheet 7 may be intermittently provided between the absorbent core 6C and the core wrap sheet 7. That is, a plurality of adhesives 21 that bond the absorbent core 6C to the core wrap sheet 7 may be provided between the absorbent core 6C and the core wrap sheet 7. By bonding the absorbent core 6C to the core wrap sheet 7, the absorbent core 6C and the core wrap sheet 7 are brought into close contact with each other.

[0074] In the groove 20A of the compression section 20, there is provided, between the upper core wrap sheet 7A and the top sheet 8, a bonded portion where the upper core wrap sheet 7A and the top sheet 8 are bonded together, and a non-bonded portion where the upper core wrap sheet 7A and the top sheet 8 are not bonded together. Similarly, in the groove 20B of the compression section 20, there is provided, between the upper core wrap sheet 7A and the top sheet 8, a bonded portion where the upper core wrap sheet 7A and the top sheet 8 are bonded together, and a non-bonded portion where the upper core wrap sheet 7A and the top sheet 8 are not bonded together.

[0075] When the upper core wrap sheet 7A of the absorbent body 6 has compressed portions 20, the upper core wrap sheet 7A is pulled along the shape of the compressed portions 20 when the absorbent body 6 is compressed from the skin-facing side. Pulling the upper core wrap sheet 7A makes the upper core wrap sheet 7A thinner and more susceptible to tearing. For example, if the entire skin-facing side of the upper core wrap sheet 7A is bonded to the top sheet 8, the force generated when the upper core wrap sheet 7A tears is more likely to be transmitted to the top sheet 8, which may tear the top sheet 8. In the fourth embodiment, by intermittently bonding the upper core wrap sheet 7A and the top sheet 8 together, the diaper 1 has a plurality of non-adhesive portions spaced apart from each other between the upper core wrap sheet 7A and the top sheet 8. The diaper 1 has a plurality of non-adhesive portions spaced apart from one another between the upper core wrap sheet 7A and the top sheet 8, which prevents the force of tearing the upper core wrap sheet 7A from being transmitted to the top sheet 8. This prevents the top sheet 8 from tearing. Furthermore, as described above, the density of SAP particles is high near the areas corresponding to the recesses 6HA, 6HB, 6HC (protrusions 18A, 18B, 18), so the upper core wrap sheet 7A near the areas corresponding to the recesses 6HA, 6HB, 6HC is prone to tearing. Therefore, the diaper 1 has a plurality of non-adhesive portions spaced apart from one another between the upper core wrap sheet 7A and the top sheet 8 in the areas corresponding to the recesses 6HA, 6HB, 6HC, which prevents the force of tearing the upper core wrap sheet 7A from being transmitted to the top sheet 8. This prevents the top sheet 8 from tearing.

[0076] 16(A), 16(B), and 16(C) are plan views of the upper-layer core wrap sheet 7A as viewed from the skin-facing side.

[0077] The adhesive 21 may have a spiral shape. In FIG. 16(A), the spiral-shaped adhesive 21 is formed on the upper core wrap sheet 7A. Alternatively, the spiral-shaped adhesive 21 may be formed between the absorbent core 6C and the upper core wrap sheet 7A. The spiral-shaped adhesive 21 is formed in a continuous line, and portions of the adhesive 21 and multiple non-adhesive portions are arranged alternately along a predetermined direction. The predetermined direction may be the orientation direction of the fibers contained in the upper core wrap sheet 7A (the fiber orientation direction of the upper core wrap sheet 7A) or a direction perpendicular to the fiber orientation direction of the upper core wrap sheet 7A. However, the predetermined direction is not limited to these, and may be another direction. When the upper layer core wrap sheet 7A is viewed in a plane, the adhesive 21 is formed in a spiral shape, and portions of the compressed portions 20 and portions of the adhesive 21 overlap each other. By applying the adhesive 21 in a spiral shape to the upper core wrap sheet 7A, areas where the adhesive 21 is applied and areas where the adhesive 21 is not applied are formed in the compressed portion 20. After applying the adhesive 21 to the upper core wrap sheet 7A, the top sheet 8 is placed on the upper core wrap sheet 7A, thereby intermittently bonding the upper core wrap sheet 7A and the top sheet 8. Furthermore, by applying the adhesive 21 in a spiral shape to the absorbent core 6C or the upper core wrap sheet 7A, areas where the adhesive 21 is applied and areas where the adhesive 21 is not applied are formed in the compressed portion 20. After applying the adhesive 21 to the absorbent core 6C or the upper core wrap sheet 7A, the upper core wrap sheet 7A is placed on the absorbent core 6C, thereby intermittently bonding the absorbent core 6C and the upper core wrap sheet 7A.

[0078] The adhesive 21 may have a serpentine shape. The serpentine shape may be a shape in which multiple mountain shapes and multiple valley shapes are arranged alternately. The serpentine shape may be a shape in which multiple arc shapes are arranged, with adjacent arc shapes facing in different directions. In Figures 16(B) and 16(C), a serpentine-shaped adhesive 21 is formed on the upper layer core wrap sheet 7A. The serpentine-shaped adhesive 21 is formed in a continuous line, with portions of the adhesive 21 and multiple non-adhesive portions arranged alternately along a predetermined direction. The predetermined direction may be the fiber orientation direction of the upper layer core wrap sheet 7A or a direction perpendicular to the fiber orientation direction of the upper layer core wrap sheet 7A. The predetermined direction is not limited to these, and may also be another direction. By applying the adhesive 21 to the upper layer core wrap sheet 7A in a serpentine shape, areas where the adhesive 21 is applied and areas where the adhesive 21 is not applied are formed in the compressed portion 20. After applying adhesive 21 to the upper core wrap sheet 7A, a top sheet 8 is placed on the upper core wrap sheet 7A, thereby intermittently bonding the upper core wrap sheet 7A and the top sheet 8. Furthermore, by applying adhesive 21 in a serpentine shape to the absorbent core 6C or the upper core wrap sheet 7A, areas where the adhesive 21 is applied and areas where the adhesive 21 is not applied are formed in the compressed portion 20. After applying adhesive 21 to the absorbent core 6C or the upper core wrap sheet 7A, the upper core wrap sheet 7A is placed on the absorbent core 6C, thereby intermittently bonding the absorbent core 6C and the upper core wrap sheet 7A. Furthermore, the adhesive 21 may have a shape in which a plurality of arc shapes and a plurality of straight lines are arranged alternately.

[0079] As shown in Figures 16(A) to 16(C), when the upper layer core wrap sheet 7A is viewed in a plane, the extension direction of the compressed portions 20 and the extension direction of the adhesive 21 intersect. Therefore, when the upper layer core wrap sheet 7A is viewed in a plane, a portion of the compressed portions 20 and a portion of the adhesive 21 overlap. When the upper layer core wrap sheet 7A is viewed in a plane, the extension direction of the grooves 20A and the extension direction of the adhesive 21 intersect, and the extension direction of the grooves 20B and the extension direction of the adhesive 21 intersect. Therefore, when the upper layer core wrap sheet 7A is viewed in a plane, a portion of the grooves 20A and a portion of the adhesive 21 overlap, and a portion of the grooves 20B and a portion of the adhesive 21 overlap.

[0080] When the extending direction of grooves 20A intersects with the extending direction of adhesive 21, adhesive 21 is present in part of the area of ​​the upper core wrap sheet 7A where grooves 20A are formed, and a non-adhesive portion is present in most of the area of ​​the upper core wrap sheet 7A where grooves 20A are formed. This prevents the force when the upper layer core wrap sheet 7A is pulled from being transmitted to the top sheet 8 in the area of ​​the upper core wrap sheet 7A where grooves 20A are formed, thereby preventing tearing of the top sheet 8. When the extending direction of grooves 20B intersects with the extending direction of adhesive 21, adhesive 21 is present in part of the area of ​​the upper core wrap sheet 7A where grooves 20B are formed, and a non-adhesive portion is present in most of the area of ​​the upper core wrap sheet 7A where grooves 20A are formed. This prevents the force when the upper layer core wrap sheet 7A is pulled from being transmitted to the top sheet 8 in the area of ​​the upper core wrap sheet 7A where grooves 20A are formed, thereby preventing tearing of the top sheet 8.

[0081] <Other embodiments> The present invention is applicable not only to tape-type diapers but also to pants-type diapers and absorbent pads.

[0082] The features included in each of the embodiments and modifications thereof disclosed above can be combined with each other. [Explanation of symbols]

[0083] 1. Diapers 1F: Front body area 1B...Inseam area 1R: Back area 2F Front patch 2L, 2R Tape 3LL, 3LR... Folded line 3BL,3BR··Leakage prevention wall 33L,33R・Fixed part 4. Cover sheet 4SL, 4SR, 9EL, 9ER... Elastic thread 5. Back seat 6. Absorber 6K...intersection 6C··Absorbent core 6HA, 6HB, 6HC recess 7. Core wrap sheet 7A··Upper layer core wrap sheet 7B··Lower layer core wrap sheet 8. Top sheet 9L, 9R side seats 9LA,9RA·Fixed area 9LB,9RB··Free end 11 Pressing section 11A, 11B Roll 11AA, 11AB, 11AC Recess 11AD·· Nearby pressing part 11T·Protrusion 12. Transport path 13. Lower layer core wrap sheet supply section 14. Absorbent core supply unit 15. Upper layer core wrap sheet supply section 16. Top sheet supply unit 17. Absorbent material supply section 18D forming drum 18F Forming Plate 18S··Molded Plate 18A, 18B, 18C··Convex part 19,20 Compression section 20A,20B·Groove 21. Adhesive M··Absorbent core manufacturing equipment

Claims

1. a depositing step of depositing an absorbent material containing SAP particles on a forming plate having a continuous series of protrusions; a transfer step of transferring the absorbent material deposited on the forming plate onto a first water-permeable sheet; a coating step of coating a second water-permeable sheet on the absorbent material on the side opposite to the side on which the first water-permeable sheet is transferred in the transferring step; a pressing step of pressing a region of the laminate covered with the first water-permeable sheet and the second water-permeable sheet corresponding to the convex portion and the vicinity of the region with a pressing force lower than that of other portions of the laminate simultaneously with the other portions, A method for manufacturing an absorbent article.

2. The pressing step presses the laminate by passing it between a pair of press rolls. A method for manufacturing the absorbent article according to claim 1.

3. In the pressing step, the depth to which the region corresponding to the convex portion is pressed is shallower within a range of 0.05 mm to 1 mm than the depth to which the vicinity of the region corresponding to the convex portion is pressed, and the depth to which the vicinity of the region corresponding to the convex portion is pressed is shallower within a range of 0.05 mm to 1 mm than the depth to which the other region is pressed. A method for manufacturing the absorbent article according to claim 1 or 2.

4. In the pressing step, a first extending pressing portion extending in one direction and a second extending pressing portion intersecting the first extending pressing portion and extending in another direction are formed, the pressing force is higher in the vicinity of the first extending pressing portion and the vicinity of the second extending pressing portion other than the intersection point than in the vicinity of the intersection point where the first extending pressing portion and the second extending pressing portion overlap, and is highest in a portion other than the vicinity of the first extending pressing portion and the portion other than the vicinity of the second extending pressing portion; A method for manufacturing the absorbent article according to claim 1 or 2.

5. the first extending pressing portion and the second extending pressing portion intersect in a lattice pattern; A method for manufacturing an absorbent article according to claim 4.

6. The vicinity is within a range of 10 mm. A method for manufacturing the absorbent article according to claim 1 or 2.

7. After the pressing step, a top sheet placing step is included in which a top sheet is placed on the second water-permeable sheet. A method for manufacturing the absorbent article according to claim 1 or 2.

8. The second water-permeable sheet and the top sheet are not bonded to each other in the vicinity of the second water-permeable sheet. A method for manufacturing an absorbent article according to claim 7.

9. the second water-permeable sheet and the top sheet are adhered to each other; When the second water-permeable sheet is viewed in plan, a continuous linear adhesive that bonds the second water-permeable sheet and the top sheet is formed in a spiral shape or a serpentine shape. A method for manufacturing an absorbent article according to claim 7.

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