Method for manufacturing absorbent article and absorbent article

Abstract

To provide a technology capable of improving wearing feeling of an absorbent article.SOLUTION: A manufacturing method of an absorbent article having an absorber for absorbing liquid discharged from a wearer, includes a recess / protrusion formation step for forming a protrusion by protruding partially the skin surface side of the absorber, while forming a recess by recessing partially the non-skin surface side of the absorber, and a skin surface side sheet sticking step for sticking a skin surface side sheet on the skin surface side of the absorber.SELECTED DRAWING: Figure 6

Description

[Technical field]

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

[0002] 2. Description of the Related Art It is known that in absorbent articles for absorbing liquids such as urine and body fluids, recesses such as compressed grooves are provided on the skin-facing side of an absorbent body (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-103782 A Summary of the Invention [Problem to be solved by the invention]

[0004] The recesses formed on the skin-facing side of the absorbent body expand and collapse when the absorbent body absorbs urine. When the recesses of the absorbent article collapse, the breathability secured by the recesses is lost. Therefore, the absorbent article has a problem in that the breathability decreases after the absorbent body absorbs urine, and the wearing comfort decreases.

[0005] An object of the present invention is to provide a technique capable of improving the wearing comfort of an absorbent article. [Means for solving the problem]

[0006] In order to solve the above problems, in the present invention, a recess is formed on the non-skin facing side of the absorbent body, and a protrusion is formed on the skin facing side of the absorbent body.

[0007] In detail, the present invention is a method for manufacturing an absorbent article having an absorbent body that absorbs liquid excreted by a wearer, and includes an unevenness forming process of partially indenting the non-skin-facing side of the absorbent body to form a recess, while partially making the skin-facing side of the absorbent body convex to form a convex portion, and a skin-facing sheet attachment process of attaching a skin-facing side sheet to the skin-facing side of the absorbent body.

[0008] In the manufacturing method of the above-mentioned absorbent article, in the unevenness forming step, the recesses may be formed in a groove shape on the non-skin side of the absorbent body, and the protrusions may be formed on the skin side of the absorbent body so as to correspond to the recesses.

[0009] In the method for producing an absorbent article, before the unevenness forming step, The above The method may include a step of arranging particles of SAP, which is a highly absorbent polymer, on the non-skin facing side.

[0010] The method for manufacturing the absorbent article includes: Not The non-skin-facing sheet attaching step of attaching the skin-facing sheet may include a non-skin-facing sheet attaching step of non-adhering at least a portion of the surface of the recess to the non-skin-facing sheet.

[0011] In the method for manufacturing an absorbent article described above, in the unevenness forming step, tops of a pair of adjacent protrusions may be formed so as to be inclined in directions facing each other.

[0012] In the method for manufacturing the absorbent article, the skin-facing sheet attachment step may be carried out after the unevenness forming step, and in the skin-facing sheet attachment step, the skin-facing sheet may be attached to the skin-facing side of the absorbent body in a state where it is aligned with the convex portions.

[0013] In the manufacturing method of the above-mentioned absorbent article, the skin-facing side sheet may be prepared with cuts, and the skin-facing side sheet attachment step may be carried out before the unevenness forming step, and in the unevenness forming step, the skin-facing side sheet may be pressed to align the skin-facing side sheet with the convex portions.

[0014] In the above-mentioned method for manufacturing an absorbent article, the absorbent body may have an absorbent core and a core wrap sheet that wraps the absorbent core and has an incision on the skin-facing side, and the unevenness forming process may be carried out in a state in which the absorbent core is wrapped in the core wrap sheet.

[0015] The present invention can also be understood from the aspect of an absorbent article. For example, the present invention is an absorbent article including an absorbent body that absorbs liquid discharged by a wearer, Non The absorbent body may be provided with a concave portion which is a partially concave portion on the skin side, a convex portion which is a partially convex portion on the skin side of the absorbent body, and a skin side sheet which is attached to the skin side of the absorbent body so as to follow the convex portion. Effect of the Invention

[0016] According to the present invention, it is possible to improve the wearing comfort of an absorbent article. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a perspective view of a diaper according to a first embodiment. [Diagram 2] FIG. 2 is an exploded perspective view of the diaper according to the first embodiment. [Diagram 3] FIG. 3 is a plan view of the diaper according to the first embodiment in a stretched state, as viewed from the skin-facing side. [Figure 4] FIG. 4 is a cross-sectional view of the diaper according to the first embodiment taken along the width direction. [Diagram 5] FIG. 5 is an enlarged cross-sectional view of the vicinity of recesses and protrusions of the diaper according to the first embodiment. [Figure 6] FIG. 6 is a flowchart showing a method for producing the diaper according to the first embodiment. [Figure 7] FIG. 7 is a diagram showing a manufacturing apparatus used in the method for manufacturing the diaper according to the first embodiment. [Figure 8] FIG. 8 is a cross-sectional view of a pressing device of the manufacturing apparatus used in the method for manufacturing the diaper according to the first embodiment, taken along the rotation axis direction. [Figure 9] FIG. 9 is an enlarged cross-sectional view of the vicinity of recesses and protrusions of a diaper according to Modification 1-1 of Embodiment 1. As shown in FIG. [Figure 10] FIG. 10 is a flowchart showing a method for producing a diaper according to Modification 1-1 of the first embodiment. [Figure 11] FIG. 11 is a diagram showing a manufacturing apparatus used in the method for manufacturing a diaper according to Modification 1-1 of the first embodiment. [Figure 12] FIG. 12 is a flowchart showing a method for producing a diaper according to Modification 1-2 of the first embodiment. [Figure 13] FIG. 13 is a diagram showing a manufacturing apparatus used in the method for manufacturing a diaper according to Modification 1-2 of the first embodiment. [Figure 14] FIG. 14 is a plan view of the diaper according to the second embodiment in a stretched state, as viewed from the skin-facing side. [Figure 15] FIG. 15 is a cross-sectional view of the diaper according to the second embodiment cut in the width direction. [Figure 16] FIG. 16 is an enlarged cross-sectional view of the vicinity of recesses and protrusions of the diaper according to the second embodiment. [Figure 17] FIG. 17 is a cross-sectional view of a pressing device of a manufacturing apparatus used in a method for manufacturing a diaper according to the second embodiment, taken along the axis of rotation. [Figure 18] FIG. 18 is a plan view of a diaper according to the third embodiment in a stretched state, as viewed from the skin facing side. [Figure 19] FIG. 19 is a cross-sectional view of the diaper according to the third embodiment cut in the width direction. [Figure 20] FIG. 20 is a flowchart showing a method for producing a diaper according to the third embodiment. [Figure 21] FIG. 21 is a plan view of the top sheet as viewed from the skin facing side. [Figure 22] FIG. 22 is a diagram showing a manufacturing apparatus used in the method for manufacturing a diaper according to the third embodiment. [Diagram 23] FIG. 23 is a plan view of a diaper according to the fourth embodiment in a stretched state, as viewed from the skin facing side. [Figure 24]FIG. 24 is a cross-sectional view of the diaper according to the fourth embodiment taken along the width direction. [Diagram 25] FIG. 25 is a plan view of the absorbent body as viewed from the skin facing side. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Hereinafter, absorbent articles according to embodiments of the present invention will be described with reference to the drawings. Note that the configurations of the following embodiments are merely examples, and the present invention is not limited to the configurations of these embodiments.

[0019] <Embodiment 1> In this 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 a "diaper") is the direction connecting the front body arranged opposite the wearer's abdomen and the rear body arranged opposite the wearer's back. Between the front body (one side in the longitudinal direction) and the rear body (the other side in the longitudinal direction) (the center in the longitudinal direction), a crotch portion arranged under the wearer's crotch (opposed to the crotch). In addition, 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 opposite side of the skin-facing side (the outer side when worn) is the non-skin-facing side. Furthermore, the direction connecting the skin-facing side and the non-skin-facing side is the thickness direction, and the direction perpendicular to both the longitudinal direction and the thickness direction is the width direction. In addition, the view from the thickness direction is the planar view.

[0020] FIG. 1 is a perspective view of a diaper according to the present embodiment. The diaper 1 has a crotch region 1B, which is a region corresponding to the crotch of the wearer covering the pubic area when worn, a front body region 1F, which is located in front of the crotch region 1B and corresponds to the front body of the wearer, and a back body region 1R, which is located behind the crotch region 1B and corresponds to the back body of the wearer. Tapes 2L and 2R that can be attached to a front patch 2F provided on the non-skin-facing surface of the front body region 1F are provided on both left and right edges of the back body region 1R. When the tapes 2L and 2R are attached to the front patch 2F with the front body region 1F positioned on the wearer's abdomen and the back body region 1R positioned on the wearer's back, the diaper 1 is fixed to the wearer's body in a state surrounding the wearer's waist circumference and thighs. Since the diaper 1 is fixed to the wearer's body in this manner, the wearer can stand and walk while wearing the diaper 1.

[0021] In the diaper 1, an absorbent capable of absorbing and retaining liquid is mainly disposed near the crotch region 1B. In order to prevent the formation of gaps between the diaper 1 and the wearer's skin that could serve as a path for liquid to flow out, the diaper 1 is provided with leg gathers 3AL, 3AR in areas surrounding the wearer's legs (thighs), and three-dimensional gathers 3BL, 3BR are provided widthwise inward of the leg gathers 3AL, 3AR, and a waist gather 3R is provided in areas surrounding the wearer's abdominal circumference. The leg gathers 3AL, 3AR, three-dimensional gathers 3BL, 3BR, and waist gathers 3R are fitted closely to the wearer's skin by the elastic force of the elastic members. Therefore, liquid excreted from the wearer's private parts is absorbed in the absorbent body of the diaper 1 without leaking out of the diaper 1. As the elastic member, thread-like or strip-like rubber or the like can be appropriately selected.

[0022] FIG. 2 is an exploded perspective view of the diaper 1. The diaper 1 has a cover sheet 4 that forms an outer surface when worn. The cover sheet 4 is a sheet-like member having a substantially rectangular appearance with constrictions 4KL, 4KR at the portions corresponding to the long sides, and forms the exterior surface of the diaper 1. The constrictions 4KL, 4KR are provided at the portions 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, in order to suppress leakage of excrement, a liquid-impermeable nonwoven fabric made of a thermoplastic resin can be used as the material for the cover sheet 4. Examples of thermoplastic resins include polyethylene (PE) and polypropylene (PP). The cover sheet 4 is not limited to a single-layer structure, but may be a multi-layer structure having an inner cover sheet and an outer cover sheet.

[0023] The diaper 1 has a back sheet 5 (an example of the "non-skin-facing sheet" in the present application), an absorbent 6, and a top sheet 7 (an example of the "skin-facing sheet" in the present application) which are laminated in this order on the wearer-facing surface of the cover sheet 4. The back sheet 5, the absorbent 6, and the top sheet 7 are all sheet-like members having a substantially rectangular appearance, and are laminated in this order on the cover sheet 4 with their longitudinal directions coinciding with the longitudinal direction of the cover sheet 4. The back sheet 5, like the cover sheet 4, is a sheet formed of a liquid-impermeable thermoplastic resin material to suppress leakage of excrement. The back sheet 5 is preferably made of a material that also has moisture permeability in order to suppress stuffiness when worn. The top sheet 7 is made of an air-through nonwoven fabric formed containing thermoplastic resin fibers, and is disposed on the wearer's skin-facing surface so as to cover the water-absorbing surface of the absorbent 6. The top sheet 7 is liquid-permeable in part or in whole. Therefore, when the diaper 1 is worn, liquid excreted by the wearer passes through the top sheet 7, which may come into contact with the wearer's skin, and enters the absorbent body 6, where it is absorbed. The top sheet 7 may be hydrophilic. The longitudinal direction of the diaper 1 is the same as the longitudinal directions of the absorbent body 6 and the top sheet 7.

[0024] The back sheet 5, absorbent body 6, and top sheet 7 all extend from the front body region 1F to the rear body region 1R. Therefore, when the wearer's private parts are covered with the cover sheet 4 in which the back sheet 5, absorbent body 6, and top sheet 7 are laminated, both ends in the longitudinal direction of the back sheet 5, absorbent body 6, and top sheet 7 are located on the wearer's ventral side and back side. In other words, the wearer's private parts are covered by the absorbent body 6 from the wearer's ventral side to the back side. Therefore, whether the wearer is in a ventral or back-facing position when excreting liquid, the excreted liquid comes into contact with the absorbent body 6 via the top sheet 7.

[0025] 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 stretch in the longitudinal direction of the diaper 1. The elastic members 4SL, 4SR are provided in an appropriate number (three in this embodiment) determined according to the elastic force (contractile force) required for the design of the diaper 1.

[0026] The diaper 1 also has long, narrow, strip-like side sheets 8L, 8R. The side sheets 8L, 8R are liquid-impermeable sheets provided on the long sides of the top sheet 7. Like the cover sheet 4, the side sheets 8L, 8R have constrictions 8KL, 8KR at the locations where the wearer's thighs are located. The side sheets 8L, 8R have elastic members 8EL, 8ER arranged along the longitudinal direction for forming three-dimensional gathers 3BL, 3BR. When the diaper 1 is worn, i.e., when the diaper 1 is U-shaped in side view, the side sheets 8L, 8R are pulled in the longitudinal direction by the contractile force of the elastic members 8EL, 8ER and rise from the top sheet 7, forming three-dimensional gathers 3BL, 3BR that prevent liquid from leaking out.

[0027] The cover sheet 4 is provided with elastic members 4C, which prevent a gap from being formed between the diaper 1 and the wearer's abdominal circumference, on the inner side in the width direction of the diaper 1 than the elastic members 4SL, 4SR and along the longitudinal direction of the diaper 1. The elastic members 4C are provided according to the elastic force (contractile force) required for the design of the diaper 1.

[0028] Furthermore, the elastic member 9ER for forming the above-mentioned waist gather 3R is provided between the back sheet 5 and the top sheet 7, at a position further back than the end of the absorbent body 6. The elastic member 9ER is provided between the back sheet 5 and the top sheet 7 with its longitudinal direction, which is the stretch direction, oriented in the left-right direction of the diaper 1. Thus, when the tapes 2L, 2R provided on both the left and right sides of the elastic member 9ER are attached to the front patch 2F on the abdominal side of the wearer, the elastic member 9ER exerts a contractile force to bring the diaper 1 into close contact with the wearer and prevent the formation of a gap between the diaper 1 and the wearer's abdominal circumference.

[0029] The absorbent body 6 has an absorbent core and a core wrap sheet that wraps the entire absorbent core (see FIG. 4). For the core wrap sheet, tissue paper or liquid-permeable nonwoven fabric is used. The absorbent core has a structure in which granular absorbent resin such as SAP (Super Absorbent Polymer), which is 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 fibers, rayon fibers, or cotton fibers, or short fibers obtained by hydrophilizing synthetic fibers such as polyethylene, polypropylene, or polyethylene terephthalate. Therefore, in the absorbent core, the volume change of the absorbent resin before and after absorbing liquid basically occurs within the short fibers that hold the absorbent resin in the gaps. Therefore, when the entire absorbent core is viewed from the outside, it can be said that the expansion rate of the thickness of the absorbent core that absorbs liquid is not as large as the expansion rate of the absorbent resin itself.

[0030] The SAP particles of this embodiment refer to a resin composition containing SAP in a granular form. The term "SAP-containing resin composition" as used herein includes both a composition consisting of SAP alone and a composition containing SAP as the main component and containing other substances to the extent that they do not adversely affect the water absorption. Examples of "other substances" include additives (such as surface modifiers added to make the particle surface hydrophobic) and unreacted monomers remaining during the synthesis of SAP.

[0031] Fig. 3 is a plan view of the diaper 1 in an extended state, as viewed from the skin side. Fig. 4 is a widthwise cross-sectional view of the diaper 1 taken along line AA in Fig. 3. Note that the front patch 2F, elastic members 4C, 4SR, 4SL, 8EL, 8ER, 9ER, and side sheets 8L, 8R are omitted from Figs. 3 and 4.

[0032] The diaper 1 according to this embodiment includes a rectangular absorbent body 6 and recesses 40 and protrusions 41 formed in a diagonal lattice pattern. The recesses 40 are formed on the non-skin-facing side of the absorbent body 6 and are concave on the skin-facing side. The protrusions 41 are formed on the skin-facing side of the absorbent body 6 and are convex on the skin-facing side. The protrusions 41 are formed by forming the recesses 40 so that the parts corresponding to the recesses 40 are convex on the skin-facing side. The corresponding positions here refer to positions that overlap in the thickness direction of the diaper 1. The process of forming the recesses 40 and the protrusions 41 will be described later.

[0033] Moreover, the recesses 40 are formed in the shape of grooves extending obliquely in the absorbent body 6. In the diaper 1, urine that has permeated the non-skin-facing side of the absorbent body 6 can be diffused throughout the absorbent body 6 along the recesses 40. This allows the diaper 1 to efficiently absorb urine excreted by the wearer with the entire absorbent body 6.

[0034] 4, the diaper 1 has protrusions 41 on the skin-facing side of the absorbent body 6, so that the top sheet 7 arranged on the skin-facing side of the absorbent body 6 is also raised by the protrusions 41 and becomes convex on the skin-facing side. This allows the diaper 1 to reduce the contact area between the skin and the top sheet 7, while forming a gap between the top sheet 7 in contact with the wearer's skin and the skin, thereby ensuring breathability (the ability to pass air, moisture, etc.) on the skin-facing side and improving the wearing comfort.

[0035] In addition, the top sheet 7 is attached to the skin-facing side of the absorbent body 6 so as to fit along the convex portions 41. The position and shape of the convex portions 41 are fixed by the top sheet 7. The top sheet 7 above the convex portions 41 is stretched more than other parts by being lifted toward the skin-facing side by the convex portions 41. Therefore, when the wearer urinates into the diaper 1 and the absorbent body 6 absorbs the urine and expands, the top sheet 7 above the convex portions 41 has more room than other parts, so that the convex portions 41 protrude further toward the skin-facing side than other parts after the absorbent body 6 absorbs urine. As a result, the diaper 1 can reduce the contact area between the skin and the top sheet 7 even after urine absorption, while ensuring breathability on the skin-facing side and suppressing stuffiness when worn, thereby improving the wearing comfort.

[0036] Furthermore, when a recess formed by squeezing is provided on the skin-facing side of the absorbent body, even if the recess ensures breathability before the absorbent body absorbs urine, the SAP expands and the recess collapses after the absorbent body absorbs urine, resulting in a problem that breathability cannot be ensured. However, according to the diaper 1 of this embodiment, by providing the protrusions 41 on the skin-facing side of the absorbent body 6, a gap is formed between the wearer and the top sheet 7, and breathability can be ensured. Furthermore, the diaper 1 can ensure breathability by maintaining the shape of the protrusions 41 even after the absorbent body 6 absorbs urine. This allows the diaper 1 to improve the wearing comfort.

[0037] Fig. 5 is an enlarged view of the vicinity of the recessed portions 40 and the protruding portions 41 in Fig. 4. The top sheet 7 is not adhered to the entire surface of the protruding portions 41, and is adhered to the surface of the absorbent body 6 outside the protruding portions 41 with a hot melt adhesive 30. Because the top sheet 7 is not adhered on the protruding portions 41, the protruding portions 41 are more likely to become convex on the skin-facing side after the absorbent body 6 absorbs urine.

[0038] 5, the recess 40 has a substantially trapezoidal cross-sectional shape, and includes a bottom 40B and a pair of walls 41L, 41R provided on the left and right sides of the bottom 40B. The protrusion 41 has a substantially trapezoidal cross-sectional shape similar to the recess 40, and includes a top 41T and a pair of walls 41L, 41R provided on the left and right sides of the top 41T. Here, the recess 40 may be formed by squeezing at least a part of the absorbent 6, and in this embodiment, the region P between the walls 40L, 40R and the walls 41L, 41R in the absorbent core 6A is squeezed. The diaper 1 is more likely to retain the shape of the protrusion 41 by squeezing the region P of the absorbent core 6A. Furthermore, by making the compression rate of the skin-facing side of the apex 41T of the convex portion 41 lower than the compression rate of area P which is the skin-facing side of the wall portions 41L, 41R, the apex 41T which indirectly comes into contact with the skin via the top sheet 7 is not hardened, preventing a decrease in texture and thereby preventing a decrease in wearing comfort.

[0039] Next, a method for manufacturing the diaper 1 according to this embodiment will be described. The method for manufacturing the diaper 1 according to this embodiment is characterized by the steps of forming the recesses 40 and the protrusions 41 in the absorbent body 6, and therefore these steps will be mainly described below. FIG. 6 is a flow chart showing an outline of the method for manufacturing the diaper 1 according to this embodiment. In the method for manufacturing the diaper 1 according to this embodiment, first, the recesses 40 and the protrusions 41 are formed in the absorbent body 6 (step S101, an example of the "protrusion-recess forming step" in this application). Next, the top sheet 7 is attached to the skin-facing side of the absorbent body 6 so as to be aligned with the protrusions 41 (step S102, an example of the "skin-facing sheet attaching step" in this application). In this embodiment, the top sheet attaching step is performed after the protrusion-recess forming step.

[0040] Next, a manufacturing method of the diaper 1 according to the present embodiment will be described in more detail with reference to Figs. 7 and 8. A detailed explanation will be given below. Fig. 7 is a diagram showing an example of a manufacturing apparatus for the diaper 1. The manufacturing apparatus M used in the manufacturing method for the diaper 1 includes a transfer line M1, a press device M2, an application device M4, and a top sheet supply roller M5. The transfer line M1 is a conveyor that transfers the absorbent body 6 and the top sheet 7 in a fixed direction (the direction of the arrow A1 in the figure). In the manufacturing process, the absorbent body 6 and the top sheet 7 are continuous bodies, and the absorbent body 6 and the top sheet 7 for one diaper are obtained by dividing them into individual bodies.

[0041] In the conveyor line M1, the absorbent body 6 is conveyed with the skin-facing side facing up. The press device M2 has an upper roller M21 and a lower roller M22. FIG. 8 is a cross-sectional view of the press device M2 cut in the rotation axis direction. The upper roller M21 is disposed on the skin-facing side of the absorbent body 6 (upper side in the figure), and the lower roller M22 is disposed on the non-skin-facing side of the absorbent body 6 (lower side in the figure). The upper roller M21 and the lower roller M22 are disposed opposite each other with a predetermined clearance. The lower roller M22 has a cylindrical shape, and a convex portion M22C for forming the oblique lattice-shaped concave portion 40 in the absorbent body 6 is provided on the side of the cylindrical shape. The upper roller M21 has a cylindrical shape, and a concave portion M21D for forming the oblique lattice-shaped convex portion 41 in the absorbent body 6 is provided on the side of the cylindrical shape. When the absorbent body 6 passes between the upper roller M21 and the lower roller M22, the recessed portion 40 and the protruding portion 41 are formed in the portion sandwiched between the protruding portion M22C and the recessed portion M21D. The clearance between the upper roller M21 and the lower roller M22 is D1 except for the protruding portion M22C and the recessed portion M21D, D1 between the top of the protruding portion M22C and the bottom of the recessed portion M21D, and D2 between the side of the protruding portion M22C and the side of the recessed portion M21D. D1 is approximately the same as the thickness of the absorbent body 6 in its natural state, and D2 is shorter than D1. This allows the pressing device M2 to squeeze the region P between the walls 40L, 40R of the recessed portion 40 and the walls 41L, 41R of the protruding portion 41.

[0042] An applicator M4 is provided downstream of the press device M2 on the transport path of the transport line M1. The applicator M4 applies hot melt adhesive to the skin-facing side of the absorbent body 6. The applicator M4 has multiple nozzles, and applies the hot melt adhesive to the absorbent body 6 in stripes or dots by ejecting the hot melt adhesive from each nozzle.

[0043] A top sheet supply roller M5 is provided downstream of the coating device M4 on the transport path of the transport line M1. The top sheet supply roller M5 places a continuous top sheet 7 from a long raw material roll onto the absorbent body 6 placed on the transport line M1. At this time, the top sheet 7 is placed on the absorbent body 6 in a state where it is aligned with the protrusions 41 (step S102 shown in FIG. 6).

[0044] In the diaper 1 manufactured by the manufacturing method of the diaper 1 according to this embodiment, the convex parts 41 are provided on the skin-facing side of the absorbent body 6, thereby forming gaps between the wearer and the top sheet 7 and ensuring breathability. Furthermore, the diaper 1 can ensure breathability by maintaining the shape of the convex parts 41 even after the absorbent body 6 has absorbed urine. This improves the wearing comfort of the diaper 1.

[0045] <Variation 1-1> Next, a diaper 1 according to Modification 1-1 of this embodiment will be described. FIG. 9 is an enlarged view of the recesses 40 and the protrusions 41, similar to FIG. 5. In the diaper 1 according to this modification, SAP particle groups 32 are arranged on the non-skin-facing side of the absorbent core 6A, so that the fibers on the non-skin-facing side of the absorbent core 6A and the SAP particles are entangled with each other to exert an anchor effect. When the absorbent core 6A is squeezed or compressed, a restoring force is generated in response to this, but the anchor effect of the SAP suppresses the restoring force of the absorbent core 6A. In the diaper 1, the anchor effect suppresses the restoring force of the absorbent core 6A, which makes it easier to maintain the shape of the recesses 40. The anchor effect is exerted more strongly as the density of SAP in the absorbent core 6A increases and the entanglement between the SAP and the absorbent core 6A becomes stronger.

[0046] In addition, by disposing the SAP particle group 32 on the non-skin-facing side of the absorbent core 6A, the absorbent core 6A mainly absorbs and retains urine on the non-skin-facing side, so that the non-skin-facing side of the absorbent core 6A expands after absorbing urine. If the skin-facing side of the absorbent core 6A expands, the absorbent core 6A including the convex portions 41 on the skin-facing side will become flat or nearly flat. However, in this modification, the absorbent core 6A has the SAP particle group 32 disposed on the non-skin-facing side, so that the skin-facing side is less likely to expand even after absorbing urine. Therefore, the diaper 1 according to this modification easily maintains the shape of the convex portions 41 formed on the skin-facing side. As a result, the diaper 1 maintains the convex portions 41 even after absorbing urine, ensuring breathability and improving the wearing comfort.

[0047] Next, a method for manufacturing the diaper 1 according to this modification will be described. Fig. 10 is a flow chart showing an outline of the method for manufacturing the diaper 1 according to this modification. In the method for manufacturing the diaper according to this modification, first, SAP particles are dispersed on the non-skin facing side of the absorbent core 6A (step S201, an example of the "SAP disposing step" as referred to in this application). The following steps S202 and S203 are the same as steps S101 and S102 shown in Fig. 6, and therefore description thereof will be omitted.

[0048] Next, the manufacturing method of the diaper 1 according to this modification will be described in more detail with reference to Fig. 11. Fig. 11 is a diagram showing an example of a manufacturing apparatus for the diaper 1. The manufacturing apparatus M used in the manufacturing method for the diaper 1 includes a conveying line M10, a SAP spraying device M11, a conveying line M1, a pressing device M2, an application device M4, and a top sheet supply roller M5. The conveying line M10 is a conveyor that conveys the absorbent core 6A in a fixed direction (the direction of the arrow A1 in the figure).

[0049] On the conveyor line M10, the absorbent core 6A is conveyed with the non-skin facing side facing up. The SAP spraying device M11 sprays SAP particles onto the non-skin facing side of the absorbent core 6A (step S201 shown in FIG. 10). After the SAP particles are sprayed onto the absorbent core 6A, it is wrapped in a core wrap sheet 6B (not shown). This completes the absorbent body 6. The absorbent body 6 is conveyed to the conveyor line M1 where the next manufacturing process is carried out. The process on the conveyor line M1 is the same as that in the above-mentioned embodiment 1.

[0050] According to the manufacturing method of the diaper 1 of this modified example, the SAP particle group 32 is arranged on the non-skin facing side of the absorbent core 6A, thereby exerting an anchor effect, suppressing the restoring force of the absorbent core 6A and making it easier to maintain the shape of the recesses 40.

[0051] <Variation 1-2> Next, a method for manufacturing the diaper 1 according to the modified example 1-2 of this embodiment will be described. FIG. 12 is a flow chart showing an outline of the method for manufacturing the diaper 1 according to this modified example. In the method for manufacturing the diaper according to this modified example, after the top sheet 7 is attached in a stretched state to the skin-facing side of the absorbent body 6 (after step S102 shown in FIG. 6), the back sheet 5 is attached to the non-skin-facing side of the absorbent body 6 (step S103, an example of the "non-skin-facing sheet attachment step" in this application). In step S103, at least a part of the surface of the recess 40 is not bonded to the back sheet 5. As a result, a gap is formed between the recess 40 and the back sheet 5, so that the recess 40 can function as a flow path for diffusing urine. As a result, the diaper 1 can easily diffuse urine on the non-skin-facing side of the absorbent body 6, and can absorb and retain more urine on the non-skin-facing side of the absorbent body 6. Therefore, the diaper 1 can maintain the convex parts 41 formed on the skin-facing side of the absorbent body 6 even after absorbing urine, and the convex parts 41 can ensure breathability. In this modification, step S201 (SAP placement step) shown in Fig. 10 may be performed before step S101. In this case, by covering the non-skin facing side of the absorbent body 6 with the back sheet 5, it is possible to prevent the SAP from spilling out of the diaper 1 even if the non-skin facing side of the core wrap sheet 6B is torn.

[0052] Next, the manufacturing method of the diaper 1 according to this modification will be described in more detail with reference to FIG. 13. FIG. 13 is a diagram showing an example of a manufacturing apparatus for the diaper 1. The manufacturing apparatus M used in the manufacturing method for the diaper 1 includes a conveying line M30, an applicator M7, and a backsheet supply roller M8. The conveying line M30 is a conveyor that conveys the backsheet 5, the absorbent body 6, and the topsheet 7 in a fixed direction (the direction of the arrow A1 in the figure). In the manufacturing process, the backsheet 5, the absorbent body 6, and the topsheet 7 are continuous bodies, and the backsheet 5, the absorbent body 6, and the topsheet 7 for one diaper are obtained by dividing them individually. Note that the topsheet 7 has already been attached to the absorbent body 6, and the absorbent body 6 and the topsheet 7 are conveyed with the absorbent body 6 facing up.

[0053] The applicator M7 has a plurality of nozzles for discharging hot melt adhesive, and applies the hot melt adhesive in stripes or dots to the absorbent body 6. A back sheet supply roller M8 is provided downstream of the applicator M7 on the conveying path of the conveying line M30. The back sheet supply roller M8 places the back sheet 5, which is a continuous body, from a long original roll onto the absorbent body 6 placed on the conveying line M1 (step S103 shown in FIG. 12). At this time, the back sheet 5 is placed on the absorbent body 6 in a stretched state. As in this modification, by not adhering at least a part of the surface of the recess 40 to the back sheet 5, a gap can be formed between the recess 40 and the back sheet 5.

[0054] Furthermore, urine that reaches the non-skin facing side of the absorbent body 6 spreads throughout the absorbent body 6 through the recesses 40. Because SAP is disposed on the non-skin facing side of the absorbent core 6A, the absorbent body 6 retains urine on the non-skin facing side, which causes the non-skin facing side to expand. Therefore, even after absorbing urine, the absorbent body 6 is less likely to expand on the skin facing side, and the shape of the protrusions 41 formed on the skin facing side can be easily maintained.

[0055] <Embodiment 2> Next, a diaper 1 according to a second embodiment will be described. The same components as those of the diaper 1 and the manufacturing apparatus M according to the above embodiment will be denoted by the same reference numerals and will not be described. FIG. 14 is a plan view of the diaper 1 in an extended state as viewed from the skin side. FIG. 15 is a cross-sectional view of the diaper 1 in the width direction taken along line BB in FIG. 14. The front patch 2F, the elastic members 4C, 4SR, 4SL, 8EL, 8ER, 9ER, and the side sheets 8L and 8R are omitted in FIGS. 14 and 15. FIG. 16 is an enlarged view of two recesses 40 and protrusions 41 in FIG. 15. The dashed line CL in FIG. 14 is the center line of the diaper 1 in the width direction. The center of the diaper 1 in the width direction coincides with the center of the absorbent body 6 in the width direction.

[0056] 16, in this embodiment, the apex 41T of the convex portion 41 on the left side in the width direction of the absorbent body 6 is inclined to the right side in the width direction, and the apex 41T of the convex portion 41 on the right side in the width direction of the absorbent body 6 is inclined to the left side in the width direction. This allows the diaper 1 to direct urine discharged by the wearer to the widthwise center portion, prevent lateral leakage of urine, and retain feces discharged by the wearer in the widthwise center portion.

[0057] Here, the two convex portions 41 shown in Fig. 16 can be regarded as a pair of adjacent convex portions 41 in the present application. By inclining the tops 41T of the pair of adjacent convex portions 41 in a direction facing each other, urine and feces can be guided between the pair of convex portions 41, and this space can function as a storage space. For example, the convex portions 41 surrounding the anus contact position of the diaper 1 are regarded as a pair of adjacent convex portions 41, and by inclining the tops 41T of the pair of convex portions 41 in a direction facing each other, the space between the pair of convex portions 41 can function as a storage space for storing feces.

[0058] Next, a method for manufacturing the diaper 1 according to the present embodiment will be described. In the manufacturing method according to the present embodiment, a press machine M2 shown in FIG. 17 is used. FIG. 17 shows the press machine M2 shown in FIG. 17 is a cross-sectional view of the device M2 cut in the direction of the rotation axis. For example, as shown in FIG. 17, by inclining the tops M21T of the recesses M21D of the upper roll M21 inward in the width direction, the tops 41T of the protrusions 41 can be formed to be inclined inward in the width direction in the unevenness forming step. The tops 41T of the protrusions 41 on the left side in the width direction of the absorbent 6 are inclined to the right side in the width direction, and the tops 41T of the protrusions 41 on the right side in the width direction of the absorbent 6 are inclined to the left side in the width direction. By inclining the tops M21T of the recesses M21D of the upper roll M21 in this way, the protrusions 41 can be formed so that the tops 41T are inclined.

[0059] <Embodiment 3> Next, a diaper 1 according to a third embodiment will be described. The same components as those of the diaper 1 and manufacturing apparatus M according to the above-mentioned embodiment will be denoted by the same reference numerals and will not be described. Fig. 18 is a plan view of the diaper 1 in a stretched state as viewed from the skin-facing side. Fig. 19 is a cross-sectional view of the diaper 1 in the width direction taken along line CC in Fig. 18. The front patch 2F, elastic members 4C, 4SR, 4SL, 8EL, 8ER, 9ER, and side sheets 8L, 8R are not shown in Figs. 18 and 19.

[0060] In this embodiment, holes 42 are formed in the top sheet 7. As shown in FIG. 18, for example, a plurality of holes 42 are formed in a staggered pattern. The arrangement pattern of the holes 42 does not have to be staggered, and may be, for example, a matrix pattern. Although the holes 42 are formed in a circular shape, they may be elliptical or other polygonal shapes. By providing the holes 42 in the top sheet 7, the diaper 1 according to this embodiment can improve the urine permeability and breathability of the top sheet 7. This allows the diaper 1 according to this embodiment to improve the wearing comfort.

[0061] Next, a method for manufacturing the diaper 1 according to the present embodiment will be described. In the manufacturing method according to the present embodiment, a top sheet 7 having slits is prepared, and a skin-facing sheet attachment step is performed before the unevenness forming step. FIG. 20 is a flow chart showing an outline of a manufacturing method for the diaper 1 according to the present embodiment. In the manufacturing method for the diaper according to the present embodiment, first, the prepared top sheet 7 is attached to the skin-facing side of the absorbent body 6 in a stretched state (step S301, an example of the "skin-facing sheet attachment step" in the present application). FIG. 21 is a plan view of the top sheet 7 prepared by the manufacturing method according to the present embodiment, as seen from the skin-facing side. A plurality of slits 43 extending in the width direction are formed in a staggered pattern in the top sheet 7. After step S301, recesses 40 and protrusions 41 are formed in the absorbent body 6 (step S302, an example of the "unevenness forming step" in the present application). In the present embodiment, a top sheet attachment step is performed before the unevenness forming step. When the top sheet 7 is pressed by the press device M2 in the unevenness forming step, the slits 43 extending in the width direction are stretched in the longitudinal direction to form circular holes 42.

[0062] Next, a manufacturing apparatus used in the manufacturing method of the diaper 1 according to this embodiment will be described with reference to Fig. 22. Fig. 22 is a diagram showing an example of the manufacturing apparatus for the diaper 1. The manufacturing apparatus M used in the manufacturing method of the diaper 1 includes a conveyor line M1, an application device M4, a top sheet supply roller M5, and a press device M2.

[0063] In the conveyor line M1, the absorbent body 6 is conveyed with the skin side facing up. In this embodiment, from the upstream side, the coating device M4, the top sheet supply roller M5, and the press device M2 are provided in this order. This allows the top sheet attachment process to be carried out before the unevenness formation process.

[0064] According to the manufacturing method of this embodiment, by providing cuts 43 in the top sheet 7, holes 42 can be formed from the cuts 43. Providing the holes 42 in the diaper 1 improves the urine permeability and breathability of the top sheet 7, thereby improving the wearing comfort.

[0065] <Embodiment 4> Next, a diaper 1 according to a fourth embodiment will be described. The same components as those of the diaper 1 and manufacturing apparatus M according to the above-mentioned embodiment will be denoted by the same reference numerals and will not be described. Fig. 23 is a plan view of the diaper 1 in a stretched state as viewed from the skin-facing side. Fig. 24 is a cross-sectional view of the diaper 1 in the width direction taken along line DD in Fig. 23. The front patch 2F, elastic members 4C, 4SR, 4SL, 8EL, 8ER, 9ER, and side sheets 8L, 8R are not shown in Figs. 22 and 23.

[0066] In this embodiment, holes 44 are formed on the skin-facing side of the core wrap sheet 6B. As shown in FIG. 23, for example, a plurality of holes 44 are formed in a staggered pattern. The arrangement pattern of the holes 44 does not have to be staggered, and may be, for example, a matrix pattern. The holes 44 are formed in a circular shape, but may be elliptical or other polygonal shapes. In the diaper 1 according to this embodiment, the holes 42 are provided on the skin-facing side of the core wrap sheet 6B, thereby improving the urine permeability and breathability of the skin-facing side of the absorbent 6. As a result, the diaper 1 according to this embodiment can improve the wearing comfort.

[0067] Next, a method for manufacturing the diaper 1 according to this embodiment will be described. In the manufacturing method according to this embodiment, an absorbent core 6A and a core wrap sheet 6B that wraps the absorbent core 6A and has a cut on the skin-facing side are prepared, and the unevenness forming step is performed in a state in which the absorbent core 6A is wrapped in the core wrap sheet 6B. After preparing an absorbent body 6 having a configuration in which the absorbent core 6A is wrapped in the core wrap sheet 6B, either the manufacturing method according to the above-mentioned embodiment 1 shown in FIG. 6 or the manufacturing method according to the above-mentioned embodiment 3 shown in FIG. 20 can be adopted. When the manufacturing method according to the above-mentioned embodiment 3 shown in FIG. 20 is adopted, the hole 42 is provided in the top sheet 7. The diaper 1 may be provided with the hole 42 in addition to the hole 44.

[0068] 25 is a plan view of the absorbent body 6 prepared by the manufacturing method according to this embodiment, seen from the skin side. A plurality of widthwise extending slits 45 are formed in a zigzag pattern in the core wrap sheet 6B of the absorbent body 6. In this embodiment, the absorbent core 6A is wrapped in the core wrap sheet 6B and pressed by the press device M2 in the unevenness forming step, whereby the widthwise extending slits 45 are stretched in the longitudinal direction to form circular holes 44.

[0069] According to the manufacturing method of this embodiment, by providing cuts 45 in the core wrap sheet 6B, holes 44 can be formed from the cuts 45. By providing the holes 44, the diaper 1 can improve the urine permeability and breathability of the skin-facing side of the absorbent body 6, thereby improving the wearing comfort.

[0070] <Other embodiments> Next, other embodiments will be described. The diaper 1 according to the above embodiment is a tape-type diaper, but the manufacturing method and manufacturing device for absorbent articles according to the present invention can be applied to the manufacture of pants-type diapers. In the above embodiment, the recesses 40 and the protrusions 41 are formed in a lattice pattern, but this is not limited thereto, and they may be formed in a dot pattern or a stripe pattern. By providing the protrusions 41 on the skin-facing side of the absorbent body 6, the diaper 1 can reduce the area that comes into contact with the wearer's skin, improving the wearing comfort.

[0071] In the above embodiment, the top sheet 7 may be composed of two nonwoven fabrics, and the lower sheet may be an example of the skin-facing sheet. The absorbent body 6 may not have the core wrap sheet 6B. In the above embodiments 2 to 4, the SAP arrangement step shown in Figs. 10 and 11 may be performed before the unevenness forming step. A group of SAP particles may be arranged on the skin-facing side of the absorbent core 6A. In this case, more SAP particles are arranged on the non-skin-facing side of the absorbent core 6A than on the skin-facing side. The above embodiments and modifications may be combined with each other. [Explanation of symbols]

[0072] 1. Diapers 1B...Inseam area 1F: Front body area 1R: Back body area 2F: Front patch 2L, 2R Tape 3BL, 3BR: 3D gathers 3R: Waist gather 4. Cover sheet 4KL, 4KR... Constriction 4C, 4SL, 4SR, 8EL, 8ER, 9ER Elastic material 5. Back sheet 6. Absorber 6A··Absorbent core 6B··Core wrap sheet 7. Top sheet 8. Side seat 30. Hot melt adhesive 32...SAP particle swarm 40 Recess 41 Protruding part 42...hole 43 Cutting 44...hole 45··Notch M··Manufacturing equipment M1··Conveyor line M2 Press Equipment M4...Coating device M5··Top sheet feed roller M6··Press device M7··Applicator M8··Backsheet supply roller M20··Conveyor Line M30··Conveyor Line M11...SAP spraying device

Claims

1. A method for manufacturing an absorbent article having an absorbent body that absorbs liquid discharged by a wearer, comprising: an unevenness forming step of partially recessing the non-skin facing side of the absorbent body to form a concave portion, and partially protruding the skin facing side of the absorbent body to form a convex portion; a skin-facing sheet attaching step of attaching a skin-facing sheet to the skin-facing side of the absorbent body; Including, In the unevenness forming step, the recesses are formed in a groove shape on the non-skin side of the absorbent body, and the protrusions are formed on the skin side of the absorbent body so as to correspond to the recesses. A method for manufacturing an absorbent article.

2. A SAP arranging step of arranging particles of SAP, which is a highly absorbent polymer, on the non-skin-facing side of the absorbent body prior to the unevenness forming step. The method for producing the absorbent article of claim 1 , comprising:

3. a non-skin-facing sheet attaching step of attaching a non-skin-facing sheet to the non-skin-facing side of the absorbent body, the non-skin-facing sheet being attached to at least a portion of the surface of the recess in such a manner that the non-skin-facing sheet is not adhered to the surface of the recess; The method for producing the absorbent article according to claim 1 or 2, comprising:

4. In the unevenness forming step, the tops of the pair of adjacent protrusions are formed so as to be inclined in directions facing each other. A method for producing an absorbent article according to any one of claims 1 to 3.

5. The skin-facing sheet attaching step is carried out after the unevenness forming step, In the skin-facing side sheet attaching step, the skin-facing side sheet is attached to the skin-facing side of the absorbent body in a state where the skin-facing side sheet is aligned with the convex portion. A method for producing an absorbent article according to any one of claims 1 to 4.

6. The skin-facing sheet having cuts is prepared, and the skin-facing sheet attaching step is carried out before the unevenness forming step; In the unevenness forming step, the skin side sheet is pressed to conform to the convex portions. A method for producing an absorbent article according to any one of claims 1 to 4.

7. The absorbent body has an absorbent core and a core wrap sheet that wraps the absorbent core and has a cut on the skin-facing side, The unevenness forming step is carried out in a state where the absorbent core is wrapped in the core wrap sheet. A method for producing an absorbent article according to any one of claims 1 to 6.

8. An absorbent article having an absorbent body that absorbs liquid discharged by a wearer, A recess formed by partially recessing the non-skin facing side of the absorbent body; A convex portion that partially convexly forms a skin-facing side of the absorbent body; a skin-facing sheet attached to the skin-facing side of the absorbent body so as to follow the convex portions; Equipped with The recess is formed in a groove shape on the non-skin side of the absorbent body, and the protrusion is formed on the skin side of the absorbent body so as to correspond to the recess. Absorbent articles.

Images