Manufacturing method of worn article

Abstract

The object is to provide a method for manufacturing a wearing article that can be changed between an initial pants-like shape and a predetermined developed shape and that can improve wearing comfort. [Solution] A method for manufacturing a worn article, comprising the steps of manufacturing a waistline member 10 having a waistline main body 16 stretchable in the width direction and a male fastener 12, joining an absorbent body 20 to the waistline main body 16, and folding the absorbent body 20 in half in the orthogonal direction, then folding both side portions 10a of the waistline member 10 in the width direction and engaging the male fastener 12 with the female fastener 22 of the absorbent body 20. The step of manufacturing the absorbent body 20 includes the step of manufacturing a core by holding SAP in a core-side first nonwoven fabric so that SAP having a lower density than the holding region that holds SAP is held and first low-density regions are formed that are adjacent to both ends of the holding region in the orthogonal direction.

Description

[Technical field]

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

[0002] Patent Documents 1 to 3 disclose wearing articles that can be unfolded from an initial pants-type form into a predetermined unfolded form, and can be assembled from the unfolded form into the pants-type form. These wearing articles include a belt-shaped waist part that is placed around the waist of the wearer, and an absorbent that extends from the front abdomen to the back of the wearer via the crotch part. The waist part has elasticity that allows it to stretch and contract along the width direction of the belt. The absorbent is joined to the waist part, and extends from the joining part perpendicular to the width direction of the waist part.

[0003] Before use, both ends of the waist portion are detachably engaged with the front end of the absorbent body, so that the article can be worn like pants.

[0004] When adjusting the state of the worn article during use, the worn article can be unfolded by releasing both ends of the waist portion from the tip end of the absorbent body.

[0005] Furthermore, by re-engaging both ends of the waist portion with the front end of the absorbent body from the unfolded state, the wearing article can be assembled into a pants-type garment. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2008-73216 A [Patent Document 2] Special Publication No. 2003-527152 [Patent Document 3] U.S. Patent No. 8,343,127 Summary of the Invention [Problem to be solved by the invention]

[0007] However, although the Patent Documents 1 to 3 allow the worn article to be changed between an initial pants-type form and an unfolded form, they do not take into consideration improvement of the wearing comfort in terms of the feel of the parts of the worn article that directly contact the skin. Therefore, there is a demand for improving the wearing comfort by improving such parts that directly contact the skin.

[0008] Therefore, the present invention has been made in consideration of the above-mentioned problems, and aims to provide a manufacturing method for a wearing article that can be changed in shape between an initial pants-like shape and a predetermined developed shape and that can improve wearing comfort. [Means for solving the problem]

[0009] A method for manufacturing a worn article for solving the above-mentioned problems is a method for manufacturing a worn article having a waist member to be placed around the waist of a wearer, and an absorbent body joined to the waist member and extending in a direction perpendicular to a width direction from a joint with the waist member so as to be placed from the back part of the wearer through the crotch part to the front abdomen, the method comprising the steps of: manufacturing the waist member having a waist main body to be placed around the waist of the wearer, the waist main body extending in the width direction and having elasticity to be stretchable and contractible in the width direction, and a first engagement portion provided on a surface facing the skin side of the wearer at both ends of the waist main body in the width direction; the absorbent body has a second engagement portion provided on an outer surface opposite to the surface facing the skin side and detachable from the first engagement portion; joining the absorbent body to the joint portion of the waist body so as to extend in the perpendicular direction from the waist body; and folding the absorbent body in half in the perpendicular direction, and then folding both side portions of the waist body member located on both sides of the joint portion in the width direction in the width direction to engage the first engagement portion with the second engagement portion. The manufacturing process of the absorbent body includes a step of manufacturing the core by retaining the absorbent polymer in a core-side first nonwoven fabric so as to form a retention region and a first low-density region that retains an absorbent polymer having a lower density than the retention region and is adjacent to both ends of the retention region in the perpendicular direction.

[0010] According to the above manufacturing method, a wearing article capable of improving wearing comfort can be manufactured. Specifically, according to the wearing article, the core-side first nonwoven fabric holds a water-absorbent polymer. Since the absorbent polymer has a higher absorption performance per unit volume than the fluff pulp, the amount of fluff pulp used can be reduced when fluff pulp is used. Therefore, the thickness of the core can be made thinner than that of a nonwoven fabric formed only from an amount of fluff pulp required for a predetermined absorption performance. Since the thickness of the wearing article including this core-side first nonwoven fabric is also thin, the wearing article can be easily adapted to fit the waist shape of the wearer, improving the fit of the wearing article.

[0011] In addition, the retention region has poor flexibility because the distribution density of the absorbent polymer is higher than that of the first low-density region. In contrast, the first low-density region has higher flexibility than the retention region because the distribution density of the absorbent polymer is lower than that of the retention region. Therefore, the core having the first low-density region is easily deformed. Here, when a wearer wears the worn article, both ends in the orthogonal direction of the retention region are arranged facing the front abdomen and back of the wearer, respectively. A first low-density region having a distribution density of the absorbent polymer lower than that of the retention region is arranged in a portion adjacent to both ends in the orthogonal direction of the retention region in the orthogonal direction. Therefore, the portion of the core where the first low-density region is arranged flexibly deforms to fit the body shape of the front abdomen and back, and the portion abuts against the front abdomen and back with a soft touch, thereby improving the wearing comfort of the worn article.

[0012] The above-mentioned worn article is in a pants-type form since the second engagement portion is engaged with the first engagement portion in the initial state, and the wearer can wear the worn article like pants. In addition, the worn article can be deployed into a predetermined form by releasing the engagement between the first engagement portion and the second engagement portion. In the deployed form, both sides of the waistband member protrude from the absorbent body arranged at the joint of the waistband member. These both sides can be brought toward the tip of the absorbent body along the wearer's waist and abutted against the back sheet of the absorbent body arranged along the wearer's crotch area. Then, the first engagement portions at both ends in the width direction of the waistband member are engaged with the second engagement portions of the back sheet to support the worn article with the waistband, and the absorbent body is pulled up and comes into close contact with the wearer's crotch area.

[0013] In the method for manufacturing the worn article, in the step of manufacturing the core, it is preferable that the absorbent polymer is retained in the core-side first nonwoven fabric so as to form a second low-density region having a lower density than the retention region and sandwiched in the width direction by the retention region.

[0014] According to the above manufacturing method, the core of the absorbent body is formed having a second low-density region in which the distribution density of the absorbent polymer is lower than that of the retention region. The retention region has poor flexibility due to the high distribution density of the absorbent polymer, whereas the second low-density region has higher flexibility than the retention region due to the low distribution density of the absorbent polymer. Therefore, the core having the second low-density region is easy to deform. Specifically, the second low-density region is formed so as to be sandwiched between the retention regions in the width direction. Therefore, by bending the core based on the second low-density region, the absorbent body can be easily deformed to fit the body shape, improving the fit.

[0015] In addition, urine, etc. can be effectively absorbed by diffusing urine, etc. in the perpendicular direction along the second low-density region, which absorbs less urine, etc. Furthermore, the second low-density region can be used as a region for the expansion of the water-absorbent polymer in the retention region, so that excessive adhesion of the absorbent body to the skin surface can be suppressed. Therefore, the sticky feeling on the skin surface caused by urine, etc. can be more quickly eliminated, and discomfort can be alleviated.

[0016] When the first engaging portion and the second engaging portion are engaged to support the wearing article around the waist and the absorbent body is in close contact with the crotch portion, the second low-density region of the core can improve the fit to the crotch portion before the absorption of bodily fluids. Furthermore, even after the absorption of bodily fluids, the second low-density region of the core can ensure expansion space for the absorbent polymer, so that the core can be prevented from expanding more than necessary toward the skin side, and a pleasant feel can be maintained.

[0017] In the method for manufacturing the wearing article, in the step of manufacturing the core, it is preferable that the second low-density region is formed so as to extend in the orthogonal direction.

[0018] According to the above-mentioned manufacturing method, it is possible to manufacture a wearing article having a core in which a second low-density region extending in the orthogonal direction is formed. In the wearing article, by bending the core with respect to the second low-density region extending in the orthogonal direction, it is possible to deform the absorbent body so as to conform to the body shape of the wearer over the range in which the second low-density region is formed in the orthogonal direction, and it is possible to further improve the fit of the wearing article.

[0019] In the above-mentioned method for manufacturing a worn article, the step of manufacturing the absorbent body preferably includes the steps of forming an uneven shape in a surface-side first nonwoven fabric, and, while maintaining the uneven shape, joining a surface-side second nonwoven fabric to an outer surface of the surface-side first nonwoven fabric opposite to the surface facing the skin side, thereby manufacturing the top sheet.

[0020] According to the wearing article manufactured by the above manufacturing method, the surface-side first nonwoven fabric of the topsheet is provided with an uneven shape. Thus, the convex parts of the uneven shape elastically come into point contact with the wearer's skin surface, and the concave parts allow air to pass through, providing good breathability, thereby improving the feel against the skin compared to a surface-contact between the topsheet and the skin surface. In addition, the surface-side first nonwoven fabric having the uneven shape is bonded to the surface-side second nonwoven fabric so that the uneven shape is maintained. Therefore, for example, even if the wearer presses the uneven shape by contact, the convex parts are unlikely to deform, and the pleasant feel due to the point contact with the convex parts can be maintained.

[0021] When the first engaging portion and the second engaging portion are engaged to support the wearing article around the waist and the absorbent body is in close contact with the crotch portion, the uneven shape of the topsheet can provide good breathability and texture before the absorption of bodily fluids. Furthermore, even after the absorption of bodily fluids, the uneven shape of the topsheet can maintain the good breathability and texture.

[0022] In addition, when the first nonwoven fabric on the front side of the topsheet has an uneven shape, and the second low-density region in the core is sandwiched in the width direction by the retaining region, the following effect is achieved: When the first engaging portion and the second engaging portion are engaged to support the wearing article around the waist and the absorbent body is in close contact with the crotch portion, before the absorption of bodily fluids, the uneven shape of the topsheet and the second low-density region of the core can improve the fit to the crotch portion while improving breathability and texture. Furthermore, even after the absorption of bodily fluids, the second low-density region of the core can ensure expansion space for the absorbent polymer, so that the core can be prevented from expanding more than necessary toward the skin side, and the uneven shape of the topsheet can maintain breathability and texture.

[0023] In the method for manufacturing the worn article, in the step of manufacturing the topsheet, it is preferable that the surface-side first nonwoven fabric and the surface-side second nonwoven fabric are overlapped to simultaneously form the uneven shape, and the surface-side second nonwoven fabric is joined to the surface-side first nonwoven fabric while applying tension to the surface-side second nonwoven fabric so that the undulations of the surface-side second nonwoven fabric are made gentle.

[0024] According to the above manufacturing method, the uneven shape is formed simultaneously on the two nonwoven fabrics in a state where the surface side first nonwoven fabric and the surface side second nonwoven fabric are bonded to each other while being overlapped. Then, of the two nonwoven fabrics with the uneven shape formed, the surface side second nonwoven fabric is bonded to the surface side first nonwoven fabric while maintaining the uneven shape of the surface side first nonwoven fabric in a state where tension is applied to the surface side second nonwoven fabric so that the undulations of the surface side second nonwoven fabric are made gentle. Therefore, the process and manufacturing equipment can be simplified compared to a case where the process of forming the uneven shape on the surface side first nonwoven fabric and the process of forming the surface side second nonwoven fabric with gentle undulations are separately performed, and a process of overlapping the surface side first nonwoven fabric and the surface side second nonwoven fabric that have been subjected to these processes is further performed. In other words, according to the above manufacturing method, for example, different undulating shapes can be formed on the same line for the surface-side first nonwoven fabric and the surface-side second nonwoven fabric, and the number of lines can be reduced compared to the case where a line for producing the surface-side first nonwoven fabric and a line for producing the surface-side second nonwoven fabric are provided separately, and a configuration in which separate lines are joined can be omitted.

[0025] In the method for manufacturing the worn article, in the step of manufacturing the core, it is preferable to raise the core-side first nonwoven fabric and spray the water-absorbent polymer so that the water-absorbent polymer penetrates into gaps in the fiber layer formed by the raising.

[0026] According to the above manufacturing method, a fiber layer having gaps is formed in the core side first nonwoven fabric by raising the core side first nonwoven fabric, and a water-absorbent polymer is sprayed on the fiber layer, so that a large amount of water-absorbent polymer can be supported in the gaps in the fiber layer of the core side first nonwoven fabric.

[0027] In the above-mentioned method for manufacturing a worn article, it is preferable that the step of manufacturing the core further includes the steps of raising a core-side second nonwoven fabric and spraying the water-absorbent polymer so that the water-absorbent polymer penetrates into gaps in the fiber layer formed by the raising, and laminating the core-side first nonwoven fabric and the core-side second nonwoven fabric so that the fiber layer of the core-side first nonwoven fabric and the fiber layer of the core-side second nonwoven fabric face each other.

[0028] According to the above-mentioned manufacturing method, the water-absorbent polymer is sprayed on the fiber layers of the two-layered core-side first nonwoven fabric and the core-side second nonwoven fabric, and the fiber layers are laminated facing each other, so that it is possible to manufacture a wearing article that can suppress the water-absorbent polymer from falling off from the fiber layers. Furthermore, when the core formed by laminating the fiber layers facing each other in this way is used in a subsequent process, it is possible to suppress the water-absorbent polymer from falling off from the core.

[0029] In the above-mentioned method for manufacturing a worn article, it is preferable that the step of manufacturing the absorbent body further includes a step of providing an absorbent body elastic member at a tip end portion opposite to the end portion joined to the waist main body in the orthogonal direction so as to be stretchable in the width direction.

[0030] According to the above manufacturing method, a wearing article can be manufactured having an absorbent body elastic member at a tip portion opposite to an end portion of the absorbent body joined to the waist body in the orthogonal direction. The absorbent body of the wearing article is stretchable in the width direction at a tip portion opposite to an end portion joined to the waist body by the absorbent body elastic member. The waist body is also stretchable in the width direction. This allows both the waist body and the absorbent body to stretch in the width direction according to the waist length of the wearer, so there is a large degree of freedom in selecting the engagement position between the first engagement portion provided on the waist body and the second engagement portion of the absorbent body. This improves the fit of the wearing article.

[0031] In the above-mentioned method for manufacturing a worn article, it is preferable that the step of manufacturing the absorbent body further includes a step of providing the second engagement portion on an outer surface of the tip portion of the backsheet opposite the waistband member in the orthogonal direction, over substantially the entire width direction of the tip portion of the backsheet.

[0032] According to the above manufacturing method, a wearing article can be manufactured in which the second engagement portion is provided on the outer surface of the distal end of the backsheet across the entire width of the distal end. Thus, by stretching the waistband member in the width direction, the first engagement portion can be engaged with the second engagement portion at any position in the width direction, allowing for a large degree of freedom in selecting the engagement position. Thus, the engagement position between the waistband member and the absorbent can be easily adjusted according to the waist length of each wearer, improving the fit.

[0033] In the above-mentioned method for manufacturing a worn article, the step of manufacturing the waistline member preferably includes the steps of: joining a waistline elastic member to at least one of an inner sheet extending in the width direction and an outer sheet extending in the width direction and covering the outer surface of the inner sheet opposite the surface facing the skin side, so that the waistline elastic member is stretchable along the width direction; and applying a weakening treatment to the joint of the waistline main body to which the absorbent is joined, so that the elastic force of a core arrangement portion where the core is arranged is weaker than the elastic force of a portion adjacent in the width direction to the core arrangement portion.

[0034] According to the above manufacturing method, a wearing article can be manufactured in which the elastic force of the core-arrangement portion of the waistline body where the core is arranged is weaker than the elastic force of the portion adjacent in the width direction to the core-arrangement portion. By joining the core to the core-arrangement portion of the waistline body of the wearing article, shrinkage of the core can be suppressed. Therefore, the core can reliably cover the back part, etc. In addition, since the portion adjacent to the core-arrangement portion stretches and contracts, it is possible to improve the degree of freedom in selecting the engagement position between the second engagement portion of the tip of the absorbent arranged along the crotch part of the wearer and the first engagement portion provided on the waistline body.

[0035] In the above-mentioned method for manufacturing a worn article, it is preferable that the step of manufacturing the waistband member further includes a step of arranging the inner sheet on the outer sheet so as to form an extension portion that protrudes beyond the edge of the inner sheet in the orthogonal direction in a direction away from the inner sheet, and a step of folding back the extension portion in the orthogonal direction to cover the end portion of the absorbent in the orthogonal direction.

[0036] According to the above manufacturing method, it is possible to manufacture a wearing article with improved wearing comfort and good appearance. Specifically, in the wearing article manufactured by the above manufacturing method, the extension portion formed on the outer sheet so as to protrude beyond the edge of the inner sheet in a direction away from the inner sheet is folded back, so that the end portion of the absorbent body that is joined to the waistband member is covered by the extension portion of the outer sheet. Therefore, it is possible to suppress discomfort caused by the end portion of the absorbent body contacting the skin. In addition, the end portion of the absorbent body is not exposed, and the appearance can be improved.

[0037] In the above-mentioned method for manufacturing a worn article, it is preferable that the step of manufacturing the waistline member further includes a step of performing a weakening treatment on a portion of the waistline body where the first engagement portion is arranged so that the elastic force of the portion is weaker than the elastic force of a portion adjacent to the first engagement portion in the width direction.

[0038] According to the above manufacturing method, by weakening the elasticity of the portion of the waistband main body where the first engagement part is arranged, it is possible to suppress contraction of the first engagement part that is provided later, and therefore it is possible to suppress loss of the engagement force between the first engagement part and the second engagement part.

[0039] In the method for manufacturing the wearing article, in the step of manufacturing the waistline member, a waistline continuum in which each waistline main body of a plurality of wearing articles is continuous in the width direction is prepared, and the waistline main body is manufactured by cutting the waistline continuum into regions corresponding to each waistline main body. In the step of joining the absorbent body to the joint portion of the waistline main body, the absorbent body is joined to the joint portion of the region corresponding to each waistline main body in the waistline continuum so as to extend from the joint portion in the perpendicular direction, and the first engagement portion and the second engagement portion are joined to each other. The engaging process preferably includes, at a stage before the waist continuum is cut into the waist main bodies, a step of folding the absorbent body in the orthogonal direction so that the waist continuum overlaps the tip of the absorbent body, while holding a tip end of the absorbent body joined to the waist continuum in the orthogonal direction opposite the end part joined to the waist continuum in the orthogonal direction, and a step after the waist continuum is cut into the waist main bodies, a step of folding back both side ends of the waist main body so that both ends in the width direction of the waist main body overlap the tip of the absorbent body.

[0040] According to the above manufacturing method, the absorbent body is joined to each of the regions corresponding to each waistline body in the waistline continuum in which the waistline bodies are continuous in the width direction. Then, the absorbent body is folded in half so that the waistline continuum overlaps the tip of the absorbent body while the tip of the absorbent body is held. Thus, a plurality of wearing articles can be folded in the orthogonal direction continuously. Therefore, each wearing article can be folded in the orthogonal direction at high speed compared to folding each wearing article separately. In addition, since the absorbent body is folded in the state where the tip of the absorbent body opposite to the end joined to the waistline continuum is held, the absorbent body can be folded in half in the orthogonal direction so that the tip of the absorbent body overlaps the waistline continuum while suppressing the movement of the absorbent body. In addition, folded wearing articles can be manufactured by folding back both sides of each waistline body cut from the waistline continuum as they are.

[0041] In the above-mentioned method for manufacturing a wearing article, the step of engaging the first engagement portion with the second engagement portion preferably includes a step of forming a temporary fastening, after the absorbent body has been folded in half in the orthogonal direction, between an end portion of the absorbent body opposite an end portion joined to the waist member and at least one of the absorbent body and the waist member overlapping the end portion in a releasable manner.

[0042] According to the above manufacturing method, a temporary fastening is formed so that an end portion of the absorbent body opposite to the end portion joined to the waistline member and at least one of the absorbent body and the waistline member overlapping the end portion can be peeled off, so that the absorbent body can be maintained in a folded state in two. If a step of forming the waistline member by cutting a continuous waistline body in which the waistline main body is continuous in the width direction after the temporary fastening is formed is adopted, the waistline continuum can be cut while maintaining the folded state of the absorbent body before and after cutting.

[0043] In the method for manufacturing the wearing article, in the step of forming the temporary fasteners, the temporary fasteners are preferably formed on the outer side of the core in the width direction.

[0044] According to the above manufacturing method, since the core is not subjected to a temporary fixing process, deterioration of the absorption performance of the core can be suppressed. Effect of the Invention

[0045] It is possible to provide a method for manufacturing a wearing article that is changeable between an initial pants-like shape and a predetermined developed shape and that is capable of improving wearing comfort. [Brief description of the drawings]

[0046] [Figure 1] FIG. 2 is a front view showing the appearance of the refastenable-type wearing article after assembly. [Diagram 2] FIG. 2 is a rear view showing the appearance of the refastenable-type wearing article after assembly. [Diagram 3] FIG. 2 is a development view of a refastenable type wearing article. [Figure 4]FIG. 2 is an exploded perspective view of a refastenable type wearing article. [Figure 5A] FIG. 2 is a plan view showing the distribution of SAP in a core that is continuous in a direction perpendicular to the waist circumference. [Figure 5B] FIG. 5B is a cross-sectional view taken along line 5B-5B of FIG. 5A. [Figure 5C] FIG. 5C is a cross-sectional view taken along line 5C-5C in FIG. 5A. [Figure 6A] FIG. 13 is a plan view showing another distribution state of SAP in the core. [Figure 6B] FIG. 6B is a cross-sectional view taken along line 6B-6B in FIG. 6A. [Figure 6C] FIG. 6B is a cross-sectional view taken along line 6B-6B in FIG. 6A, illustrating how the core is bent into an inverted V shape. [Figure 6D] FIG. 6B is a cross-sectional view taken along line 6B-6B of FIG. 6A, illustrating how the core is bent into a V shape. [Figure 7A] FIG. 13 is a plan view showing another distribution state of SAP in the core. [Figure 7B] FIG. 13 is a plan view showing another distribution state of SAP in the core. [Figure 7C] FIG. 13 is a plan view showing another distribution state of SAP in the core. [Figure 8] FIG. 1 is a system diagram of a manufacturing process for a refastenable-type wearing article. [Figure 9] FIG. 2 is a plan view showing a manufacturing process from step 1 to step 2. [Figure 10] FIG. 1 is a plan view of the manufacturing process from step 3 to step 7. [Figure 11] FIG. 2 is a schematic diagram of a topsheet manufacturing device. [Figure 12A] FIG. 2 is an explanatory diagram of the process of forming the uneven shape in the topsheet, showing how the first and second surface-side nonwoven fabrics are wound around the outer circumferential surface of the first roll. [Figure 12B] FIG. 2 is an explanatory diagram of the process of forming the uneven shape in the topsheet, showing how the top-side first nonwoven fabric and the top-side second nonwoven fabric are pressed into the recesses of the first roll. [Figure 12C]FIG. 2 is an explanatory diagram of the process of forming the uneven shape on the topsheet, showing how the uneven shape is formed only on the first nonwoven fabric on the top surface side. [Figure 13] FIG. 2 is a schematic diagram of a core manufacturing apparatus. [Figure 14] FIG. 2 is an explanatory diagram of a process for manufacturing a core by laminating a core-side first nonwoven fabric and a core-side second nonwoven fabric. [Figure 15A] 4 is a cross-sectional view showing the manufacturing process of the core, illustrating the state before the core-side first nonwoven fabric and the core-side second nonwoven fabric are raised. FIG. [Figure 15B] 4 is a cross-sectional view showing the manufacturing process of the core, illustrating the state after the core-side first nonwoven fabric and the core-side second nonwoven fabric have been raised. FIG. [Figure 15C] FIG. 2 is a cross-sectional view showing a manufacturing process of a core, illustrating a state in which a core-side first nonwoven fabric and a core-side second nonwoven fabric support SAP. [Figure 15D] FIG. 2 is a cross-sectional view showing a manufacturing process of a core, illustrating a state in which a core-side first nonwoven fabric and a core-side second nonwoven fabric are laminated to form a laminate. [Figure 15E] 1 is a cross-sectional view showing the manufacturing process of the core, showing the state in which tissue paper is supplied to the laminate. [Figure 15F] 1 is a cross-sectional view showing the manufacturing process of the core, illustrating the state in which the laminate is wrapped in tissue paper. [Figure 16] FIG. 11 is a plan view of the manufacturing process from step 8 to step 13. [Figure 17A] FIG. 2 is a cross-sectional view of a main part of the manufacturing process in step 1, showing the outer sheet being conveyed. [Figure 17B] FIG. 2 is a cross-sectional view of a main part of the manufacturing process in step 1, showing how waistline elastic members are arranged on the outer sheet. [Figure 17C] FIG. 13 is a cross-sectional view of a main portion of the manufacturing process in step 2, showing how the inner sheet is conveyed so as to cover the upper portions of the outer sheet and the waistline elastic members. [Figure 18A] 13 is a cross-sectional view of a main part of the manufacturing process in step 3, showing how the sheet for the rising flap is cut. [Figure 18B] 13 is a cross-sectional view of a main part of the manufacturing process in step 3, showing how the cut rising flaps are expanded in the width direction at regular intervals. [Figure 18C] 13 is a cross-sectional view of a main part of the manufacturing process in step 3, showing how the three-dimensional gather elastic member is arranged on the rising flap. [Figure 18D] FIG. 11 is a cross-sectional view of a main part of the manufacturing process in step 3, showing how the three-dimensional gathers are manufactured by joining the three-dimensional gather elastic member to the inside bent portion of the rising flap. [Figure 18E] This is a cross-sectional view of a key part of the manufacturing process in step 3, showing how the three-dimensional gathers are joined to the top sheet. [Figure 18F] This is a cross-sectional view of a key part of the manufacturing process in step 6, showing the formation of an absorbent work-in-progress by combining the top sheet work-in-progress formed in step 3, the core formed in step 4, and the back sheet work-in-progress formed in step 5. [Figure 19A] 13 is a cross-sectional view of a main part of the manufacturing process in steps 8 and 9, showing how the absorbent body turned in a predetermined direction in step 7 is joined to a continuous waistband body. [Figure 19B] 10 is a cross-sectional view of a main part of the manufacturing process in step 10, showing how the extended portion is folded back. [Figure 19C] 10 is a cross-sectional view of a main part of the manufacturing process from step 11 to step 13, showing the state in which the worn article is folded in half. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. Note that the following embodiment is an example of the present invention, and is not intended to limit the technical scope of the present invention.

[0048] <Configuration of refastenable-type worn articles> (Overall composition) The structure of the refastenable type wearing article will be described below.

[0049] The refastenable-type wearing article 1 according to this embodiment comprises a waist member 10 that is placed around the waist of the wearer, and an absorbent body 20 that is placed from the rear of the wearer through the crotch portion to the front of the abdomen.

[0050] The waist member 10 extends in the width direction and has elasticity that allows it to stretch and contract in the width direction. The waist member 10 has a waist body 16 (Figure 4) that is placed around the wearer's waist, and male fasteners (first engagement portions) 12 provided on the surfaces of the waist body 16 at both widthwise end portions 10c that face the skin of the wearer.

[0051] In the following, as shown in Figures 1 to 3 etc., in a refastenable-type wearing article 1, the direction in which the waist body 16 (Figure 4) in the waist member 10 extends is referred to as the waist width direction (width direction), and the direction roughly perpendicular to the waist width direction is referred to as the waist orthogonal direction (orthogonal direction).

[0052] This waistline main body 16 has an inner sheet 14 (Figure 4), an outer sheet 15 (Figure 4), and a waistline elastic member 11 (Figure 4) that is sandwiched between the inner sheet 14 and the outer sheet 15 and joined to the inner sheet 14 and the outer sheet 15.

[0053] The absorbent body 20 is a member for absorbing mainly bodily fluids such as urine and sweat. The absorbent body 20 is joined to a joint 10b (FIGS. 3 and 4) of the waistline member 10. In this embodiment, the joint 10b is a central portion in the waistline width direction of the waistline member 10 and a portion that is offset downward from the edge on the waist side. The absorbent body 20 extends in a direction perpendicular to the waistline from the joint 10b so as to be disposed from the wearer's back region through the crotch portion to the front abdomen. The absorbent body 20 has a female fastener (second engagement portion) 22 on the outer surface opposite the surface facing the skin side at the tip end in the waistline direction.

[0054] The refastenable-type wearing article 1 having such a configuration is folded in a final form (at the stage when the wearing article is used for the first time) with the male fastener 12 and the female fastener 22 engaged with each other. Specifically, in the refastenable-type wearing article 1 folded as shown in the final step 13 of Fig. 16, the absorbent body 20 is folded in half in a direction perpendicular to the waistline, and the male fastener 12 and the female fastener 22 are engaged with each other with both side portions 10a of the waistline member 10 adjacent to the joint portion 10b in the waistline width direction folded in the waistline width direction.

[0055] A wearer spreads the waistband member 10 of the refastenable-type wearing article 1 assembled into a pants-type configuration with the male fastener 12 and the female fastener 22 engaged, and inserts his / her legs to wear the wearing article 1 like pants. In the refastenable-type wearing article 1, the male fastener 12 and the female fastener 22 are engaged in advance, but the wearing article 1 can be developed into the configuration shown in Fig. 3 by disengaging the fasteners 12 and 22. Furthermore, the engagement and disengagement of the fasteners 12 and 22 is repeated when the wearing article 1 is adapted to the wearer and when the wearing article 1 is replaced.

[0056] In contrast to such a refastenable-type wearing article 1, an open-type wearing article is folded in a final form (at the stage when the wearing article is used for the first time) with the male fastener 12 and the female fastener 22 not engaged with each other. Specifically, in an open-type wearing article, for example, in a state where both side portions 10a of the waistline member 10 of the wearing article in the developed form shown in Fig. 3 are folded in the waist width direction so that the skin-facing side of the absorber 20 faces the absorber 20, the absorber 20 is folded in a direction perpendicular to the waistline so that the leading end of the absorber 20 is located on the waistline member 10 side. In other words, the open-type wearing article is folded so that both side portions 10a of the waistline member 10 are sandwiched between the joint portions 10b of the waistline member 10 and the absorber 20. In this case, the male fastener 12 and the female fastener 22 are not engaged with each other.

[0057] The open-type wearing article may include an unfolded, deployed form as shown in FIG.

[0058] Next, each part of the refastenable-type wearing article 1 will be further described.

[0059] (Waist Circumference Member) The waistline member 10 has elasticity that extends in the waistline width direction and is stretchable in the waistline width direction, and has a waistline main body 16 (Fig. 4) that is placed around the wearer's waist, and male fasteners 12 provided on the surfaces facing the wearer's skin at both ends 10c in the waistline width direction of the waistline main body 16. The waistline main body 16 has an inner sheet (Fig. 4, etc.) 14, an outer sheet (Fig. 4, etc.) 15, and a waistline elastic member 11, which will be described later.

[0060] Here, the portion of the waistline main body 16 to which the absorbent body 20 is joined is the joint 10b. In this embodiment, as shown in Fig. 2, a part of the waistline elastic member 11 is located above the joint 10b in the waistline orthogonal direction.

[0061] Moreover, both side portions 10a of the waistline main body 16 are regions adjacent to the joint portion 10b in the waistline width direction. Both side portions 10a include both end portions 10c, which are both ends in the waistline width direction of the waistline main body 16. At least a part of both end portions 10c is a joint portion 15a2 (FIGS. 3 and 4) to which the male fastener 12 is joined.

[0062] The waist main body 16 has elasticity in the waist width direction as a whole. The joint 10b of the waist main body 16 is a portion where one end of the absorbent body 20 is arranged. The joint 10b also includes a core arrangement portion 15a1 where the core 25 that constitutes part of the absorbent body 20 is arranged (FIG. 2). The joint 15a2 of the waist main body 16 is a portion where the male fastener 12 is arranged.

[0063] In the joint 10b, the elasticity in the waist width direction is smaller or almost nonexistent in the core arrangement portion 15a1 than in the region excluding the core arrangement portion 15a1. In other words, in the waist body 16, the elasticity in the waist width direction is larger in the region excluding the core arrangement portion 15a1 than in the core arrangement portion 15a1. In addition, in the joint 15a2, the elasticity in the waist width direction is smaller or almost nonexistent than in the region excluding the joint 15a2. In other words, in the waist body 16, the elasticity in the waist width direction is larger in the region excluding the core arrangement portion 15a1 and the joint 15a2 than in the joint 15a2. As a result, the waist body 16 has elasticity in the waist width direction as a whole due to the elasticity in the region excluding the core arrangement portion 15a1 and the joint 15a2 in the waist width direction.

[0064] Here, the refastenable-type wearing article 1 is folded into a pants-like shape in its final form (at the stage when the wearing article is used for the first time) with the absorbent body 20 folded in half and temporarily fastened in a releasable manner, and the male fastener 12 and the female fastener 22 are engaged with each other. When a wearer puts on this refastenable-type wearing article 1, the wearer peels off the temporary fastening with the male fastener 12 and the female fastener 22 engaged, spreads the waist member 10 of the wearing article 1, and inserts his / her legs to put on the wearing article 1 like pants.

[0065] In the refastenable-type wearing article 1, the male fastener 12 and the female fastener 22 are disengaged from each other, and the wearing article 1 is in an unfolded form, and can be worn as follows. With the joint 10b of the waist main body 16 in contact with the back part, the absorbent body 20 is disposed over the range from the wearer's back part through the crotch part to the front abdomen. In this state, the side parts 10a adjacent to the joint 10b of the waist main body 16 are extended to the outer surface of the tip of the absorbent body 20 located at the front abdomen. Then, the male fastener 12 provided on the waist main body 16 is engaged with the female fastener 22 provided on the absorbent body 20, and the refastenable-type wearing article 1 is put on the wearer.

[0066] Next, the planar shape of the waistline main body 16 will be described. The upper edge of the waistline main body 16 in the waistline orthogonal direction is generally straight along the waistline width direction. In contrast, the lower edge of the waistline member 10 in the waistline orthogonal direction, i.e., the lower edge on the leg base side, is provided with leg-around curved parts 15b (Figs. 3, 4, etc.) for forming leg holes that follow the shape of the legs. The leg-around curved parts 15b have a curved shape such that the length of the waistline main body 16 in the waistline orthogonal direction increases from both side parts 10a toward the joint parts 10b.

[0067] A further description will be given of the specific configuration of such a waistline main body 16. As shown in Fig. 4, the waistline main body 16 has an inner sheet 14 extending in the waistline width direction, an outer sheet 15 extending in the waistline width direction and covering the outer surface opposite to the surface of the inner sheet 14 facing the skin side, and waistline elastic members 11 having elasticity that allows them to expand and contract along the waistline width direction.

[0068] 3 and 4, the inner sheet 14 is, for example, a nonwoven fabric sheet, and is a belt-shaped member extending in the waist width direction. One end of the absorbent body 20 is joined to a portion of the inner sheet 14 that corresponds to the joint portion 10b.

[0069] The male fasteners 12 extend in the direction perpendicular to the waist on the surfaces facing the skin of both end portions 10c in the waist width direction of the inner sheet 14. Specifically, the male fasteners 12 are joined to the inner sheet 14. The length of the male fasteners 12 in the waist width direction may be such that the male fasteners 12 do not easily come out of engagement with the female fasteners 22. For example, if the length of the male fasteners 12 in the waist width direction is approximately the same as the length of the inner sheet 14 in the waist width direction, the waist body 16 can be reliably engaged with the female fasteners 22 of the absorber 20 over the entire length in the waist width direction.

[0070] The outer sheet 15 is made of, for example, a nonwoven fabric, and is a belt-shaped member extending in the waist width direction similar to the inner sheet 14. The outer sheet 15 is disposed on the outer surface side opposite the skin-facing side of the inner sheet 14, and covers the outer surface of the inner sheet 14 opposite the surface facing the skin-facing side.

[0071] The planar shape of the inner sheet 14 is the same as that of the waistline main body 16 described above. As shown in Fig. 4, the upper edge of the inner sheet 14 in the direction perpendicular to the waistline is formed in a straight line along the waistline width direction. The lower edge of the inner sheet 14 on the side of the base of the legs in the direction perpendicular to the waistline has a leg-surrounding curved portion 15b that is curved along the shape of the legs. Both ends of the inner sheet 14 in the waistline width direction are straight along the direction perpendicular to the waistline.

[0072] The lower edge of the outer sheet 15 has a leg curved portion 15b that is curved along the shape of the legs at the base of the legs in plan view, similar to the inner sheet 14. In addition, the outer sheet 15 has an extension portion 15c that extends upward in the direction perpendicular to the waist of the inner sheet 14 when the inner sheet 14 is superimposed so as to cover the waist elastic member 11.

[0073] 3 and other figures, the extension 15c is joined to the inner sheet 14 and the absorbent body 20 in a folded state so as to cover the waist elastic member 11 and to cover the end of the absorbent body 20 that is joined to the waist member 10 in the direction perpendicular to the waistline. This makes it possible to suppress discomfort caused by the end of the absorbent body 20 contacting the skin. In addition, the end of the absorbent body 20 is not exposed, improving the appearance.

[0074] The waist elastic member 11 is joined to at least one of the inner sheet 14 and the outer sheet 15 in a state where the waist elastic member 11 is stretched linearly in the waist width direction and is sandwiched between the inner sheet 14 and the outer sheet 15. The waist elastic member 11 is arranged in a range from the upper end edge of the inner sheet 14 to the leg curved portion 15b on the base of the legs, in a region excluding the extension portion 15c. The waist elastic member 11 is weakened at weakened portions 15a1 and 15a2 described below.

[0075] The leg curved portion 15b constitutes a part of the leg hole curved along the shape of the base of the leg. The waist elastic member 11 adjacent to the leg curved portion 15b elastically attaches a part of the periphery of the leg hole to the upper part of the base of the leg, improving the wearing comfort. The waist elastic member 11 adjacent to the leg curved portion 15b may be curved along the curve of the leg curved portion 15b.

[0076] The waist elastic member 11 is formed from, for example, a material such as polyurethane, natural rubber, thermoplastic resin, etc. The shape of the waist elastic member 11 is, for example, a thread-like, ribbon-like, sheet-like, etc. Elastic members constituting the leg gathers 31 described below, the three-dimensional gather elastic member 41, the absorber elastic member 21, and other elastic members are also made of the same material and have the same shape.

[0077] The waist elastic member 11 can be bonded to the inner sheet 14 and the outer sheet 15 by adhesion using a hot melt adhesive or welding by heat sealing, but ultrasonic welding is preferable. Compared to the case where an adhesive is used, ultrasonic welding allows the flexibility of the inner sheet 14 and the outer sheet 15 to be maintained, and reduces the crisp, stiff feel and discomfort.

[0078] The waist elastic member 11 has elasticity in the waist width direction. As a result, the waist elastic member 11 elastically adheres the waist body 16 of the waist member 10 to the waist. In this embodiment, the waist elastic member 11 is made of a plurality of thread-like elastic members, which extend in the waist width direction of the waist member 10 and are arranged at intervals in the direction perpendicular to the waist.

[0079] In this embodiment, a weakening process is applied to the waistline elastic member 11 at a core arrangement portion 15a1 (also referred to as a weakened portion 15a1) of the joint portion 10b to which the absorbent 20 of the waistline member 10 is joined (see FIG. 2). In this embodiment, the area of ​​the joint portion 10b is larger than the area of ​​the core arrangement portion 15a1.

[0080] Specifically, in the absorbent body 20, the core 25 is disposed in the center in the waist width direction, and the leg gathers 31 are disposed along each of both edges in the waist width direction, and are sandwiched between the top sheet 24 and the back sheet 26. The back sheet 26 is joined to the joint 10b of the waist member 10. In the joint 10b, at least the core arrangement portion 15a1 where the core 25 is arranged, the waist elastic member 11 is subjected to a weakening treatment.

[0081] On the other hand, in the joint portion 10b other than the core arrangement portion 15a1 (for example, both edge portions of the topsheet 24 and the backsheet 26 in the portion sandwiching the leg gathers 31), the waistline elastic members 11 are not subjected to the weakening treatment.

[0082] Specifically, in this embodiment, as described above, a part of the waistline elastic member 11 is located above the joint 10b in the waistline orthogonal direction. That is, a part of the waistline elastic member 11 is disposed between the upper end edge of the waistline main body 16 in the waistline orthogonal direction and the joint 10b. Therefore, in this embodiment, the waistline elastic member 11 is not subjected to a weakening treatment in three directions of the joint 10b, namely, both side portions adjacent to the core arrangement portion 15a1 in the waistline width direction and an upper portion of the core arrangement portion 15a1 in the waistline orthogonal direction.

[0083] As in this embodiment, at least one of the waistline elastic members 11 is provided in a stretched state in a portion of the joint 10b that is above the core arrangement portion 15a1 in the waistline perpendicular direction. By joining the absorbent body 20 to such a joint 10b, the tip end of the absorbent body 20 on the waistline member 10 side overlaps with the waistline elastic member 11 arranged in the upper portion. Thus, just as the free end (the end opposite the waistline member 10) of the absorbent body 20 in the waistline perpendicular direction can be stretched and contracted by the absorbent body elastic member 21 described below, the tip end of the absorbent body 20 on the waistline member 10 side can also be stretched and contracted by the waistline elastic member 11.

[0084] Further, at joints 15a2 (hereinafter also referred to as weakened portions 15a2) to which the male fasteners 12 are joined at both ends 10c of the waistline member 10 in the waistline width direction, the waistline elastic member 11 is subjected to a weakening treatment.

[0085] In the above description, the area of ​​the joint 10b is larger than the area of ​​the core arrangement portion 15a1, but the area of ​​the joint 10b and the area of ​​the core arrangement portion 15a1 may be the same.

[0086] Additionally, the joints 15a2 to which the male fasteners 12 are joined are at least a part of both end portions 10c of the waist member 10. However, the areas of both end portions 10c and the joints 15a2 may coincide. Furthermore, although the areas of the joints 15a2 and the areas of the weakened portions coincide in this embodiment, the areas of the weakened portions may be larger than the areas of the joints 15a2.

[0087] The weakening process is a process for weakening the elastic force of the waistline main body 16 by the elastic member. The weakening process also includes a process for nullifying the elastic force of the elastic member. The weakening process is performed, for example, by cutting the portions of the waistline elastic member 11 located within the core arrangement portion 15a1 and the joint portion 15a2. For example, the waistline elastic member 11 that is joined to the inner sheet 14 and the outer sheet 15 at a portion other than the core arrangement portion 15a1 and the joint portion 15a2 and is not joined to the core arrangement portion 15a1 and the joint portion 15a2 can be weakened at the core arrangement portion 15a1 and the joint portion 15a2 by cutting the waistline elastic member 11. The cutting is performed, for example, by cutting the elastic member with a blade or by applying heat to the elastic member to melt it. Since the elastic member is divided by the weakening process, the elastic force at the core arrangement portion 15a1 and the joint portion 15a2 is weakened.

[0088] The weakening treatment includes not only the above-mentioned treatment of removing elasticity by cutting the elastic member, but also the treatment of modifying the elastic member so that its elasticity is reduced. Another example of the weakening treatment is a method of intermittently joining the elastic member to the nonwoven fabric and cutting the elastic member between the joining parts. This weakens the elastic force of the elastic member in the area where the elastic member is cut.

[0089] By the weakening treatment, the elastic force of the waist main body 16 due to the waist elastic members 11 is weakened in the weakened portion 15a1 where the absorber 20 is arranged and in the weakened portion 15a2 where the male fastener 12 is arranged. In other words, the elastic force of the weakened portion 15a1 and the weakened portion 15a2 of the waist main body 16 due to the waist elastic members 11 is weaker than the elastic force of the portions of the waist main body 16 adjacent to the weakened portions 15a1 and 15a2 in the waist width direction.

[0090] In this manner, the elastic force of the waistline main body 16 due to the waistline elastic members 11 is weakened in the weakened portion 15a1 where the absorbent body 20 is arranged. Therefore, it is possible to suppress contraction of the core 25 joined to the weakened portion 15a1 of the waistline main body 16, so that the core 25 can reliably cover the back area, etc.

[0091] In addition, in the weakened portion 15a2 where the male fastener 12 is arranged, the elastic force of the waistline main body 16 by the waistline elastic member 11 is weakened. Therefore, the contraction of the male fastener 12 is suppressed, and the engaging force between the male fastener 12 and the female fastener 22 can be suppressed from being impaired.

[0092] (Absorbent) The absorbent body 20 is a belt-shaped member capable of absorbing body fluids such as urine, and is joined to the joint 10b of the waist main body 16 and extends from the joint 10b in a direction perpendicular to the waist. The absorbent body 20 is disposed from the wearer's back through the crotch area to the front abdomen.

[0093] The absorbent body 20 has a core 25 for absorbing bodily fluids, a top sheet 24 provided on the wearer's skin side of the core 25, a back sheet 26 provided on the outer surface of the core 25 opposite the skin side so as to sandwich the core 25 between the top sheet 24 and the core 25, and a female fastener 22 provided on the outer surface of the back sheet 26 opposite the surface facing the skin side and removably engaged with the male fastener 12. The absorbent body 20 further has an absorbent body elastic member 21, leg gathers 31, three-dimensional gathers 40, and an indicator 50.

[0094] The top sheet 24 is a strip-shaped sheet extending in a direction perpendicular to the waist circumference, and is provided on the wearer's skin side relative to the core 25. The top sheet 24 is formed by laminating two sheets of a surface-side first nonwoven fabric 24a and a surface-side second nonwoven fabric 24b (FIGS. 11, 12, etc.) having approximately the same degree of liquid permeability, and bonding the surface-side first nonwoven fabric 24a and the surface-side second nonwoven fabric 24b.

[0095] The front-side first nonwoven fabric 24a has a surface facing the wearer's skin when worn, and a plurality of concave-convex shapes 20a are provided on the surface facing the skin. The back surface of the front-side first nonwoven fabric 24a has a concave-convex shape opposite to the concave-convex shape 20a on the front surface. The shape of the concave and convex parts forming the concave-convex shape 20a is not particularly limited, and may be, for example, a circular shape, an elliptical shape, a polygonal shape, etc., in a plan view. The size of the concave and convex parts may be sufficient to provide a comfortable feeling to the skin surface, such as preventing the concave and convex parts from sticking to the skin surface due to contact, and may be, for example, about 3 to 5 mm in a plan view if they are circular.

[0096] In this way, the uneven shape 20a is provided on the first surface-side nonwoven fabric 24a on the skin side of the top sheet 24. Therefore, the convex parts of the uneven shape 20a elastically come into point contact with the wearer's skin surface, and the concave parts allow air to pass through, providing good breathability. Therefore, the top sheet 24 can improve the feel on the skin compared to a surface contact between the top sheet 24 and the skin surface. Even after the absorber 20 has absorbed bodily fluids such as urine and sweat, the convex parts of the top sheet 24 come into point contact with the skin surface wet with urine, etc., and further, the concave parts provide breathability, thereby reducing the discomfort of the feel on the skin surface.

[0097] The surface side second nonwoven fabric 24b is joined to the outer surface opposite to the surface facing the skin side of the surface side first nonwoven fabric 24a. The surface side second nonwoven fabric 24b has a shape with gentler undulations than the uneven shape 20a of the surface side first nonwoven fabric 24a. The surface facing the skin side of the surface side second nonwoven fabric 24b is, for example, flat. In this way, the undulations of the surface side second nonwoven fabric 24b are smaller than those of the surface side first nonwoven fabric 24a. Therefore, the surface side second nonwoven fabric 24b is less likely to stretch in the surface direction than the surface side first nonwoven fabric 24a. As a result, the stretch of the surface side first nonwoven fabric 24a is restrained by the surface side second nonwoven fabric 24b, and the uneven shape 20a of the surface side first nonwoven fabric 24a is maintained. At this time, the concave portions of the uneven shape 20a of the front-side first nonwoven fabric 24a are bonded to the flat surface of the front-side second nonwoven fabric 24b, and the shape of the convex portions of the uneven shape 20a is maintained by the bonding of the concave portions. For example, even if the wearer presses the uneven shape 20a by touch, the convex portions are unlikely to deform, and the pleasant feel due to point contact with the convex portions can be maintained.

[0098] Although the top sheet 24 is formed from two sheets of nonwoven fabric (the top-side first nonwoven fabric 24a and the top-side second nonwoven fabric 24b), the number of sheets of nonwoven fabric may be three or more.

[0099] Furthermore, when providing the unevenness 20a on the topsheet 24, it is sufficient that the unevenness 20a is provided on the surface of at least one of the nonwoven fabrics that faces the skin side among the multiple nonwoven fabrics. Therefore, the unevenness 20a may be provided on all of the nonwoven fabrics that constitute the topsheet 24.

[0100] Furthermore, the topsheet 24 may be formed from a single sheet of nonwoven fabric. In this case, the uneven shape 20a is provided on the surface of the single sheet of nonwoven fabric that faces the skin side.

[0101] The first nonwoven fabric 24a and the second nonwoven fabric 24b can be joined by a hot melt adhesive or heat sealing, but ultrasonic welding is preferred. When ultrasonic welding is used for the joining, the flexibility of the top sheet 24 can be maintained and there is less of a crisp, stiff feel and discomfort compared to when an adhesive is used.

[0102] In the above, a plurality of concave and convex shapes 20a are provided on the surface of the front side first nonwoven fabric 24a facing the skin side. However, the form of the topsheet 24 also includes a form in which the surface of the front side first nonwoven fabric 24a facing the skin side is flat. In this case, the topsheet 24 may be formed only from one nonwoven fabric having a flat surface. In other words, the topsheet 24 may be formed only from the front side first nonwoven fabric 24a having a flat surface, with the front side second nonwoven fabric 24b omitted.

[0103] As shown in Fig. 4 etc., the core 25 is a rectangular band-like sheet extending in a direction perpendicular to the waistline in a plan view. Note that a constriction may be formed at the center position of both edges of the core 25 in the direction perpendicular to the waistline. The constriction is formed by depressing both edges in the direction perpendicular to the waistline so that the core 25 can be positioned around the legs of the wearer without any gaps. The constriction has a curved shape for extending the curve of the leg-surrounding curved portion 15b described above.

[0104] The cores 25 are manufactured by being continuously connected in a direction perpendicular to the waist circumference as shown in FIG. 5A, which will be described in detail later in the manufacturing method. A cut area CUT is provided between the consecutive cores 25. The consecutive cores 25 are cut at a cutting line N in the cut area CUT and divided into individual cores 25 having a predetermined length 25L. The distribution density of SAP in the cut area CUT is lower than the distribution density of SAP in a holding area R2 described later. Specifically, in this embodiment, the cut areas CUT of the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2 hardly hold SAP. It is not necessary that no SAP is held in the cut area CUT.

[0105] The core 25 is formed of two sheets of a core-side first nonwoven fabric S1 and a core-side second nonwoven fabric S2, and a superabsorbent polymer (SAP) supported on the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2. In the core 25, the two sheets of the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2 are laminated as shown in Fig. 5B etc. The SAP is a water-absorbing substance having water-absorbing properties, and for example, sodium polyacrylate or the like is used.

[0106] More specifically, the core 25 further has a core-side second nonwoven fabric S2 laminated on the core-side first nonwoven fabric S1 so as to face the core-side first nonwoven fabric S1 via the SAP. A raised fiber layer is formed on each of the facing surfaces of the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2 to form gaps for supporting the SAP. By disposing the SAP in the gaps of this fiber layer, a large amount of SAP can be supported on the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2. An example of a nonwoven fabric having such a fiber layer is an airlaid nonwoven fabric.

[0107] Furthermore, by supporting SAP in two layers of core-side first nonwoven fabric S1 and core-side second nonwoven fabric S2, the amount of SAP supported can be greater than in the case where one layer of core-side first nonwoven fabric is provided, and the amount of urine and other substances absorbed by SAP can be increased.

[0108] Furthermore, as shown in Figs. 5A to 5C, the core-side first nonwoven fabric S1 supports SAP so as to form a first low-density region R11 and a holding region R2. The first low-density region R11 is disposed adjacent to both ends of the holding region R2 in the waist-line perpendicular direction. The first low-density region R11 is a region from the end of the holding region R2 in the waist-line perpendicular direction to the cutting line N in the cut region Cut in Fig. 5A. The distribution density of SAP in the first low-density region R11 is lower than the distribution density of SAP in the holding region R2. The first low-density region R11 may not support SAP. The holding region R2 is a region in which SAP is supported so as to have a predetermined water absorption performance for urine, etc. The core-side first nonwoven fabric S1 exerts a preset water absorption performance as the first low-density region R11 and the holding region R2 as a whole.

[0109] On the other hand, as shown in Fig. 5B and Fig. 5C, the retaining region R3 of the core-side second nonwoven fabric S2 is arranged at a position overlapping the retaining region R2 of the core-side first nonwoven fabric S1 in a plan view. The third low-density region R13 of the core-side second nonwoven fabric S2 is arranged at a position overlapping the first low-density region R11 of the core-side first nonwoven fabric S1 in a plan view. The distribution density of SAP in the third low-density region R13 is lower than the distribution density of SAP in the retaining region R2 and the retaining region R3. The third low-density region R13 may not support SAP. The distribution density of SAP in the retaining region R3 is set to have a predetermined water absorption performance for urine, etc. The distribution density of SAP in the third low-density region R13 and the entire retaining region R3 of the core-side second nonwoven fabric S2 is set to exhibit a preset water absorption performance.

[0110] The density of SAP in the holding region R3 may be the same as or different from that in the holding region R2, and the density of SAP in the third low-density region R13 may be the same as or different from that in the first low-density region R11.

[0111] The core-side first nonwoven fabric S1 is disposed on the wearer's skin side of the worn article 1, and the core-side second nonwoven fabric S2 is laminated on the back side of the core-side first nonwoven fabric S1.

[0112] These two core-side first nonwoven fabric S1 and core-side second nonwoven fabric S2 are laminated so that the raised fiber layers carrying SAP face each other. This makes it possible to prevent the SAP from falling off. In other words, in the non-raised outer parts on the outer surface sides of the core-side first nonwoven fabric S1 and core-side second nonwoven fabric S2, the fibers are entangled at high density. The SAP is carried in the core-side first nonwoven fabric S1 and core-side second nonwoven fabric S2 by this outer part.

[0113] The core-side first nonwoven fabric S1 is formed by retaining SAP. Since the absorption performance per unit volume of SAP is higher than that per unit volume of fluff pulp, the amount of fluff pulp used can be reduced when fluff pulp is used. Therefore, the thickness of the core 25 can be made thinner than that of a nonwoven fabric formed only from an amount of fluff pulp required for a predetermined absorption performance. Since the thickness of the wearing article 1 including this core-side first nonwoven fabric S1 is also thin, the wearing article 1 can be easily adapted to fit the waist shape of the wearer, improving the fit of the wearing article 1.

[0114] Furthermore, the thickness of the core 25 can be made thinner than that of a nonwoven fabric formed only from an amount of fluff pulp required for a predetermined absorption performance. By making the core-side first nonwoven fabric S1 and the core-side second nonwoven fabric S2 thinner, the thickness of the wearing article 1 can also be made thinner, so that the wearing article 1 can be easily adapted to fit the waist shape of the wearer, improving the fit of the wearing article 1.

[0115] Moreover, the retention region R2 has a lower distribution density of SAP than the first low-density region R11, and therefore has poor flexibility. On the other hand, the first low-density region R11 has a lower distribution density of SAP than the retention region R2, and therefore has higher flexibility than the retention region R2. Therefore, the core 25 having the first low-density region R11 is easily deformed. Here, when a wearer wears the wearing article 1, both ends of the retention region R2 in the direction perpendicular to the waistline are disposed facing the front abdomen and the back of the wearer, respectively. The first low-density region R11, in which the distribution density of SAP is lower than that of the retention region R2, is disposed in a portion adjacent to both ends of the retention region R2 in the direction perpendicular to the waistline. Therefore, the portion of the core 25 where the first low-density region R11 is disposed flexibly deforms to conform to the shape of the front abdomen and the back, and the portion abuts against the front abdomen and the back with a soft touch, and therefore the wearing comfort of the wearing article 1 can be improved.

[0116] 5A to 5C may be combined with a topsheet 24 having an uneven shape 20a to produce the wearing article 1. In this case, the uneven shape 20a of the topsheet 24 can improve breathability and texture. Even after absorbing bodily fluids, the uneven shape 20a of the topsheet 24 can maintain the good breathability and texture.

[0117] Furthermore, the arrangement of the low-density regions in the core 25 is not limited to the above-mentioned form, and may be, for example, as shown in FIGS. 6A to 6D.

[0118] In the core-side first nonwoven fabric S1 shown in Figs. 6A and 6B, the first low-density region R11 is disposed adjacent to both ends of the retention region R2 in the waist-girth ...

[0119] To further explain the position of the second low-density region R12 in this embodiment, as shown in Fig. 6A, the second low-density region R12 is provided so as to be continuous along the direction perpendicular to the waistline in the center of the waistline width direction of the core 25. The retaining regions R2 are provided so as to be adjacent to both sides of the second low-density region R12 in the waistline width direction.

[0120] The amount of SAP held in the second low-density region R12 is less than the amount of SAP held in the retention region R2. Therefore, the flexibility of the core 25 in the second low-density region R12 is greater than the flexibility of the core 25 in the retention region R2. This makes it easier for the core 25 to deform to fit the body shape and reduces the stiffness of the core 25, improving the fit of the wearing article 1.

[0121] 6A to 6D, for example, the second low-density region R12 extends continuously in the waist-perpendicular direction in the center in the waist-perpendicular direction of the core 25. This allows the core 25 to bend based on the second low-density region R12, which has a smaller amount of SAP and is more flexible than the retaining region R2, so that the core 25 can be deformed to fit the wearer's body shape over the formation range of the second low-density region R12 in the waist-perpendicular direction, improving the fit of the worn article.

[0122] Specifically, since the second low-density region R12 is disposed in the center of the waist width direction, the core 25 can be easily deformed into a shape that is bent in an inverted V shape generally symmetrically around the second low-density region R12 in the center, as shown in FIG. 6C. Therefore, when a wearer wears the wearing article, the core 25 extending from the rear part to the front abdomen through the crotch part is deformed as shown in FIG. 6C to match the shape of the wearer's crotch part. This can further improve the wearing comfort of the wearing article 1. Note that the core 25 can also be deformed into a shape that is bent in an inverted V shape generally symmetrically around the second low-density region R12, as shown in FIG. 6D. In this case, the core 25 is also less likely to be bulky between the crotch parts, and the wearing comfort of the wearing article 1 can be improved.

[0123] In addition, since the second low-density region R12 absorbs less urine and the like than the retention region R2, the urine and the like can be diffused along the second low-density region R12 in the direction perpendicular to the waistline. Therefore, the core 25 can effectively absorb urine and the like by using the retention regions R2 adjacent to both sides of the second low-density region R12 in the waistline width direction.

[0124] More specifically, in the arrangement of the second low-density region R12 and the retaining region R2 shown in FIG. 6A, the second low-density region R12 is located at the center of the waist width direction of the core 25, that is, at a position in the crotch area where a relatively large amount of urine, etc. is received. Therefore, there is a high possibility that urine, etc. will be guided to the second low-density region R12 and the retaining region R2 adjacent thereto in the waist width direction. When urine, etc. is guided to the second low-density region R12 and the retaining region R2, the urine, etc. can be absorbed in the second low-density region R12 and the retaining region R2 surrounding it, while the urine, etc. can be diffused along the second low-density region R12 extending along the waist orthogonal direction. At this time, the urine, etc. diffused along the second low-density region R12 is also absorbed in the second low-density region R12 and the retaining region R2 adjacent thereto in the waist width direction. This allows urine, etc. to be diffused and absorbed more quickly by utilizing a wider area of ​​the retention area R2, compared to when the second low-density area R12 does not exist (when the density of SAP is constant throughout the entire retention area). Therefore, the sticky feeling on the skin surface caused by urine, etc. can be more quickly eliminated, and discomfort can be alleviated.

[0125] Furthermore, since the second low-density region R12 can be used as a region for the expansion of SAP in the retention region R2, excessive adhesion of the absorbent body 20 to the skin surface can be suppressed. This makes it possible to more quickly eliminate the sticky feeling on the skin surface caused by urine or the like, and to alleviate discomfort.

[0126] 6A to 6D, the wearing article 1 having the core 25 is worn around the waist by engaging the male fastener 12 with the female fastener 22. With the absorbent 20 in close contact with the crotch area, the flexibility of the second low-density region R12 of the core 25 can improve the fit to the crotch area before the absorption of bodily fluids. Even after the absorption of bodily fluids, the second low-density region R12 of the core 25 can ensure expansion space for SAP, so that the core 25 can be prevented from expanding more than necessary toward the skin-facing side, and a pleasant feel can be maintained.

[0127] 6A to 6D may be combined with a topsheet 24 having an uneven shape 20a to manufacture the wearing article 1. In this case, when the absorber 20 is in close contact with the crotch area, the uneven shape 20a of the topsheet 24 and the second low-density region R12 of the core 25 improve the fit to the crotch area while providing good breathability and texture before the body fluid is absorbed. Even after the body fluid is absorbed, the second low-density region R12 of the core 25 ensures expansion space for SAP, so that the core 25 is prevented from expanding more than necessary toward the skin side, and the uneven shape 20a of the topsheet 24 maintains good breathability and texture.

[0128] The second low-density region R12 and the retaining region R2 are not limited to being formed by adjusting the amount of SAP carried in the core-side nonwoven fabric. For example, the core-side nonwoven fabric in which the retaining region R2 is formed may be divided and the divided portions may be separated in the width direction to form a space, which may be used as the second low-density region R12. Alternatively, the surface (the surface that has been subjected to a nap treatment) of the core-side nonwoven fabric in the retaining region R2 may be pressed to crush the fibers in a napped state, thereby reducing the gaps that retain the SAP, and the resulting portion may be used as the second low-density region R12.

[0129] In the above, the core-side second nonwoven fabric S2 has only the third low-density region R13 as a low-density region. However, both of the two core-side nonwoven fabrics S1 and S2 may have the first low-density region R11, the second low-density region R12, and the holding region R2. For example, the core-side first nonwoven fabric S1 has the first low-density region R11 provided at both ends of the core-side first nonwoven fabric S1 and the second low-density region R12 between the first low-density regions R11. Similarly, the core-side second nonwoven fabric S2 has the third low-density region R13 provided at both ends of the core-side second nonwoven fabric S2 and the second low-density region R12 between the third low-density regions R13. In this case, the second low-density region R12 of the first core-side nonwoven fabric S1 and the second low-density region R12 of the core-side second nonwoven fabric S2 may be disposed at different positions in a plan view, or may be disposed at overlapping positions in a plan view.

[0130] 6A to 6D may have the form shown in, for example, Figures 7A to 7C. Regarding the second low-density region R12 in Figures 7A to 7C, only the differences from Figures 6A to 6D will be mainly described.

[0131] 7A, the first low-density regions R11 are disposed adjacent to both ends of the retention region R2 in the waist-circumference-orthogonal direction, and multiple second low-density regions R12 are intermittently provided along the waist-circumference-orthogonal direction in the center of the waist-circumference-width direction of the core-side first nonwoven fabric S1. With this, the retention region R2 between the multiple second low-density regions R12 can be used as a dam to roughly divide the diffusion range of urine, etc. in the core 25 and the absorption range by the retention region R2 into three.

[0132] In addition, at the center of the waist width direction of the core-side first nonwoven fabric S1, at both ends in the waist-perpendicular direction, the retaining region R2 is provided adjacent to the second low-density region R12 in the waist-perpendicular direction. That is, in the core-side first nonwoven fabric S1, both ends in the waist-perpendicular direction of the second low-density region R12 are closed by the retaining region R2. This allows the retaining region R2 to be used as a dam for the second low-density region R12. Therefore, according to the configuration shown in FIG. 7A, it is possible to prevent urine, etc. from being guided to the outside of the core 25 in the waist-perpendicular direction by the second low-density region R12.

[0133] In the example shown in Fig. 7B, in the core-side first nonwoven fabric S1, the first low-density region R11 is arranged adjacent to both ends of the retention region R2 in the waist-line perpendicular direction, and in addition to the second low-density region R12 similar to that in Fig. 6A provided at the center in the waist-line width direction, a second low-density region R12 is provided on both sides of the second low-density region R12 in the waist-line width direction. The three second low-density regions R12 extend parallel to each other in the waist-line perpendicular direction. The two additional second low-density regions R12 make it easier for urine, etc., that has spread on the surface of the core 25 to be diffused throughout the core 25, and further improves the flexibility of the core 25 in the waist-line perpendicular direction.

[0134] In the example shown in Fig. 7C, the first low-density region R11 is disposed adjacent to both ends of the retention region R2 in the waist-line perpendicular direction, and the second low-density region R12 shown in Fig. 7B, which is provided at the center of the waist-line width direction of the core-side first nonwoven fabric S1, is not provided. That is, the retention region R2 is provided at the center of the waist-line width direction of the core-side first nonwoven fabric S1, and the second low-density region R12 is provided on both sides of the center in the waist-line width direction. The two second low-density regions R12 extend parallel to each other in the waist-line perpendicular direction. The two second low-density regions R12 make it easier to spread urine, etc., over the entire core 25 than the single second low-density region R12 shown in Fig. 6A, and further improves the flexibility of the core 25 in the waist-line width direction.

[0135] 7A and 7B, similarly to the example shown in Fig. 6A, the core 25 can be easily deformed into a generally symmetrical V-shaped or inverted V-shaped bent shape with the center in the waist width direction where the second low-density regions R12 are arranged as the center. Also, in the example shown in Fig. 7C, the core 25 can be easily deformed into a generally symmetrical U-shaped or inverted U-shaped bent shape with the two second low-density regions R12 spaced apart from the center in the waist width direction.

[0136] Furthermore, the direction in which the second low-density region R12 extends is not limited to the direction perpendicular to the waistline. For example, the second low-density region R12 may be aligned along the waistline width direction in the core 25 and sandwiched between the retaining region R2 in the waistline width direction. For example, if the second low-density region R12 is arranged along the waistline width direction in the crotch area, urine, etc. can be diffused along the second low-density region R12 in the waistline width direction and absorbed by the retaining region R2 adjacent to the second low-density region R12. In addition, since the retaining region R2 is adjacent to the end of the second low-density region R12 in the waistline width direction, the retaining region R2 can be used as a dam. Therefore, urine, etc. can be prevented from being guided to the outside of the waistline width direction of the core 25 by the second low-density region R12.

[0137] The second low-density region R12 may have a portion extending along the waist-line orthogonal direction and a portion extending along the waist-line width direction. For example, the second low-density region R12 may have a portion extending along the waist-line orthogonal direction in the center of the waist-line width direction of the core 25, and a portion branching off from the portion extending in the waist-line orthogonal direction in the waist-line width direction. This allows urine, etc. to be diffused along the second low-density region R12 in both the waist-line orthogonal direction and the waist-line width direction, and to be quickly absorbed by the retention region R2.

[0138] Furthermore, the regions with different SAP distribution densities are not limited to the low-density regions R11, R12, and R13 and the holding regions R2 and R3. For example, with the holding region R2 as a reference, multiple regions with different SAP distribution densities selected from distribution regions with SAP distribution densities ranging from 0 to the SAP distribution density in the holding region R2 may be provided in the core 25.

[0139] In the above, both of the two core-side nonwoven fabrics support SAP, but only one of the core-side nonwoven fabrics may support SAP, and the remaining core-side nonwoven fabric may not support SAP.Furthermore, the core-side nonwoven fabric may contain fluff pulp.

[0140] For example, in the core 25 of Fig. 5A to Fig. 5C, the core-side nonwoven fabric containing fluff pulp may be disposed on the wearer's skin side, and the core-side first nonwoven fabric S1 shown in Fig. 5A to Fig. 5C may be disposed on the opposite side to the skin side. In this case, the fluff pulp of the core-side nonwoven fabric on the skin side absorbs bodily fluids faster than the SAP, and the SAP of the core-side first nonwoven fabric S1 on the opposite side further absorbs the bodily fluids absorbed by the fluff pulp. In the core 25 of Fig. 6A to Fig. 6D and Fig. 7A to Fig. 7C, similarly to the above, the core-side nonwoven fabric containing fluff pulp may be disposed in the upper layer, and the core-side first nonwoven fabric S1 shown in Fig. 6A to Fig. 6D and Fig. 7A to Fig. 7C may be disposed in the lower layer.

[0141] The method of supporting SAP in the core-side nonwoven fabric is not limited to the method of supporting SAP in the fiber layer of the core-side nonwoven fabric that has been raised to form gaps for supporting SAP. For example, an adhesive may be applied to the surface of the core-side nonwoven fabric, and SAP may be sprinkled on the applied adhesive to place SAP on the surface of the core-side nonwoven fabric. In this case, the amount of adhesive applied per unit area for the low-density regions R11, R12, and R13 is less than the amount of adhesive applied per unit area for the holding regions R2 and R3. Alternatively, SAP may be supported in the fiber layer of the core-side nonwoven fabric by sprinkling SAP on the fiber layer of the raised core-side nonwoven fabric and sucking from the side opposite to the side where SAP is sprinkled.

[0142] Furthermore, the number of core-side nonwoven fabrics forming the core 25 is not limited to two, and the core 25 may be formed from one core-side nonwoven fabric.

[0143] The back sheet 26 is a rectangular band-like sheet extending in a direction perpendicular to the waist circumference, as shown in Fig. 4 etc. The back sheet 26 is provided on the outer surface of the core 25 opposite to the surface facing the skin side, and sandwiches the core 25 between the back sheet 26 and the top sheet 24. The back sheet 26 has a liquid-impermeable sheet 26a facing the core 25, and an outer layer sheet 26b covering the outer surface of the liquid-impermeable sheet 26a opposite to the surface facing the core 25.

[0144] The liquid-impermeable sheet 26a is a strip-shaped sheet that is water-repellent and does not allow urine and the like to pass through. The liquid-impermeable sheet 26a is formed of a nonwoven fabric made of, for example, polypropylene, polyethylene, etc. It is preferable that the liquid-impermeable sheet 26a has breathability.

[0145] The core 25 is joined to the liquid-impermeable sheet 26a in a state in which the core 25 is disposed within the range of the waist width direction and the waist perpendicular direction of the liquid-impermeable sheet 26a. Since the liquid-impermeable sheet 26a is provided on the outer surface of the core 25 opposite to the surface facing the skin, even if the core 25 cannot absorb all the urine, etc., it is possible to prevent the urine, etc. from leaking out of the liquid-impermeable sheet 26a.

[0146] In the example shown in Fig. 4, the liquid-impermeable sheet 26a is rectangular. However, the liquid-impermeable sheet 26a may have leg-surrounding curved portions formed at the center positions in the direction perpendicular to the waistline of both edge portions in the waistline width direction of the liquid-impermeable sheet 26a in a plan view. The leg-surrounding curved portions are formed by depressing both edge portions in the waistline width direction in order to position the liquid-impermeable sheet 26a around the legs of the wearer without any gaps.

[0147] The leg gathers 31 are elastic members that correspond to the base of the legs when the wearer wears the wearing article 1. The leg gathers 31 are provided along both edges of the liquid-impermeable sheet 26a in the waist width direction, and are provided over substantially the entirety of the liquid-impermeable sheet 26a in the direction perpendicular to the waist. The leg gathers 31 are arranged in a stretched state in the direction perpendicular to the waist between the liquid-impermeable sheet 26a and the top sheet 24, and are joined to at least one of the liquid-impermeable sheet 26a and the top sheet 24. The joining may be performed by adhesion using a hot melt adhesive or welding by heat sealing, but ultrasonic welding is preferred. By providing such leg gathers 31, a softer feel can be given to the base of the legs compared to when both edges of the absorbent body 20 are directly in contact with the base of the legs, and the wearing comfort of the wearing article 1 is further improved.

[0148] The leg gathers 31 may be disposed between the liquid-impermeable sheet 26a and the outer sheet 26b and joined to at least one of them.

[0149] The absorbent elastic member 21 is provided at the free end (the end opposite to the waistline member 10) of the liquid-impermeable sheet 26a in the direction perpendicular to the waistline, and has elasticity that allows it to stretch in the waistline width direction. Therefore, the tip end of the absorbent 20 having this liquid-impermeable sheet 26a, opposite to the side joined to the waistline member 10, is stretchable in the waistline width direction. As described above, the waistline member 10 is also stretchable in the waistline width direction by the waistline elastic member 11. As a result, both the waistline member 10 and the tip end of the absorbent 20 are stretchable in the waistline width direction according to the length of the wearer's waistline, so there is a large degree of freedom in selecting the engagement position between the male fastener 12 of the waistline member 10 and the female fastener 22 of the absorbent 20. This allows the fitting feeling of the worn article 1 to be improved.

[0150] The absorber elastic member 21 is not an essential component. Even if the absorber elastic member 21 is omitted, the waist member 10 has elasticity in the waist width direction, so that the fit of the wearing article 1 can be improved.

[0151] The outer layer sheet 26b is a sheet extending in the direction perpendicular to the waistline and formed of a nonwoven fabric, and is attached to the outer surface of the liquid-impermeable sheet 26a opposite to the surface facing the skin side, with the liquid-impermeable sheet 26a covered from the outer surface side. This improves the appearance of the worn article 1 from the outside and the feel of the worn article 1 against the skin. In the example shown in FIG. 4, the outer layer sheet 26b is rectangular. However, the outer layer sheet 26b may have leg-surrounding curved portions formed at the center positions of both edges in the direction perpendicular to the waistline in a plan view. In this case, the leg-surrounding curved portions are formed by recessing both edges in the direction parallel to the waistline so that the outer layer sheet 26b can be positioned around the legs of the wearer without any gaps.

[0152] As described above, the liquid-impermeable sheet 26a and the outer layer sheet 26b may be provided with leg-circumference curved portions. Furthermore, as described above, the waistline member 10 has a leg-circumference curved portion 15b at its lower edge on the leg base side. In this case, as shown in Figs. 1 and 2, by engaging the male fastener 12 of the waistline member 10 with the female fastener 22 of the absorber 20 to assemble the wearing article 1, the leg-circumference curved portions of the liquid-impermeable sheet 26a and the outer layer sheet 26b and the leg-circumference curved portion 15b of the waistline member 10 can form curved leg holes arranged along the entire circumference of the leg base.

[0153] In addition, the periphery of the leg holes is elastically fitted to the base of the legs all around by the leg gathers 31 and the waist elastic member 11 arranged near the leg curved portion 15b, thereby improving the wearing comfort.

[0154] The female fastener 22 is provided on the outer surface of the tip of the outer layer sheet 26b on the opposite side to the waistline member 10 in the waistline orthogonal direction. The female fastener 22 is provided over almost the entire width of the waistline at the tip of the outer layer sheet 26b. The length of the female fastener 22 in the waistline orthogonal direction may be, for example, approximately the same as the length of the male fastener 12 in the waistline orthogonal direction, or may be longer than the length of the male fastener 12 in the waistline orthogonal direction.

[0155] In this way, the female fastener 22 is provided over almost the entire tip of the outer layer sheet 26b in the waist width direction. Therefore, by stretching the waist member 10 in the waist width direction, the male fastener 12 can be engaged with the female fastener 22 at any position in the waist width direction, allowing for a large degree of freedom in selecting the engagement position. This makes it easy to adjust the engagement position between the waist member 10 and the absorbent body 20 according to the waist length of each wearer, and improves the fit.

[0156] The indicator 50 changes color according to the amount of urine or the like absorbed by the core 25, to indicate that the wearer has urinated. The indicator 50 extends perpendicular to the waist circumference at the center of the waist width direction of the outer sheet 26b on the surface facing the skin side of the outer sheet 26b. For example, an adhesive that changes color according to the amount of urine or the like absorbed is used as the indicator 50.

[0157] As shown in Fig. 4, the three-dimensional gathers 40 are provided on the surface of the topsheet 24 facing the skin side. The three-dimensional gathers 40 have a pair of rising flaps 42 and three-dimensional gather elastic members 41 provided on each of the rising flaps 42. The rising flaps 42 extend in a direction perpendicular to the waistline and are joined to both edges of the topsheet 24 in the waistline width direction. Specifically, one edge (e.g., the right edge) of each rising flap 42 in the waistline width direction is joined to one edge (e.g., the right edge) of the topsheet 24. Each three-dimensional gather elastic member 41 is joined in a stretched state to the other edge (e.g., the left edge) of the rising flap 42 in the waistline width direction. With the absorbent body 20 curved in a direction perpendicular to the waist along the crotch portion of the wearer, the other edge (e.g., the left edge) of each rising flap 42 in the waist width direction is contracted by the biasing force of the three-dimensional gather elastic member 41, causing each rising flap 42 to rise up against the topsheet 24. When worn, the rising flap 42 elastically adheres to the back portion, the crotch portion, the front abdominal portion, etc. Thus, it is possible to prevent urine and the like from leaking out of the wearing article 1.

[0158] The lengths of the female fastener 22 in the waist width direction and the direction perpendicular to the waist may be set so as to obtain an engagement force capable of engaging with the male fastener 12 so as not to unfold the waist member 10 and the absorbent body 20 when worn. For example, the female fastener 22 may be provided only in the center in the waist width direction at the tip of the outer layer sheet 26b, or may be provided divided into two on both sides in the waist width direction.

[0159] Also, as long as the waist member 10 and the absorbent body 20 can be engaged with each other, the waist member 10 may be provided with a female fastener 22 and the absorbent body 20 may be provided with a male fastener 12 .

[0160] The back sheet 26 may be formed only from the liquid-impermeable sheet 26a.

[0161] A transfer sheet (not shown) may be interposed between the top sheet 24 and the core 25. This transfer sheet quickly diffuses urine and the like along the surface of the core 25 and prevents urine and the like absorbed by the core 25 from leaking out from the top sheet 24.

[0162] In such a refastenable-type wearing article 1, the absorbent body 20 is folded in half in a direction perpendicular to the waistline, and the male fastener 12 and the female fastener 22 are engaged with each other in a state in which both side portions 10a located on both sides of the joint portion 10b in the waistline member 10 are folded in the width direction of the waistline. As a result, the refastenable-type wearing article 1 described above has a pants-like shape because the female fastener 22 is engaged with the male fastener 12 in the initial state, and the wearer can wear the wearing article like pants.

[0163] Moreover, the article can be deployed into a predetermined deployed form by releasing the engagement between the male fasteners 12 and the female fasteners 22. In the deployed form, both side portions 10a of the waist member 10 protrude from the absorbent body 20 arranged at the joint portion 10b of the waist member 10. These both side portions 10a can be brought toward the tip portion of the absorbent body 20 along the waist of the wearer and brought into contact with the back sheet 26 of the absorbent body 20 arranged along the crotch portion of the wearer. Then, the male fasteners 12 at both end portions 10c in the waist width direction of the waist member 10 are engaged with the female fasteners 22 of the back sheet 26 to support the refastenable-type wearing article 1 at the waist, whereby the absorbent body 20 is pulled up and brought into close contact with the crotch portion of the wearer.

[0164] Moreover, the articles can be folded into a compact form, allowing a plurality of the articles 1 to be in a form suitable for packing, storage, etc.

[0165] <Method of manufacturing refastenable wearing article> A method for manufacturing the above-mentioned refastenable-type wearing article 1 will be described below.

[0166] In each of the following steps, a machine direction (MD) A is a conveying direction of a sheet or the like, and a cross direction (CD) W is a direction generally perpendicular to the length direction (A).

[0167] (1) Process 1~Process 2 As shown in Figures 8, 9 and 17, steps 1 and 2 are an example of a process for producing a waistline continuum in which a plurality of waistline bodies 16 are connected together in a transverse flow state as shown in Figure 9. In the transverse flow state of Figure 9, the MD direction A coincides with the waistline width direction, and the CD direction W coincides with the direction perpendicular to the waistline.

[0168] (Process 1) In step 1, a continuous body of outer sheets 15, which is a continuous body of outer sheets 15, is transported in the MD direction A (see FIG. 17A), and the waist elastic members 11 are arranged linearly along the MD direction A on the continuous body of outer sheets 15 (see FIG. 17B). The waist elastic members 11 are arranged below the upper edge of the outer sheets 15 with a gap therebetween, and spaced apart from each other in the direction perpendicular to the waistline.

[0169] 9 and 17C, a continuous body of the inner sheets 14, which is a continuous body of the inner sheets 14, is transported in the MD direction A, and the continuous body of the inner sheets 14 is placed on the continuous body of the outer sheets 15 so as to cover the upper part of the waist elastic members 11. As shown in Fig. 9, the continuous body of the inner sheets 14 is positioned in a state in which the upper side of the outer sheets 15 is exposed, and is joined to the continuous body of the outer sheets 15 while covering it. As a result, the exposed part of the outer sheet 15 forms the extended part 15c.

[0170] In the above, the waist elastic members 11 are arranged linearly along the MD direction A on the continuum of the outer sheet 15. However, among the waist elastic members 11, the waist elastic members 11 arranged on the lower edge of the inner sheet 14 may be arranged in a curved shape so as to follow the curve of the leg curved parts 15b formed in step 8 described later. For example, the waist elastic members 11 arranged on the lower edge of the inner sheet 14 may be arranged on the outer sheet 15 along a substantially sinusoidal locus that meanders in the MD direction A.

[0171] The waist elastic member 11 is in a stretched state sandwiched between the continuous outer sheet 15 and the continuous inner sheet 14, and joined to at least one of the continuous outer sheet 15 and the continuous inner sheet 14. As a joining means, adhesion using a hot melt adhesive or welding by heat sealing can be used, but ultrasonic welding is preferable.

[0172] (Process 2) In step 2, the outer sheet 15 continuum and the inner sheet 14 continuum undergo a weakening process on the waistline elastic members 11 at the weakened portions 15a1 where the absorber 20 is disposed and at the weakened portions 15a2 where the male fasteners 12 are disposed. The weakening process is a process for making the elasticity at a predetermined portion weaker than that of the portion adjacent to the predetermined portion or nullifying it by cutting the elastic member at the predetermined portion with a blade or fusing it by applying heat, as described below. Specifically, the weakening process makes the elastic force of the weakened portions 15a1, 15a2 weaker than that of the portion adjacent to the weakened portions 15a1, 15a2 in the waistline width direction (MD direction A in Fig. 9).

[0173] The weakening treatment can be performed, for example, by melting the waist elastic member 11 using an embossing roll (heat embossing) (see JP 2002-113042 A) or by cutting the waist elastic member 11 with a gather cutter 60 (see FIG. 8).

[0174] The weakening process may be performed before step 8 in which the absorbent body 20 is attached, which will be described later.

[0175] (2) Process 3~Process 7 Steps 3 to 7 are an example of a process for producing the absorbent body 20 in a vertical flow state as shown in Fig. 10. In the vertical flow state of Fig. 10, the MD direction A coincides with the direction perpendicular to the waistline, and the CD direction W coincides with the width direction of the waistline.

[0176] (Step 3) In step 3, a topsheet work-in-progress is formed by combining a continuous body of topsheets 24 in which a plurality of topsheets 24 are continuous with a continuous body of three-dimensional gathers 40 in which a plurality of three-dimensional gathers 40 are continuous.

[0177] 8, 10, and 18, a nonwoven sheet for forming a continuous body of the rising flaps 42, in which a plurality of the rising flaps 42 are continuous, is continuously fed in the MD direction A, and cut in the MD direction A by a slitter 62 (see FIG. 18A). The cut continuous body of a pair of strip-shaped rising flaps 42 is widened in the CD direction W at a constant interval W2 (see FIG. 18B). Next, a three-dimensional gather elastic member 41 is arranged in a stretched state in the MD direction A on the inner edge of each of the continuous bodies of the pair of rising flaps 42 (the edge of the continuous body of one rising flap 42 closer to the continuous body of the other rising flap 42 in the CD direction W) (see FIG. 18C).

[0178] The inner edge of the continuum of the rising flaps 42, on which the three-dimensional gather elastic member 41 is disposed, is folded back by the sailor 63 so that the three-dimensional gather elastic member 41 is sandwiched inside the rising flaps 42, as shown in Fig. 18D. This forms the inwardly bent portion 40a. At this time, the three-dimensional gather elastic member 41 is joined to the continuum of the rising flaps 42 by adhesion using a hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like, while being sandwiched within the inwardly bent portion 40a in a stretched state in the MD direction A. In this way, the continuum of the three-dimensional gathers 40 is manufactured.

[0179] Thereafter, the outer edge 40b (the edge of the continuum of one rising flap 42 in the CD direction W that is farther from the continuum of the other rising flap 42 in the CD direction W) of the continuum of the three-dimensional gathers 40 is joined to both outer edges in the CD direction W of the continuum of the topsheet 24, which is continuously fed in the MD direction A, by bonding with a hot melt adhesive, welding by heat sealing, ultrasonic welding, etc., to produce a work-in-progress topsheet (see Figure 18E).

[0180] Next, a description will be given of a method for manufacturing a continuous body of the topsheet 24. First, the configuration of an apparatus 85 for manufacturing a continuous body of the topsheet 24 will be described.

[0181] Fig. 11 is a schematic diagram of the manufacturing apparatus 85. As shown in Fig. 11, the manufacturing apparatus 85 includes first and second rolls 92, 94 disposed adjacent to each other, and a bonding apparatus 100 disposed adjacent to the first roll 92.

[0182] The first roll 92 has a cylindrical outer peripheral surface 92s, and has a plurality of recesses 92a that are recessed radially inward from the outer peripheral surface 92s and engage with a plurality of protrusions 94a described below. The second roll 94 has a cylindrical outer peripheral surface 94s, and has a plurality of protrusions 94a that protrude radially outward from the outer peripheral surface 94s. The shape of the protrusions 94a is, for example, a hemispherical shape with a protruding tip being a hemispherical shape, and may also be, for example, a rectangular parallelepiped shape, a cylindrical shape, a truncated pyramid shape, or the like. The first and second rolls 92 and 94 rotate in opposite directions to each other as indicated by arrows 92r and 94r. The recesses 92a of the first roll 92 and the protrusions 94a of the second roll 94 engage with each other in an engagement region 93. More specifically, the first and second rolls 92, 94 rotate so that the recessed portions 92a and the protruding portions 94a engage with each other in an engagement region 93 with a gap formed therebetween, that is, in a non-contact state.

[0183] The joining device 100 is an ultrasonic sealing device, and produces a continuous top sheet 24 by joining two sheets, a continuous top first nonwoven fabric 24a having a plurality of continuous top first nonwoven fabrics 24a, and a continuous top second nonwoven fabric 24b having a plurality of continuous top second nonwoven fabrics 24b. Although adhesion using a hot melt adhesive or welding by heat sealing can be used as a joining means, ultrasonic welding is preferred. When ultrasonic welding is used, it is preferable because stiffness of the top sheet 24 is suppressed compared to when an adhesive or heat sealing is used.

[0184] By using the manufacturing device 85, the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b can be overlapped to form the uneven shape 20a. Furthermore, by using the manufacturing device 85, the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b can be joined together while tension is applied to the continuum of the front side second nonwoven fabric 24b, while maintaining the uneven shape 20a of the continuum of the front side first nonwoven fabric 24a, so that the undulations of the continuum of the front side second nonwoven fabric 24b are gentler than the uneven shape 20a of the continuum of the front side first nonwoven fabric 24a. The manufacturing method of such a continuum of the top sheet 24 will be further described.

[0185] As shown in Fig. 11 and Fig. 12A, the continuous body of the front side first nonwoven fabric 24a is wound around the outer circumferential surface 92s of the first roll 92 before the continuous body of the front side second nonwoven fabric 24b. Since the recessed portion 92a of the first roll 92 is connected to a negative pressure source, the continuous body of the front side first nonwoven fabric 24a is adsorbed and held along the outer circumferential surface 92s of the first roll 92. Next, the continuous body of the front side second nonwoven fabric 24b is wound around the outer circumferential surface 92s of the first roll 92 via the continuous body of the front side first nonwoven fabric 24a at the meshing region 93 or a position slightly upstream from it. In other words, the continuous body of the front side second nonwoven fabric 24b is overlapped on the outside of the continuous body of the front side first nonwoven fabric 24a at the meshing region 93 or a position slightly upstream from it. As described above, the continuous body of the surface side first nonwoven fabric 24a and the continuous body of the surface side second nonwoven fabric 24b are guided to the first roll 92 along the directions indicated by arrows B and C (Figure 11) so that the continuous body of the surface side first nonwoven fabric 24a and the continuous body of the surface side second nonwoven fabric 24b are wound around the outer peripheral surface 92s of the first roll 92.

[0186] The portions 24a1, 24b1 covering the recesses 92a in the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are pushed into the recesses 92a by the protrusions 94a while overlapping in the meshing region 93. As a result, the portions 24a2, 24b2 pushed into the recesses 92a are formed in the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b (see Figs. 12A and 12B). That is, the uneven shape 20a is formed by forming a plurality of portions 24a2, 24b2 in the continuum of the overlapped front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b.

[0187] As described above, the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are overlapped in the meshing region 93 and joined by the joining device 100 downstream of the meshing region 93 (on the right side in Figs. 12A to 12C). In this way, the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are overlapped, and the relative movement of the two continuums is suppressed by the frictional resistance generated between the two continuums. Furthermore, the relative movement between the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b is restricted by the joining. Meanwhile, the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are transported in a non-contact and non-joined state on the upstream side of the meshing region 93 (on the left side in Figs. 12A to 12C) as shown in Fig. 11. Thus, relative movement between the continuum of the front-side first nonwoven fabric 24a and the continuum of the front-side second nonwoven fabric 24b is permitted on the upstream side of the meshing region 93. For this reason, relative movement between the continuum of the front-side first nonwoven fabric 24a and the continuum of the front-side second nonwoven fabric 24b is more likely to occur upstream of the meshing region 93 than downstream.

[0188] As shown in FIG. 12B, the convex portion 94a meshing with the concave portion 92a gradually comes out of the concave portion 92a in response to the rotation of the first roll 92. As described above, the air in the concave portion 92a is sucked. Therefore, by inserting the convex portion 94a into the concave portion 92a, the multiple portions 24a2 of the continuum of the front side first nonwoven fabric 24a remain in the concave portion 92a and are shaped. On the other hand, as shown in FIG. 12C, the portion 24b2 of the continuum of the front side second nonwoven fabric 24b is pulled out of the concave portion 92a by the tension applied to the continuum of the front side second nonwoven fabric 24b as the convex portion 94a gradually comes out of the concave portion 92a. Therefore, the undulations formed in the continuum of the front side second nonwoven fabric 24b are gentler than the uneven shape formed in the continuum of the front side first nonwoven fabric 24a.

[0189] When the convex portion 94a completely exits the concave portion 92a, the portion 24b2 pushed into the concave portion 92a of the continuous body of the second nonwoven fabric 24b on the surface side is completely pulled out of the concave portion 92a by the tension applied to the continuous body of the second nonwoven fabric 24b on the surface side. Therefore, the undulations formed in the continuous body of the second nonwoven fabric 24b on the surface side become gentler than the uneven shape 20a formed in the continuous body of the first nonwoven fabric 24a on the surface side. On the other hand, since the portion 24a2 pushed into the concave portion 92a of the continuous body of the first nonwoven fabric 24a on the surface side remains in the concave portion 92a as described above, the uneven shape 20a is formed only in the continuous body of the first nonwoven fabric 24a on the surface side.

[0190] In order to form the uneven shape 20a only in the continuous body of the first nonwoven fabric 24a on the surface side as described above, the tension T2 applied to the continuous body of the second nonwoven fabric 24b on the surface side is set to be greater than the tension T1 applied to the continuous body of the first nonwoven fabric 24a on the surface side (T1 < T2). As a result, the portion 24b2 of the continuous body of the second nonwoven fabric 24b on the surface side is pulled out of the concave portion 92a while moving relatively with respect to the continuous body of the first nonwoven fabric 24a on the surface side as the convex portion 94a exits the concave portion 92a. Therefore, the uneven shape 20a is formed in the continuous body of the first nonwoven fabric 24a on the surface side, while a gentler undulation is formed in the continuous body of the second nonwoven fabric 24b on the surface side compared to the uneven shape 20a of the continuous body of the first nonwoven fabric 24a on the surface side (in this embodiment, a continuous body of the second nonwoven fabric 24b on the surface side that is generally flat is formed).

[0191] As shown in FIG. 11, the continuous body of the first nonwoven fabric 24a on the surface side contacts the outer peripheral surface 92s of the first roll 92 at a position upstream of the meshing region 93 and is conveyed while being sucked into the concave portion 92a. As a result, a frictional force is generated between the portion of the continuous body of the first nonwoven fabric 24a on the surface side from the upstream side of the meshing region 93 to the bonding device 100 and the first roll 92. Therefore, the portion 24a2 pushed into the concave portion 92a of the continuous body of the first nonwoven fabric 24a on the surface side is likely to remain in the concave portion 92a due to the above frictional force even when the convex portion 94a exits the concave portion 92a. Therefore, the uneven shape 20a can be effectively formed in the continuous body of the first nonwoven fabric 24a on the surface side.

[0192] On the other hand, as described above, the continuum of the front side second nonwoven fabric 24b is wound around the outer peripheral surface 92s of the first roll 92 via the continuum of the front side first nonwoven fabric 24a at the meshing region 93 or a position slightly upstream of the meshing region 93. That is, the continuum of the front side second nonwoven fabric 24b is transported in a non-contact state with the continuum of the front side first nonwoven fabric 24a, the first roll 92, and the second roll 94 at a position upstream of the meshing region 93. Therefore, no frictional force is generated between the continuum of the front side first nonwoven fabric 24a, the first roll 92, and the second roll 94 in the upstream part of the meshing region 93 of the continuum of the front side second nonwoven fabric 24b. Therefore, the upstream part of the meshing region 93 of the continuum of the front side second nonwoven fabric 24b can easily move relative to the continuum of the front side first nonwoven fabric 24a and the first roll 92. Therefore, in order to pull out the portion 24b2 of the continuum of the front side second nonwoven fabric 24b from the recess 92a, the tension T2 can encourage the movement of the continuum of the front side second nonwoven fabric 24b upstream of the meshing region 93.

[0193] 12B, the continuum of the front side second nonwoven fabric 24b is interposed between the continuum of the front side first nonwoven fabric 24a and the convex portion 94a, so that the continuum of the front side first nonwoven fabric 24a is not in contact with the convex portion 94a. As a result, no frictional force is generated between the continuum of the front side first nonwoven fabric 24a and the convex portion 94a, so that when the convex portion 94a comes out of the concave portion 92a, the continuum of the front side first nonwoven fabric 24a is prevented from following the convex portion 94a. Therefore, even if the tension T1 applied to the continuum of the front side first nonwoven fabric 24a is set to be extremely small, the portion 24a2 pressed into the concave portion 92a of the continuum of the front side first nonwoven fabric 24a can be kept in the concave portion 92a. On the other hand, the portion 24b2 of the continuum of the front-side second nonwoven fabric 24b pressed into the recess 92a is in contact with the protrusion 94a, and therefore the continuum of the front-side second nonwoven fabric 24b is likely to follow the protrusion 94a when the protrusion 94a comes out of the recess 92a. Therefore, in combination with the tension T2, the portion 24b2 of the continuum of the front-side second nonwoven fabric 24b can be efficiently pulled out of the recess 92a.

[0194] As described above, the first and second rolls 92, 94 rotate with the continuous body of the front side first nonwoven fabric 24a and the continuous body of the front side second nonwoven fabric 24b sandwiched between them. As the rolls rotate, the convex portions 94a and the concave portions 92a mesh with each other, and thus the continuous body of the front side first nonwoven fabric 24a is intermittently formed with a plurality of raised portions 24a2. As a result, the continuous body of the front side first nonwoven fabric 24a is formed with an uneven shape 20a. On the other hand, the continuous body of the front side second nonwoven fabric 24b is pulled out of the concave portions 92a by the tension T2 as described above, and is formed into a generally flat surface shape.

[0195] Next, a continuous body of the surface side second nonwoven fabric 24b having a generally flat surface shape is bonded to the outer surface opposite to the surface facing the skin side of the continuous body of the surface side first nonwoven fabric 24a having the uneven shape 20a. Specifically, the recesses of the continuous body of the surface side first nonwoven fabric 24a and the continuous body of the surface side second nonwoven fabric 24b are bonded. The bonding of the continuous body of the surface side first nonwoven fabric 24a and the continuous body of the surface side second nonwoven fabric 24b is performed by passing the continuous body of the surface side first nonwoven fabric 24a and the continuous body of the surface side second nonwoven fabric 24b between the first roll 92 and the ultrasonic horn of the bonding device 100. This forms a continuous body of the surface sheet 24. The continuous body of the surface sheet 24 is separated from the first roll 92 as shown by the arrow D (FIG. 11) and transported to a subsequent process.

[0196] According to the above manufacturing method, the uneven shape 20a is formed simultaneously on the two nonwoven fabrics in a state where the surface side first nonwoven fabric 24a and the surface side second nonwoven fabric 24b are joined to each other while overlapping them. Then, of the two nonwoven fabrics on which the uneven shape 20a is formed, the surface side second nonwoven fabric 24b is joined to the surface side first nonwoven fabric 24a while maintaining the uneven shape 20a of the surface side first nonwoven fabric 24a in a state where tension is applied to the surface side second nonwoven fabric 24b so that the undulations of the surface side second nonwoven fabric 24b are made gentle. Therefore, the process and manufacturing equipment can be simplified compared to a case where a process of forming the uneven shape 20a on the surface side first nonwoven fabric 24a and a process of forming the surface side second nonwoven fabric 24b with gentle undulations are separately performed, and a process of overlapping the surface side first nonwoven fabric 24a and the surface side second nonwoven fabric 24b that have been subjected to these processes is further performed. In other words, according to the above manufacturing method, for example, different undulating shapes can be formed on the same line for the surface-side first nonwoven fabric 24a and the surface-side second nonwoven fabric 24b, and the number of lines can be reduced compared to the case where a line for manufacturing the surface-side first nonwoven fabric 24a and a line for manufacturing the surface-side second nonwoven fabric 24b are provided separately, and a configuration in which separate lines are joined can be omitted.

[0197] In the above, a continuous top sheet 24 is formed in which only the continuum of the front side first nonwoven fabric 24a has the uneven shape 20a. Alternatively, a continuous top sheet 24 in which both the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b have the uneven shape may be formed by the following manufacturing process. Specifically, after passing through the meshing region 93, the tension of the continuous top side second nonwoven fabric 24b can be adjusted so that a part or all of the portion 24b2 pressed into the recess 92a of the continuous top side second nonwoven fabric 24b remains in the recess 92a. This allows a part or all of the portion 24b2 pressed into the recess 92a of the continuous top side second nonwoven fabric 24b to remain in the recess 92a. In this way, both the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are shaped, and a continuous top sheet 24 having an uneven shape can be formed. In this case, there is no need to prepare a roll for shaping the continuous body of the front side second nonwoven fabric 24b separately from the roll for shaping the continuous body of the front side first nonwoven fabric 24a.

[0198] As yet another embodiment, in addition to or instead of the continuum of the front side second nonwoven fabric 24b, a member that plastically deforms when the convex portion 94a and the concave portion 92a engage can be applied. In this way, the continuum of the front side second nonwoven fabric 24b or the plastically deforming member is plastically deformed when passing through the engagement region 93, and the plastically deformed portion can hold the continuum of the front side first nonwoven fabric 24a in the concave portion 92a. Thus, both the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b are shaped, and an uneven shape can be formed in the continuum of the front side first nonwoven fabric 24a and the continuum of the front side second nonwoven fabric 24b.

[0199] In the above process, at least the inside of the recesses 92a of the first roll 92 may be heated at a temperature lower than the melting point of the continuum of the front side first nonwoven fabric 24a. This allows the continuum of the front side first nonwoven fabric 24a to be shaped more reliably. For example, the periphery of the recesses 92a can be heated by providing a heater inside the first roll 92. In addition to or instead of heating the first roll 92, the second roll 94 (particularly the periphery of the protrusions 94a) can also be heated at a temperature lower than the melting point of the continuum of the front side first nonwoven fabric 24a.

[0200] Unlike the above, the flat surface-side first nonwoven fabric 24 a can be used as a continuous body of the topsheet 24 .

[0201] (Step 4) In step 4, a continuum of cores 25 in which the multiple cores 25 are connected together is formed, and the cores 25 are manufactured using the continuum of cores 25. The manufacturing method of the continuum of cores 25 and the cores 25 will be described with reference to Figs. 13 to 15.

[0202] In the above-mentioned wearing article 1, the continuous core 25 is formed by laminating two sheets, a continuous core-side first nonwoven fabric S1 in which a plurality of core-side first nonwoven fabrics S1 are continuous, and a continuous core-side second nonwoven fabric S2 in which a plurality of core-side second nonwoven fabrics S2 are continuous. In the example of Figs. 5A to 5C, the continuous core-side first nonwoven fabric S1 is produced by holding SAP so as to form a holding region R2 for holding SAP and a first low-density region R11 for holding SAP having a lower density than the holding region R2. In the example of Figs. 6A to 7C, the continuous core-side first nonwoven fabric S1 is produced by holding SAP so as to form a holding region R2, a first low-density region R11, and a second low-density region R12. The manufacturing method of such a continuous core 25 will be described below. As described above, the continuous core 25 can also be formed from a single continuous core-side nonwoven fabric.

[0203] 13, the manufacturing apparatus for the continuum of cores 25 includes first and second units U1 and U2, a laminating roller R, a control device C, a laminating conveyor C3, a third applicator 96, a fourth applicator 97, a folder 98, and a pair of pressure rollers 99. The first and second units U1 and U2 have the same structure and are disposed approximately symmetrically with respect to a plane including the central axis of the laminating roller R.

[0204] The first unit U1 includes a first conveyor C1, a raising roller 90, a first applicator 91, a first sprinkler 71, and a negative pressure case 79 provided on the first conveyor C1. The second unit U2 includes a second conveyor C2, a raising roller 90, a first applicator 91, a second applicator 95, a second sprinkler 72, and a negative pressure case 79 provided on the second conveyor C2. The control device C drives and controls both the first and second units U1 and U2 to stack two continuous bodies of the core-side nonwoven fabrics S1 and S2, thereby manufacturing a continuous body of the core 25. When the continuous body of the core 25 is formed from a continuous body of one core-side nonwoven fabric, the control device C only needs to control the drive of one of the two units U1 and U2.

[0205] In this embodiment, the core 25 continuum has a core-side first nonwoven fabric S1 continuum and a core-side second nonwoven fabric S2 continuum. The core-side first nonwoven fabric S1 continuum and the core-side second nonwoven fabric S2 continuum include a diffusion layer 81 as a base and a short fiber layer 82 laminated on the diffusion layer 81 (see Figs. 14 and 15). The short fiber layer 82 is a layer of nonwoven fabric formed of short fibers, for example, a layer of nonwoven fabric that has been subjected to air-through processing. Such a nonwoven fabric layer can be formed by arranging short fibers and blowing hot air onto them, and is also called an air-laid nonwoven fabric. On the other hand, the diffusion layer 81 has a smaller thickness than the short fiber layer 82 and a higher fiber density than the short fiber layer 82. This diffusion layer 81 has high diffusivity in the surface direction and can penetrate liquid over a wide range.

[0206] The continuous body of the core side first nonwoven fabric S1 and the continuous body of the core side second nonwoven fabric S2 are supplied to the raising roller 90. The raising roller 90 is a roller having an outer surface on which many teeth are formed, and rotates at a circumferential speed slower than the conveying speed of the continuous body of the core side first nonwoven fabric S1 and the continuous body of the core side second nonwoven fabric S2. By setting the speed difference between the conveying speed and the circumferential speed in this manner, the raising roller 90 can raise the short fiber layer 82 of the continuous body of the core side first nonwoven fabric S1 and the continuous body of the core side second nonwoven fabric S2 shown in FIG. 15A as shown in FIG. 15B. The speed difference between the conveying speed and the circumferential speed is not necessarily limited to the speed difference in the same direction, but also includes the speed difference when the conveying direction and the rotation direction are in the opposite directions. By the above-mentioned raising, the short fiber layer 82 of the continuous body of the core side first nonwoven fabric S1 and the continuous body of the core side second nonwoven fabric S2 changes from the lying state shown in FIG. 15A to the raised state shown in FIG. 15B. As a result, the bulk density of the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 decreases, and the thickness of the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 increases. In other words, the raising of the fibers forms gaps in the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 to support SAP80.

[0207] 13, between the raising roller 90 and the first and second conveyors C1, C2 described below in the conveying direction, there are provided first applicators 91 for applying adhesive to support the SAP 80 on the continuum of core-side first nonwoven fabric S1 and the continuum of core-side second nonwoven fabric S2. The first applicator 91 applies adhesive to the surfaces of the raised short fiber layer 82 of the continuum of core-side first nonwoven fabric S1 and the continuum of core-side second nonwoven fabric S2.

[0208] After the adhesive is applied, the continuous body of the core-side first nonwoven fabric S1 is transported along the flat first inclined surface F1 of the first conveyor C1 while being sucked by the negative pressure supplied by the negative pressure case 79. The continuous body of the core-side second nonwoven fabric S2 is transported along the flat second inclined surface F2 of the second conveyor C2, which has an opposite inclination to the first inclined surface F1, while being sucked by the negative pressure supplied by the negative pressure case 79.

[0209] Each of the first and second sprinklers 71 and 72 in Fig. 13 sprinkles SAP80 (see Fig. 14), which is an absorbent powder or granular material, on the upper surface of the continuum of the core-side first nonwoven fabric S1 being transported along the first inclined surface F1 and the continuum of the core-side second nonwoven fabric S2 being transported along the second inclined surface F2. During this sprinkling, the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 are sucked by the negative pressure case 79, so that the sprinkled SAP80 penetrates into the gaps in the short fiber layer 82 formed by raising, as shown in Figs. 14 and 15C. The SAP80 is also adhered to the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 by the adhesive applied by the first applicator 91.

[0210] The first absorbent layer L1 is formed by the short fiber layer 82 supporting the continuous SAP80 of the core side first nonwoven fabric S1, and the second absorbent layer L2 is formed by the short fiber layer 82 supporting the continuous SAP80 of the core side second nonwoven fabric S2.

[0211] Further explaining each of the spraying devices 71, 72, each of the spraying devices 71, 72 includes a hopper 73 that stores SAP80, an amount adjusting section 74, a guider 75, and a spray case 76. The amount adjusting section 74 adjusts the amount of SAP80 dropped from the hopper 73 to be sprayed. The guider 75 guides the SAP80 guided from the amount adjusting section 74 to the spray case 76. The spray case 76 sprays the SAP80 supplied from the guider 75 in a predetermined area on the surface of the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2, and prevents the SAP80 from scattering in areas other than the predetermined areas. Specifically, the spray case 76 is provided with a spray opening (not shown) through which the SAP80 guided by the guider 75 falls, a case body that prevents the SAP80 falling from the spray opening from scattering around, and a shutter (not shown) that is housed within the case body and intermittently opens and closes the opening. The spray case 76 sprays SAP80 over predetermined regions of the short fiber layer 82 of the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 (FIGS. 5A to 7C).

[0212] The method of forming the first and second low-density regions R11, R12 and the retaining region R2 in the continuum of the core-side first nonwoven fabric S1 shown in Figs. 5A to 7C will be further described.

[0213] First, a first method for forming the first low-density region R11, the second low-density region R12, and the holding region R2 will be described. In the first method, the second low-density region R12 and the holding region R2 of the continuum of the core-side first nonwoven fabric S1 are formed as follows. The first applicator 91 applies the adhesive in a state adjusted so that the amount of adhesive per unit area applied to the region of the continuum of the core-side first nonwoven fabric S1 corresponding to the second low-density region R12 (the second low-density region R12 in Figs. 6A to 7C) is less than the amount of adhesive per unit area applied to the region corresponding to the holding region R2. Therefore, the amount of SAP80 sprayed in the region corresponding to the second low-density region R12 is less than the amount of SAP80 sprayed in the region corresponding to the holding region R2 of the continuum of the core-side first nonwoven fabric S1. For example, the application area of ​​the first applicator 91 can be set so that adhesive is applied to an area corresponding to the holding area R2 in the continuum of the core side first nonwoven fabric S1, and adhesive is not applied to an area corresponding to the second low density area R12.

[0214] On the other hand, the amount of adhesive applied by the first applicator 91 to the continuum of the core-side second nonwoven fabric S2 is adjusted according to the amount of SAP to be held in the holding region R3 (FIG. 5B).

[0215] In the first method, the first low-density region R11 of the continuum of the core-side first nonwoven fabric S1 is formed by stopping or substantially stopping the supply of SAP80 to a region of the continuum of the core-side first nonwoven fabric S1 that corresponds to the cut region Cut (see FIG. 5A) between adjacent cores 25. Specifically, the supply of SAP80 to the cut region Cut is stopped or suppressed by closing or substantially closing the dispersion opening with the shutter of the dispersion case 76. As a result, the first low-density region R11 is formed in the cut region Cut of the core-side first nonwoven fabric S1. In the cut region Cut, application of adhesive from the first applicator 91 is stopped or suppressed.

[0216] Similarly, the supply of SAP80 and adhesive to the area corresponding to the cut area Cut between adjacent cores 25 in the continuum of the core-side second nonwoven fabric S2 is stopped or suppressed, thereby forming a third low-density area R13 in the core-side second nonwoven fabric S2.

[0217] As a second method for forming the first low-density region R11, the second low-density region R12, and the holding region R2, the amount adjusting unit 74 adjusts the amount of SAP80 supplied in a direction perpendicular to the conveyance direction of the continuum of the core-side first nonwoven fabric S1, thereby forming the first low-density region R11, the second low-density region R12, and the holding region R2 as shown in Figs. 5A to 7C. Specifically, the amount adjusting unit 74 adjusts the amount of SAP80 supplied per unit area in the first low-density region R11 and the second low-density region R12 to be less than the amount of SAP80 supplied per unit area in the holding region R2. The scattering case 76 scatters the amount of SAP80 adjusted by the amount adjusting unit 74 onto the continuum of the core-side first nonwoven fabric S1. This makes it possible to make the amount of SAP80 supported in the first low-density region R11 and the second low-density region R12 less than the amount of SAP80 supported in the holding region R2.

[0218] In the second method, the first low-density region R11 of the continuum of the core-side first nonwoven fabric S1 can also be formed by closing or substantially closing the dispersing opening with a shutter in the first method.

[0219] As a third method for forming the first low-density region R11, the second low-density region R12, and the holding region R2, a transfer body capable of holding SAP80 in a predetermined pattern and transferring SAP80 to the continuous core-side first nonwoven fabric S1 can be used to form the first low-density region R11, the second low-density region R12, and the holding region R2 as shown in Figs. 5A to 7C. Specifically, the transfer body has a region corresponding to the holding region R2, which holds SAP80 at a predetermined distribution density, and a region corresponding to the first low-density region R11 and the second low-density region R12, which hold SAP80 at a lower density than the region corresponding to the holding region R2. The transfer body is provided on the outer surface of a transfer roller. The continuous core-side first nonwoven fabric S1 is sandwiched between a transport roller around which the continuous core-side first nonwoven fabric S1 is wound, and a transfer roller. As a result, the SAP80 held by the transfer body of the transfer roller is transferred to the continuous body of core-side first nonwoven fabric S1, forming a first low-density region R11, a second low-density region R12, and a holding region R2.

[0220] On the other hand, the continuous core-side second nonwoven fabric S2 having the retaining region R3 can be formed by using a transfer body having an area corresponding to the retaining region R3, which retains SAP80 at a predetermined distribution density.

[0221] As yet another alternative method, the retention region R2 (uncut region) and the low-density region R1 (cut region) can be formed by cutting out the portion to be formed of the low-density region R1 (first low-density region R11 in the example of Figures 5A to 5C, and first low-density region R11 and second low-density region R12 in the example of Figures 6A to 7C) in the continuum of the core-side first nonwoven fabric S1 into which SAP80 has been dispersed.

[0222] As yet another alternative method, SAP80 can be sprayed over the entire area in the continuum of the core-side first nonwoven fabric S1 where the low-density area R1 (first low-density area R11 in the example of FIGS. 5A to 5C, and first low-density area R11 and second low-density area R12 in the example of FIGS. 6A to 7C) and the retaining area R2 are to be formed, and then SAP80 is additionally sprayed only over the area where the retaining area R2 is to be formed, thereby forming the low-density area R1 and the retaining area R2.

[0223] The conveyance of the continuous body of core-side first nonwoven fabric S1 and the continuous body of core-side second nonwoven fabric S2 and the spraying of SAP80 thereon are disclosed, for example, in WO2017 / 131014, the entire disclosure of which is incorporated herein by reference.

[0224] Next, after SAP80 has been sprayed, adhesive is applied from a second applicator 95 to the surface of one of the continuums of core-side second nonwoven fabric S2, as shown in Fig. 13. As a result, an adhesive layer 83 is formed on the continuum of core-side second nonwoven fabric S2, as shown in Fig. 15D. The continuum of core-side second nonwoven fabric S2 with the adhesive layer 83 formed thereon is transported to the laminating roller R by the second conveyor C2, and the continuum of core-side first nonwoven fabric S1 is transported to the laminating roller R by the first conveyor C1.

[0225] As shown in Fig. 13 and Fig. 14, the first conveyor C1, the second conveyor C2 and the laminating roller R are configured so that the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 being transported are arranged in a V-shape in a side view. The laminating roller R sandwiches the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 in a laminated state between the laminating roller R and the laminating conveyor C3. At this time, the first absorbent layer L1 of the continuum of the core-side first nonwoven fabric S1 transported by the first conveyor C1 and the second absorbent layer L2 of the continuum of the core-side second nonwoven fabric S2 transported by the second conveyor C2 face each other. 14 and 15D, the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2 are laminated and joined via the adhesive layer 83 with the first absorbent layer L1 and the second absorbent layer L2 facing each other, thereby forming one thick laminate S. In the laminate S, the first absorbent layer L1 and the second absorbent layer L2 face each other via the adhesive layer 83, and both layers L1, L2 are sandwiched between the diffusion layers 81, 81 of the continuum of the core-side first nonwoven fabric S1 and the continuum of the core-side second nonwoven fabric S2.

[0226] As described above, the first absorbent layer L1 and the second absorbent layer L2 of the two-layer core-side first nonwoven fabric S1 and core-side second nonwoven fabric S2 are laminated facing each other, which makes it possible to prevent SAP80 from falling off from the first absorbent layer L1 and the second absorbent layer L2. Furthermore, when the core 25 formed by laminating the first absorbent layer L1 and the second absorbent layer L2 facing each other in this manner is used in a subsequent process, it is possible to prevent SAP80 from falling off from the core 25.

[0227] As shown in Fig. 13, thin paper (tissue paper) T is fed onto a stacking conveyor C3. A third applicator 96 (Fig. 13) provided upstream of the stacking conveyor C3 applies adhesive to the upper surface of the thin paper T.

[0228] 13 and 14, the stacking conveyor C3 supplies the adhesive-coated tissue paper T under the laminate S and clamps the laminate S between the stacking conveyor C3 and the stacking roller R. This causes the laminate S to be bonded to the surface of the tissue paper T, as shown in FIG. 15E. Furthermore, the stacking conveyor C3 transports the bonded laminate S and tissue paper T downstream.

[0229] 13, a fourth applicator 97, a folder 98, and a pair of pressure rollers 99 are provided downstream of the stacking conveyor C3. The stacking conveyor C3 is provided with a negative pressure case 78 that sucks the thin paper T.

[0230] The fourth applicator 97 applies adhesive to at least one edge of both side edges in a direction perpendicular to the conveying direction on the upper surface of the thin paper T. In this example, the width of the thin paper T in the direction perpendicular to the conveying direction is greater than twice the width of the laminate S.

[0231] The folder 35 wraps the laminate S in the tissue paper T by folding back the side portions of the tissue paper T that extend on both sides in the width direction from the laminate S as shown in FIG. 15F. The pressure roller 99 presses the laminate S and the tissue paper T in the thickness direction to join the tissue paper T to the laminate S. This produces a continuous body of cores 25 in which the cores 25 are connected together. The continuous body of cores 25 is cut into individual cores 25 by a cutter not shown.

[0232] The continuous body of the core-side first nonwoven fabric S1 and the continuous body of the core-side second nonwoven fabric S2 may not have the diffusion layer 81. In this case, the step of laminating the diffusion layer 81 can be omitted. The continuous body of the core-side first nonwoven fabric S1 and the continuous body of the core-side second nonwoven fabric S2 may not be wrapped in tissue paper T. In this case, the step of laminating the tissue paper T and wrapping the laminate S can be omitted. Furthermore, the core 25 may be manufactured only from the continuous body of the core-side first nonwoven fabric S1, rather than being formed from the laminate S of the continuous body of the core-side first nonwoven fabric S1 and the continuous body of the core-side second nonwoven fabric S2.

[0233] (Step 5) In step 5, as shown in Fig. 10, a back sheet work-in-progress is formed in which the continuous back sheet 26 and the continuous leg gathers 31 are joined together. Specifically, the continuous liquid-impermeable sheet 26a and the continuous outer layer sheet 26b are transported along the MD direction A. An adhesive is applied to at least one of these sheets, and the continuous sheets 26a and 26b are sandwiched between a pair of nip rolls (reference numbers omitted) shown in Fig. 8 in a superimposed state, whereby the continuous sheets 26a and 26b are joined together by adhesion using a hot melt adhesive, welding by heat sealing, ultrasonic welding, or the like. In this way, the continuous back sheet 26 is formed.

[0234] Furthermore, a continuous body of leg gathers 31, which is an elastic member, is joined to both sides of the liquid-impermeable sheet 26a in the CD direction W perpendicular to the MD direction A by adhesion using a hot melt adhesive, welding by heat sealing, ultrasonic welding, etc. In this way, the continuous body of leg gathers 31 is provided on the continuous body of the backsheet 26, and a backsheet work-in-progress is manufactured.

[0235] (Step 6) In step 6, the top sheet work-in-progress formed in step 3, the core 25 formed in step 4, and the back sheet work-in-progress formed in step 5 are combined to form an absorbent body work-in-progress.

[0236] In a nip roll (reference number omitted) provided at the junction of steps 4 and 5, the core 25 produced in step 4 is placed on and joined to the liquid impermeable sheet 26a of the backsheet work-in-progress produced in step 5. A plurality of absorbent elastic members 21 of a predetermined length are held on the drum surface (outer surface) of a rotating drum P (FIG. 8) provided downstream of the nip roll. As the rotating drum P rotates, the absorbent elastic members 21 are joined in a stretched state in a direction perpendicular to the conveying direction between adjacent cores 25 on the backsheet work-in-progress.

[0237] The top sheet work-in-progress is fed onto the back sheet work-in-progress so as to sandwich the core 25, the continuum of leg gathers 31, and the absorbent body elastic member 21, and the top sheet work-in-progress is joined onto the back sheet work-in-progress (see FIG. 18F).

[0238] Further, a female fastener 22 (FIGS. 1 and 2) is provided over the entire width direction (corresponding to the waist width direction) on the outer surface opposite to the core 25 of the end portion of the backsheet work-in-progress where the absorbent elastic member 21 is provided.

[0239] Furthermore, an indicator 50 (FIGS. 1 and 2) extending in the conveying direction (MD direction A) of the back sheet work-in-progress is provided in the center of the CD direction W of the outer layer sheet 26b on the surface facing the skin side where the core 25 is provided in the back sheet work-in-progress. This allows the manufacture of a work-in-progress of the absorbent body 20 (absorbent body work-in-progress) that is continuous in the MD direction A.

[0240] The step of providing the female fastener 22 may be performed between steps 5 to 12. The step of providing the indicator 50 may be performed between steps 5 to 13.

[0241] (Step 7) In step 7, the absorbent work-in-progress formed in step 6 is cut into individual absorbents 20. Specifically, the absorbent work-in-progress consisting of the absorbent 20 and the three-dimensional gathers 40 extending in the MD direction A is cut by the interior cutter 64 at regular lengths in the MD direction A to produce individual absorbents 20. Thereafter, the orientation of the absorbent 20 is reversed 90 degrees by the interior turn drum 65 so that it is in a position suitable for the subsequent assembly process in a lateral flow state. At this time, the absorbent elastic member 21 is arranged so as to be located at the tip of the absorbent 20 on the opposite side to the waistline main body 16 in the MD direction A (see FIG. 3).

[0242] (3) Process 8~Process 13 Steps 8 to 13 are steps for assembling the wearing article 1 in the transverse flow state shown in Fig. 16. In these steps, first, the absorbent body 20 produced in step 7 is joined to the waistline continuum produced in steps 1 and 2. Next, the absorbent body 20 is folded in half in the direction perpendicular to the waistline (CD direction W in Fig. 16) and the waistline continuum is cut into individual waistline members 10, after which, in the waistline member 10, both side portions 10a located on both sides in the waistline width direction (MD direction A in Fig. 16) of the joint portion 10b are folded in the waistline width direction (MD direction A in Fig. 16), and the male fastener 12 and the female fastener 22 are engaged with each other.

[0243] In the lateral flow state of FIG. 16, the MD direction A coincides with the waist width direction, and the CD direction W coincides with the direction perpendicular to the waist.

[0244] (Step 8) 8, 16 and 19, in step 8, one end of the absorbent 20 inverted by 90 degrees (the end opposite the female fastener 22) is placed on the joint 10b of each waistline main body 16 in the waistline continuum produced in step 2 (see FIG. 19A). The absorbent 20 is joined to the joint 10b on the surface of the inner sheet 14 of each waistline main body 16 facing the skin side. The joining means is not limited to adhesion using a hot melt adhesive, and heat sealing welding or ultrasonic welding can also be used.

[0245] In this embodiment, in steps 1 and 2, a waistline continuum is manufactured in which the waistline main bodies 16 of a plurality of wearing articles 1 are connected in the waistline width direction (MD direction A in Figs. 9 and 16). That is, in the waistline continuum, both ends 10c of the waistline main bodies 16 of a plurality of wearing articles 1 are connected to each other so that the waistline main bodies 16 are connected in the waistline width direction. Then, the absorbent bodies 20 of each wearing article 1 extending in the waistline orthogonal direction (CD direction W in Figs. 9 and 16) are joined to the joints 10b of the portions of the waistline continuum that correspond to the waistline main bodies 16.

[0246] (Step 9) In step 9, the waistline continuum (a continuum of a plurality of waistline main bodies 16) is cut by an elliptical die cutter 66 so as to provide leg holes SP in Fig. 16. This forms the leg-hole curved portions 15b.

[0247] It should be noted that steps 8 and 9 can be interchanged. That is, first, the portion between the joints 10b in the waistline continuum is cut by the die cutter 66 so as to provide the leg holes SP. Then, one end of the absorbent body 20, which has been inverted 90 degrees, is placed on the joints 10b of each waistline main body 16 in the waistline continuum.

[0248] (Step 10) In step 10, the extending portion 15c of the waistline continuum is folded back so as to cover a part of the waistline elastic member 11, and the male fastener 12 is joined (see FIG. 19B). Specifically, the extending portion 15c is joined to each absorbent body 20 in a state where it covers the end portion of each absorbent body 20 joined to the waistline continuum. The joining means is not limited to adhesion using a hot melt adhesive, and heat sealing or ultrasonic welding can also be used.

[0249] The male fastener 12 is joined to a weakened portion 15a2 on the skin-facing surface of the waistline continuum. The weakened portion 15a2 is provided over a range from the folded-back portion of the extension portion 15c to a position below it. The joining means is not limited to adhesion using a hot melt adhesive, and heat sealing or ultrasonic welding can also be used. The weakened portion 15a2 is located in the middle of the waistline continuum between adjacent absorbents 20 in the MD direction A. The male fastener 12 is joined to this middle position.

[0250] (Step 11) In step 11, the absorbent body 20 is folded in half in the CD direction W. Specifically, the free end of the absorbent body 20 in the CD direction W, i.e., the leading end opposite to the end joined to the waistline continuum in the CD direction W, is held by a suction device (not shown), while tension is applied to the waistline continuum, and the waistline continuum and the absorbent body 20 are conveyed in the MD direction A. In the folding device 67, multiple pairs of rollers are arranged to sandwich the waistline continuum from the front and back so that the waistline continuum is turned over toward the free end of the absorbent body 20. As a result, the absorbent body 20 is folded in half with the middle position in the CD direction W as the boundary (see FIG. 19C).

[0251] In addition, the absorbent body 20 may be folded in half so that the waistline continuum moves toward the absorbent body 20 while at least one tip end of the absorbent body 20 is held by the suction device and held down by the holding device.

[0252] In step 11, each absorbent body 20 is folded in the CD direction W so that the surface of each absorbent body 20 facing the skin side faces the surface of each waistline main body 16 of the waistline continuum at a position corresponding to the joint 10b. In order to maintain this folded state, it is desirable that the end of the absorbent body 20 opposite the end joined to each waistline member 10 and at least one of the absorbent body 20 and each waistline member 10 overlapping the end are temporarily fixed in a peelable manner (temporary fixing 110 in FIG. 16). As a temporary fixing means, adhesion by hot melt adhesive, welding by heat sealing, ultrasonic welding, etc. may be used, or temporary fixing may be performed by mechanical engagement such as pin embossing.

[0253] From the viewpoint of reducing the influence on the core 25, the temporary fastening position is preferably outside the core 25 in the waist width direction. Furthermore, the temporary fastening position is preferably near both ends of each absorbent 20, at a position outside the waist width direction with respect to the three-dimensional gathers 40 extending in the direction perpendicular to the waist. In this case, the standing up of the three-dimensional gathers 40 when worn is not hindered by the temporary fastening 110, and as a result, the three-dimensional gathers 40 reliably function as a dam against bodily fluids.

[0254] Moreover, it is preferable that the temporary fasteners 110 are disposed between the multiple waistline elastic members 11 in the direction perpendicular to the waistline. In this way, a decrease in elastic force due to the waistline elastic members 11 being cut or the like is suppressed.

[0255] It is most preferable that the position of the temporary fastener 110 is within the area of ​​the weakened portion 15a1. This is because by preventing the position of the temporary fastener 110 from moving due to the elasticity of the waistline elastic member 11, the final shape of the wearing article 1 in which the male fastener 12 and the female fastener 22 are engaged can be maintained.

[0256] Here, when it is difficult to form the temporary fastening 110 within the area of ​​the weakened portion 15a1, it is possible to form an excess portion in the weakened portion 15a1 by making the weakened portion 15a1 larger relative to the core 25, and to form the temporary fastening 110 in this excess portion. As a method for forming the excess portion, for example, at least one of making the core 25 smaller while maintaining the size of the weakened portion 15a1 unchanged, and making the weakened portion 15a1 larger while keeping the size of the core 25 unchanged, can be adopted. Note that when the core 25 is made smaller, the final shape of the worn article 1 can be maintained as described above, but the absorption performance of the worn article 1 is reduced. Also, when the weakened portion 15a1 is made larger, the final shape of the worn article 1 can be maintained as described above, but the elastic force of the waist member 10 is reduced.

[0257] On the other hand, as an alternative method, if it is difficult to form the temporary fastening 110 within the area of ​​the weakened portion 15a1, it may be possible to temporarily fasten the temporary fastening outside the weakened portion 15a1, although this would reduce the ability of the wearing article 1 to retain its final shape.

[0258] Whether or not the temporary fastenings 110 are formed in the area of ​​the weakened portion 15a1 is determined taking into consideration the balance between the degree of retention of the final shape of the wearing article 1, the absorption performance, and the degree of elasticity of the waist member .

[0259] In this embodiment, taking these factors into consideration, temporary fastening is performed on the outside of the weakened portion 15a1.

[0260] By performing such temporary fastening, the absorbent body 20 can be maintained in a state folded in two in the CD direction W until the cutting step in step 12 and the engagement step in step 13, which will be described later. As a result, when the waistline continuum is cut in step 12 after the absorbent body 20 is temporarily fastened, the absorbent body 20 can be maintained in a folded state both before and after the cutting.

[0261] The temporary fastening is performed with an adhesive strength that allows the absorbent body 20 to be easily pulled apart when the worn article is worn. In step 11, the absorbent body 20 is folded in half so that the female fastener 22 is exposed on the outer surface opposite to the surface facing the skin of each absorbent body 20.

[0262] In addition, in this step 11, the absorbent body 20 is folded in half so that the waistline continuum overlaps the tip of the absorbent body 20 while the tip of the absorbent body 20 is held. Thus, a plurality of wearing articles 1 can be folded continuously in the direction perpendicular to the waistline. Therefore, each wearing article 1 can be folded in the direction perpendicular to the waistline at a high speed compared to folding each wearing article 1 separately. In addition, since the absorbent body 20 is folded in a state where the tip of the absorbent body 20 opposite to the joint 10b joined to the waistline continuum of the absorbent body 20 is held, the absorbent body 20 can be folded in half in the direction perpendicular to the waistline so that the tip of the absorbent body 20 overlaps the waistline continuum while suppressing the movement of the absorbent body 20. In addition, the folded wearing article 1 can be manufactured by folding back both ends of each waistline main body 16 cut from the waistline continuum as they are.

[0263] (Step 12) In step 12, the waistline continuum is cut in the CD direction W by a cutter 68 at the intermediate position between the adjacent absorbents 20 and at the intermediate position in the MD direction A of the male fastener 12. As a result, the waistline continuum and the multiple absorbents 20 are separated into each waistline main body 16 and each absorbent 20 joined thereto. The male fastener 12 is also divided into two in the MD direction A along the CD direction W between the adjacent absorbents 20, and is left at both end portions 10c of each of the adjacent waistline main bodies 16. In this state, each waistline main body 16 is deployed in the MD direction A. Note that the male fastener 12 is not limited to being divided into two by the above-mentioned cut, and pre-divided male fasteners 12 may be arranged at an interval between both end portions 10c of the adjacent waistline main bodies 16.

[0264] (Step 13) In step 13, both side portions 10a of the waist member 10 in the MD direction A are folded back toward the joint portions 10b of the waist member 10 so that the male fasteners 12 of both end portions 10c face the outer surface of the absorbent body 20. Next, the male fasteners 12 of the waist member 10 and the female fasteners 22 of the absorbent body 20 are engaged with each other.

[0265] The manufacturing method of the above-mentioned refastenable type wearing article 1 is a manufacturing method of a wearing article having a waist member 10 that is placed around the waist of a wearer, and an absorbent body 20 that is joined to a joint 10b in the waist width direction of the waist member 10 and extends from the joint 10b in a direction perpendicular to the waist width direction so as to be positioned from the wearer's back through the crotch area to the front abdomen, and the manufacturing method includes the following steps of manufacturing the waist member 10, manufacturing the absorbent body 20, joining the absorbent body 20 to the joint 10b of the waist main body 16, and engaging the male fastener 12 and the female fastener 22 with each other.

[0266] (Step of manufacturing waistband member 10) The process for manufacturing the above-mentioned waist member 10 includes steps 1 and 2 for manufacturing a continuous waist body, a step (part of step 10) for joining male fasteners 12 to each waist body 16 constituting the continuous waist body, and step 12 for cutting the continuous waist body.

[0267] (Process for manufacturing absorbent body 20) The process for manufacturing the above-mentioned absorbent body 20 includes step 3 of manufacturing a top sheet work-in-progress, step 4 of manufacturing a core 25, step 5 of manufacturing a back sheet work-in-progress, step 6 of manufacturing an absorbent body work-in-progress, and step 7 of cutting the absorbent body work-in-progress into individual absorbent bodies 20.

[0268] (Step of joining the absorbent body 20 to the joining portion 10b of the waist body 16) Step 8 corresponds to a step of joining the absorbent body 20 to the joining portion 10 b of the waistline main body 16 .

[0269] (Step of engaging male fastener 12 and female fastener 22 with each other) Step 13 corresponds to engaging the male fastener 12 and the female fastener 22 with each other.

[0270] The present invention is not limited to the above-described embodiment, and may adopt the following aspects, for example.

[0271] In the above-mentioned refastenable-type wearing article 1, the joint 10b of the waistline member 10 is disposed in the rear region. The absorbent body 20 extends from the joint 10b disposed in the rear region through the crotch portion to the front abdominal region, and a tip portion is disposed in the front abdominal region. The side portions 10a of the waistline member 10 are stretched from the rear region to the front abdominal region, and are engaged with the tip portions of the absorbent body 20. However, the joint 10b of the waistline member 10 may be disposed in the front abdominal region. The absorbent body 20 may extend from the joint 10b disposed in the front abdominal region to the rear abdominal region through the crotch portion, and a tip portion is disposed in the rear region. The side portions 10a of the waistline member 10 may be stretched from the front abdominal region to the rear abdominal region, and are engaged with the tip portions of the absorbent body 20.

[0272] In the above-mentioned refastenable-type wearing article 1, the female fastener 22 is provided on the outer surface of the back sheet 26 of the absorbent body 20. However, the female fastener 22 may be omitted, and the outer surface of the back sheet 26 may be treated so as to be engageable with the male fastener 12. Also, a back sheet 26 having properties that allow it to be engaged with the male fastener 12 may be used. Furthermore, the male fastener 12 may be provided on the outer surface of the back sheet 26 of the absorbent body 20, and the skin-facing surface of the waist member 10 may be configured to be engageable with the male fastener 12. [Explanation of symbols]

[0273] 10: Waist material 10a: Both sides 10b: Joint 11: Waist elastic member 12: Male fastener (first engagement portion) 14: Inner sheet 15: Outer sheet 15c: Extension part 20: Absorbent 20a: Uneven shape 21: absorbent elastic member 22: Female fastener (second engagement portion) 24: Surface sheet 25: Core 26: Back sheet 82: Short fiber layer (fiber layer) R1: Low density area R2: Holding area

Claims

1. A method for manufacturing a wearing article comprising: a waistband member to be placed around the waist of a wearer; and an absorbent body joined to the waistband member and extending from a joint with the waistband member in a direction perpendicular to a width direction so as to be placed from a rear part of the wearer through a crotch part to a front part of the abdomen, the method comprising the steps of: A process for manufacturing the waistband member, the waistband member having a waistband main body that extends in the width direction and has elasticity that can be stretched and contracted in the width direction and is placed around the waist of a wearer, and a first engagement portion provided on a surface facing the skin side of the wearer at both ends of the waistband main body in the width direction; a process for manufacturing the absorbent body, the absorbent body having a core for absorbing bodily fluids, a top sheet provided on the wearer's skin side of the core, a back sheet provided on the outer surface side of the core opposite the skin side so as to sandwich the core between the top sheet and the core, and a second engagement part provided on the outer surface of the back sheet opposite the surface facing the skin side and detachable from the first engagement part; joining the absorbent to the joint portion of the waistline body so as to extend from the waistline body in the orthogonal direction; a step of folding the absorbent body in half in the orthogonal direction, and then folding both side portions of the waistband member located on both sides of the joint in the width direction in the width direction, and engaging the first engagement portion and the second engagement portion with each other, The process for producing the absorbent body includes: The method includes a step of manufacturing the core by holding the water-absorbent polymer in a core-side first nonwoven fabric so as to form a holding region and a first low-density region that holds a water-absorbent polymer having a lower density than the holding region and is adjacent to both ends of the holding region in the perpendicular direction, The step of manufacturing the waistband member includes: a step of joining a waistline elastic member to at least one of the inner sheet and the outer sheet so as to be stretchable along the width direction while the inner sheet is sandwiched between the inner sheet extending in the width direction and an outer sheet extending in the width direction and covering an outer surface of the inner sheet opposite to the surface facing the skin side; a step of weakening the joint so that the elastic force of a core arrangement portion where the core is arranged, among the joints of the waistline main body to which the absorbent body is joined, is weaker than the elastic force of both side portions adjacent to both sides of the core arrangement portion in the width direction, among the joints of the waistline main body to which the absorbent body is joined, and the elastic force of an upper portion in the perpendicular direction of the core arrangement portion, among the joints of the waistline main body to which the absorbent body is joined; In the step of joining the absorbent body to the joining portion of the waistline body, the absorbent body is joined to the waistline member so that both ends of the retention region in the orthogonal direction are disposed facing the front abdominal region and the back abdominal region of the wearer when the wearing article is worn, In the step of manufacturing the core, the water-absorbent polymer is held in the core-side first nonwoven fabric so as to form a second low-density region that is lower in density than the holding region and is sandwiched between the holding regions in the width direction and extends in the perpendicular direction; The second low-density region extends in an orthogonal direction from one of the first low-density regions closer to the waistband member to the other of the first low-density regions.

2. 2. The method for manufacturing a wearing article according to claim 1, wherein the step of manufacturing the absorbent body includes the steps of forming a concave-convex shape in a surface-side first nonwoven fabric, and bonding a surface-side second nonwoven fabric to an outer surface of the surface-side first nonwoven fabric opposite to the surface facing the skin side while maintaining the concave-convex shape, thereby manufacturing the top sheet.

3. 3. The method for manufacturing a wearing article according to claim 2, wherein in the step of manufacturing the topsheet, the surface-side first nonwoven fabric and the surface-side second nonwoven fabric are overlapped to simultaneously form the uneven shape, and the surface-side second nonwoven fabric is joined to the surface-side first nonwoven fabric while applying tension to the surface-side second nonwoven fabric so that the undulations of the surface-side second nonwoven fabric are made gentle.

4. The method for manufacturing a wearing article according to any one of claims 1 to 3, wherein in the step of manufacturing the core, the core-side first nonwoven fabric is raised, and the water-absorbent polymer is sprayed so that the water-absorbent polymer penetrates into gaps in a fiber layer formed by the raising.

5. The step of manufacturing the core comprises: a step of raising the core-side second nonwoven fabric and scattering the water-absorbent polymer so that the water-absorbent polymer penetrates into gaps in the fiber layer formed by the raising; 5. The method for manufacturing a wearing article according to claim 4, further comprising a step of laminating the core-side first nonwoven fabric and the core-side second nonwoven fabric so that a fiber layer of the core-side first nonwoven fabric and a fiber layer of the core-side second nonwoven fabric face each other.

6. 6. The method for manufacturing a wearing article according to claim 1, wherein the step of manufacturing the absorbent body further comprises a step of providing an absorbent body elastic member at a tip end portion of the absorbent body opposite to an end portion joined to the waistline main body in the orthogonal direction, so as to be stretchable in the width direction.

7. 7. The method for manufacturing a wearing article according to claim 1, wherein the step of manufacturing the absorbent body further comprises a step of providing the second engagement portion on an outer surface of a tip portion of the backsheet opposite to the waistband member in the orthogonal direction, over substantially the entire width direction of the tip portion of the backsheet.

8. The step of manufacturing the waistband member includes: placing the inner sheet on the outer sheet such that an extension is formed that projects beyond an edge of the inner sheet in the orthogonal direction and away from the inner sheet; The method for manufacturing a wearing article according to any one of claims 1 to 7, further comprising the step of: folding back the extension in the orthogonal direction to cover an end portion of the absorbent body in the orthogonal direction.

9. The step of manufacturing the waistband member includes:

8. The method for manufacturing a wearing article according to claim 1, further comprising a step of weakening a portion of the waist body where the first engagement portion is arranged so that the elastic force of the portion of the waist body where the first engagement portion is arranged is weaker than the elastic force of a portion adjacent to the portion in the width direction.

10. In the step of manufacturing the waistline member, a waistline continuum in which the waistline bodies of the plurality of wearing articles are continuous in the width direction is prepared, and the waistline bodies are manufactured by cutting the waistline continuum into regions corresponding to the respective waistline bodies; In the step of joining the absorbent body to the joint portion of the waistline body, the absorbent body is joined to the joint portion of the region corresponding to each waistline body in the waistline continuum so as to extend from the joint portion in the perpendicular direction; The step of engaging the first engagement portion and the second engagement portion with each other includes: a step before cutting the waistline continuum into the waistline main bodies, in which a tip end of the absorbent body joined to the waistline continuum in the orthogonal direction is held on the opposite side to the end joined to the waistline continuum in the orthogonal direction, folding the absorbent body in half so that the waistline continuum overlaps the tip end of the absorbent body; and at a stage after the waist continuum is cut into the waist main bodies, folding back both side portions of the waist main body so that both end portions in the width direction of the waist main body overlap with the tip portions of the absorbent body.

11. The step of engaging the first engagement portion and the second engagement portion with each other includes:

11. The method for manufacturing a wearing article according to claim 1, further comprising: forming a temporary fastening in a releasable manner between an end portion of the absorbent body opposite to an end portion joined to the waist member and at least one of the absorbent body and the waist member overlapping the end portion, at a stage after the absorbent body is folded in half in the orthogonal direction.

12. The method for manufacturing a wearing article according to claim 11 , wherein in the temporarily fastening step, the temporarily fastening is formed on an outer side of the core in the width direction.

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