Stretch sheet manufacturing apparatus, stretch sheet manufacturing method, and worn article

Abstract

Provided is a stretchable sheet manufacturing device that forms a stretchable sheet continuous body in which sheets and an elastic member are integrated, and then performs a weakening process for cutting off a portion of the elastic member, wherein bonding failure defects between the sheets and the elastic member are suppressed. The stretchable sheet manufacturing device comprises: a forming device that has an anvil roll (210) and an ultrasonic horn, and forms a stretchable sheet continuous body in which a pair of sheets and an elastic member disposed between the sheets are integrated; and a cutting device. The anvil roll has first protrusions (212a) and second protrusions (212b), and the ultrasonic horn forms a restricting portion on the stretchable sheet continuous body by bonding the pair of sheets between the first protrusions, and forms a fixing portion by bonding the sheets and the elastic member between the second protrusions. The cutting unit cuts off the elastic member of the stretchable sheet continuous body at the restricting portion. The sheets and the elastic member are not bonded at the restricting portion, and the pair of sheets restrict contraction movement of the elastic member during cutting of the elastic member.

Description

[Technical Field]

[0001] The present invention relates to an apparatus for manufacturing a stretch sheet, a method for manufacturing a stretch sheet, and a wearing article including a stretch sheet manufactured using the apparatus and method. [Background technology]

[0002] BACKGROUND ART As disclosed in Patent Document 1 (Japanese Patent No. 6903810), a wearing article is known that includes a stretchable waistband member that is attached to the body of a wearer.

[0003] In the manufacture of the waistband member in Patent Document 1 (Japanese Patent Publication No. 6903810), a continuous stretch sheet is formed by integrating a pair of sheets and an elastic member placed between the pair of sheets. In the continuous stretch sheet, the pair of sheets and the elastic member are partially joined. In the manufacture of the waistband member, a weakening process is then carried out in which the elastic member is partially cut in the continuous stretch sheet, for the purpose of joining other members (such as fasteners or absorbers) to predetermined positions on the waistband member. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6903810 Summary of the Invention [Problem to be solved by the invention]

[0005] In the weakening process, the elastic member is cut in a stretched state. Therefore, during the weakening process, the elastic member contracts due to a restoring force. If the elastic member has a high elongation rate before cutting, the restoring force may cause the elastic member to contract forcefully, causing the bond between the sheet and the elastic member to come loose, potentially causing the weakening process to extend to areas where weakening is not required.

[0006] An object of the present invention is to provide an apparatus and method for manufacturing a stretch sheet that forms a continuous stretch sheet having a pair of sheets and an elastic member disposed between the pair of sheets, and that can prevent the sheets and the elastic member in the continuous stretch sheet from coming loose even when the continuous stretch sheet is subjected to a weakening treatment in which the elastic member is cut. Another object of the present invention is to provide a wearing article including a stretch sheet manufactured using the apparatus and method for manufacturing a stretch sheet. [Means for solving the problem]

[0007] The stretch sheet manufacturing apparatus of the present invention includes a forming unit and a cutting unit. The forming unit forms a continuous stretch sheet formed by integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets. The cutting unit cuts the elastic member from the continuous stretch sheet. The forming unit includes a first joining member and a second joining member. The first joining member supports the first sheet, the elastic member, and the second sheet transported in the transport direction. The second joining member sandwiches the first sheet, the elastic member, and the second sheet between itself and the first joining member. The first joining member has a first portion and a second portion on a surface facing the second joining member. The second portion is disposed adjacent to the first portion in the transport direction of the first sheet, the elastic member, and the second sheet transported while supported by the first joining member. The second joining member sandwiches the elastic member, the first sheet, and the second sheet between itself and the first portion of the first joining member, thereby joining the first sheet and the second sheet, thereby forming a limiting portion in the stretch sheet continuous body. The second joining member sandwiches the elastic member, the first sheet, and the second sheet between itself and the second portion of the first joining member, thereby joining the elastic member and at least one of the first sheet and the second sheet, thereby forming a fixing portion in the stretch sheet continuous body. The cutting portion cuts the elastic member of the stretch sheet continuous body at the limiting portion of the stretch sheet continuous body being conveyed. At the limiting portion of the stretch sheet continuous body, the first sheet, the second sheet, and the elastic member are not joined. Furthermore, at the limiting portion of the stretch sheet continuous body, the contraction movement of the elastic member cut by the cutting portion is limited by the first sheet and the second sheet.

[0008] Another embodiment of the stretch sheet manufacturing apparatus of the present invention includes a forming unit that forms a continuous stretch sheet web by integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets. The forming unit includes a first joining member and a second joining member. The first joining member supports the first sheet, the elastic member, and the second sheet that are conveyed in the conveyance direction. The second joining member sandwiches the first sheet, the elastic member, and the second sheet between itself and the first joining member. Two or more second joining members are arranged along the conveyance direction. At least the second joining member located most upstream in the conveyance direction sandwiches the first sheet, the elastic member, and the second sheet between itself and the first joining member to form a temporary joint where the elastic member and at least one of the first sheet and the second sheet are temporarily joined. At least the second joining member located most downstream in the conveyance direction sandwiches the temporary joint between itself and the first joining member to permanently join the elastic member and at least one of the first sheet and the second sheet to form a continuous stretch sheet.

[0009] The method for producing a stretch sheet of the present invention includes a forming step and a cutting step. In the forming step, a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets are integrated to form a continuous stretch sheet. In the cutting step, the elastic member of the continuous stretch sheet is cut. The forming step includes a conveying step, a first forming step, and a second forming step. In the conveying step, the first sheet, the second sheet, and the elastic member are conveyed in a conveying direction with the elastic member disposed between the first and second sheets. In the first forming step, the elastic member, the first sheet, and the second sheet are sandwiched between a first joining member and a second joining member that support the first sheet, elastic member, and second sheet conveyed in the conveying direction, and the elastic member is joined to at least one of the first sheet and the second sheet, thereby forming a fixing portion in the continuous stretch sheet. In the second forming step, the elastic member, the first sheet, and the second sheet are sandwiched between the first joining member and the second joining member, and the first sheet and the second sheet are joined to form a restricting portion in the continuous stretch sheet. In the cutting step, the elastic member of the continuous stretch sheet is cut at the restricting portion of the continuous stretch sheet. The restricting portion of the continuous stretch sheet is formed at a position adjacent to the fixed portion of the continuous stretch sheet. In the restricting portion of the continuous stretch sheet, the first sheet and the second sheet are not joined to the elastic member. In the restricting portion of the continuous stretch sheet, the contraction movement of the elastic member cut in the cutting step is restricted by the first sheet and the second sheet.

[0010] Another method for producing a stretch sheet of the present invention includes a forming step of integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets to form a continuous stretch sheet. The forming step includes a conveying step, a first forming step, and a second forming step. In the conveying step, the first sheet, the second sheet, and the elastic member are conveyed in a conveyance direction with the elastic member disposed between the first and second sheets. In the first forming step, the elastic member, the first sheet, and the second sheet are sandwiched between a first joining member supporting the first sheet, the elastic member, and the second sheet conveyed in the conveyance direction and an upstream second joining member to form a temporary joint portion where the elastic member and at least one of the first sheet and the second sheet are temporarily joined. In the second forming process, the temporary joining portion is sandwiched between the first joining member and a downstream second joining member that is positioned downstream in the conveying direction from the upstream second joining member, and the elastic member and at least one of the first sheet and the second sheet are finally joined to form a stretch sheet continuum.

[0011] The wearing article of the present invention includes a stretch sheet. The stretch sheet includes at least a first sheet piece, a second sheet piece, and an elastic member. The elastic member extends in a first direction and is disposed between the first sheet piece and the second sheet piece. The stretch sheet includes a first portion and a second portion in the first direction. The first portion does not include an elastic member. In the second portion, the elastic member is bonded to at least one of the first sheet piece and the second sheet piece. In a cross section taken perpendicular to the first direction, the first portion includes a portion where the maximum gap between the first and second sheet pieces, which communicates with a space in a third portion where the elastic member is disposed, is smaller than the diameter of the elastic member when no tension is applied. [Effects of the Invention]

[0012] The stretch sheet manufacturing apparatus of the present invention can prevent the occurrence of problems such as the bond between the sheet and the elastic members in the stretch sheet coming loose during the weakening process of cutting the elastic members.

[0013] In another example of a stretch sheet manufacturing apparatus of the present invention, the elastic member may be cut during joining of the elastic member to at least one of the first sheet and the second sheet, and the restoring force may cause the elastic member to be pulled back upstream, thereby preventing the occurrence of a malfunction that requires the stretch sheet manufacturing apparatus to be stopped in order to reposition the elastic member.

[0014] The method for producing a stretch sheet of the present invention can prevent the occurrence of problems such as the bond between the sheet and the elastic members in the stretch sheet coming loose during the weakening treatment in which the elastic members are cut.

[0015] In another example of a stretch sheet manufacturing method of the present invention, the elastic member may be cut during joining of the elastic member to at least one of the first sheet and the second sheet, and the restoring force may cause the elastic member to be pulled back upstream, thereby preventing the occurrence of a malfunction that requires the stretch sheet manufacturing device to be stopped in order to reposition the elastic member.

[0016] The wearing article of the present invention can prevent the occurrence of a problem in which the elastic member and the sheet piece become disengaged from each other in the second portion of the stretch sheet. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a front view showing a state in which a refastenable wearing article according to one embodiment of the present invention is worn, the wearing article including a stretch sheet according to one embodiment of the present invention. FIG. [Figure 2] 2 is a rear view of the worn article of FIG. 1, showing the state when worn. FIG. [Figure 3] 2 is a development view of the worn article of FIG. 1 in an unfolded state. FIG. [Figure 4] FIG. 2 is an exploded perspective view of the wearing article of FIG. [Figure 5] 2 is a schematic view of a manufacturing apparatus for a worn article, including a manufacturing apparatus for a stretch sheet according to one embodiment of the present invention, for manufacturing the worn article of FIG. 1. FIG. [Figure 6] 6 is a diagram schematically illustrating a stretch sheet continuous body forming device of the manufacturing apparatus for the worn article of FIG. 5. FIG. [Figure 7]7 is a schematic diagram showing a part of the outer peripheral surface of the anvil roll of the forming device of FIG. 6 developed into a plane. [Figure 8] 8 shows a view of the second groove formation portion surrounded by a circle α in FIG. 7 as seen along the radial direction of the anvil roll, and a cross-sectional view of the second groove formation portion as seen in the direction of the arrows X1-X1 in this figure. [Figure 9] 8 shows a view of the first groove formation portion surrounded by a circle β in FIG. 7 as viewed along the circumferential direction of the anvil roll, and a cross-sectional view of the first groove formation portion as viewed along the X2-X2 arrows in this view. [Figure 10] 8 shows a view of the first groove formation portion surrounded by an ellipse γ in FIG. 7 as viewed along the circumferential direction of the anvil roll, and a cross-sectional view of the first groove formation portion as viewed along arrows X3-X3 in this view. [Figure 11] 6 is a diagram showing a schematic view of a continuous stretch sheet formed by the stretch sheet manufacturing apparatus of FIG. 5. FIG. [Figure 12] 12 is a partial cross-sectional view showing the region indicated by B3 in FIG. 11 cut in a direction perpendicular to the conveying direction of the continuous stretch sheet (the direction around the waist when formed into a worn article). FIG. [Figure 13] 12 is a partial cross-sectional view showing the region indicated by B1 in FIG. 11 cut in a direction perpendicular to the conveying direction of the continuous stretch sheet (the direction around the waist when formed into a worn article). FIG. [Figure 14] 10 is a diagram showing a schematic view of a stretch sheet continuous body forming device of a stretch sheet manufacturing apparatus according to Modification A. FIG. [Figure 15] 10 is a diagram showing a schematic view of a stretch sheet continuous body forming device of a stretch sheet manufacturing apparatus according to Modification C. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0018] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a stretch sheet manufacturing apparatus, a stretch sheet manufacturing method, and a wearing article including a stretch sheet according to the present invention will be described with reference to the drawings.

[0019] It should be noted that the embodiment described below is merely an example of the present invention and does not limit the scope of the present invention. Those skilled in the art will understand that various modifications can be made to the following embodiment without departing from the spirit and scope of the present invention as defined in the claims.

[0020] (1) Overview of wearable items A wearing article to which a stretch sheet according to the present invention is applied will be outlined with reference to Figs. 1 to 4. Fig. 1 is a front view of a refastenable wearing article 1, showing the state when worn. Fig. 2 is a back view of the wearing article 1, showing the state when worn. Fig. 3 is a development view of the wearing article 1, showing the wearing article 1 in an unfolded state. Fig. 4 is an exploded perspective view of the wearing article 1.

[0021] The worn article 1 is a worn article including a stretchable waistband member 10 to be worn on the body of a wearer, to which a stretch sheet manufactured by the stretch sheet manufacturing apparatus 100 and stretch sheet manufacturing method according to one embodiment of the present invention is applied. The waistband member 10 uses a stretch sheet in which an elastic member is disposed between a pair of sheets. In particular, the worn article 1 is a worn article including a waistband member 10 to which a stretch sheet is applied, in which a portion of the elastic member has been weakened (the elastic member has been partially cut).

[0022] The stretch sheet of the present invention can be widely used as a waistband member, a cuff member, a hem member, etc. in disposable diapers, disposable medical gowns, etc., and its uses are not limited.

[0023] In this embodiment, a wearing article 1 that is a refastenable diaper will be used as an example to describe a wearing article equipped with a stretch sheet according to the present invention. This section will briefly outline the structure and configuration of the wearing article 1, and the characteristic structure and configuration of the stretch sheet according to the present invention will be described later. Note that the wearing article 1 of this embodiment has a structure and configuration similar to that of the wearing article disclosed in Patent Document 1 (Japanese Patent Publication No. 6903810). Therefore, a detailed description of the wearing article 1 will be omitted here unless otherwise necessary.

[0024] In the following description, the terms waist direction and orthogonal waist direction may be used to explain directions and positions. The waist direction refers to the direction that runs along the waist of the wearer when the wearing article 1 is worn by the wearer. The orthogonal waist direction refers to the direction that runs perpendicular to the waist direction and runs along the body length direction (height direction) of the wearer when the wearing article 1 is worn by the wearer.

[0025] As shown in Figures 1 to 4, the refastenable wearing article 1 according to this embodiment mainly 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 region of the wearer through the crotch region to the front abdominal region.

[0026] As shown in FIG. 3, the waistband member 10 has a waistband main body 16 that is placed around the waist of the wearer, and a male fastener 12 attached to the waistband main body 16.

[0027] The waistline body 16 is a member that is worn around the waist of the wearer and is stretchable in the waist direction. The waistline body 16 uses the stretch sheet according to the present invention. As shown in FIG. 4, the waistline body 16 mainly includes an inner sheet 14, an outer sheet 15, and an elastic member 11 disposed between the inner sheet 14 and the outer sheet 15. One of the inner sheet 14 and the outer sheet 15 is an example of the first sheet piece in the present invention, and the other of the inner sheet 14 and the outer sheet 15 is an example of the second sheet piece in the present invention.

[0028] The inner sheet 14 is, for example, a sheet piece of nonwoven fabric. The inner sheet 14 is a belt-shaped member extending in the waist direction. The inner sheet 14 has an inner surface 16i of the waistline main body 16 that faces the skin of the wearer when the wearing article 1 is worn by the wearer (see FIG. 4). One end of the absorber 20 is joined to a portion of the inner sheet 14 corresponding to an absorber joining portion 10b (described later) (a portion of the inner surface 16i of the waistline main body 16 corresponding to the absorber joining portion 10b). In addition, a male fastener 12 is joined to a male fastener joining portion 10d (described later) of the inner sheet 14 (a portion of the inner surface 16i of the waistline main body 16 corresponding to the male fastener joining portion 10d).

[0029] The outer sheet 15 is, for example, a nonwoven sheet piece. The outer sheet 15 is a belt-shaped member extending in the waist direction of the wearing article 1. The outer sheet 15 is disposed on the opposite side to the inner surface 16i of the waist-circumference main body 16, and has an outer surface 16o of the waist-circumference main body 16 that faces outward (away from the wearer's skin) when the wearing article 1 is worn by a wearer (see FIG. 4).

[0030] As shown in FIG. 4, the elastic members 11 are disposed between the inner sheet 14 and the outer sheet 15 and have elasticity that stretches in the waist direction. In the manufactured wearing article 1, the elastic members 11 are in a stretched state, and a restoring force acts on the elastic members 11 in a direction that causes them to contract in the waist direction. Since the waist body 16 has the elastic members 11, when a wearer puts on the wearing article 1, the restoring force of the elastic members 11 allows the waist body 16 to fit closely to the wearer's waist. The elastic members 11 are formed of, for example, polyurethane, natural rubber, thermoplastic resin, or other material. In this embodiment, the shape of the elastic members 11 is thread-like, although this is not intended to be limiting. In this embodiment, a plurality of thread-like elastic members 11 extending in the waist direction are disposed between the inner sheet 14 and the outer sheet 15 (see FIGS. 1 to 4).

[0031] The elastic members 11 are partially joined to at least one of the inner sheet 14 and the outer sheet 15. As shown in Fig. 4, the elastic members 11 are arranged in a region facing the inner sheet 14, excluding absorber joining portions 10b and end portions 10c of the waistline main body 16, which will be described later. At the absorber joining portions 10b and end portions 10c of the waistline main body 16, which will be described later, the elastic members 11 are cut by a weakening treatment during the manufacturing process of the wearing article 1, as shown in Figs. 3 and 4.

[0032] The waistline body 16, in which the inner sheet 14, outer sheet 15, and elastic member 11 are integrated, includes an absorbent body joint portion 10b and two side portions 10a arranged on either side of the absorbent body joint portion 10b in the waistline direction of the wearer, as shown in Figure 3.

[0033] The absorbent body joining portion 10b is a portion to which the absorbent body 20 is joined. The absorbent body joining portion 10b is located in the center of the waistline main body 16 in the waistline direction and at the lower portion of the waistline main body 16 in the direction perpendicular to the waistline (the side that is located lower when the wearer stands upright while wearing the wearing article 1).

[0034] As described above, the elastic members 11 are weakened at the absorbent body joining portions 10b, and therefore the elastic members 11 are not present. Alternatively, as a result of the weakening treatment, the elastic force of the elastic members 11 does not substantially act at the absorbent body joining portions 10b. On the other hand, the elastic members 11 are arranged above the waistline main body 16 in the direction perpendicular to the waistline of the absorbent body joining portions 10b (above the absorbent body joining portions 10b when the wearer is standing upright while wearing the wearing article 1). Therefore, above the waistline main body 16 in the direction perpendicular to the waistline of the absorbent body joining portions 10b, the elastic force of the elastic members 11 allows the waistline main body 16 to fit closely to the wearer's torso when the wearer puts on the wearing article 1.

[0035] Each of the two side portions 10a of the waistline main body 16 extends in the waist direction from the position where the absorber joint portion 10b is located in a direction away from the absorber joint portion 10b to an end portion 10c of the side portion 10a. The two end portions 10c are both ends of the waistline main body 16 in the waist direction. The side portions 10a are members that cover the left and right sides and the front of the wearer's torso when the wearable article 1 is worn by the wearer.

[0036] A male fastener 12 is joined to each of the two end portions 10c of the waistline main body 16. The male fastener 12 functions as a hook-and-loop fastener when used in combination with a female fastener 22, which will be described later. More specifically, the male fastener 12 is joined to the end portion 10c of the waistline main body 16, on the inner surface 16i of the waistline main body 16 (the surface of the inner sheet 14 that faces the wearer's skin). The portion of the waistline main body 16 to which the male fastener 12 is joined is called the male fastener joining portion 10d.

[0037] The absorbent body 20 is a member for absorbing body fluids such as urine. The absorbent body 20 mainly includes a core 25, a topsheet 24, a backsheet 26, a female fastener 22, leg gathers 31, and three-dimensional gathers 40.

[0038] The core 25 includes a nonwoven fabric carrying a highly absorbent polymer, and has the function of absorbing body fluids such as urine.

[0039] The topsheet 24 is a member provided on the wearer's skin side relative to the core 25. The topsheet 24 is a sheet-like member made of a single sheet of nonwoven fabric, or a sheet-like member formed by layering multiple sheets of nonwoven fabric.

[0040] The backsheet 26 is a sheet-like member provided on the side of the core 25 opposite the wearer's skin side (outer surface side) so as to sandwich the core 25 between itself and the topsheet 24. The backsheet 26 includes a liquid-impermeable sheet 26a, which is a nonwoven fabric made of polypropylene, polyethylene, or the like, and an exterior sheet 26b that covers the outside of the backsheet 26. The liquid-impermeable sheet 26a is a member that is water-repellent and prevents the passage of bodily fluids such as urine. A female fastener 22 is attached to the outer surface of the exterior sheet 26b (the side of the exterior sheet 26b opposite the wearer's skin side) and functions as a hook-and-loop fastener when used in combination with the male fastener 12 of the waistband main body 16.

[0041] The leg gathers 31 are elastic members arranged at positions corresponding to the base of the legs when the wearer wears the wearing article 1. When the wearing article 1 is unfolded as shown in Fig. 3, the leg gathers 31 are arranged along both edges of the liquid-impermeable sheet 26a in the waist-circumference direction and over substantially the entire liquid-impermeable sheet 26a in the direction perpendicular to the waist-circumference. When the wearing article 1 is unfolded as shown in Fig. 3, the leg gathers 31 are arranged between the liquid-impermeable sheet 26a and the topsheet 24 in a stretched state in the direction perpendicular to the waist-circumference.

[0042] As shown in Fig. 4, the three-dimensional gathers 40 are provided on the skin-facing surface of the topsheet 24. When the wearing article 1 is worn by a wearer, the three-dimensional gathers 40 elastically fit closely to the back, crotch, front abdomen, etc. of the wearer, and prevent body fluids such as urine from leaking out of the wearing article 1.

[0043] As shown in Figures 3 and 4, the absorbent body 20 is joined to the absorbent body joint part 10b of the waistline main body 16. When the wearing article 1 is unfolded (before being assembled for wearing), the absorbent body 20 extends from the absorbent body joint part 10b in a direction perpendicular to the waistline, away from the waistline main body 16, as shown in Figure 3. When a wearer puts on the wearing article 1, the absorbent body 20 is arranged from the wearer's back region through the crotch region to the front abdomen. The aforementioned female fastener 22 is attached to the end of the absorbent body 20 distal to the absorbent body joint part 10b in the waistline perpendicular direction, on the outer surface facing away from the wearer when the wearer puts on the wearing article 1.

[0044] In the assembled state of the wearing article 1 (when the wearing article is in use), the absorbent body 20 is folded back so that the top sheet 24 is disposed on the inside, and further, the surface of at least the end 10c of the side portion 10a of the waistline body 16 on which the male fastener 12 is disposed is deformed so that it overlaps with the exterior sheet 26b of the backsheet 26 of the absorbent body 20. Then, as shown in Figs. 1 and 2, the male fastener 12 of the waistline body 16 is engaged with the female fastener 22 attached to the exterior sheet 26b of the absorbent body 20. A wearer of the wearing article 1 pushes open the waistline member 10 of the refastenable wearing article 1, which has been assembled into a pants-like shape with the male fastener 12 and the female fastener 22 engaged, and inserts their legs into the waistline member 10 to put on the wearing article 1 like pants.

[0045] (2) Overview of the stretch sheet manufacturing equipment and manufacturing method An apparatus 1000 for manufacturing the worn article 1, which includes an apparatus 100 for manufacturing a stretch sheet, and a method for manufacturing the worn article 1, which includes a process for manufacturing a stretch sheet (a continuous stretch sheet), will be described with reference to FIG.

[0046] The stretch sheet manufacturing apparatus 100, which constitutes part of the manufacturing apparatus 1000 for the worn article 1, is an apparatus for forming a stretch sheet continuous web 116, which will be described later. The stretch sheet manufacturing apparatus 100 mainly includes a forming apparatus 200 and a cutting apparatus 300, which will be described later. The characteristic configuration and method of the stretch sheet manufacturing apparatus 100 of this embodiment will be described later.

[0047] The manufacturing apparatus 1000 for the wearing article 1 and the manufacturing method for the wearing article 1 are similar in many respects to the manufacturing apparatus and method for the wearing article disclosed in Patent Document 1 (Japanese Patent No. 6903810). Therefore, detailed descriptions of the manufacturing apparatus 1000 for the wearing article 1 and the manufacturing method for the wearing article 1 will be omitted here unless otherwise necessary. In the following description, the conveying direction of a sheet or the like in each process will be referred to as the MD direction, and the direction perpendicular to this will be referred to as the CD direction.

[0048] Steps P1 and P2 in FIG. 5 are an example of a process for producing a continuous stretch sheet body 116 in which a plurality of waistband bodies 16 are continuous.

[0049] <Process P1> In step P1, as shown in Fig. 5, a continuous sheet 115 (an example of a second sheet) made up of a plurality of continuous outer sheets 15 is conveyed in the MD direction, and continuous stretched elastic members 11 are arranged linearly along the MD direction on the continuous sheet 115. A plurality of continuous elastic members 11 are arranged on the continuous sheet 115 at intervals in the direction perpendicular to the waistline (CD direction). Also, in step P1, as shown in Fig. 5, a continuous sheet 114 (an example of a first sheet) made up of a plurality of continuous inner sheets 14 is conveyed in the MD direction, and the continuous sheet 114 is arranged on the continuous sheet 115 so as to cover the elastic members 11 from above.

[0050] In this way, when the elastic member 11 is placed in a stretched state between the continuum 115 and the continuum 114, a forming device 200, which is an example of a forming section, bonds the elastic member 11 to at least one of the continuum 115 and the continuum 114. Here, the forming device 200 bonds the elastic member 11 to at least one of the continuum 115 and the continuum 114 by ultrasonic welding. The bonding method used by the forming device 200 may be heat sealing. Hereinafter, the continuum in which the continuum 114, the elastic member 11, and the continuum 115 are layered and bonded together will be referred to as the stretch sheet continuum 116.

[0051] The forming device 200 for joining the continuum 115 and the continuum 114 to the elastic member 11 will be described in detail later.

[0052] <Process P2> In step P2, a weakening treatment is applied to the elastic members 11 at positions on the continuous stretch sheet web 116 that correspond to absorber joint portion 10b where absorber 20 is located and male fastener joint portion 10d where male fastener 12 is located. The weakening treatment here is a process in which the elastic members 11 on the continuous stretch sheet web 116 are cut using a cutting device 300. The cutting device 300 may be a gather cutter that uses a blade to cut the elastic members 11, or an embossing roll (heat embossing) device that applies heat to melt and cut the elastic members 11.

[0053] <Process P3~Process P7> Steps P3 to P7 are an example of a process for manufacturing the absorbent body 20.

[0054] In step P3, a topsheet work-in-progress is formed by combining a continuous topsheet 24 body in which a plurality of topsheets 24 are continuous with a continuous three-dimensional gather 40 body in which a plurality of three-dimensional gathers 40 are continuous.

[0055] In step P4, a continuous body of the cores 25 is formed by connecting the cores 25 together, and the cores 25 are manufactured using the continuous body of the cores 25.

[0056] In step P5, a backsheet work-in-progress is formed in which the continuous backsheet 26 and the continuous leg gathers 31 are joined together.

[0057] In process P6, an absorbent body work in process is formed by combining the topsheet work in process P3, the core 25 formed in process P4, and the backsheet work in process P5.

[0058] In step P7, the absorbent work-in-progress formed in step P6 is cut to produce individual absorbent bodies 20.

[0059] <Process P8~Process P11> Steps P8 to P11 are an example of steps for assembling the wearing article 1.

[0060] In step P8, one end (the end opposite the female fastener 22) of the absorbent body 20 produced in step P7 and inverted 90 degrees is placed on the absorbent body joint portion 10b of each waistline body 16 in the continuous stretch sheet 116 produced in step P2. The absorbent body 20 is joined to the inner surface 16i of each waistline body 16 at a position corresponding to the absorbent body joint portion 10b. The joining means may be adhesion using a hot melt adhesive, thermal welding using a heat sealing device, or ultrasonic welding using an ultrasonic welding device.

[0061] In step P9, the portion of the continuous body 115 of the outer sheet 15 of the continuous stretch sheet 116 where the elastic members 11 are not disposed and which is not covered by the continuous body 114 of the inner sheet 14 (referred to as the extension portion 15c, see FIG. 4) is folded back. The extension portion 15c is then joined to each absorber 20 while covering the end portion above the absorber joint portion 10b of each absorber 20 (the end portion joined to the continuous stretch sheet 116). Also in step P9, male fasteners 12 are joined to the portions of each waistline main body 16 corresponding to the male fastener joint portion 10d. The joining method here may be adhesion using a hot melt adhesive, welding by heat sealing, or ultrasonic welding.

[0062] In step P10, the absorbent body 20 is folded in half in the CD direction by the folding device 54.

[0063] In step P11, the continuous stretch sheet 116 is cut in the CD direction by the cutter 56 at the midpoint between adjacent absorbers 20 and at the midpoint in the MD direction of the male fasteners 12. As a result, the continuous stretch sheet 116 and the plurality of absorbers 20 are separated into each waistline body 16 and each absorber 20 joined thereto.

[0064] In step P12, the side portions 10a arranged on both sides in the MD direction of the waist member 10 are folded back toward the absorber joining portions 10b of the waist member 10 so that the male fasteners 12 on both end portions 10c face the outer surface of the absorber 20. Next, the male fasteners 12 of the waist member 10 and the female fasteners 22 of the absorber 20 are engaged with each other.

[0065] (3) Forming device for stretch sheet manufacturing equipment The forming device 200 of the stretch sheet manufacturing apparatus 100 will be described with reference to FIGS. 6 to 13. FIG. 6 is a schematic diagram illustrating the forming device 200. FIG. 7 is a schematic diagram illustrating a portion of the outer peripheral surface 211 of the anvil roll 210 of the forming device 200, developed into a plan view. FIG. 8 shows the second groove-forming portion 216 (part of the second protrusion 212b) enclosed by the circle α in FIG. 7, viewed along the radial direction of the anvil roll 210, and a cross-sectional view of the second groove-forming portion 216 taken along the X1-X1 arrows in the figure. FIG. 9 shows the first groove-forming portion 214 (part of the first widthwise protrusion 212aa) enclosed by the circle β in FIG. 7, viewed along the radial direction of the anvil roll 210, and a cross-sectional view of the first groove-forming portion 214 taken along the X2-X2 arrows in the figure. FIG. 10 shows the first groove-forming portion 215 (first circumferential protrusion 212ab) surrounded by the ellipse γ in FIG. 7 as viewed along the radial direction of the anvil roll 210, and a cross-sectional view of the first groove-forming portion 215 taken along the X3-X3 arrows in FIG. 10. In the view of the first groove-forming portion 215 as viewed along the radial direction of the anvil roll 210 in FIG. 10, the length of the first groove-forming portion 215 in the circumferential direction R of the anvil roll 210 is shortened. FIG. 11 is a schematic diagram of a continuous stretch sheet 116 formed by a stretch sheet manufacturing apparatus 100 (forming device 200 and cutting device 300). FIG. 12 is a partial cross-sectional view showing the region indicated by B3 (third region B3) in FIG. 11 cut in a direction perpendicular to the conveying direction D of the continuous stretch sheet 116 (the waist-circumference direction when formed into the wearing article 1). Fig. 13 is a partial cross-sectional view showing the region indicated by B1 (first region B1) in Fig. 11 cut in a direction perpendicular to the conveying direction D of the continuous stretch sheet 116 (the waist-circumference direction when formed into the wearing article 1). Note that Figs. 6 to 13 are for explanatory purposes only and do not accurately represent the actual dimensions and shapes of each component. In addition, some reference numerals have been omitted in Figs. 6 to 13 to avoid cluttering the drawings.

[0066] The forming device 200 is an example of a forming section, and forms a stretch sheet continuum 116 that is an integrated combination of a continuum 114 that is an example of a continuous first sheet, a continuum 115 that is an example of a continuous second sheet, and a continuous elastic member 11 that is arranged between the continuum 114 and the continuum 115.

[0067] The forming device 200 mainly includes an anvil roll 210, which is an example of a first joining member, an introduction device 220, and an ultrasonic horn 230, which is an example of a second joining member (see FIG. 6). The ultrasonic horn 230 vibrates due to ultrasonic waves generated by an oscillator (not shown).

[0068] The anvil roll 210 is a member that supports the continuum 114, the elastic member 11, and the continuum 115, which are transported in a transport direction D (see the arrow in FIG. 6).

[0069] The introduction device 220 introduces the elastic member 11 while guiding it to the anvil roll 210. Furthermore, a continuum 115 is introduced into the anvil roll 210 upstream of the introduction position of the elastic member 11 in the rotation direction of the anvil roll 210. Furthermore, a continuum 114 is introduced into the anvil roll 210 downstream of the introduction position of the elastic member 11 in the rotation direction of the anvil roll 210. The anvil roll 210 transports the pair of continuums 115, 114 and the elastic member 11 so that the elastic member 11 is disposed between the pair of continuums 115, 114.

[0070] The ultrasonic horn 230 sandwiches the continuum 114, the elastic member 11, and the continuum 115 between itself and the anvil roll 210. The ultrasonic horn 230 cooperates with the anvil roll 210 to partially join (ultrasonic weld) the pair of continuums 115, 114 to one another. The ultrasonic horn 230 also cooperates with the anvil roll 210 to partially join at least one of the pair of continuums 115, 114 to the elastic member 11, thereby holding the elastic member 11 to the pair of continuums 115, 114. Note that the second joining member according to the present invention is not limited to the ultrasonic horn 230, and may be a roll with a built-in heater for thermally welding the continuums 115, 114 to one another or the continuums 115, 114 to the elastic member 11.

[0071] The anvil roll 210 will now be described in more detail.

[0072] The anvil roll 210 is a cylindrical member that rotates around an axis, and as shown in FIGS. 6 and 7, has a number of ridges 212 on its outer circumferential surface 211 that protrude radially outward from the anvil roll 210. The outer circumferential surface 211 of the anvil roll 210 is an example of a facing surface of the anvil roll 210 as a first joining member that faces an ultrasonic horn 230 as a second joining member. The ridges 212 have a first surface 212f that faces the ultrasonically vibrating ultrasonic horn 230 (see FIG. 6). The first surface 212f protrudes radially outward from the anvil roll 210 by a certain height h from the outer circumferential surface 211 of the anvil roll 210, for example, as shown in FIGS. 8 to 10. The first surface 212f of the protrusion 212 and the ultrasonically vibrating ultrasonic horn 230 sandwich and pressurize the continuum 115 and the continuum 114, thereby ultrasonically welding the continuum 115 and the continuum 114. Note that even when the continuum 115 and the continuum 114 are transported between the anvil roll 210 and the ultrasonic horn 230, portions of these components that are not pressurized between the ultrasonic horn 230 and the first surface 212f of the protrusion 212 are not ultrasonically welded to the continuum 115 and the continuum 114.

[0073] As shown in FIG. 7, the protrusions 212 are spaced apart from one another in the circumferential direction R of the anvil roll 210. One or more grooves G extending in the circumferential direction R of the anvil roll 210 are formed in the first surface 212f of each protrusion 212. In other words, the grooves G extend along the conveying direction D of the continuum 114, the elastic member 11, and the continuum 115 that are supported and conveyed by the anvil roll 210. The grooves G are grooves into which the continuum 115 and the elastic member 11 fit, among the continuum 114, the elastic member 11, and the continuum 115 that are supported and conveyed by the anvil roll 210. As shown in FIG. 7, the grooves G formed in the first surface 212f of each protrusion 212 are aligned in a straight line with the grooves G formed in the adjacent protrusions 212 along the circumferential direction R of the anvil roll 210. Therefore, each elastic member 11 introduced into the anvil roll 210 by the introducing device 220 is guided by the grooves G arranged in a straight line and transported along the circumferential direction R of the anvil roll 210.

[0074] The protrusions 212 include first protrusions 212a (an example of a first portion in the claims) and second protrusions 212b (an example of a second portion in the claims). The first protrusions 212a include first widthwise protrusions 212aa and first circumferential protrusions 212ab.

[0075] The second protrusions 212b are provided in regions in the circumferential direction R of the anvil roll 210 where the first protrusions 212a are not provided. Specifically, in the circumferential direction R of the anvil roll 210, the second protrusions 212b are arranged on both sides of the region in which the first protrusions 212a are provided, adjacent to the region in which the first protrusions 212a are provided (see FIG. 7). In other words, in the conveying direction D of the continuum 114, the elastic member 11, and the continuum 115 that are supported and conveyed by the anvil roll 210, the second protrusions 212b are arranged adjacent to the upstream and downstream sides of the first protrusions 212a (see FIG. 7).

[0076] As shown in FIG. 7, the second protrusions 212b, which are part of the protrusions 212, extend in the width direction S of the anvil roll 210 (the CD direction perpendicular to the MD direction in which the continuums 114, 115 and the elastic member 11 are transported). In other words, the second protrusions 212b extend along a generatrix parallel to the axial direction of the anvil roll 210. Two second protrusions 212b are disposed adjacent to each of the upstream and downstream sides of the first protrusions 212a in the transport direction D (see FIG. 7). However, the number of second protrusions 212b is merely an example, and one or three or more second protrusions 212b may be disposed adjacent to each of the upstream and downstream sides of the first protrusions 212a in the transport direction D. As shown in FIG. 7, the second protrusion 212b extending in the width direction S has a plurality of grooves G formed therein that extend in the circumferential direction R of the anvil roll 210 and are spaced apart from each other in the width direction S of the anvil roll 210.

[0077] 7, the first circumferential protrusions 212ab, which are some of the protrusions 212, extend in the circumferential direction R of the anvil roll 210 (the MD direction in which the continuums 114, 115 and the elastic member 11 are transported). Each of the first circumferential protrusions 212ab extending in the circumferential direction R has one groove G formed therein, which extends in the circumferential direction R of the anvil roll 210. Note that the first circumferential protrusions 212ab may be divided into multiple parts in the circumferential direction R of the anvil roll 210, instead of extending elongatedly in the circumferential direction R of the anvil roll 210.

[0078] As shown in FIG. 7, the first widthwise ridges 212aa, which are part of the ridges 212, extend in the width direction S of the anvil roll 210 (the CD direction perpendicular to the MD direction in which the continuums 114, 115 and the elastic member 11 are transported). In other words, the first widthwise ridges 212aa extend along a generatrix parallel to the axial direction of the anvil roll 210. One first widthwise ridge 212aa is disposed adjacent to each of the upstream and downstream sides of the first circumferential ridge 212ab in the transport direction D (between the first circumferential ridge 212ab and the second ridge 212b) (see FIG. 7). However, the number of first widthwise ridges 212aa is merely an example, and two or more first widthwise ridges 212aa may be disposed adjacent to each of the upstream and downstream sides of the first circumferential ridge 212ab in the transport direction D. In another example, the first widthwise protrusion 212aa may be omitted. The first widthwise protrusion 212aa extending in the width direction S has a plurality of grooves G formed therein that are spaced apart from one another in the width direction S of the anvil roll 210 and extend in the circumferential direction R of the anvil roll 210.

[0079] As shown in FIG. 7, the grooves G formed in the first protrusion portion 212a and the second protrusion portion 212b are arranged in a straight line with the grooves G formed in the adjacent first protrusion portion 212a or second protrusion portion 212b along the circumferential direction R of the anvil roll 210.

[0080] The formation of the continuous stretch sheet web 116 by the forming apparatus 200 will now be described.

[0081] In the forming device 200, when the continuum 114, the elastic member 11, and the continuum 115 are transported in the transport direction D, the continuum 115 and the elastic member 11 enter grooves G that are arranged side by side in the circumferential direction R of the anvil roll 210 (that are arranged at the same position in the width direction S) of the multiple protrusions 212 arranged along the circumferential direction R of the anvil roll 210. In other words, the forming device 200 transports the continuum 114, the elastic member 11, and the continuum 115 in the transport direction D with the continuum 115 and the elastic member 11 entered in the grooves G. Note that, although a mode in which the continuum 115 and the elastic member 11 enter the grooves G is assumed here, the present invention is not limited thereto, and the continuum 114 and the elastic member 11 may also enter the grooves G (in other words, in the forming device 200, the continuum 114, the elastic member 11, and the continuum 115 may be transported with the continuum 114 side disposed on the inside).

[0082] The continuum 114 and the continuum 115 with the elastic member 11 sandwiched therebetween are conveyed along the outer peripheral surface 211 of the anvil roll 210, and when the continuum 114, the elastic member 11, and the continuum 115 pass between the ultrasonic horn 230 and the protrusions 212, the ultrasonic horn 230 and the protrusions 212 of the anvil roll 210 sandwich the continuum 114, the elastic member 11, and the continuum 115 therebetween. At this time, the ultrasonic horn 230 vibrates ultrasonically.

[0083] As a result, the continuum 114 and the continuum 115, which are sandwiched between the ultrasonic horn 230 and the first surface 212f of the protrusion portion 212 of the anvil roll 210 and pressurized between the ultrasonic horn 230 and the first surface 212f of the protrusion portion 212 of the anvil roll 210, are joined (ultrasonic welded).

[0084] Furthermore, when the continuum 114, the elastic member 11, and the continuum 115 pass between the ultrasonic horn 230 and the protrusion 212, the ultrasonic horn 230 is ultrasonically vibrated, and when the elastic member 11 is pressed between the ultrasonic horn 230 and the bottom surface of the groove G of the protrusion 212 of the anvil roll 210, via the continuum 114 and the continuum 115, by the ultrasonic horn 230 and the groove surface of the groove G of the protrusion 212 of the anvil roll 210, the continuum 114 and the continuum 115 and the elastic member 11 are joined (ultrasonic welded).

[0085] As described above, the protrusions 212 of the anvil roll 210 include the first protrusions 212a and the second protrusions 212b. The continuum 114, the continuum 115, and the elastic member 11 are not joined between the ultrasonic horn 230 and the first protrusions 212a, but at least one of the continuum 114 and the continuum 115 and the elastic member 11 is joined between the ultrasonic horn 230 and the second protrusions 212b. Details will be explained below.

[0086] The first protrusions 212a are portions that come into contact with the portion that will become the male fastener joining portion 10d and the surrounding outer sheet 15 when the wearing article 1 is manufactured from the continuous stretch sheet 116 formed by the forming device 200. The first protrusions 212a sandwich the continuum 114, the elastic member 11, and the continuum 115 between themselves and the ultrasonic horn 230, and join the continuum 114 and the continuum 115 together, thereby forming the limiting portions 116b (see FIGS. 9 and 10 ) in the continuous stretch sheet 116. More specifically, the first protrusions 212a sandwich the continuum 114 and the continuum 115 between their first surfaces 212f and the ultrasonic horn 230, and apply pressure to join the continuum 114 and the continuum 115 together, thereby forming the limiting portions 116b in the continuous stretch sheet 116.

[0087] At the limiting portion 116b, the continuum 114 and the continuum 115 are not joined to the elastic member 11. Furthermore, when the elastic member 11 is cut by the cutting device 300, the limiting portion 116b limits the contraction movement of the elastic member 11 cut by the cutting device 300 using the continuum 114 and the continuum 115. Note that the continuum 114 and the continuum 115 limiting the contraction movement of the elastic member 11 does not mean that the continuum 114 and the continuum 115 do not allow the contraction movement of the elastic member 11 (the elastic member 11 does not contract), but rather that the continuum 114 and the continuum 115 limit (suppress) the momentum of the contraction movement of the elastic member 11. In other words, due to the presence of the limiting portion 116b, the elastic member 11 cut by the cutting device 300 contracts more slowly than when the limiting portion 116b is not present.

[0088] Since the restricting portion 116b restricts the contraction movement of the elastic member 11, specifically, at the restricting portion 116b, the elastic member 11 is compressed by the continuum 114 and the continuum 115. In other words, at the restricting portion 116b of the stretch sheet continuum 116, there is a space in which the elastic member 11 is disposed, surrounded by the continuum 114 and the continuum 115, and there is a portion in this space where the maximum gap between the formed continuum 114 and the continuum 115 is smaller than the diameter of the elastic member 11 when no tension is applied.

[0089] Next, the second protrusion 212b is a portion that comes into contact with the outer sheet 15 on the absorber joint portion 10b side of the male fastener joint portion 10d in the waist direction when the wearing article 1 is manufactured from the continuous stretch sheet 116 formed by the forming apparatus 200. The second protrusion 212b sandwiches the continuum 114, the elastic member 11, and the continuum 115 between itself and the ultrasonic horn 230, and joins at least one of the continuum 114 and the continuum 115 to the elastic member 11, thereby forming the fixing portion 116a in the continuous stretch sheet 116. In this embodiment, both the continuum 114 and the continuum 115 are joined to the elastic member 11 at the fixing portion 116a.

[0090] In order to form such restricting portions 116b and fixing portions 116a in the continuous stretch sheet 116, it is preferable that the first protruding portions 212a and the second protruding portions 212b each have the following configuration.

[0091] The second protrusion 212b has a plurality of second groove-forming portions 216 that extend further in the circumferential direction R of the anvil roll 210 than other portions of the second protrusion 212b, as depicted in a circle α in Fig. 7 (see Fig. 8). The plurality of second groove-forming portions 216 are arranged at intervals from one another in the width direction S of the anvil roll 210.

[0092] A second groove 216a (groove G) is formed on the first surface 212f of the second groove forming portion 216. The second groove 216a (groove G) receives the continuum 115 and the elastic member 11 among the continuum 114, the elastic member 11, and the continuum 115 transported in the transport direction D (see FIG. 8). While not limiting the shape, the second groove 216a is a V-shaped groove as shown in FIG. 8. The depth of the second groove 216a is smaller than the sum (first sum) of the diameter of the elastic member 11 transported under tension in the forming device 200 and the thickness of the continuum 115. As a result, the elastic member 11 transported through the second groove 216a of the second groove forming portion 216 at least partially protrudes from the second groove 216a to the radially outer side of the anvil roll 210, as shown in the cross-sectional view of FIG. 8. Therefore, when the continuum 114, the elastic member 11, and the continuum 115 are sandwiched between the second groove forming portion 216 of the second protrusion portion 212b and the ultrasonic horn 230, the elastic member 11 is pressurized between the ultrasonic horn 230 and the second groove forming portion 216 via the continuum 114 and the continuum 115, and the continuum 114 and the continuum 115 are joined to the elastic member 11.

[0093] The first widthwise ridges 212aa have a plurality of first groove-forming portions 214 that extend further in the circumferential direction R of the anvil roll 210 than other portions of the first widthwise ridges 212aa, as depicted within a circle β in Figure 7. The multiple first groove-forming portions 214 are arranged at intervals from one another in the width direction S of the anvil roll 210. The first widthwise ridges 212aa have first groove-forming portions 214 with shapes described below at positions corresponding to at least the first circumferential ridges 212ab in the width direction S of the anvil roll 210.

[0094] In the first groove forming portion 214, a first groove 214a (groove G) is formed into which the continuum 115 and the elastic member 11, among the continuum 114, elastic member 11, and continuum 115 transported in the transport direction D, fit. Although the shape is not limited thereto, the first groove 214a is a U-shaped groove as shown in FIG.

[0095] The depth of the first groove 214a is greater than the sum (first total value) of the diameter of the elastic member 11 transported under tension in the forming device 200 and the thickness of the continuum 115. As a result, the elastic member 11 transported through the first groove 214a of the first groove-forming portion 214 is entirely contained within the first groove 214a. Therefore, when the continuum 114, the elastic member 11, and the continuum 115 are sandwiched between the first groove-forming portion 214 of the first widthwise protrusion 212aa and the ultrasonic horn 230, the elastic member 11 is not pressurized between the ultrasonic horn 230 and the bottom surface of the first groove 214a of the first groove-forming portion 214, and the continuum 114 and the continuum 115 are not bonded to the elastic member 11. When the continuum 114, the elastic member 11, and the continuum 115 are sandwiched between the first groove forming portion 214 of the first widthwise protrusion portion 212aa and the ultrasonic horn 230, only the continuum 114 and the continuum 115 are joined between the first surface 212f of the first widthwise protrusion portion 212aa and the ultrasonic horn 230.

[0096] Furthermore, it is preferable that the depth of the first groove 214a is smaller than the sum (second total value) of the diameter of the elastic member 11 and the thickness of the continuum 115 when no tension is applied. As a result, when the elastic member 11 is partially cut as described below and attempts to return to its original state (its natural length when no tension is applied) due to its restoring force, pressure is applied to the elastic member 11 by the continuum 114 and the continuum 115, and the contraction movement of the elastic member 11 is restricted by the frictional force between the elastic member 11 and at least one of the continuum 114 and the continuum 115.

[0097] Furthermore, it is preferable that the width of the first groove 214a (dimension in the width direction S of the anvil roll 210) is greater than the sum (third total value) of the diameter of the elastic member 11 being transported through the forming device 200 in the transport direction D and twice the thickness of the continuum 115, and is smaller than the sum (fourth total value) of the diameter of the elastic member 11 and twice the thickness of the continuum 115 when no tension is applied.

[0098] As a result, the elastic member 11 is partially cut as described below, and when the elastic member 11 tries to return to its original state (a state of natural length when no tension is applied) due to a restoring force, the diameter of the elastic member 11 becomes larger than when stretched. Therefore, pressure is applied to the elastic member 11 by the continuum 114 and the continuum 115, and the contraction movement of the elastic member 11 is restricted by the frictional force between the elastic member 11 and at least one of the continuum 114 and the continuum 115.

[0099] The first circumferential protrusions 212ab have first groove-forming portions 215 that protrude radially outward from the anvil roll 210 to the same height h as the first widthwise protrusions 212aa, as depicted within the ellipse γ in FIG. 7 (see FIG. 10). The first groove-forming portions 215 differ from the first groove-forming portions 214 in that they extend longer in the circumferential direction R of the anvil roll 210 than the first groove-forming portions 214. However, the cross-sectional shape of the first grooves 215a formed in the first groove-forming portions 215 is similar to that of the first grooves 214a (see FIG. 10). The first grooves 215a and 214a serve the same purpose. Detailed descriptions of the first groove-forming portions 215 and the first grooves 215a are omitted here.

[0100] The cutting device 300 cuts the elastic members 11 of the continuous stretch sheet web 116 in the CD direction, which is perpendicular to the MD direction of the continuous stretch sheet web 116, at the limiting portions 116b formed by the first protrusions 212a (the first circumferential protrusions 212ab and 212ab). Although not limited thereto, the cutting device 300 cuts the elastic members 11 of the continuous stretch sheet web 116 in the waist direction (the MD direction of the continuous stretch sheet web 116) at the center of the limiting portions 116b formed by the first protrusions 212a (the first circumferential protrusions 212ab and 212ab). When the elastic member 11 is cut at this position, the elastic member 11 moves at a relatively slow speed toward the fixing portion 116a adjacent to the limiting portion 116b, with its contraction movement restricted by the limiting portion 116b, and one of the male fastener joints 10d of the waistline main body 16 manufactured from the stretch sheet continuous body 116 transported downstream in the transport direction D from the cutting position, and one of the male fastener joints 10d of the waistline main body 16 manufactured from the stretch sheet continuous body 116 transported upstream in the transport direction D from the cutting position, are formed.

[0101] FIG. 11 illustrates a continuous stretch sheet 116 in which the elastic members 11 have been partially cut by the cutting device 300 to form absorber joint portions 10b and male fastener joint portions 10d.

[0102] As a result of providing limiting portion 116b, a first region B1, which becomes the first portion in the claims, and a third region B3, which becomes the third portion in the claims, are formed around male fastener joining portion 10d of stretch sheet continuous body 116 and its surrounding area when applied as a stretch sheet to waistline main body 16. Also, as a result of providing fixing portion 116a, a second region B2, which becomes the second portion in the claims, is formed around stretch sheet continuous body 116 when applied as a stretch sheet to waistline main body 16.

[0103] The first region B1 is a region where the elastic member 11 is not present as a result of contraction of the elastic member 11. The second region B2 corresponds to the fixed portion 116a of the continuous stretch sheet 116, and the elastic member 11 is joined to at least one (here, both) of the continuous body 114 and the continuous body 115. The third region B3 is a region located between the first region B1 and the second region B2.

[0104] 13, in the first region B1, in a cross section taken in a direction perpendicular to the waist-girth direction (roughly the first direction in which the elastic members 11 extend) (i.e., in a cross section taken in a direction perpendicular to the conveying direction D of the stretch sheet continuous web 116), there is a portion where the maximum gap between the inner sheet 14 and the outer sheet 15 that communicates with the space in which the elastic members 11 of the second region B2 are disposed is smaller than the diameter of the elastic members 11 (drawn by a two-dot chain line in FIG. 13) (at their natural length) in the absence of tension. Further / or, in the third region B3, in a cross section taken in a direction perpendicular to the waist-girth direction, there is a portion where the maximum gap between the inner sheet 14 and the outer sheet 15 that communicates with the space in which the elastic members 11 of the second region B2 are disposed is smaller than the diameter of the elastic members 11 (drawn by a two-dot chain line in FIG. 12) (at their natural length) in the absence of tension.

[0105] The effects obtained by the presence of the first region B1 or the third region B3 will be described.

[0106] Here, in at least one of the first region B1 and the third region B3, the maximum gap of the space between the inner sheet 14 and the outer sheet 15 (here referred to as the space for elastic member placement) that communicates with the space in which the elastic member 11 in the second region B2 is placed is smaller than the diameter of the elastic member 11 (at its natural length) when no tension is applied.

[0107] Therefore, in the manufacturing process of the stretch sheet, when the cutting device 300 cuts the elastic member 11 and the elastic member 11 shrinks and disappears from the elastic member placement space in the first region B1 where the elastic member 11 was originally placed, the sliding friction force generated between the elastic member 11 and at least one of the inner sheet 14 (continuum 114) and the outer sheet 15 (continuum 115) can reduce the shrinkage speed of the elastic member 11.

[0108] Similarly, when the cutting device 300 cuts the elastic member 11 and the elastic member 11 shrinks and disappears from the elastic member placement space in the third region B3 where the elastic member 11 was originally placed, the sliding friction force generated between the elastic member 11 and at least one of the inner sheet 14 (continuum 114) and the outer sheet 15 (continuum 115) can reduce the shrinkage speed of the elastic member 11.

[0109] (4) Features (4-1) The stretch sheet manufacturing apparatus 100 of this embodiment includes a forming device 200 as an example of a forming section and a cutting device 300 as an example of a cutting section. The forming device 200 forms a continuous stretch sheet web 116, which is an integrated combination of a continuous web 114, a continuous web 115, and a continuous elastic member 11 disposed between the continuous webs 114 and 115. The cutting device 300 cuts the elastic member 11 from the continuous stretch sheet web 116. The forming device 200 includes an anvil roll 210 as an example of a first joining member and an ultrasonic horn 230 as an example of a second joining member. The anvil roll 210 supports the continuous web 114, the elastic member 11, and the continuous web 115, which are transported in the transport direction D. The ultrasonic horn 230 sandwiches the continuous web 114, the elastic member 11, and the continuous web 115 between the anvil roll 210 and the anvil roll 210. The anvil roll 210 has first protrusions 212a (an example of a first portion) and second protrusions 212b (an example of a second portion) on an outer peripheral surface 211 (an example of a surface facing an ultrasonic horn 230 serving as a second joining member). The second protrusions 212b are disposed adjacent to the first protrusions 212a in the conveyance direction D. The ultrasonic horn 230 sandwiches the elastic member 11, the continuum 114, and the continuum 115 between itself and the first protrusions 212a of the anvil roll 210, and joins the continuum 114 and the continuum 115 together, thereby forming limiting portions 116b in the stretch sheet continuum 116. The ultrasonic horn 230 sandwiches the elastic member 11, the continuum 114, and the continuum 115 between itself and the second protrusions 212b of the anvil roll 210, and bonds the elastic member 11 to at least one of the continuum 114 and the continuum 115, thereby forming a fixed portion 116a on the continuous stretch sheet 116. The cutting device 300 cuts the elastic member 11 of the continuous stretch sheet 116 at the limiting portion 116b of the continuous stretch sheet 116 being conveyed. At the limiting portion 116b of the continuous stretch sheet 116, the continuum 114 and the continuum 115 are not bonded to the elastic member 11. At the limiting portion 116b of the continuous stretch sheet 116, the contraction movement of the elastic member 11 cut by the cutting device 300 is limited by the continuum 114 and the continuum 115.

[0110] The manufacturing apparatus 100 for the worn article 1 can prevent the occurrence of a problem in which the bond between the sheet and the elastic members 11 in the continuous stretch sheet web 116 comes loose during the weakening process of cutting the elastic members 11.

[0111] (4-2) In a preferred embodiment of the manufacturing apparatus 100 for a wearing article 1, the first protrusions 212a of the anvil roll 210 include first groove-forming portions 214, 215, and the second protrusions 212b of the anvil roll 210 include a second groove-forming portion 216. The first groove-forming portions 214, 215 are formed with first grooves 214a, 215a extending along the conveyance direction D, into which the elastic members 11 and the continuum 115 conveyed in the conveyance direction D fit. The second groove-forming portion 216 is formed with a second groove 216a extending along the conveyance direction D, into which the elastic members 11 and the continuum 115 conveyed in the conveyance direction D fit. The depths of the first grooves 214a, 215a are greater than a first sum, which is the sum of the diameter of the elastic members 11 conveyed through the forming apparatus 200 in the conveyance direction D and the thickness of the continuum 115. The depth of the second groove 216a is greater than the first sum.

[0112] In the manufacturing apparatus 100 for the worn article 1, the elastic member 11 and the continuous body 114 or the continuous body 115 are joined at the restricting portion 116b, which prevents the elastic force of the elastic member 11 from remaining in the portion of the stretch sheet continuous body 116 where weakening treatment is desired.

[0113] (4-3) In the manufacturing apparatus 100 for the wearing article 1 of the preferred embodiment, the depth of the first grooves 214a, 215a is smaller than a second sum, which is the sum of the diameter of the elastic member 11 in an untensioned state and the thickness of the continuum 115.

[0114] In the manufacturing apparatus 100 for this worn article 1, when the elastic member 11 is cut, the rapid contraction movement of the elastic member 11 is restricted by the continuum 114 and the continuum 115, thereby preventing the occurrence of a defect in which the connection between the continuum 114 and / or the continuum 115 and the elastic member 11 comes loose at the fixing portion 116a.

[0115] (4-4) In a preferred embodiment of the manufacturing apparatus 100 for a wearing article 1, the width of the first grooves 214a, 215a in the width direction S of the anvil roll 210 is greater than a third sum, which is the sum of the diameter of the elastic member 11 being transported through the forming apparatus 200 in the transport direction D and twice the thickness of the continuum 115. The width of the first grooves 214a, 215a in the width direction of the anvil roll 210 is smaller than a fourth sum, which is the sum of the diameter of the elastic member 11 in an untensioned state and twice the thickness of the continuum 115.

[0116] The manufacturing apparatus 100 for the wearing article 1 can prevent the first grooves 214a, 215a from interfering with the transport of the elastic member 11 and the continuum 115. Meanwhile, the manufacturing apparatus 100 for the wearing article 1 can prevent the continuum 114 and 115 from restricting the rapid contraction of the elastic member 11 when the elastic member 11 is cut by the cutting device 300, thereby preventing the joining of the continuum 114 and / or 115 to the elastic member 11 at the fixing portion 116a from coming loose.

[0117] (4-5) The method for manufacturing the wearing article 1 of this embodiment includes a forming step and a cutting step. In the forming step, a continuous web 114, a continuous web 115, and continuous elastic members 11 disposed between the webs 114 and 115 are integrated to form a continuous stretch sheet web 116. In the cutting step, the elastic members 11 of the continuous stretch sheet web 116 are cut. The forming step includes a conveying step, a first forming step, and a second forming step. In the conveying step, the continuous web 114, the continuous web 115, and the elastic members 11 are conveyed in the conveying direction D with the elastic members 11 disposed between the continuous webs 114 and 115. In the first forming step, the elastic member 11, the continuum 114, and the continuum 115 are sandwiched between an anvil roll 210, which is an example of a first joining member supporting the continuum 114, the elastic member 11, and the continuum 115 transported in the transport direction D, and an ultrasonic horn 230, which is an example of a second connecting member, to bond the elastic member 11 to at least one of the continuum 114 and the continuum 115, thereby forming a fixing portion 116a in the stretch sheet continuum 116. In the second forming step, the elastic member 11, the continuum 114, and the continuum 115 are sandwiched between the anvil roll 210 and the ultrasonic horn 230, to bond the continuum 114 and the continuum 115, thereby forming a limiting portion 116b in the stretch sheet continuum 116. The limiting portion 116b of the stretch sheet continuum 116 is formed at a position adjacent to the fixing portion 116a of the stretch sheet continuum 116. In the cutting step, the elastic members 11 of the continuous stretch sheet web 116 are cut at the limiting portions 116b of the continuous stretch sheet web 116. At the limiting portions 116b of the continuous stretch sheet web 116, the continua 114 and 115 are not joined to the elastic members 11. Furthermore, at the limiting portions 116b of the continuous stretch sheet web 116, the contraction movement of the elastic members 11 cut in the cutting step is limited by the continua 114 and 115.

[0118] This method of manufacturing the wearing article 1 can prevent the occurrence of a problem in which the bond between the sheet in the continuous stretch sheet web 116 and the elastic members 11 comes loose during the weakening process of cutting the elastic members 11.

[0119] (4-6) The wearing article 1 of this embodiment is a wearing article including a stretch sheet. In particular, in the wearing article 1, a stretch sheet manufactured by a stretch sheet manufacturing apparatus 100 is applied to a waistline member 10 that is placed around the waist of a wearer. The stretch sheet applied to the waistline member 10 includes at least an inner sheet 14, an outer sheet 15, and an elastic member 11. The elastic member 11 extends in a first direction (here, the waistline direction along the waist of the wearer) and is placed between the inner sheet 14 and the outer sheet 15. The stretch sheet applied to the waistline member 10 includes a first portion (first region B1) and a second portion (second region B2) in the first direction. The elastic member 11 is not present in the first region B1. In the second region B2, the elastic member 11 is bonded to at least one of the inner sheet 14 and the outer sheet 15. In the first region B1, when viewed in a cross section cut in a direction perpendicular to the first direction, there is a portion where the maximum gap in the space between the inner sheet 14 and the outer sheet 15 that communicates with the space in which the elastic member 11 in the third region B3 is arranged is smaller than the diameter of the elastic member 11 (at its natural length) when no tension is applied.

[0120] With the above-described configuration, the wearing article 1 can restrict the contraction movement of the elastic members 11 in the first region B1 by the inner sheet 14 and the outer sheet 15. Therefore, the wearing article 1 of the present invention can prevent the elastic members 11 from being disengaged from the sheet pieces in the second region B2 of the waistband member.

[0121] (4-7) In the wearing article 1 of this embodiment, the stretch sheet applied to the waistline member 10 includes a third portion (third region B3) disposed between the first region B1 and the second region B2 in a first direction (here, the waistline direction along the waist of the wearer). In the third region B3, in a cross section taken in a direction perpendicular to the first direction, there is a portion where the maximum gap between the inner sheet 14 and the outer sheet 15, which communicates with the space in which the elastic members 11 of the second region B2 are disposed, is smaller than the diameter of the elastic members 11 (at their natural lengths) in the absence of tension.

[0122] With the above-described configuration, the wearing article 1 can restrict the contraction movement of the elastic members 11 in the third region B3 by the inner sheet 14 and the outer sheet 15. Therefore, the wearing article 1 of the present invention can prevent the elastic members 11 from coming loose from the sheet pieces in the second region B2 of the waistband member.

[0123] (5) Variations A modification of the above embodiment will now be described.

[0124] (5-1) Variation A A forming apparatus 200A for forming a continuous stretch sheet web 116 of the stretch sheet manufacturing apparatus 100 according to Modification A will be described with reference to Fig. 14. Fig. 14 is a diagram showing a schematic view of the forming apparatus 200A.

[0125] Since the forming apparatus 200A has many similarities to the forming apparatus 200 of the above embodiment, differences between the forming apparatus 200A and the forming apparatus 200 will be mainly described here.

[0126] The main difference in configuration between the forming apparatus 200A and the forming apparatus 200 is that the forming apparatus 200A has two or more second bonding members arranged along the conveying direction D. In particular, in this embodiment, the forming apparatus 200A has an ultrasonic horn 230 (the most upstream second bonding member) as well as an ultrasonic horn 230A (the most downstream second bonding member) arranged downstream of the ultrasonic horn 230 in the conveying direction D. The ultrasonic horn 230 and the ultrasonic horn 230A sandwich the continuum 114, the continuum 115, and the elastic member 11, which are conveyed in the conveying direction D, between themselves and the anvil roll 210 serving as the first bonding member, to bond the continuum 114 and the continuum 115, and also bond the elastic member 11 to at least one of the continuum 114 and the continuum 115. The ultrasonic horn 230 and the ultrasonic horn 230A may be, for example, a horn for ultrasonic welding as illustrated in FIG. 14, or may be a roll with a built-in heater.

[0127] The ultrasonic horn 230A, which is an example of a most downstream second bonding member, is arranged downstream of the ultrasonic horn 230, which is an example of a most upstream second bonding member, in the conveying direction D of the continuum 114, the elastic member 11, and the continuum 115. In Fig. 14, the position where the ultrasonic horn 230A and the anvil roll 210 face each other in the circumferential direction of the anvil roll 210 is arranged 180° apart from the position where the ultrasonic horn 230 and the anvil roll 210 face each other. However, Fig. 14 is merely one example of the arrangement of the ultrasonic horn 230 and the ultrasonic horn 230A, and the angle between the position where the ultrasonic horn 230A and the anvil roll 210 face each other in the circumferential direction of the anvil roll 210 and the position where the ultrasonic horn 230 and the anvil roll 210 face each other may be less than 180° or greater than 180°.

[0128] The main functional difference between forming device 200A and forming device 200 is that forming device 200A performs the joining of continuum 114 and continuum 115, and the joining of elastic member 11 and at least one of continuum 114 and continuum 115, in two stages: temporary joining using ultrasonic horn 230, and actual joining using ultrasonic horn 230A.

[0129] First, the reason for performing welding in two stages will be explained.

[0130] When the elastic member 11 is joined to at least one of the continuum 114 and the continuum 115, heat may reduce the strength of the elastic member 11, potentially resulting in the cutting of the elastic member 11. If the elastic member 11 is cut, the restoring force of the elastic member 11 may cause the elastic member 11 to return to the upstream side in the conveying direction, and the operation of the manufacturing apparatus 100 may need to be stopped in order to reposition the elastic member 11 between the continuum 114 and the continuum 115.

[0131] Therefore, in this embodiment, first, the elastic member 11 is temporarily joined between the continuum 114 and the continuum 115 under conditions that make it difficult for the elastic member 11 to break, and then the elastic member 11 is firmly joined (mainly joined) by welding between the continuum 114 and the continuum 115. With this configuration, even if the elastic member 11 breaks during the main joining, it is possible to prevent the elastic member 11 from moving upstream in the conveyance direction at the location where the elastic member 11 is temporarily joined between the continuum 114 and the continuum 115.

[0132] Here, temporary bonding means a state in which the members to be joined are bonded together in a manner that allows them to be separated. In other words, temporary bonding means a weak bonding state in which the members to be joined are not subjected to material destruction when they are separated from each other. Furthermore, permanent bonding means a state in which the members to be joined are bonded together in a manner that prevents them from being separated from each other. In other words, permanent bonding means a strong bonding state in which, if the members to be joined were to be separated from each other, material destruction would occur in at least one of the members to be separated.

[0133] In order to achieve such two-stage bonding, the seal strength between the ultrasonic horn 230A and the anvil roll 210 is set to be greater than the seal strength between the ultrasonic horn 230 and the anvil roll 210.

[0134] For example, the ultrasonic horn 230 on the most upstream side in the conveying direction D sandwiches the continuum 114, the elastic member 11, and the continuum 115 between itself and the anvil roll 210 with a relatively weak pressure (first pressure), and forms a temporary bonded portion where the elastic member 11, the continuum 114, and / or the continuum 115 are temporarily bonded by ultrasonic welding. On the other hand, the ultrasonic horn 230A on the most downstream side in the conveying direction D sandwiches the temporary bonded portion between itself and the anvil roll 210 with a relatively strong pressure (second pressure greater than the first pressure), and finally bonds the elastic member 11, the continuum 114, and / or the continuum 115 by ultrasonic welding. Although the numerical values ​​are not limited, for example, the first pressure is 700 to 800 N, and the second pressure is 1250 N.

[0135] Furthermore, when the ultrasonic horn 230 and the ultrasonic horn 230A are rolls with heaters built in, the force clamping the continuum 114, the elastic member 11, and the continuum 115 between the ultrasonic horn 230, 230A and the anvil roll 210 may be constant, and the heater temperature may be set low for the ultrasonic horn 230 and high for the ultrasonic horn 230A.

[0136] In the forming apparatus 200A, the continuous stretch sheet obtained by the main joining using the ultrasonic horn 230A may be the same as the continuous stretch sheet 116 described in the above embodiment.

[0137] However, the features of the forming apparatus 200A are also useful in producing a continuous stretch sheet that does not have the fixing portions 116a and restricting portions 116b described in the above embodiment. In other words, the features of the forming apparatus 200A are useful even if the forming apparatus 200A does not have a configuration that includes the first protrusions 212a and the second protrusions 212b.

[0138] A method for producing a stretch sheet in the forming apparatus 200A will be described.

[0139] The method for manufacturing a stretch sheet includes a forming step of integrating a continuum 114 as an example of a continuous first sheet, a continuum 115 as an example of a continuous second sheet, and a continuous elastic member 11 disposed between the continuum 114 and the continuum 115 to form a stretch sheet continuum 116. The forming step includes a conveying step, a first forming step, and a second forming step.

[0140] In the conveying step, the continuum 114, the continuum 115, and the elastic member 11 are conveyed in a conveying direction D with the elastic member 11 disposed between the continuum 114 and the continuum 115.

[0141] In the first forming process, the elastic member 11, the continuum 114, and the continuum 115 are sandwiched between an anvil roll 210 as an example of a first joining member that supports the continuum 114, the elastic member 11, and the continuum 115 transported in the transport direction D, and an ultrasonic horn 230 as an example of an upstream second joining member, to form a temporary joining portion in which the elastic member 11 and at least one of the continuum 114 and the continuum 115 are temporarily joined.

[0142] In the second forming process, the temporary bonded portion is sandwiched between the anvil roll 210 and an ultrasonic horn 230A as an example of a downstream second bonding member, and the elastic member 11 is bonded to at least one of the continuum 114 and the continuum 115 to form the stretch sheet continuum 116.

[0143] Finally, the characteristics of the manufacturing apparatus 100 for the wearing article 1 equipped with the forming apparatus 200A will be described.

[0144] The manufacturing apparatus 100 for the worn article 1 includes a forming device 200A as an example of a forming section that forms a continuous stretch sheet 116, which is an integrated assembly of a continuum 114 as an example of a continuous first sheet, a continuum 115 as an example of a continuous second sheet, and continuous elastic members 11 arranged between the continuum 114 and the continuum 115. The forming device 200A includes an anvil roll 210 as an example of a first joining member and ultrasonic horns 230, 230A as examples of a second joining member. The anvil roll 210 supports the continuum 114, the elastic members 11, and the continuum 115, which are transported in the transport direction D. Two or more (two in this embodiment) second joining members are arranged along the transport direction D. The ultrasonic horns 230, 230A of the second joining members sandwich the continuum 114, the elastic members 11, and the continuum 115 between themselves and the anvil roll 210. At least the ultrasonic horn 230 on the most upstream side in the conveying direction D sandwiches the continuum 114, the elastic member 11, and the continuum 115 between itself and the anvil roll 210, forming a temporary bonded portion where the elastic member 11 is temporarily bonded to at least one of the continuum 114 and the continuum 115. The ultrasonic horn 230A sandwiches the temporary bonded portion between itself and the anvil roll 210, and permanently bonds the elastic member 11 to at least one of the continuum 114 and the continuum 115, forming the stretch sheet continuous body 116.

[0145] In this manufacturing apparatus 100, the elastic member 11 is cut during joining between the elastic member 11 and at least one of the continuum 114 and the continuum 115, and the elastic member 11 is pulled back upstream due to the restoring force, thereby preventing the occurrence of a malfunction that requires the manufacturing apparatus 100 for the worn article 1 to be stopped in order to reposition the elastic member 11.

[0146] Although the example described here uses two second joining members, three or more second joining members may be arranged along the conveying direction D. In this case, at least the second joining member on the most upstream side is used to form the temporary joined portion, and at least the second joining member on the most downstream side is used to actually join the elastic member to at least one of the first sheet and the second sheet.

[0147] (5-2) Variation B In Modification A, at the temporary joining portion, the elastic member 11 is joined to at least one of the continuum 114 and the continuum 115. However, at the temporary joining portion, the elastic member 11 does not have to be joined to at least one of the continuum 114 and the continuum 115.

[0148] Specifically, at the temporary joining portion, only the continuum 114 and the continuum 115 may be joined by welding or the like, and the elastic member 11 may not be joined to the continuum 114 and the continuum 115. Even in this mode, even if the elastic member 11 is cut during the actual joining, the diameter of the elastic member 11 increases when the elastic member 11 tries to return to its natural length after being cut, so that the elastic member 11 is sandwiched at the joining portion between the continuum 114 and the continuum 115, thereby preventing the elastic member 11 from shrinking and moving upstream in the conveying direction.

[0149] (5-3) Variation C In the forming device 200A of Modification A, the ultrasonic horn 230 and the ultrasonic horn 230A are arranged for one anvil roll 210 as the first joining member, but the configuration of the forming device is not limited to this. The forming device may have two or more first joining members arranged along the conveying direction D.

[0150] 15 , the forming apparatus 200B may include an anvil roll 210A disposed at the most downstream side in the conveyance direction D, in addition to the anvil roll 210 disposed at the most upstream side in the conveyance direction D. In the forming apparatus 200B, the ultrasonic horn 230 sandwiches the continuum 114, the elastic member 11, and the continuum 115 between itself and the anvil roll 210, thereby forming a temporary bonded portion where the elastic member 11 is temporarily bonded to at least one of the continuum 114 and the continuum 115. In the forming apparatus 200B, the ultrasonic horn 230A sandwiches the temporary bonded portion between itself and the anvil roll 210A, thereby permanently bonding the elastic member 11 to at least one of the continuum 114 and the continuum 115, thereby forming the stretch sheet continuous body 116.

[0151] In this case, the anvil roll 210 and the anvil roll 210A have the same pattern of protrusions 212 on the outer circumferential surface 211, and the forming device 200B is preferably designed so that the continuum 115 contacts the same (corresponding) positions on the anvil roll 210 and the anvil roll 210A. Specifically, if a certain portion of the continuum 115 contacts the first protrusions 212a of the anvil roll 210, the forming device 200B is preferably designed so that the same portion of the continuum 115 also contacts the first protrusions 212a on the anvil roll 210A.

[0152] (5-4) Variation D In the above embodiment, the first joining member is described as an anvil roll, but the first joining member is not limited to a roll. For example, the first joining member may be a flat plate-like member having a protrusion 212 on the surface facing the second joining member, as shown in FIG.

[0153] Finally, the technical ideas that can be understood from the above embodiment will be added below.

[0154] A first aspect of the stretch sheet manufacturing apparatus includes a forming unit and a cutting unit. The forming unit forms a continuous stretch sheet web in which a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets are integrated. The cutting unit cuts the elastic member from the continuous stretch sheet web. The forming unit includes a first joining member and a second joining member. The first joining member supports the first sheet, the elastic member, and the second sheet transported in a transport direction. The second joining member sandwiches the first sheet, the elastic member, and the second sheet between itself and the first joining member. The first joining member has a first portion and a second portion on a surface facing the second joining member. The second portion is disposed adjacent to the first portion in the transport direction of the first sheet, the elastic member, and the second sheet transported while supported by the first joining member. The second joining member sandwiches the elastic member, the first sheet, and the second sheet between itself and the first portion of the first joining member, thereby joining the first sheet and the second sheet, thereby forming a limiting portion in the stretch sheet continuous body. The second joining member sandwiches the elastic member, the first sheet, and the second sheet between itself and the second portion of the first joining member, thereby joining the elastic member and at least one of the first sheet and the second sheet, thereby forming a fixing portion in the stretch sheet continuous body. The cutting portion cuts the elastic member of the stretch sheet continuous body at the limiting portion of the stretch sheet continuous body being conveyed. At the limiting portion of the stretch sheet continuous body, the first sheet, the second sheet, and the elastic member are not joined. Furthermore, at the limiting portion of the stretch sheet continuous body, the contraction movement of the elastic member cut by the cutting portion is limited by the first sheet and the second sheet.

[0155] In the stretch sheet manufacturing apparatus according to the first aspect, it is possible to prevent the occurrence of a problem in which the bond between the sheet and the elastic member in the stretch sheet continuous body comes loose during the weakening process in which the elastic member is cut.

[0156] A stretch sheet manufacturing apparatus according to a second aspect is the stretch sheet manufacturing apparatus according to the first aspect, wherein the first portion of the first joining member includes a first groove-forming portion, and the second portion of the first joining member includes a second groove-forming portion. The first groove-forming portion has a first groove formed therein, extending in the conveyance direction, into which the elastic member and second sheet conveyed in the conveyance direction fit. The second groove-forming portion has a second groove formed therein, extending in the conveyance direction, into which the elastic member and second sheet conveyed in the conveyance direction fit. The depth of the first groove is greater than a first sum, which is the sum of the diameter of the elastic member conveyed in the conveyance direction through the forming portion and the thickness of the second sheet. The depth of the second groove is less than the first sum.

[0157] In the stretch sheet manufacturing device of the second aspect, the elastic member and the first sheet or the second sheet are joined in the restricting section, which prevents the elastic force of the elastic member from remaining in the portion of the stretch sheet continuous body where weakening treatment is desired.

[0158] A third aspect of the stretch sheet manufacturing apparatus is the second aspect of the stretch sheet manufacturing apparatus, wherein the depth of the first groove is smaller than a second sum, which is the sum of the diameter of the elastic member in an untensioned state and the thickness of the second sheet.

[0159] In the stretch sheet manufacturing apparatus of the third aspect, when the elastic member is cut, the first sheet and the second sheet restrict the rapid contraction movement of the elastic member, thereby preventing the occurrence of a defect in which the first sheet and / or the second sheet come loose from the bond with the elastic member at the fixing portion.

[0160] A fourth aspect of the stretch sheet manufacturing apparatus is the stretch sheet manufacturing apparatus of the second or third aspect, wherein the width of the first groove in the width direction of the first joining member is greater than a third sum, which is the sum of the diameter of the elastic member being transported in the transport direction through the forming unit and twice the thickness of the second sheet, and the width of the first groove in the width direction of the first joining member is smaller than a fourth sum, which is the sum of the diameter of the elastic member in an untensioned state and twice the thickness of the second sheet.

[0161] The stretch sheet manufacturing device of the fourth aspect can prevent the first groove from interfering with the conveyance of the elastic member or the second sheet. Meanwhile, the stretch sheet manufacturing device of the fourth aspect can prevent the first sheet and the second sheet from restricting the rapid contraction of the elastic member when the elastic member is cut by the cutting section, thereby preventing the first sheet and / or the second sheet from being separated from the elastic member at the fixing section.

[0162] A fifth aspect of the present invention relates to a manufacturing device for stretch sheets for wearing articles, the manufacturing device comprising a forming unit that forms a continuous stretch sheet web, which is an integrated assembly of a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets. The forming unit has a first joining member and a second joining member. The first joining member supports the first sheet, the elastic member, and the second sheet, which are conveyed in the conveyance direction. Two or more second joining members are disposed along the conveyance direction. At least the second joining member located most upstream in the conveyance direction sandwiches the first sheet, the elastic member, and the second sheet between itself and the first joining member, thereby forming a temporary joint portion where the elastic member and at least one of the first sheet and the second sheet are temporarily joined. At least the second joining member located most downstream in the conveyance direction sandwiches the temporary joint portion between itself and the first joining member, thereby permanently joining the elastic member and at least one of the first sheet and the second sheet, thereby forming a continuous stretch sheet.

[0163] In the stretch sheet manufacturing apparatus of the fifth aspect, it is possible to prevent the occurrence of a malfunction in which the elastic member is cut while joining the elastic member to at least one of the first sheet and the second sheet, and the elastic member is pulled back upstream due to the restoring force, requiring the stretch sheet manufacturing apparatus to be stopped in order to reposition the elastic member.

[0164] A sixth aspect of the stretch sheet manufacturing apparatus is the stretch sheet manufacturing apparatus of the fifth aspect, wherein the first joining members include at least two first joining members: one on the most upstream side in the conveying direction, and one on the most downstream side in the conveying direction. The most upstream second joining member sandwiches the first sheet, the elastic member, and the second sheet between itself and the most upstream first joining member to form a temporary joining portion where the elastic member and at least one of the first sheet and the second sheet are temporarily joined. The most downstream second joining member sandwiches the temporary joining portion between itself and the most downstream first joining member to permanently join the elastic member and at least one of the first sheet and the second sheet to form a stretch sheet continuum.

[0165] A seventh aspect of the present invention relates to a method for producing a stretch sheet, the method comprising: a forming step; and a cutting step. In the forming step, a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets are integrated to form a continuous stretch sheet. In the cutting step, the elastic member of the continuous stretch sheet is cut. The forming step includes a conveying step, a first forming step, and a second forming step. In the conveying step, the first sheet, the second sheet, and the elastic member are conveyed in a conveying direction with the elastic member disposed between the first and second sheets. In the first forming step, the elastic member, the first sheet, and the second sheet are sandwiched between a first joining member and a second joining member, which support the first sheet, elastic member, and second sheet conveyed in the conveying direction, and the elastic member is joined to at least one of the first sheet and the second sheet, thereby forming a fixing portion in the continuous stretch sheet. In the second forming step, the elastic member, the first sheet, and the second sheet are sandwiched between the first joining member and the second joining member, and the first sheet and the second sheet are joined to form a restricting portion in the continuous stretch sheet. In the cutting step, the elastic member of the continuous stretch sheet is cut at the restricting portion of the continuous stretch sheet. The restricting portion of the continuous stretch sheet is formed at a position adjacent to the fixed portion of the continuous stretch sheet. In the restricting portion of the continuous stretch sheet, the first sheet and the second sheet are not joined to the elastic member. In the restricting portion of the continuous stretch sheet, the contraction movement of the elastic member cut in the cutting step is restricted by the first sheet and the second sheet.

[0166] In the method for producing a stretch sheet according to the seventh aspect, it is possible to prevent the occurrence of a problem in which the bond between the sheet and the elastic member in the continuous stretch sheet comes loose during the weakening process in which the elastic member is cut.

[0167] An eighth aspect of the present invention relates to a method for producing a stretch sheet, which includes a forming step of integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first and second sheets to form a continuous stretch sheet. The forming step includes a conveying step, a first forming step, and a second forming step. In the conveying step, the first sheet, the second sheet, and the elastic member are conveyed in a conveyance direction with the elastic member disposed between the first and second sheets. In the first forming step, the elastic member, the first sheet, and the second sheet are sandwiched between a first joining member supporting the first sheet, the elastic member, and the second sheet conveyed in the conveyance direction and an upstream second joining member to form a temporary joint portion where the elastic member and at least one of the first sheet and the second sheet are temporarily joined. In the second forming process, the temporary joining portion is sandwiched between the first joining member and a downstream second joining member that is positioned downstream in the conveying direction from the upstream second joining member, and the elastic member and at least one of the first sheet and the second sheet are finally joined to form a stretch sheet continuum.

[0168] In the eighth aspect of the stretch sheet manufacturing method, it is possible to prevent the elastic member from being cut during joining of the elastic member to at least one of the first sheet and the second sheet, causing the elastic member to be pulled back upstream due to its restoring force, thereby preventing the occurrence of a malfunction that requires the stretch sheet manufacturing device to be stopped in order to reposition the elastic member.

[0169] A ninth aspect of the present invention provides a wearing article comprising a stretchable sheet. The stretchable sheet includes at least a first sheet piece, a second sheet piece, and an elastic member. The elastic member extends in a first direction and is disposed between the first sheet piece and the second sheet piece. The stretchable sheet includes a first portion and a second portion in the first direction. The first portion does not include an elastic member. In the second portion, the elastic member is bonded to at least one of the first sheet piece and the second sheet piece. In a cross section taken perpendicular to the first direction, the first portion includes a portion where the maximum gap between the first and second sheet pieces, which communicates with a space in a third portion where the elastic member is disposed, is smaller than the diameter of the elastic member when no tension is applied.

[0170] In the wearing article of the ninth aspect, the above-described configuration allows the contraction movement of the elastic members in the first portion to be limited by the first sheet piece and the second sheet piece, thereby preventing the elastic members from being disengaged from the sheet pieces in the second portion of the waistband member.

[0171] A tenth aspect of the wearing article is the wearing article of the ninth aspect, wherein the stretchable sheet further includes a third portion disposed between the first portion and the second portion in the first direction. In a cross section taken perpendicular to the first direction, the third portion has a portion where the maximum gap between the first sheet piece and the second sheet piece, which communicates with the space in which the elastic member of the second portion is disposed, is smaller than the diameter of the elastic member in an untensioned state.

[0172] In the wearing article of the tenth aspect, the above-described configuration allows the contraction movement of the elastic members in the third portion to be limited by the first sheet piece and the second sheet piece, thereby preventing the elastic members from being disengaged from the sheet pieces in the second portion of the waistband member. [Explanation of symbols]

[0173] 1. Wearable items 10 Waist material (stretchable sheet) 11 Elastic member 14 Inner sheet (first sheet piece) 15 Outer sheet (second sheet piece) 100 Stretch sheet manufacturing equipment 114 Continuum (1st Sheet) 115 Continuum (2nd Sheet) 116 Stretchable Sheet Continuum 116a Fixed part 116b Restrictions 200 Forming device (forming section) 210 Anvil roll (first joining member, first joining member on the most upstream side) 210A Anvil roll (first joining member, first joining member on the most downstream side) 211 Outer surface (opposing surface) 212a 1st protrusion (part 1) 212b Second protrusion (part 2) 214 First groove forming part 214a 1st groove 215 First groove forming part 215a 1st groove 216 Second groove forming part 216a 2nd groove 230 Ultrasonic horn (second joining member, upstream second joining portion) 230A Ultrasonic horn (second joining member, downstream second joining portion) 300 Cutting device (cutting section) B1 1st area (1st part) B2 2nd area (2nd part) B3 Third area (third part) D Conveying direction S Width direction

Claims

1. a forming section for forming a continuous stretch sheet body in which a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first sheet and the second sheet are integrated; a cutting section that cuts the elastic member of the continuous stretch sheet; Equipped with the forming section includes a first joining member that supports the first sheet, the elastic member, and the second sheet that are transported in a transport direction, and a second joining member that sandwiches the first sheet, the elastic member, and the second sheet between the first joining member and the second joining member, the first joint member has, on an opposing surface facing the second joint member, a first portion and a second portion disposed adjacent to the first portion in the conveyance direction; The second joining member is the elastic member, the first sheet, and the second sheet are sandwiched between the first portion of the first joining member and the first joining member to join the first sheet and the second sheet, thereby forming a restricting portion in the stretch sheet continuous body; the elastic member, the first sheet, and the second sheet are sandwiched between the second portion of the first joining member and the elastic member, and the elastic member and at least one of the first sheet and the second sheet are joined to form a fixing portion on the stretch sheet continuous body; the cutting section cuts the elastic member of the continuous stretch sheet at the limiting section of the continuous stretch sheet being conveyed, In the restricting portion, the first sheet, the second sheet, and the elastic member are not joined, and contraction movement of the elastic member cut by the cutting portion is restricted by the first sheet and the second sheet. Stretch sheet manufacturing equipment.

2. the first portion includes a first groove forming portion in which a first groove extending along the conveyance direction is formed and into which the elastic member and the second sheet conveyed in the conveyance direction fit; the second portion includes a second groove forming portion in which a second groove extending along the conveyance direction is formed, into which the elastic member and the second sheet conveyed in the conveyance direction are inserted; a depth of the first groove is greater than a first total value that is a total of a diameter of the elastic member transported through the forming portion in the transport direction and a thickness of the second sheet; The depth of the second groove is less than the first total value. The stretch sheet manufacturing apparatus according to claim 1 .

3. the depth of the first groove is smaller than a second sum which is the sum of the diameter of the elastic member in an untensioned state and the thickness of the second sheet; The stretch sheet manufacturing apparatus according to claim 2 .

4. The width of the first groove in the width direction of the first joint member is the third total value being the sum of the diameter of the elastic member conveyed through the forming portion in the conveyance direction and twice the thickness of the second sheet, is smaller than a fourth sum that is the sum of the diameter of the elastic member in an untensioned state and twice the thickness of the second sheet; The stretch sheet manufacturing apparatus according to claim 2 or 3.

5. A stretch sheet manufacturing apparatus including a forming unit that forms a continuous stretch sheet body in which a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first sheet and the second sheet are integrated, The forming portion is a first joining member that supports the first sheet, the elastic member, and the second sheet, which are transported in a transport direction; two or more second joining members arranged along the conveyance direction, sandwiching the first sheet, the elastic member, and the second sheet between the first joining members and the second joining members; and At least the second joining member on the most upstream side in the conveying direction sandwiches the first sheet, the elastic member, and the second sheet between the first joining member and the first joining member to form a temporary joining portion where the elastic member and at least one of the first sheet and the second sheet are temporarily joined, the second joining member at least on the most downstream side in the conveying direction sandwiches the temporary joined portion between itself and the first joining member, and finally joins the elastic member to at least one of the first sheet and the second sheet to form the stretch sheet continuous body; a bonding strength between the elastic member and at least one of the first sheet and the second sheet by the second bonding member on the most downstream side is greater than a bonding strength between the elastic member and at least one of the first sheet and the second sheet by the second bonding member on the most upstream side; Stretch sheet manufacturing equipment.

6. the first joint members include at least two first joint members, one being the most upstream first joint member in the conveying direction and the other being the most downstream first joint member in the conveying direction; the second joining member on the most upstream side sandwiches the first sheet, the elastic member, and the second sheet between the second joining member on the most upstream side and the first joining member on the most upstream side, thereby forming the temporary joining portion in which the elastic member and at least one of the first sheet and the second sheet are temporarily joined, the second joining member at the most downstream side sandwiches the temporary joining portion between the first joining member at the most downstream side and the elastic member and at least one of the first sheet and the second sheet, thereby forming the stretch sheet continuous body; The stretch sheet manufacturing apparatus according to claim 5 .

7. a forming step of integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first sheet and the second sheet to form a continuous stretch sheet; a cutting step of cutting the elastic member from the continuous stretch sheet; A method for producing a stretch sheet, comprising: The forming step includes: a conveying step of conveying the first sheet, the second sheet, and the elastic member in a conveyance direction with the elastic member disposed between the first sheet and the second sheet; a first forming step of sandwiching the elastic member, the first sheet, and the second sheet between a first joining member and a second joining member, the first joining member supporting the first sheet, the elastic member, and the second sheet being transported in the transport direction, and joining the elastic member and at least one of the first sheet and the second sheet, thereby forming a fixing portion on the stretch sheet continuous body; a second forming step of sandwiching the elastic member, the first sheet, and the second sheet between the first joining member and the second joining member to join the first sheet and the second sheet, thereby forming a limiting portion in the stretch sheet continuous body at a position adjacent to the fixing portion; Including, In the cutting step, the elastic member of the continuous stretch sheet is cut at the limiting portion of the continuous stretch sheet, In the restricting portion, the first sheet, the second sheet, and the elastic member are not bonded to each other, and contraction movement of the elastic member cut in the cutting step is restricted by the first sheet and the second sheet. A method for manufacturing a stretch sheet.

8. A method for manufacturing a stretch sheet, comprising: a forming step of integrating a continuous first sheet, a continuous second sheet, and a continuous elastic member disposed between the first sheet and the second sheet to form a continuous stretch sheet, The forming step includes: a conveying step of conveying the first sheet, the second sheet, and the elastic member in a conveyance direction with the elastic member disposed between the first sheet and the second sheet; a first forming step of sandwiching the elastic member, the first sheet, and the second sheet between a first joining member supporting the first sheet, the elastic member, and the second sheet, which are transported in the transport direction, and an upstream second joining member, to form a temporary joined portion in which the elastic member and at least one of the first sheet and the second sheet are temporarily joined; a second forming step of sandwiching the temporary joined portion between the first joining member and a downstream second joining member disposed downstream of the upstream second joining member in the conveying direction to permanently join the elastic member and at least one of the first sheet and the second sheet to form the stretch sheet continuous body; Including, a bonding strength between the elastic member and at least one of the first sheet and the second sheet formed by the downstream-side second bonding member is greater than a bonding strength between the elastic member and at least one of the first sheet and the second sheet formed by the upstream-side second bonding member; A method for manufacturing a stretch sheet.

9. A wearing article provided with a stretch sheet, the stretch sheet includes at least a first sheet piece, a second sheet piece, and an elastic member extending in a first direction and disposed between the first sheet piece and the second sheet piece; The stretch sheet has, in the first direction, a first portion where the elastic member is not present; a second portion where the elastic member is joined to at least one of the first sheet piece and the second sheet piece; Including, In the first portion, in a cross section cut in a direction perpendicular to the first direction, there is a portion in which a maximum gap of a space between the first sheet piece and the second sheet piece that communicates with a space in which the elastic member of the second portion is arranged is smaller than a diameter of the elastic member in a state in which no tension is applied. Wearable items.

10. the stretch sheet further includes a third portion disposed between the first portion and the second portion in the first direction, In the third portion, in a cross section cut in a direction perpendicular to the first direction, there is a portion in which a maximum gap of a space between the first sheet piece and the second sheet piece that communicates with the space in which the elastic member of the second portion is arranged is smaller than a diameter of the elastic member in a state in which no tension is applied. The wearing article according to claim 9.

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