Absorbent body manufacturing method

Abstract

The present invention provides a method for manufacturing an absorbent body. the method allowing for an increase in variations of the absorbent body.　Formed are: a first absorbent sheet (30) having a first absorbent material (33) disposed in first regions (33a–33c) of first sheets (32a–32c); and a second absorbent sheet (20) having a second absorbent material (23) disposed in second regions (23a, 23b) of a second sheet (22). A continuous body (14) is formed in which the first absorbent sheet (30) and the second absorbent sheet (20) overlap each other such that the first regions (33a–33c) and the second regions (23a, 23b) are adjacent to each other in plan view. The continuous body (14) is cut so that the first regions (33a–33c) and the second regions (23a, 23b) adjacent to each other are included, and as a result thereof, an absorbent body (10) is formed that includes the first and second absorbent materials (33, 23).

Description

[Technical Field]

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

[0002] Absorbent bodies containing absorbent material are used in diapers, sanitary napkins, and the like. For example, FIG. 10 is a schematic layout diagram of a manufacturing apparatus for manufacturing absorbent bodies, and FIG. 11 is an enlarged cross-sectional view of a main portion. As shown in FIGS. 10 and 11, this apparatus includes two units U1 and U2, each including a conveyor C1 and C2 and a sprinkler 111 and 112, and a stacking roller R. The conveyors C1 and C2 have a negative pressure case 119 and convey the sheets S1 and S2 while applying suction. The sheets S1 and S2 have a diffusion layer 121 and a short fiber layer 122, and the short fiber layer 122 is raised by a raising roller 130. The sprinklers 111 and 112 sprinkle powder 120 of the absorbent material onto the raised upper surfaces of the sheets S1 and S2 as they are conveyed along the inclined surfaces F1 and F2. As a result, absorbent layers L1 and L2 are formed on the short fiber layer 122 of the sheets S1 and S2. The laminating roller R overlaps the sheets S1 and S2 so that the absorbent layers L1 and L2 face each other (see, for example, Patent Document 1).

[0003] Furthermore, Patent Document 2 discloses that an absorbent body is produced by overlapping two sheets onto which an absorbent material has been transferred. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2021 / 015001 [Patent Document 2] International Publication No. 2015 / 123087 Summary of the Invention [Problem to be solved by the invention]

[0005] Simply stacking two sheets and disposing an absorbent material between them limits the variety of absorbent bodies available, and it is therefore desirable to further increase the variety of absorbent bodies available.

[0006] In view of the above circumstances, the problem that the present invention aims to solve is to provide a method for manufacturing an absorbent body that can increase the variety of absorbent bodies. [Means for solving the problem]

[0007] In order to solve the above problems, the present invention provides a method for manufacturing an absorbent body configured as follows.

[0008] The method for manufacturing an absorbent body includes: (i) a first step of forming a first absorbent sheet having a first absorbent material disposed in a first region of a first sheet; (ii) a second step of forming a second absorbent sheet having a second absorbent material disposed in a second region of a second sheet; (iii) a third step of forming a continuum including the first absorbent sheet and the second absorbent sheet, wherein the first region and the second region are adjacent to each other in a planar view; and (iv) a fourth step of cutting the continuum to include the adjacent first region and second region to form an absorbent body including the first absorbent material and the second absorbent material. In the first step, a first absorbent material is arranged in the first region in a plurality of rows spaced apart from one another in the direction in which the first sheet is continuous, and in the second step, a second absorbent material is arranged in the second region in a plurality of rows spaced apart from one another in the direction in which the second sheet is continuous.

[0009] According to the above method, the characteristics of the absorbent body can be changed depending on the patterns of the first and second regions, and the types and amounts of the first and second absorbent materials arranged in the first and second regions, etc. Therefore, the variety of absorbent bodies can be increased.

[0010] In a preferred embodiment of the method for manufacturing an absorbent body, in the third step, the continuum is formed in which the first absorbent sheet and the second absorbent sheet overlap each other so that the first region and the second region are adjacent to each other in a planar view.

[0011] In this case, the overlapping first and second absorbent sheets are simultaneously cut in the fourth step to form the absorbent body.

[0012] Another preferred embodiment of the method for manufacturing an absorbent body further includes: (v) a fifth step of cutting the first absorbent sheet after the first step and before the third step to form first pieces including the first region, and (vi) a sixth step of cutting the second absorbent sheet after the second step and before the third step to form second pieces including the second region. In the third step, the continuum is formed in which the first pieces and the second pieces are lined up so that the first region and the second region are adjacent to each other in a plan view.

[0013] In this case, the continuous body includes cut first and second absorbent sheets, and the first and second individual pieces of the cut first and second absorbent sheets do not overlap each other, so the thickness of the absorbent body can be made thinner or the amount of sheet material used in the absorbent body can be reduced.

[0014] Preferably, in the first step, the first absorbent material is arranged in a plurality of the first sheets, and in the third step, the plurality of first sheets are arranged at intervals to form the continuum.

[0015] In this case, channels can be formed along the gaps between adjacent first sheets. Furthermore, since the first sheets are not constrained to one another, an absorbent body can be formed that easily conforms to the shape of the area where it is worn.

[0016] As mentioned above In the first step, a first absorbent material is placed in the first region in a direction in which the first sheet is continuous, in a plurality of rows, and spaced apart from one another. In the second step, the second absorbent material is placed in the second region in a direction in which the second sheet is continuous, in a spaced apart from one another.

[0017] In this case, channels can be formed between multiple rows of the first regions aligned in the direction in which the first sheet is continuous.

[0018] Preferably, in the first step, a first covering sheet is overlaid on the first sheet to form the first absorbent sheet in which the first absorbent material is disposed between the first sheet and the first covering sheet.

[0019] In this case, the addition of the first covering sheet can increase the variety of absorbent bodies, and also suppresses the migration of the first absorbent material outside the first region, stabilizing the quality of the absorbent body.

[0020] Preferably, in the second step, a second covering sheet is overlaid on the second sheet to form the second absorbent sheet in which the second absorbent material is disposed between the second sheet and the second covering sheet.

[0021] In this case, the addition of the second covering sheet can increase the variety of absorbent bodies, and also suppresses the migration of the second absorbent material outside the second region, stabilizing the quality of the absorbent body. [Effects of the Invention]

[0022] According to the present invention, the variety of absorbent bodies can be increased. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is an explanatory diagram of a method for producing an absorbent body (Example 1). [Figure 2] Fig. 2(a) is an explanatory diagram of the first sheet, and Fig. 2(b) is an explanatory diagram of the second sheet. (Example 1) [Figure 3] Figure 3(a) is a schematic plan view of the continuum and absorbent body, and Figure 3(b) is a schematic cross-sectional view of the continuum and absorbent body. (Example 1) [Figure 4] 4 is a perspective view of a main part of the continuum (Example 1). [Figure 5] 5 is an explanatory diagram of a method for manufacturing an absorbent body (Example 2). [Figure 6] 6 is an explanatory diagram of a method for manufacturing an absorbent body (Example 3). [Figure 7] Figure 7(a) is a schematic plan view of the continuum and the absorbent body, and Figure 7(b) is a schematic cross-sectional view of the continuum and the absorbent body. (Example 3) [Figure 8] Fig. 8 is an explanatory diagram of a method for manufacturing an absorbent body (Example 4). [Figure 9] 9(a) is a schematic plan view of the continuum and the absorbent body, and FIG. 9(b) is a schematic cross-sectional view of the continuum and the absorbent body. (Example 4) [Figure 10] FIG. 10 is a schematic layout diagram of an absorbent body manufacturing apparatus (Conventional Example 1). [Figure 11] Fig. 11 is an enlarged cross-sectional view of a main part of an absorbent body manufacturing apparatus (Conventional Example 1). DETAILED DESCRIPTION OF THE INVENTION

[0024] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0025] Example 1 A method for producing an absorbent body of Example 1 will be described with reference to FIGS.

[0026] Fig. 1 is an explanatory diagram showing an outline of a manufacturing method for an absorbent body 10. As shown in Fig. 1, a first absorbent sheet 30 and a second absorbent sheet 20 are formed, then a continuous body 14 is formed in which the first and second absorbent sheets 30, 20 overlap each other, and then the continuous body 14 is cut to form the absorbent body 10.

[0027] (1) The first absorbent sheet 30 is formed as follows. Fig. 2(a) is an explanatory diagram of the first sheets 32a to 32c. As shown in Figs. 1 and 2(a), the raw sheet 32 ​​is conveyed in a direction 32x in which the raw sheet 32 ​​is continuous, and the first covering sheet 34 is conveyed in a direction 34x in which the first covering sheet 34 is continuous. For example, the raw sheet 32 ​​is an air-laid nonwoven fabric, and the first covering sheet 34 is a nonwoven fabric.

[0028] Next, slits 32p, 32q are formed through the main surfaces 32s, 32t of the raw sheet 32 ​​to divide the raw sheet 32 ​​into a plurality of first sheets 32a, 32b, 32c. Next, spaces 32u, 32v between adjacent first sheets 32a, 32b; 32b, 32c are widened, and the first sheets 32a to 32c are conveyed parallel to one another.

[0029] Next, as indicated by arrows 33x in Figure 1, first absorbent material 33 (see Figure 3(b)) is intermittently supplied to first sheets 32a-32c and / or first covering sheet 34, and then first sheets 32a-32c and first covering sheet 34 are overlapped to form first absorbent sheet 30 on which first absorbent material 33 is disposed. First absorbent material 33 is a particulate or powdery absorbent material in a dry state, such as a powder or granular material of superabsorbent polymer (abbreviated as "SAP").

[0030] The first absorbent sheet 30 can be formed, for example, using the manufacturing apparatus shown in Figure 10. In this case, one of the conveyors C1, C2 is used to transport the first sheets 32a-32c, and the other is used to transport the first covering sheet 34. Using one or both of the sprinklers 111, 112, the first absorbent material 33 is sprinkled onto the upper surface of the first sheets 32a-32c and / or the first covering sheet 34 while they are being transported along the inclined surfaces F1, F2, and then the first sheets 32a-32c and the first covering sheet 34 are superimposed using the laminating roller R. The first absorbent sheet 30 can be formed without using the raising roller 130, but the raising roller 130 may be used to raise the first sheets 32a-32c.

[0031] Alternatively, a hot melt or adhesive may be applied in advance to the first covering sheet 34 and / or the first sheets 32a to 32c using an application device 81, and the first absorbent sheet 30 may be formed by bonding the first sheets 32a to 32c to the first covering sheet 34. Note that the first absorbent sheet 30 may be formed without bonding the first sheets 32a to 32c to the first covering sheet 34.

[0032] The first absorbent material 33 is supplied to the first sheets 32a-32c and / or the first covering sheet 34 so as to form a first absorbent sheet 30 in which the first absorbent material 33 is arranged in the first regions 33a-33c of the first sheets 32a-32c shown in Fig. 2(a), which are indicated by diagonal lines. The first regions 33a-33c are arranged in multiple rows at intervals in the direction 32x in which the first sheets 32a-32c are continuous. The first absorbent material 33 may be supplied at any appropriate position and timing, but it is preferable to supply the first absorbent material 33 immediately before the first sheets 32a-32c and the first covering sheet 34 overlap, as this prevents disruption of the supply pattern of the first absorbent material 33.

[0033] The first regions 33a-33c can be designed as appropriate, and for example, may be aligned in a line in the direction 32x in which the first sheets 32a-32c are continuous, or may be continuous without any gaps in the direction 32x in which the first sheets 32a, 32c are continuous. The first regions 33a-33c may intersect with the cutting position 11 where the absorbent body 10 is to be cut, but if they are spaced apart from the cutting position 11 as shown in FIG. 2(a), wear on the cutting blades can be reduced.

[0034] A plurality of first sheets 32a to 32c prepared in advance may be used instead of dividing the plurality of first sheets 32a to 32c from the raw sheet 32. The number of first sheets 32a to 32c may be one, two, or four or more.

[0035] The first cover sheet 34 may be omitted, and the first absorbent sheet 30 may be formed by disposing the first absorbent material 33 on the first sheets 32a to 32c. In this case, after disposing the first absorbent material 33 on the plurality of first sheets 32a to 32c, the spaces 32u, 32v between the first sheets 32a to 32c may be widened.

[0036] In other words, the method for manufacturing the absorbent body 10 includes a first step of forming a first absorbent sheet 30 in which a first absorbent material 33 is arranged in first regions 33a to 33c of at least one first sheet 32a to 32c.

[0037] Preferably, in the first step, the first absorbent material 33 is arranged on a plurality of the first sheets 32a to 32c.

[0038] Preferably, in the first step, the first absorbent material 33 is arranged in the first regions 33a to 33c arranged in a plurality of rows spaced apart from one another in the direction 32x in which the first sheets 32a to 32c are continuous.

[0039] If the first covering sheet 34 is not omitted, in the first step, the first covering sheet 34 is superimposed on the first sheets 32a to 32c to form the first absorbent sheet 30 in which the first absorbent material 33 is disposed between the first sheets 32a to 32c and the first covering sheet 34.

[0040] (2) The second absorbent sheet 20 is formed as follows. Fig. 2(b) is an explanatory diagram of the second sheet 22. As shown in Figs. 1 and 2(b), the second sheet 22 is conveyed in a direction 22x in which the second sheet 22 is continuous, and the second covering sheet 24 is conveyed in a direction 24x in which the second covering sheet 24 is continuous. For example, the second sheet 22 and the second covering sheet 24 are nonwoven fabrics.

[0041] Next, as indicated by arrows 23x in FIG. 1, a second absorbent material 23 (see FIG. 3(b)) is intermittently supplied to the second sheet 22 and / or the second covering sheet 24. The second sheet 22 and the second covering sheet 24 are then superimposed to form the second absorbent sheet 20. The second absorbent sheet 20 can be formed, for example, using the manufacturing apparatus shown in FIG. 6, in the same manner as the first absorbent sheet 30. The second absorbent material 23 is a particulate or powdery absorbent material in a dry state, such as a powder of SAP, and may be the same as or different from the first absorbent material 33.

[0042] Alternatively, a hot melt or adhesive may be applied in advance to the second sheet 22 and / or the second covering sheet 24 using an application device 82, and the second absorbent sheet 20 may be formed by bonding the second sheet 22 and the second covering sheet 24 together. Note that the second absorbent sheet 20 may also be formed without bonding the second sheet 22 and the second covering sheet 24 together.

[0043] The second absorbent material 23 is supplied to the second sheet 22 and / or the second covering sheet 24 so as to form a second absorbent sheet 20 in which the second absorbent material 23 is arranged in the second regions 23a, 23b indicated by diagonal lines in the second sheet 20 shown in Figure 2(b). The second regions 23a, 23b are spaced apart and aligned in a line in the direction 22x in which the second sheet 22 continues. The second absorbent material 23 may be supplied at an appropriate position and timing, but it is preferable to supply the second absorbent material 23 immediately before the second sheet 22 and the second covering sheet 24 overlap, as this prevents disruption of the supply pattern of the second absorbent material 23.

[0044] The second absorbent material 23 can be designed as appropriate, and may, for example, be continuous without any gaps in the direction 22x in which the second sheet 22 is continuous. The second regions 23a, 23b may intersect with the cutting position 11 where cutting is to be performed to form the absorbent body 10, but if they are spaced apart from the cutting position 11 as shown in Figure 2(b), wear on the cutting blade for cutting the sheet can be reduced.

[0045] The second cover sheet 24 may be omitted, and the second absorbent sheet 20 may be formed by disposing the second absorbent material 23 on the second sheet 22. One such example will be described later as Example 4.

[0046] That is, the method for manufacturing the absorbent body 10 includes a second step of forming a second absorbent sheet 20 in which the second absorbent material 23 is arranged in the second regions 23a, 23b of the second sheet 22.

[0047] Preferably, in the second step, the second absorbent material 23 is arranged in the second regions 23a, 23b spaced apart from each other in the direction 22x in which the second sheet 22 is continuous.

[0048] If the second covering sheet 24 is not omitted, in the second step, the second covering sheet 24 is superimposed on the second sheet 22 to form the second absorbent sheet 20 in which the second absorbent material 23 is disposed between the second sheet 22 and the second covering sheet 24.

[0049] (3) The continuum 14 and the absorbent body 10 are formed as follows. FIG. 3(a) is a schematic plan view of the continuum 14 seen through and the absorbent body 10. FIG. 3(b) is a schematic cross-sectional view taken along line AA in FIG. 3(a). As shown in FIGS. 1, 3(a), and 3(b), the carrier sheet 12 is conveyed in the direction 12x in which the carrier sheet 12 is continuous, and hot melt or adhesive is applied to the first and second absorbent sheets 30 and 20 using application devices 83 and 84. Next, the second absorbent sheet 20 is placed over the widthwise intermediate region of one main surface 12s of the carrier sheet 12, and the second absorbent sheet 20 is attached to the carrier sheet 12. Next, the first absorbent sheet 30 is placed over the second absorbent sheet 20, and the first absorbent sheet 30 is attached to the second absorbent sheet 20. As a result, a continuous body 14 including the first absorbent sheet 30 and the second absorbent sheet 20 is formed.

[0050] At this time, the first and second absorbent sheets 30, 20 are overlapped so that the first regions 33a-33c in which the first absorbent material 33 is arranged in the first absorbent sheet 30 and the second regions 23a, 23b in which the second absorbent material 23 is arranged in the second absorbent sheet 20 are adjacent to each other in a planar view, and the adjacent first regions 33a-33c and second regions 23a, 23b are arranged between adjacent cutting positions 11, 11.

[0051] Next, hot melt or adhesive is applied to the carrier sheet 12 and / or the first absorbent sheet 30 using an application device 85, and then the portions 12a and 12b of the carrier sheet 12 that protrude on both sides of the first and second absorbent sheets 30 and 20 are folded back and overlapped on top of the first absorbent sheet 30. This results in the continuum 14 in which the first and second absorbent sheets 30 and 20 are wrapped in the carrier sheet 12.

[0052] Next, the continuous body 14 is cut at the cutting positions 11 to form the absorbent body 10. In this way, the absorbent body 10 having the first and second absorbent materials 23, 33 disposed therein can be formed.

[0053] It is also possible to omit some or all of the coating devices 81 to 85. Instead of adhesion, appropriate locations may be joined at appropriate times using ultrasonic waves, heat sealing, etc. It is also possible to form the first and / or second absorbent sheets 30, 20 and the continuum 14 without adhesion or joining.

[0054] The order in which the carrier sheet 12 and the first and second absorbent sheets 30, 20 are superimposed is arbitrary. For example, the second absorbent sheet 30 may be superimposed on the carrier sheet 12, and then the first absorbent sheet 20 may be superimposed on the second absorbent sheet 30. The first and second absorbent sheets 30, 20 may be superimposed on each other, and then the first and second absorbent sheets 30, 20 may be superimposed on the carrier sheet 12. Furthermore, the carrier sheet 12 may be omitted, and a continuum 14 may be formed in which the first and second absorbent sheets 30, 20 are superimposed on each other.

[0055] In other words, the method for manufacturing the absorbent body 10 comprises a third step of forming a continuum 14 including the first absorbent sheet 30 and the second absorbent sheet 20, in which the first regions 33a to 33c and the second regions 23a, 23b are adjacent to each other in a planar view, and a fourth step of cutting the continuum 14 to include the adjacent first regions 33a to 33c and the second regions 23a, 23b, to form an absorbent body 10 including the first absorbent material 33 and the second absorbent material 23.

[0056] More specifically, in the third step, the first absorbent sheet 30 and the second absorbent sheet 20 are overlapped with each other so that the first regions 33a-33c and the second regions 23a, 23b are adjacent to each other in a plan view to form the continuum 14. In this case, the overlapping first and second absorbent sheets 30, 20 are cut simultaneously in the fourth step to form an absorbent body.

[0057] Preferably, in the third step, the continuous body 14 is formed in which a plurality of the first sheets 32a to 32c are arranged at intervals from one another.

[0058] (4) Next, the arrangement pattern of the first and second regions adjacent to each other in a plan view will be described with reference to Fig. 4. Fig. 4 is a perspective view of a main part of a continuous body 14 in which first and second absorbent sheets 30, 20 overlap each other, showing the first and second regions arranged between adjacent cutting positions 11, 11. The first and second absorbent sheets 30, 20 are continuous in the first direction X.

[0059] FIG. 4(a) shows the same arrangement pattern as FIGS. 1 to 3. As shown in FIG. 4(a), three first regions 33a to 33c extending in the first direction X are arranged between two second regions 23a and 23b spaced apart from each other in the first direction X, and the first regions 33a to 33c are in contact with the two second regions 23a and 23b. The three first regions 33a to 33c are arranged spaced apart from each other in a second direction Y perpendicular to the first direction X. This forms two channels 16a surrounded by the first and second regions 33a to 33c; 23a and 23b. The first and second absorbent materials 33 and 23 are not arranged in the two channels 16a.

[0060] 4(b), three first regions 33a, 33d, and 33c extending in the first direction X are disposed between two second regions 23a and 23b spaced apart in the first direction X. Of the three first regions 33a, 33d, and 33c, the first regions 33a and 33c on both sides in the second direction Y contact the two second regions 23a and 23b, while the central first region 33d contacts only one second region 23b and is adjacent to the other second region 23a at a distance. This forms a U-shaped channel 16b.

[0061] 4(c), three first regions 33p to 33r extending in the first direction X are arranged between two second regions 23a and 23b that are spaced apart in the first direction X, and each of the three first regions 33p to 33r is adjacent to one second region 23a at a distance and in contact with the other second region 23b. This forms a π-shaped channel 16c that is open at two points on both sides in the second direction Y.

[0062] 4(d), three first regions 33u to 33w extending in the first direction X are arranged between two second regions 23a, 23b that are arranged at an interval in the first direction X, and each of the three first regions 33u to 33w is adjacent to two of the second regions 23a, 23b with an interval between them. This forms a channel 16d that is generally II-shaped or H-shaped and has four openings on both sides in the second direction Y.

[0063] 4(e), two first regions 33m, 33n extending in the first direction X are arranged at intervals in the second direction Y, and three second regions 23u to 23w are arranged between the two first regions 33m, 33n at intervals in the first direction X, and each of the three second regions 23u to 23w is in contact with two of the first regions 33m, 33n. This forms two channels 16e surrounded by the first and second regions 33m, 33n; 23u to 23w, and the two channels 16e are aligned in the first direction Y.

[0064] It is also possible to use an arrangement pattern in which the first and second regions shown in FIGS. 4(a) to 4(e) are interchanged.

[0065] When an absorbent body is formed using the method described above, the characteristics of the absorbent body can be changed depending on the patterns of the first and second regions, the types and amounts of the first and second absorbent materials disposed in the first and second regions, etc. This allows for an increased variety of absorbent bodies.

[0066] When the absorbent body 10 includes multiple first sheets 32a-32c, channels can be formed along the spaces 32u, 32v between adjacent first sheets 32a-32c. Furthermore, since the multiple first sheets 32a-32c are not constrained to one another, it is possible to form an absorbent body 10 that easily conforms to the shape of the area where it is worn.

[0067] When the first covering sheet 34 is added, the first covering sheet 32 ​​inhibits the first absorbent material 33 from migrating out of the first regions 33a-33b, stabilizing the quality of the absorbent body 10. When the second covering sheet 24 is added, the second covering sheet 24 inhibits the second absorbent material 23 from migrating out of the second regions 23a, 23b, stabilizing the quality of the absorbent body 10. By selecting various properties such as liquid permeability, liquid diffusibility, and liquid retention of the first and / or second covering sheets 33, 23, the variety of absorbent bodies 10 can be increased.

[0068] Example 2 A method for manufacturing an absorbent body 10a of Example 2 in which the number of sheets is increased will be described with reference to Fig. 5. Fig. 5 is an explanatory diagram showing an outline of the method for manufacturing the absorbent body 10a. In the following, the same reference numerals are used for the same parts as in Example 1, and the differences from Example 1 will be mainly described.

[0069] As shown in FIG. 5, the method for manufacturing the absorbent body of Example 2 is substantially the same as the method for manufacturing the absorbent body of Example 1.

[0070] The original sheet 42 is conveyed in a direction 42x in which the original sheet 42 continues, and the original sheet 42 is divided into first and third separate sheets 52, 62.

[0071] As in Example 1, the first separate sheet 52 is conveyed in a direction 52x in which the first separate sheet 52 continues, and the first covering sheet 54 is conveyed in a direction 54x in which the first covering sheet 54 continues. The first separate sheet 52 is divided to form a plurality of first sheets 52a-52c. Next, as indicated by arrow 53x, a first absorbent material is supplied to the first sheets 52a-52c and / or the first covering sheet 54. Next, the first sheets 52a-52c and the first covering sheet 54 are overlapped to form a first absorbent sheet 50 in which the first absorbent material is sandwiched between the first sheets 52a-52c and the first covering sheet 54 and disposed in first regions of the first sheets 52a-52c.

[0072] Similarly, the third divided sheet 62 is conveyed in a direction 62x in which the third divided sheet 62 continues, and the third covering sheet 64 is conveyed in a direction 64x in which the third covering sheet 64 continues. Next, the third divided sheet 62 is divided to form a plurality of third sheets 62a to 62c. Next, as indicated by arrow 63x, a third absorbent material is supplied to the third sheets 62a to 62c and / or the third covering sheet 64. Next, the third sheets 62a to 62c and the third covering sheet 64 are overlapped to form a third absorbent sheet 60 in which the third absorbent material 63 is sandwiched between the third sheets 62a to 62c and the third covering sheet 64 and the third absorbent material is disposed in a third region of the third sheet 60.

[0073] Next, as shown by arrow 43x, a fourth absorbent material is supplied to the first absorbent sheet 50 and / or the third absorbent sheet 60. The first and third absorbent sheets 50, 60 are then overlapped to form the fourth absorbent sheet 40, in which the fourth absorbent material is sandwiched between the first absorbent sheet 50 and the third absorbent sheet 60 and disposed in the fourth region.

[0074] Furthermore, the second sheet 22 is conveyed in the direction 22x in which the second sheet 22 continues, and the second covering sheet 24 is conveyed in the direction 24x in which the second covering sheet 24 continues, and as shown by arrow 23x, a second absorbent material is supplied to the second sheet 22 and / or the second covering sheet 24, and the second sheet 22 and the second covering sheet 24 are overlapped to form a second absorbent sheet 20 in which the second absorbent material is sandwiched between the second sheet 22 and the second covering sheet 24 and the second absorbent material is disposed in a second region of the second sheet 22.

[0075] Next, a second absorbent sheet 20 is placed on the carrier sheet 12, and then a fourth absorbent sheet 40 is placed on the second absorbent sheet 20. This forms a continuum 14a including the second absorbent sheet 20 and the fourth absorbent sheet 40. Since the fourth absorbent sheet 40 includes the first absorbent sheet 50, the continuum 14a includes the first absorbent sheet 50 and the second absorbent sheet 20. At this time, the continuum 14a is formed such that at least two of the first to fourth regions are adjacent to each other in a planar view. For example, the fourth absorbent sheet 40 and the continuum 14a are formed such that two of the first to fourth regions are adjacent to each other in a planar view, and the other two regions overlap one or both of the two adjacent regions. The continuum 14a may also be formed such that none of the first to fourth regions overlaps with the other regions in a planar view. Next, the widthwise opposite side portions 12a and 12b of the carrier sheet 12 are folded, so that the second absorbent sheet 20 and the fourth absorbent sheet 40 are wrapped in the carrier sheet 12.

[0076] Next, the continuous body 14a is cut to form the absorbent body 10a. At this time, the continuous body 14a is cut at the cutting positions 11 so that at least two adjacent regions are included between adjacent cutting positions 11, 11, thereby forming the absorbent body 10a including at least two of the first to fourth absorbent materials.

[0077] As in Example 1, hot melt or adhesive is applied using applicators 81 to 87 to bond the sheets as appropriate. Instead of bonding, ultrasonic waves, heat sealing, or the like may be used to bond appropriate locations at appropriate times. It is also possible to form the first to fourth absorbent sheets 50, 20, 60, 40 and the continuum 14a without adhesive or joining.

[0078] The absorbent body 10a can have more types and amounts of absorbent materials and more sheets than in Example 1. This allows for more variations in absorbent bodies.

[0079] In Example 2, as in Example 1, one or more of the first to third cover sheets 54, 24, 64 can be omitted. The first and / or third sheets 52a-52c; 62a-63c can be one, two, or four or more. The carrier sheet 12 may be omitted, and a continuum 14 may be formed in which the second and fourth absorbent sheets 20, 40 overlap each other.

[0080] Example 3 A method for manufacturing an absorbent body 10b of Example 3 in which the first and second absorbent sheets 30, 20 do not overlap each other will be described with reference to Figures 6 and 7. Figure 6 is an explanatory diagram of the method for manufacturing the absorbent body 10b of Example 3. Figure 7(a) is a schematic plan view of the continuum 14b and the absorbent body 10b. Figure 7(b) is a schematic cross-sectional view taken along line BB in Figure 7(a).

[0081] As shown in Figure 6, similar to Example 1, a first absorbent sheet 30 is formed in which a first absorbent material 33 is sandwiched between first sheets 32a to 32c and a first covering sheet 34, with the first absorbent material 33 being arranged in first regions 33a to 33c of the first sheets 32a to 32c, and a second absorbent sheet 30 is formed in which a second absorbent material 23 is sandwiched between a second sheet 22 and a second covering sheet 24, with the second absorbent material 23 being arranged in second regions 23a, 23b of the second sheet 22.

[0082] Next, unlike in Example 1, the first absorbent sheet 30 is cut as shown by arrow 31x to form first pieces 31 including first regions 33a-33c and first absorbent material 33. Furthermore, the second absorbent sheet 20 is cut as shown by arrow 21x to form second pieces 21 including second regions 23a, 23b and second absorbent material 23.

[0083] 6 and 7, a coating device 88 is used to coat one main surface 12s of the carrier sheet 12 with hot melt or adhesive, and then second pieces 21 are attached to the central region of the carrier sheet 12 at a predetermined interval. Next, first pieces 31 are attached to the regions of the carrier sheet 12 between the second pieces 21. This forms a continuum 14b including the first pieces 31 and the second pieces 21. At this time, the first pieces 31 and the second pieces 21 are arranged side by side such that the first region 31 and the second region 21 are adjacent to each other in a plan view.

[0084] Next, widthwise opposite portions 12 a and 12 b of carrier sheet 12 are folded back and placed on top of second piece 30 , and first piece 31 and second piece 21 are wrapped in carrier sheet 12 .

[0085] Next, the continuous body 14b is cut at the cutting positions 11 to form the absorbent body 10b. This allows the formation of the absorbent body 10b in which the first individual pieces 31 of the first absorbent sheet 30 and the second individual pieces 21 of the second absorbent sheet 10 are arranged.

[0086] As described above, the manufacturing method of the absorbent body 10b of Example 3 is the same as that of Example 1, and includes a first step of forming a first absorbent sheet 30 in which a first absorbent material 33 is arranged in first regions 33a to 33c of at least one first sheet 32a to 33c, a second step of forming a second absorbent sheet 20 in which a second absorbent material 23 is arranged in second regions 23a, 23b of a second sheet 22, and a second step of combining the first absorbent sheet 30 and the second absorbent sheet 20. The method includes a third step of forming a continuous body 14b including the second absorbent sheet 20, in which the first regions 33a to 33c and the second regions 23a, 23b are adjacent to each other in a planar view, and a fourth step of cutting the continuous body 14b to include the adjacent first regions 33a to 33c and the second regions 23a, 23b, to form an absorbent body 10b including the first absorbent material 33 and the second absorbent material 23.

[0087] Specifically, unlike Example 1, the present invention further includes a fifth step of cutting the first absorbent sheet 30 after the first step and before the third step to form first pieces 31 including the first regions 33a to 33c, and a sixth step of cutting the second absorbent sheet 20 after the second step and before the third step to form second pieces 21 including the second regions 23a, 23b. In the third step, the continuum 14b is formed in which the first pieces 31 and the second pieces 21 are aligned such that the first regions 33a to 33c and the second regions 23a, 23b are adjacent to each other in a plan view.

[0088] As in Example 1, preferably, in the first step, the first absorbent material 33 is arranged on the plurality of first sheets 32a to 32c. In the third step, the continuum 14 is formed in which the plurality of first sheets 32a to 32c are arranged at intervals from one another.

[0089] As in Example 1, in the first step, the first absorbent material 33 is preferably arranged in the first regions 33a to 33c arranged in a plurality of rows at intervals in the direction 32x in which the first sheets 32a to 33c are continuous. In the second step, the second absorbent material 23 is arranged in the second regions 22a, 22b arranged at intervals in the direction 22x in which the second sheet 22 is continuous.

[0090] Also, similar to Example 1, preferably, in the first step, a first covering sheet 34 is superimposed on the first sheets 32a to 33c to form the first absorbent sheet 30 in which the first absorbent material 33 is disposed between the first sheets 32a to 33c and the first covering sheet 34.

[0091] Also, similar to Example 1, preferably, in the second step, a second covering sheet 24 is superimposed on the second sheet 22 to form the second absorbent sheet 20 in which the second absorbent material 23 is disposed between the second sheet 22 and the second covering sheet 24.

[0092] According to the manufacturing method of the absorbent body of Example 3, the first and second absorbent sheets 30, 20 form a continuous body 14b that does not overlap each other, so that the thickness of the absorbent body 10b can be made thinner and the amount of sheet material used in the absorbent body 10b can be reduced compared to Example 1.

[0093] Example 4 A method for manufacturing an absorbent body of Example 4 will be described with reference to Figures 8 and 9. In Example 4, an absorbent body 10c is manufactured by omitting the second cover sheet 24 of Example 1. Figure 8 is an explanatory diagram showing an outline of the method for manufacturing the absorbent body 10c. Figure 9(a) is a schematic plan view of the continuum 14c and the absorbent body 10c, and Figure 9(b) is a schematic cross-sectional view taken along line CC in Figure 9(a).

[0094] As shown in Figures 8 and 9, similar to Example 1, a first absorbent material 33 is sandwiched between first sheets 32a to 32c and a first covering sheet 34 to form a first absorbent sheet 30 in which the first absorbent material 33 is arranged in first regions 33a to 33c of the first sheets 32a to 32c.

[0095] The second absorbent sheet 20a is formed in the same manner as in Example 1, except that a carrier sheet 12 is used instead of the second cover sheet 24 of Example 1. That is, the second sheet 22 is conveyed in the direction 22x in which the second sheet 22 continues, and a carrier sheet 12 wider than the second sheet 22 is conveyed in the direction 12x in which the carrier sheet 12 continues. Next, as shown by arrows 23x in FIG. 8 , a second absorbent material 23 is intermittently supplied to the second sheet 22 and / or the carrier sheet 12. Next, the second sheet 22 is overlapped with the widthwise central region of one main surface 12s of the carrier sheet 12 to form the second absorbent sheet 20a. This forms the second absorbent sheet 20a, in which the second absorbent material 23 is sandwiched between the second sheet 22 and the carrier sheet 12 and disposed in the second regions 23a and 23b of the second sheet 22.

[0096] Next, the second absorbent sheet 20a is conveyed in the direction 20x in which the second absorbent sheet 20a is continuous. Next, the first absorbent sheet 30, to which hot melt or adhesive has been applied using an application device 83, is attached to the second absorbent sheet 20a so as to overlap the second sheet 22 of the second absorbent sheet 20a. This forms a continuum 14c including the first absorbent sheet 30 and the second absorbent sheet 20a.

[0097] At this time, the first and second absorbent sheets 30, 20a are overlapped so that, in a plan view, the first regions 33a-33c in which the first absorbent material 33 is arranged in the first absorbent sheet 30 and the second regions 23a, 23b in which the second absorbent material 23 is arranged in the second absorbent sheet 20a are adjacent to each other, and the adjacent first regions 33a-33c and second regions 23a, 23b are arranged between adjacent cutting positions 11, 11.

[0098] Next, hot melt or adhesive is applied to the second absorbent sheet 20a and / or the first absorbent sheet 30 using an application device 85, and then the portions 12a, 12b of the carrier sheet 12 that protrude on both sides of the first absorbent sheet 30 are folded back and placed on top of the first absorbent sheet 30. This results in the continuum 14c in which the first and second absorbent sheets 30, 20a are wrapped in the carrier sheet 12.

[0099] Next, the continuous body 14c is cut at the cutting positions 11 to form the absorbent body 10c. In this way, the absorbent body 10c in which the first and second absorbent materials 23, 33 are arranged can be formed.

[0100] It is also possible to omit some or all of the application devices 81 to 83, 85. Instead of adhesion, appropriate locations may be joined at appropriate times using ultrasonic waves, heat sealing, etc. It is also possible to form the first and / or second absorbent sheets 30, 20a and the continuum 14c without adhesion or joining.

[0101] In Example 4, the variation of the absorbent body 10c can be increased by omitting the second covering sheet 24. In addition, the amount of material used to manufacture the absorbent body 10c can be reduced.

[0102] <Summary> The method for manufacturing an absorbent body explained above can increase the variety of absorbent bodies.

[0103] The present invention is not limited to the above-described embodiment, but can be implemented with various modifications.

[0104] For example, the first to fourth sheets may be made of materials other than nonwoven fabrics. Alternatively, one of the first and second absorbent sheets may be cut into individual pieces, while the other may be formed into a continuous piece without being cut into individual pieces, and then the continuous piece may be cut to form the absorbent body. [Explanation of symbols]

[0105] 10, 10a, 10b, 10c absorber 14, 14a, 14b, 14c Continuum 20, 20a Second absorbent sheet 21 Second piece 22 Second Sheet 23 Second absorbent material 23a, 23b, 23u~23w Second Area 24 Second covering sheet 30 First absorbent sheet 31 First piece 32a~32c First sheet 33 First absorbent material 33a~33d, 33m, 33n, 33p~33r, 33u~33w First Region 34 First covering sheet

Claims

1. a first step of forming a first absorbent sheet having a first absorbent material disposed in a first region of the first sheet; a second step of forming a second absorbent sheet having a second absorbent material disposed in a second region of the second sheet; a third step of forming a continuum including the first absorbent sheet and the second absorbent sheet, wherein the first region and the second region are adjacent to each other in a plan view; a fourth step of cutting the continuous body to include the first region and the second region adjacent to each other to form an absorbent body including the first absorbent material and the second absorbent material; Equipped with In the first step, a first absorbent material is arranged in the first regions arranged in a direction in which the first sheet is continuous, in a plurality of rows, and spaced apart from one another; A method for manufacturing an absorbent body, wherein in the second step, the second absorbent material is arranged in the second regions spaced apart from each other in the direction in which the second sheet is continuous.

2. 2. The method for manufacturing an absorbent body according to claim 1, wherein in the third step, the continuous body is formed in which the first absorbent sheet and the second absorbent sheet overlap each other so that the first region and the second region are adjacent to each other in a planar view.

3. a fifth step of cutting the first absorbent sheet to form first individual pieces including the first region, after the first step and before the third step; a sixth step of cutting the second absorbent sheet to form second individual pieces including the second region, after the second step and before the third step; Furthermore, The method for manufacturing an absorbent body according to claim 1, wherein in the third step, the continuum is formed in which the first individual pieces and the second individual pieces are arranged so that the first region and the second region are adjacent to each other in a planar view.

4. In the first step, the first absorbent material is disposed on a plurality of the first sheets; The method for manufacturing an absorbent body according to claim 1 , wherein in the third step, the continuous body is formed in which a plurality of the first sheets are arranged at intervals from one another.

5. 5. A method for manufacturing an absorbent body according to claim 1, wherein in the first step, a first covering sheet is overlaid on the first sheet to form the first absorbent sheet in which the first absorbent material is disposed between the first sheet and the first covering sheet.

6. 5. A method for manufacturing an absorbent body according to claim 1, wherein in the second step, a second covering sheet is overlaid on the second sheet to form the second absorbent sheet in which the second absorbent material is disposed between the second sheet and the second covering sheet.

7. 6. The method for manufacturing an absorbent body according to claim 5, wherein in the second step, a second covering sheet is overlaid on the second sheet to form the second absorbent sheet in which the second absorbent material is disposed between the second sheet and the second covering sheet.

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