Device for producing stretchable laminated sheet, method for producing stretchable laminated sheet, and wearable article using stretchable laminated sheet

Abstract

Provided are a device and a method for producing a stretchable laminated sheet having excellent breathability. This device (100) for producing a stretchable laminated sheet (L) stacks nonwoven sheets (S1, S2) and a stretchable film (F) and joins the nonwoven sheets and the film. The device for producing a stretchable laminated sheet comprises a laminating / joining mechanism (48) and a laminated-sheet-stretching mechanism (60). The laminating / joining mechanism has an elongation roll (40) and a horn (43). The laminating / joining mechanism sandwiches a laminate (B) in which the nonwoven sheets and the stretched film are stacked between an elongation roll and a horn and thermally bonds the nonwoven sheets and the film together to form a stretchable laminated sheet. The laminated-sheet-stretching mechanism has a pair of gear rolls (62, 64) having bumps and dips on the circumferential surfaces thereof. The laminated-sheet-stretching mechanism stretches the stretchable laminated sheet that is conveyed between the pair of gear rolls.

Description

Apparatus for manufacturing a stretchable laminated sheet, method for manufacturing a stretchable laminated sheet, and worn article using the stretchable laminated sheet

[0001] The present invention relates to an apparatus and method for manufacturing a stretchable laminate sheet used in a worn article, and to a worn article using the stretchable laminate sheet.

[0002] Conventionally, there have been known a manufacturing apparatus and a manufacturing method for a stretch laminate sheet for use in a worn article, which is formed by stacking a nonwoven fabric sheet and a stretchable film (see, for example, Patent Document 1 (WO 2019 / 150801)). The stretch laminate sheet is used, for example, in the waist portion of the worn article and is worn around the waist of a wearer.

[0003] Among the sheets used in the manufacture of stretch laminate sheets, nonwoven fabric sheets are breathable, but stretchable films are not, and therefore, when such stretch laminate sheets are used in wearable articles, there is a risk of the wearer becoming stuffy.

[0004] However, when the nonwoven fabric sheet and the film are heat-sealed during the manufacturing process of the stretch laminate sheet, the film breaks around the heat-sealed area, so that when a wearer puts on a garment using the stretch laminate sheet, air can pass through the broken area of ​​the film, which can reduce stuffiness to some extent when worn.

[0005] International Publication No. 2019 / 150801

[0006] However, if the film breaks around the heat-sealed portion in this manner, it may not be possible to ensure an opening of sufficient area when the garment is worn, and stuffiness may not be sufficiently suppressed.

[0007] An object of the present invention is to provide an apparatus and method for manufacturing a breathable stretch laminate sheet, and a wearing article using the breathable stretch laminate sheet.

[0008] The stretch laminate sheet manufacturing apparatus of the present invention is an apparatus for manufacturing a stretch laminate sheet in which a base sheet and a stretchable film are arranged one on top of the other, and the base sheet and the film are bonded together. The stretch laminate sheet manufacturing apparatus includes a joining unit and a stretching unit. The joining unit has a first bonding member and a second bonding member. The joining unit sandwiches a laminate in which the base sheet and the stretched film are bonded together between the first bonding member and the second bonding member, and heat-welds the base sheet and the film to form a stretch laminate sheet. The stretching unit has a pair of gear rolls with uneven peripheral surfaces. The stretching unit stretches the stretch laminate sheet as it is conveyed between the pair of gear rolls.

[0009] The method for producing a stretch laminate sheet of the present invention is a method for producing a stretch laminate sheet in which a base sheet and a stretchable film are arranged one on top of the other and the base sheet and the film are bonded together. The method for producing a stretch laminate sheet includes a welding step and a stretching step. In the welding step, the base sheet and the stretched film are thermally welded to form a stretch laminate sheet. In the stretching step, the stretch laminate sheet is transported between a pair of gear rolls having uneven peripheral surfaces and is stretched by the pair of gear rolls.

[0010] In the manufacturing apparatus and method for a stretchable laminate sheet of the present invention, a base sheet and a film are heat-sealed to form a stretchable laminate sheet, and then the sheet is stretched using a gear roll having an uneven surface, thereby forming openings of sufficient area at the heat-sealed points between the base sheet and the film and / or in the surrounding area, thereby producing a stretchable laminate sheet with good breathability.

[0011] 1 is a schematic diagram showing the overall configuration of an apparatus for manufacturing a stretch laminate sheet according to a first embodiment; FIG. 1 is a schematic cross-sectional view of a stretch laminate sheet in which the film is in a stretched state; FIG. 1 is a schematic cross-sectional view of a stretch laminate sheet in which the film is in a non-stretched state; FIG. 12 is a schematic diagram of a worn article using a stretch laminate sheet; FIG. 13 is a control block diagram of the apparatus for manufacturing the stretch laminate sheet of FIG. 1; FIG. 14 is a schematic enlarged view of a stretch roll and a horn of the apparatus for manufacturing the stretch laminate sheet of FIG. 1; FIG. 15 is a diagram showing an example of the arrangement of joints formed on a stretch laminate sheet; FIG. 16 is a schematic enlarged partial plan view of a stretch laminate sheet before gear stretching, and a schematic cross-sectional view taken along arrows X1-X1 in the schematic enlarged partial plan view; FIG. 17 is a schematic enlarged partial plan view of a stretch laminate sheet after gear stretching, and a schematic cross-sectional view taken along arrows X2-X2 in the schematic enlarged partial plan view; FIG. 18 is a photograph of a stretch laminate sheet before gear stretching; FIG. 19 is a photograph of a stretch laminate sheet after gear stretching; FIG. 19 is a schematic diagram showing the configuration of an apparatus for manufacturing a stretch laminate sheet according to a second embodiment, with the film forming portion not shown; FIG. 19 is a control block diagram of the apparatus for manufacturing a stretch laminate sheet of FIG. 12; FIG. 19 is a schematic diagram showing the configuration of an apparatus for manufacturing a stretch laminate sheet according to a second embodiment, with the film forming portion not shown. Fig. 15 is a control block diagram of the manufacturing apparatus for the stretchable laminate sheet of Fig. 14. Fig. 16 is a diagram showing an example of a location where the stretchable laminate sheet is used in a wearing article according to one example. Fig. 17 is a diagram showing an example of a location where the stretchable laminate sheet is used in a wearing article according to another example.

[0012] Hereinafter, an apparatus and method for manufacturing a stretch laminate sheet according to an embodiment of the present invention will be described with reference to the drawings.

[0013] <First Embodiment> (1) Overall Overview An apparatus 100 for manufacturing a stretch laminate sheet L according to a first embodiment will be described with reference to Figs. 1 to 4. Fig. 1 is a schematic diagram showing the overall configuration of the apparatus 100 for manufacturing a stretch laminate sheet L. Fig. 2 is a cross-sectional view of the stretch laminate sheet L when the film F constituting the stretch laminate sheet L is in a stretched state. Fig. 3 is a cross-sectional view of the stretch laminate sheet L when the film F is in a non-stretched state. Fig. 4 is a schematic diagram of a worn article 200 using the stretch laminate sheet L.

[0014] (1-1) Stretchable Laminate Sheet First, the stretchable laminate sheet L to be manufactured by the manufacturing apparatus 100 will be described.

[0015] The stretch laminate sheet L is a stretchable sheet formed by laminating multiple sheets / films. As shown in Figures 2 and 3, the stretch laminate sheet L includes an elastic (stretchable) film F, a first nonwoven fabric sheet S1 as an example of a base sheet, and a second nonwoven fabric sheet S2 as an example of a base sheet. In the stretch laminate sheet L, the film F is disposed between the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2. In other words, in the stretch laminate sheet L, the nonwoven fabric sheets and the film F are disposed one on top of the other. In the stretch laminate sheet L, the first nonwoven fabric sheet S1 and the film F are intermittently bonded at bonding points J, and the second nonwoven fabric sheet S2 and the film F are intermittently bonded at bonding points J.

[0016] Although a three-layer structure of the first nonwoven fabric sheet S1, the second nonwoven fabric sheet S2, and the film F is described here as an example, the stretch laminate sheet may be a laminate of four or more sheets / films. Alternatively, the stretch laminate sheet may be a two-layer structure of the film F and one of the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2.

[0017] Furthermore, the nonwoven fabric sheet is an example of a base sheet, and the base sheet may be a sheet other than a nonwoven fabric sheet.

[0018] When the stretch laminate sheet L is sufficiently stretched along the conveying direction A of the stretch laminate sheet L in the manufacturing apparatus 100 described below, the first nonwoven fabric sheet S1, the film F, and the second nonwoven fabric sheet S2 are parallel to one another as shown in Figure 2. In other words, when the film F of the stretch laminate sheet L is stretched along the conveying direction A, the first nonwoven fabric sheet S1, the film F, and the second nonwoven fabric sheet S2 are parallel to one another as shown in Figure 2.

[0019] On the other hand, when the stretched state of the stretch laminate sheet L is released (when no force is acting on the stretch laminate sheet L in the direction along the conveying direction A), the film F shrinks from the state shown in Figure 2, and the distance between the joints J (the dotted areas) decreases, as shown in Figure 3. As a result, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 curve, and irregularities are formed on the surface of the stretch laminate sheet L (see Figure 3).

[0020] Such a stretch laminate sheet L is used in a worn article. Specifically, a sheet piece cut from the stretch laminate sheet L in a direction perpendicular to the conveying direction A is used in the worn article. Here, the sheet piece cut from the stretch laminate sheet L is also simply referred to as the stretch laminate sheet L. While not limiting the type of worn article in which the stretch laminate sheet L is used, examples of the worn article include disposable diapers and disposable medical gowns. Furthermore, while not limiting the use of the stretch laminate sheet L, the stretch laminate sheet L can be widely used in worn articles, for example, as a waistband member attached around the waist of a wearer, a cuff member attached around the wrist of a wearer, or a hem member attached around the ankles of a wearer.

[0021] As an example, a disposable diaper as a wearing article 200 in which the stretchable laminate sheet L is used will be described with reference to FIG.

[0022] As shown in Fig. 4, the wearing article 200 has a front torso section 210, a rear torso section 220, a crotch section 230, and an absorbent article 240. In the wearing article 200, a gap is provided between the front torso section 210 and the rear torso section 220. When the wearing article 200 is worn, the front torso section 210 and the rear torso section 220 face each other. The crotch section 230 is connected to the front torso section 210 and the rear torso section 220. The front torso section 210 and the rear torso section 220 are connected via the crotch section 230. The absorbent article 240 is disposed so as to straddle the crotch section 230. When the wearing article 200 is worn, the wearing article 200 is folded at the crotch section 230, with the front torso section 210 disposed on the ventral side and the rear torso section 220 disposed on the dorsal side. When the worn article 200 is worn, the front torso section 210 and the rear torso section 220 are fastened together with a fastening member such as tape (not shown).

[0023] In the wearing article 200, the stretch laminate sheet L is used in the front torso section 210 and the rear torso section 220. The stretch laminate sheet L is used in the front torso section 210 and the rear torso section 220 in a state in which the conveying direction A and the waist-circumference direction are aligned.

[0024] Specific examples of locations where the stretchable laminate sheet L is used in a worn article will be described with reference to FIGS. 16 and 17. FIG.

[0025] The wearing article 300 illustrated in Fig. 16 is a disposable diaper that is generally T-shaped when unfolded (before being worn). The wearing article 300 has a single waistband member 310 and an absorber 320 attached to the waistband member 310.

[0026] The waistband member 310 is a member that is placed around the waist of the wearer. The waistband member 310 includes a waist portion 312 (the portion hatched with straight lines slanting upward to the right in FIG. 16 ) and a lower waistband portion 314 (the portion hatched with straight lines slanting downward to the right in FIG. 16 ). The waist portion 312 is a portion that is placed at the upper end of the waistband member 310 when worn, and is placed around the wearer's waist (at a height near the hip bones) (covering the waist). The lower waistband portion 314 is a portion that is placed below the waistband portion 312 when worn, and covers the wearer's torso below the waist. An absorber 320 is attached to the center of the lower waistband portion 314 in the left-right direction (width direction) so as to be perpendicular to the lower waistband portion 314.

[0027] The waist portion 312 and the lower waist portion 314 may be separate members that are joined together to form the waist member 310. Alternatively, the waist portion 312 and the lower waist portion 314 may be integrally formed (from the same material).

[0028] The absorber 320 is joined to the waistband member 310 and is a member that is placed in the crotch region of the wearer when worn. The absorber 320 has an absorbent article (not shown), and the absorbent article mainly absorbs bodily fluids such as urine and sweat.

[0029] The stretch laminate sheet L manufactured by the manufacturing method of the present disclosure is used in the waist circumference portion 312 and / or the lower waist circumference portion 314 of the waist circumference member 310 of the wearing article 300. This allows the wearing article 300 to have good breathability even in the stretch laminate sheet L portion.

[0030] The stretch laminate sheet L manufactured by the manufacturing method of the present disclosure has openings Op1 formed around the joint J between the pair of nonwoven fabric sheets S1, S2 and the film F, as well as at the joint J. This allows the stretch laminate sheet L provided in the wearing article 300 to have high breathability. Furthermore, by providing sufficient openings in the stretch laminate sheet L, a stretch laminate sheet L with high stretchability can be obtained, and by using this, an effect is achieved in that the wearing article 300 fits the wearer well.

[0031] The wearing article 400 illustrated in Fig. 17 has a front torso section 410, a rear torso section 420, a crotch section 430, and an absorbent article 440, similar to the wearing article 200 illustrated in Fig. 4. The crotch section 430 and the absorbent article 440 are examples of an absorbent body in the claims. The wearing article 400 further has a fastening tape 450 as an example of a fastening member.

[0032] The front torso section 410 and the rear torso section 420 are each an example of a waistline member that is placed around the waist of a wearer. In the wearing article 400, a gap is provided between the front torso section 410 and the rear torso section 420. When the wearing article 400 is worn, the front torso section 410 and the rear torso section 420 face each other.

[0033] The front torso section 410 and the rear torso section 420 each include waist sections 412, 422 (hatched with straight lines slanting upward to the right in FIG. 17 ) and lower waist sections 414, 424 (hatched with straight lines slanting downward to the right in FIG. 17 ). The waist section 412 is located at the upper end of the front torso section 410 when worn, and is positioned around the wearer's waist (at a height near the hip bones) of the front torso. The waist section 422 is located at the upper end of the rear torso section 420 when worn, and is positioned around the wearer's waist (near the hip bones) of the rear torso. The lower waist section 414 is located below the waist section 412 when worn, and covers the wearer's front torso below the waist. The lower waist section 424 is located below the waist section 422 when worn, and covers the wearer's rear torso below the waist.

[0034] A crotch section 430 is attached to the center of the lower waist sections 414, 424 in the left-right direction (width direction) so as to be perpendicular to the lower waist sections 414, 424 and to straddle the lower waist sections 414, 424. In other words, the crotch section 430 is connected to the front torso section 410 and the rear torso section 420. In other words, the front torso section 410 and the rear torso section 420 are connected via the crotch section 430.

[0035] The crotch portion 430 is a component that is placed in the crotch region of the wearer when worn. The absorbent article 440 is placed in the center of the crotch portion 430 so as to overlap the crotch portion 430, and is a component that is placed in the crotch region of the wearer together with the crotch portion 430 when the wearing article 400 is worn.

[0036] The crotch region 430 may be a separate member from the front torso region 410 and the rear torso region 420, and these may be joined together to form the wearing article 400. Alternatively, the front torso region 410, the rear torso region 420, and the crotch region 430 may be integrally formed (from the same material).

[0037] Attachment portions 416 (hatched with dots in FIG. 17 ) for fastening tape 450, which are an example of connecting member attachment portions, are provided at both widthwise (left-right) ends of the front torso portion 410. Note that attachment portion 416 here refers not only to the portion where fastening tape 450 is attached, but also to the area surrounding the portion where fastening tape 450 is attached.

[0038] The fastening tape 450 includes a hook portion 452 having a hook-shaped protrusion, and a connecting portion 454 (hatched with crosses in FIG. 17 ) having one end attached to the attachment portion 416 and the other end to which the hook portion 452 is attached. When a wearer puts on the wearing article 400, the hook portion 452 of the fastening tape 450 is connected (attached) to loop portions (connectable portions) 426 (hatched with dots in FIG. 17 ) provided near both ends of the rear torso portion 420 in the width direction (left-right direction). The loop portions 426 are provided with a number of loop-shaped protrusions onto which the hook-shaped protrusions of the hook portion 452 can be hooked. The loop portions 426 may be separate members from the rear torso portion 420, or may be formed by processing the rear torso portion 420.

[0039] The stretch laminate sheet L manufactured by the manufacturing method of the present disclosure is used in the waist circumference portion 412 and / or the lower waist circumference portion 414 of the front torso portion 410, and / or the waist circumference portion 422 and / or the lower waist circumference portion 424 of the back torso portion 420 in the wearing article 400. Additionally or instead of this, the stretch laminate sheet L is used in the attachment portion (connecting member attachment portion) 416 of the front torso portion 410 and / or the loop portion (connected portion) 426 of the rear torso portion 420. Additionally or instead of this, the stretch laminate sheet L is used in the connecting portion 454 of the fastening tape 450.

[0040] By using the stretch laminate sheet L in this manner, the wearing article 400 can be made to have good breathability even in the area of ​​the stretch laminate sheet L. Note that the stretch laminate sheet L manufactured by the manufacturing method of the present disclosure has openings Op1 formed not only around the joint J between the pair of nonwoven fabric sheets S1, S2 and the film F but also at the joint J. This allows the stretch laminate sheet L provided in the wearing article 400 to have high breathability. Furthermore, by providing sufficient openings in the stretch laminate sheet L, a stretch laminate sheet L with high stretchability can be obtained, and by using this, it is possible to achieve an effect of making the wearing article 400 fit the wearer well.

[0041] (1-2) Stretchable Laminate Sheet Manufacturing Apparatus In general, the manufacturing apparatus 100 is an apparatus as follows.

[0042] The manufacturing apparatus 100 produces a stretchable film F from raw materials. The manufacturing apparatus 100 transports the produced film F in a stretched state. The manufacturing apparatus 100 then joins a pair of nonwoven fabric sheets S1, S2 to the transported film F, and, with the stretched film F disposed between the pair of nonwoven fabric sheets S1, S2, heat-welds the pair of nonwoven fabric sheets S1, S2 to the film F to form a stretch laminate sheet L. In other words, the manufacturing apparatus 100 joins the nonwoven fabric sheets S1, S2 to the transported film F, and, with the stretched film F and the nonwoven fabric sheets S1, S2 overlapped, heat-welds the nonwoven fabric sheets S1, S2 to the film F to form a stretch laminate sheet L. Furthermore, the manufacturing apparatus 100 stretches (gear stretches) the stretch laminate sheet L using gear rolls 62, 64 to improve the breathability of the stretch laminate sheet L (specifically, the breathability of the film F of the stretch laminate sheet L).

[0043] Details of the configuration of the manufacturing apparatus 100 will be described later. (2) Details of the Manufacturing Apparatus for Stretchable Laminate Sheet The manufacturing apparatus 100 for the stretchable laminate sheet L will be described in more detail with reference to Fig. 5 in addition to Figs. 1 to 4. Fig. 5 is a control block diagram of the manufacturing apparatus 100 for the stretchable laminate sheet L according to the first embodiment.

[0044] As shown in Figures 1 and 5, the manufacturing apparatus 100 mainly includes a discharge mechanism 20, a cooling roll 30, a film stretching mechanism 38, a lamination and joining mechanism 48, a laminated sheet stretching mechanism 60, and a control device 90.

[0045] (2-1) Discharge Mechanism The discharge mechanism 20 is a device that forms a film-like intermediate Fa from raw materials (resin materials). The intermediate Fa is ultimately formed into a film F. Specifically, the discharge mechanism 20 heats and melts the resin material to a temperature higher than the temperature range in which the resin material elastically deforms, and discharges the molten resin material in the form of a film from the discharge port 24 to form the film-like intermediate Fa. The film-like intermediate Fa formed by the discharge mechanism 20 is transported to a cooling roll 30 that is arranged below the discharge mechanism 20 as shown in FIG. 1 .

[0046] The resin material is, for example, a material whose main component is a thermoplastic elastic resin and exhibits elasticity at room temperature. For example, as described in Patent Document 1 (International Publication No. 2019 / 150801), although not limited thereto, any of the thermoplastic elastomers specified in JIS K 6418:2007 (ISO 18064:2003) is used as the resin material.

[0047] (2-2) Chilling Roll The chilling roll 30 is a device that cools and solidifies the intermediate Fa to form a film F having elasticity (stretchability).

[0048] The cooling roll 30 is rotated by a driving device such as a motor (not shown). A flow path (not shown) is formed inside the cooling roll 30, through which a fluid for cooling the intermediate Fa flows.

[0049] As described above, the intermediate Fa discharged from the discharge mechanism 20 is supplied to the cooling roll 30. The intermediate Fa discharged from the discharge port 24 of the discharge mechanism 20 is stretched in a first section 80 (see FIG. 1 ) until it reaches the cooling roll 30. To achieve this, the cooling roll 30 rotates at a peripheral speed that is higher than the feed speed of the resin material when it is discharged from the discharge port 24 of the discharge mechanism 20, and stretches the film-like intermediate Fa until the thickness of the film-like intermediate Fa reaches a predetermined value.

[0050] The cooling roll 30 is rotated by a drive device, and transports the intermediate Fa along the outer circumferential surface of the cooling roll 30. In a second section 82 where the intermediate Fa is in contact with the outer circumferential surface of the cooling roll 30, the cooling roll 30 cools and solidifies the intermediate Fa to a temperature range where the resin material constituting the intermediate Fa elastically deforms. As a result, the intermediate Fa becomes a film F in the second section 82, and is drawn out from the cooling roll 30. The film F drawn out from the cooling roll 30 passes through a guide roll 32 and is sent to a film stretching mechanism 38. The guide roll 32 may have a function of cooling the film F, similar to the cooling roll 30.

[0051] The film F transported from the cooling roll 30 to the film stretching mechanism 38 is stretched by α% relative to its natural length (the length of the film F when no force is applied).

[0052] (2-3) Film Stretching Mechanism The film stretching mechanism 38 is a device that further stretches the film F that is conveyed from the cooling roll 30 in a stretched state.

[0053] The film stretching mechanism 38 mainly includes a pull-out roll 34, a pinch roll 36, and a stretching roll 40. The pull-out roll 34 is driven to rotate by a driving device such as a motor (not shown). The stretching roll 40 is driven to rotate by a driving device such as a motor (not shown).

[0054] The pull-out roll 34 and the pinch roll 36 are disposed adjacent to each other. The pull-out roll 34 and the pinch roll 36 sandwich the film F between them so that the film F, which is transported from the cooling roll 30 to the pull-out roll 34, does not slip along the outer circumferential surface of the pull-out roll 34. The pull-out roll 34 rotates in synchronization with the cooling roll 30.

[0055] The film F is stretched by the film stretching mechanism 38 in a third section 84 from between the pull-out roll 34 and the pinch roll 36 until it reaches the stretching roll 40. To achieve this, the stretching roll 40 rotates at a peripheral speed faster than that of the pull-out roll 34, causing the film F to be stretched by β% with respect to the natural length of the film F (the length of the film F when no force is applied). β% is a value greater than the aforementioned α%. The film F stretched by β% with respect to the natural length of the film F is transported along the outer peripheral surface of the stretching roll 40.

[0056] (2-4) Stacking Joining Mechanism The stacking joining mechanism 48 forms a stack B in which nonwoven fabric sheets S1, S2 and a film F in a stretched state are stacked one on top of the other. In particular, in this embodiment, the stacking joining mechanism 48 forms a stack B in which a film F in a stretched state is disposed between a pair of nonwoven fabric sheets S1, S2. Furthermore, the stacking joining mechanism 48 functions as a joining section in the claims, and forms a stretch laminate sheet L in the stack B by heat-welding the nonwoven fabric sheets S1, S2 and the film F disposed therebetween. In particular, in this embodiment, the stacking joining mechanism 48 functions as a joining section in the claims, and forms a stretch laminate sheet L in the stack B by heat-welding the pair of nonwoven fabric sheets S1, S2 and the film F disposed therebetween.

[0057] The extension roll 40, which is a part of the configuration of the film stretching mechanism 38, also functions as a part of the lamination and bonding mechanism 48. The lamination and bonding mechanism 48 also has an ultrasonic bonding device 42.

[0058] A continuous first nonwoven fabric sheet S1 unwound from a raw fabric roll (not shown) is supplied to the stretching roll 40 of the layer joining mechanism 48 via a guide roll 50. A continuous second nonwoven fabric sheet S2 unwound from a raw fabric roll (not shown) is supplied to the stretching roll 40 via guide rolls 52 and 54. In the layer joining mechanism 48, the stretched film F transported along the stretching roll 40 is sandwiched between the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 transported to the stretching roll 40, and a laminate B is formed in which the stretched film F is disposed between the pair of nonwoven fabric sheets S1, S2.

[0059] When the stretch laminate sheet L has a two-layer structure, for example, a continuous first nonwoven fabric sheet S1 unwound from a raw fabric roll (not shown) is supplied to the stretching roll 40 of the laminate joining mechanism 48 via a guide roll 50. Then, in the laminate joining mechanism 48, the stretched film F transported along the stretching roll 40 is superimposed on the first nonwoven fabric sheet S1 transported to the stretching roll 40 to form a laminate B.

[0060] The laminate B moves as the stretching roll 40 rotates, passing between the stretching roll 40, which functions as an anvil roll, and a horn 43 of an ultrasonic bonding device 42. The surface of the stretching roll 40 is provided with a plurality of convex portions 40a arranged along the axial direction of the stretching roll 40 and along the circumferential direction of the stretching roll 40 (see FIG. 6 ). While not intended to be limiting, the convex portions 40a have a rectangular or oblong shape extending in the axial direction of the stretching roll 40 when viewed radially toward the axial direction of the stretching roll 40. However, the shape of the convex portions 40a described here is merely an example, and other shapes may also be used.

[0061] The stretching roll 40 and the horn 43 are examples of the first and second joining members in the claims. The horn 43 is vibrated by an ultrasonic oscillator (not shown) while sandwiching the laminate B between itself and the stretching roll 40 (more specifically, between itself and the protruding portion 40a of the stretching roll 40), ultrasonically welding the nonwoven fabric sheets S1 and S2 (particularly the pair of nonwoven fabric sheets S1 and S2) and the film F. Ultrasonic welding is a form of thermal welding. By ultrasonically welding the pair of nonwoven fabric sheets S1 and S2 and the film F together, a stretch laminate sheet L is formed in which the pair of nonwoven fabric sheets S1 and S2 and the film F are intermittently joined at joints J, and the stretch laminate sheet L is then drawn out from the lamination joining mechanism 48. As shown in FIG. 7 , for example, joints J (dotted areas) are locally arranged on the stretch laminate sheet L. The stretchable laminated sheet L drawn out from the lamination joining mechanism 48 is conveyed to the laminated sheet stretching mechanism 60 in a conveying direction A along the stretching direction of the film F.

[0062] As described above, the layer joining mechanism 48, which is an example of a joining unit, ultrasonically welds the nonwoven fabric sheets S1, S2 and the film F together. However, the heat welding method is not limited to ultrasonic welding. For example, the layer joining mechanism 48 may sandwich the laminate B between two rollers equipped with heaters inside, and heat-seal the nonwoven fabric sheets S1, S2 and the film F together in a manner such as that shown in FIG. 7 .

[0063] As described above, the extension roll 40, which is a part of the configuration of the film stretching mechanism 38, also functions as an anvil roll in the layer joining mechanism 48. However, this is not limiting, and the layer joining mechanism 48 may have an anvil roll separate from the extension roll 40 that forms the layered body B.

[0064] (2-5) Laminated Sheet Stretching Mechanism The laminated sheet stretching mechanism 60 is an example of a stretching unit in the claims. The laminated sheet stretching mechanism 60 stretches the stretchable laminated sheet L by gear rolls 62 and 64 (gear stretching).

[0065] Specifically, the laminated sheet stretching mechanism 60 has a pair of gear rolls 62, 64 having concave and convex surfaces. More specifically, the gear roll 62 has a plurality of teeth 62a and valleys 62b arranged alternately along the circumferential direction of the gear roll 62, like a spur gear. The gear roll 64 also has a plurality of teeth 64a and valleys 64b arranged alternately along the circumferential direction of the gear roll 64, like a spur gear. When the gear rolls 62 and 64 are rotated by a drive mechanism such as a motor (not shown), the teeth 62a of the gear roll 62 and the valleys 64b of the gear roll 64, and the valleys 62b of the gear roll 62 and the teeth 64a of the gear roll 64, mesh with each other.

[0066] The stretch laminate sheet L, conveyed from the lamination joining mechanism 48 in the conveying direction A, is supplied to the meshing portion between the gear rolls 62 and 64 and stretched. As a result of stretching the stretch laminate sheet L by the laminate sheet stretching mechanism 60, the film F is stretched by γ% with respect to the natural length of the film F (the length of the film F when no force is applied). The stretch laminate sheet L stretched by the laminate sheet stretching mechanism 60 (the stretch laminate sheet L in which the film F constituting the stretch laminate sheet L is stretched by γ% with respect to the natural length of the film F) is conveyed by the downstream conveying mechanism 70 while maintaining the elongation rate, and is conveyed to the next process (a manufacturing process of a wearing article not shown and not described).

[0067] Although not limited thereto, γ% is a value greater than the aforementioned β%. In other words, the film F (including the film F included in the stretch laminate sheet L) may be stretched by extension rates of α%, β (>α)%, and γ (>β)%, respectively, relative to the natural length of the film F, by the second section 82, the third section 84, and the laminated sheet stretching mechanism 60. In other words, the laminated sheet stretching mechanism 60 stretches the film F by a relatively large amount relative to the natural length of the film F, but because the film F is reinforced by being joined to the nonwoven fabric sheets S1 and S2, damage to the film F is likely to be suppressed even if the film F is stretched by a relatively large amount.

[0068] By stretching the stretchable laminate sheet L using the laminate sheet stretching mechanism 60, openings of sufficient area are formed at the heat-sealed locations between the nonwoven fabric sheets S1, S2 and the film F and / or around those locations, making it possible to produce a stretchable laminate sheet L with good breathability.

[0069] Specifically, when the stretch laminate sheet L is stretched in the conveying direction A before being stretched by the laminate sheet stretching mechanism 60, the film F is cut around the joint J (the dotted area) of the stretch laminate sheet L, and as a result, an opening Op is formed around the joint J, as shown in Fig. 8. However, as can be seen from the photograph in Fig. 10, such an opening Op is relatively small, and there is a risk that the opening Op will not have a sufficient area to ensure the breathability of the stretch laminate sheet L.

[0070] In contrast, by performing stretching using the laminate sheet stretching mechanism 60, the film F is cut, for example, at a portion of the joint J of the stretch laminate sheet L, and as shown in FIG. 8 , in addition to the opening Op around the joint J, the film F is also cut at the joint J (the portion marked with a dot) of the stretch laminate sheet L, forming an opening Op1. As a result, when the stretch laminate sheet L is stretched in the conveying direction A, a relatively large opening is formed in the stretch laminate sheet L, as shown in FIG. 8 . Note that the opening formed by stretching using the laminate sheet stretching mechanism 60 is not limited to the joint J, and may also be formed around the joint J (so that the opening Op is large). In this way, by performing gear stretching on the stretch laminate sheet L, good breathability can be achieved for the stretch laminate sheet L (of the film F of the stretch laminate sheet L).

[0071] 8 and 9 are merely diagrams for the purpose of explanation, and the shapes and dimensions of the openings Op and Op1 shown in FIGS. 8 and 9 do not limit the shapes of the openings that are actually formed.

[0072] In the laminate sheet stretching mechanism 60, when the stretch laminate sheet L made of a nonwoven fabric, a thermoplastic elastic resin, etc. is sandwiched between the metal gear rolls 62, 64, the stretch laminate sheet L may become statically charged. If the stretch laminate sheet L becomes statically charged, the static electricity may adversely affect the process of manufacturing a worn article by processing the stretch laminate sheet L. Therefore, it is preferable to bring the stretch laminate sheet L into contact with a conductor connected to earth downstream of the laminate sheet stretching mechanism 60 in the conveying direction A of the stretch laminate sheet L.

[0073] (2-6) Control Device The control device 90 includes a CPU, memories such as ROM and RAM, input / output devices, various electric and electronic components, and the like, all of which are not shown.

[0074] 5, the control device 90 is electrically connected to the discharge mechanism 20, the cooling roll 30, the film stretching mechanism 38, the lamination and joining mechanism 48, and the laminated sheet stretching mechanism 60. The control device 90 controls the discharge mechanism 20, the cooling roll 30, the film stretching mechanism 38, the lamination and joining mechanism 48, and the laminated sheet stretching mechanism 60 to operate in coordination with each other by the CPU executing a program stored in the memory.

[0075] In addition, as long as the control device 90 is capable of performing the functions described here, it may be realized by software, by hardware (various electrical circuits and electronic circuits), or by a combination of software and hardware.

[0076] (3) Manufacturing Method of Stretchable Laminate Sheet A manufacturing method of the stretchable laminate sheet L will be described.

[0077] First, the formation of the film F will be described.

[0078] In the discharge mechanism 20, for example, a resin material that exhibits elasticity at room temperature is heated and melted, and is discharged from the discharge port 24 as a film-shaped intermediate Fa. The intermediate Fa is then cooled and solidified by the cooling roll 30, and an elastic (stretchable) film F is formed. In other words, the discharge mechanism 20 and the cooling roll 30 function as a molding unit in the claims, and the film F is formed from the resin material as a raw material. Note that in the cooling roll 30, the film F is stretched to a state in which it is elongated by α% with respect to the natural length of the film F (the length of the film F when no force is applied).

[0079] The film F, which is drawn out from the cooling roll 30 and conveyed from the cooling roll 30 in a stretched state, is further stretched by the film stretching mechanism 38. Specifically, in the film stretching mechanism 38, the film F is stretched to a state in which it is elongated by β (>α)% with respect to the natural length of the film F.

[0080] The layer joining mechanism 48 then forms a laminate B in which nonwoven fabric sheets S1, S2 unwound from a raw fabric roll (not shown) and a stretched film F are stacked together. In particular, in this embodiment, the layer joining mechanism 48 forms a laminate B in which a stretched film F is disposed between a first nonwoven fabric sheet S1 unwound from a raw fabric roll (not shown) and a second nonwoven fabric sheet S2 unwound from a raw fabric roll (not shown). The layer joining mechanism 48 then sandwiches the laminate B between the stretching roll 40 and the horn 43 of the ultrasonic bonding device 42, and thermally welds the pair of nonwoven fabric sheets S1, S2 and the film F to form a stretch laminate sheet L.

[0081] Next, the laminate sheet stretching mechanism 60 stretches (gear stretching) the stretch laminate sheet L, which is conveyed from the lamination joining mechanism 48 along the conveying direction A and passes between a pair of gear rolls 62, 64. Specifically, the laminate sheet stretching mechanism 60 stretches the film F to a state in which it is elongated by γ% relative to the natural length of the film F. For example, γ% is a value greater than the aforementioned β%. As a result of the gear stretching, openings of sufficient area are formed in the stretch laminate sheet L at and / or around the heat-sealed locations between the nonwoven fabric sheets S1, S2 and the film F.

[0082] (4) Features (4-1) The manufacturing apparatus 100 for the stretch laminate sheet L is an apparatus 100 for manufacturing the stretch laminate sheet L in which nonwoven fabric sheets S1, S2 as an example of a base sheet and a stretchable film F are arranged in a stacked manner, and the nonwoven fabric sheets S1, S2 and the film F are joined together. The manufacturing apparatus 100 for the stretch laminate sheet L includes a stacking and joining mechanism 48 as an example of a joining section, and a laminate sheet stretching mechanism 60 as an example of a stretching section. The stacking and joining mechanism 48 has an extension roll 40 (anvil roll) and a horn 43 as examples of a first joining member and a second joining member. The stacking and joining mechanism 48 sandwiches a laminate B, in which the nonwoven fabric sheets S1, S2 and the stretched film F are stacked together, between the extension roll 40 and the horn 43, and heat-welds the nonwoven fabric sheets S1, S2 and the film F to form the stretch laminate sheet L. The laminated sheet stretching mechanism 60 has a pair of gear rolls 62, 64 having concave and convex peripheral surfaces. The laminated sheet stretching mechanism 60 stretches the stretchable laminated sheet L that is conveyed between the pair of gear rolls 62, 64.

[0083] In the manufacturing apparatus 100 for the stretch laminate sheet L, the nonwoven fabric sheets S1, S2 and the film F are heat-welded to form the stretch laminate sheet L, and then the sheet is stretched using gear rolls 62, 64 having uneven surfaces, thereby forming openings of sufficient area at the heat-welded points between the nonwoven fabric sheets S1, S2 and the film F and / or in the surrounding area, thereby producing a stretch laminate sheet L with good breathability.

[0084] (4-2) The manufacturing apparatus 100 for the stretch laminate sheet L includes a discharge mechanism 20 and a cooling roll 30 that function as a forming section, and a film stretching mechanism 38 that is an example of a film stretching section. The forming section forms a film F from a raw material (resin material). The film stretching mechanism 38 is disposed between the forming section and the lamination joining mechanism 48 in the conveying direction A of the film F, and stretches the film F. The elongation rate of the film F transported between the film stretching mechanism 38 and the lamination joining mechanism 48 relative to its natural length is greater than the elongation rate of the film F transported between the forming section and the film stretching mechanism 38 relative to its natural length. Furthermore, the elongation rate of the film F of the stretch laminate sheet L in the laminate sheet stretching mechanism 60 relative to its natural length is greater than the elongation rate of the film F transported between the film stretching mechanism 38 and the lamination joining mechanism 48 relative to its natural length.

[0085] In the manufacturing apparatus 100 for the stretch laminate sheet L, it is possible to reduce the thickness of the film F by gradually stretching the film F. In particular, in the manufacturing apparatus 100 for the stretch laminate sheet L, after forming the stretch laminate sheet L using the film F, it is possible to reduce the thickness of the film F while suppressing breakage of the film F by further stretching the film F.

[0086] (4-3) A method for manufacturing a stretch laminate sheet L is a method for manufacturing a stretch laminate sheet L in which nonwoven fabric sheets S1, S2, which are an example of a base sheet, and a stretchable film F are arranged one on top of the other, and the nonwoven fabric sheets S1, S2 and the film F are joined together. The method for manufacturing a stretch laminate sheet L includes a welding step and a stretching step. In the welding step, the nonwoven fabric sheets S1, S2 and the stretched film F are thermally welded to form the stretch laminate sheet L. In the stretching step, the stretch laminate sheet L is transported between a pair of gear rolls 62, 64 having uneven peripheral surfaces, and is stretched by the pair of gear rolls 62, 64.

[0087] In the method for manufacturing this stretch laminate sheet L, the nonwoven fabric sheets S1, S2 and the film F are heat-welded to form the stretch laminate sheet L, and then the sheet is stretched using gear rolls 62, 64 having uneven surfaces, thereby forming openings of sufficient area at the heat-welded points between the nonwoven fabric sheets S1, S2 and the film F and / or around those points, thereby producing a stretch laminate sheet L with good breathability.

[0088] Second Embodiment A manufacturing apparatus 100A for a stretch laminate sheet L according to a second embodiment will be described below with reference to Figs. 12 and 13. Fig. 12 is a schematic diagram showing the configuration of the manufacturing apparatus 100A for a stretch laminate sheet L, and the film F forming section (discharge mechanism 20, cooling roll 30, etc.) is not shown. Fig. 13 is an example of a control block diagram of the manufacturing apparatus 100A for a stretch laminate sheet L.

[0089] The manufacturing apparatus 100A of the second embodiment differs from the manufacturing apparatus 100 of the first embodiment mainly in the following configurations a to c. The manufacturing apparatus 100A does not need to have all of the configurations a to c. The manufacturing apparatus 100A may have any one of the configurations a to c, or two of the configurations a to c. Configuration a: An adjustment unit 110 that adjusts the conveying speed of the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 is provided between the laminate joining mechanism 48 and the laminate sheet stretching mechanism 60 in the conveying path of the stretchable laminate sheet L, and the control device 90 functions as a speed control unit that controls the operation of the adjustment unit 110. Configuration b: A heater 66 that heats at least one of the pair of gear rolls 62, 64 is provided (in this embodiment, at least the gear roll 64 is provided with the heater 66). -Configuration c: The manufacturing apparatus 100A has a reception unit 92 that receives information regarding the size of the opening that the laminated sheet stretching mechanism 60 forms in the stretchable laminated sheet L, and the control device 90 determines the settings of the gear rolls 62, 64 in the laminated sheet stretching mechanism 60 based on this information.

[0090] Here, only the configurations a to c of the manufacturing apparatus 100A of the second embodiment, which are differences from the manufacturing apparatus 100 of the first embodiment, will be described, and a description of the similarities will be omitted unless necessary. In addition, since the stretch laminate sheet L manufactured by the manufacturing apparatus 100A is the same as the stretch laminate sheet L manufactured by the manufacturing apparatus 100, a description of the stretch laminate sheet L will also be omitted here.

[0091] (1) Details of Configurations a to c (1-1) Configuration a The above configuration a will be explained.

[0092] First, the reason for providing the configuration a will be explained.

[0093] As described in the first embodiment, the stretchable laminated sheet L formed by the lamination joining mechanism 48 is gear-stretched in the laminated sheet stretching mechanism 60 to form openings.

[0094] The size of the opening formed in the laminate sheet stretching mechanism 60 varies depending on how much the stretch laminate sheet L is stretched in the laminate sheet stretching mechanism 60. Furthermore, how much the stretch laminate sheet L is stretched in the laminate sheet stretching mechanism 60 also varies depending on how much tension is applied to the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60. Specifically, even if the operating conditions of the laminate sheet stretching mechanism 60 are not particularly changed, if a relatively large tension is applied to the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60, a relatively large opening is likely to be formed in the stretch laminate sheet L, whereas if only a relatively small tension is applied to the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60, only a relatively small opening is formed in the stretch laminate sheet L.

[0095] Furthermore, if excessive tension is applied to the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60, damage to the stretchable laminate sheet L may occur when stretched by the laminate sheet stretching mechanism 60.

[0096] Therefore, in order to form openings of approximately the same size throughout the stretchable laminate sheet L and to suppress damage to the stretchable laminate sheet L, it is preferable that the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 be controlled to an appropriate value.

[0097] Furthermore, since the tension acting on the stretchable laminate sheet L changes depending on the conveying speed of the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60, the manufacturing apparatus 100A of the second embodiment has an adjustment unit 110 between the laminate joining mechanism 48 and the laminate sheet stretching mechanism 60 that adjusts the conveying speed of the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60.

[0098] The adjustment unit 110 mainly includes a speed adjustment roller 112 (an example of a second roller around which the stretch laminate sheet L is wound) and a speed adjustment motor 114 that rotates and drives the speed adjustment roller 112 (see FIGS. 12 and 13 ). The speed adjustment motor 114 is electrically connected to the control device 90, and the operation (start / stop, rotation speed, etc.) of the speed adjustment motor 114 is controlled by the control device 90. The speed adjustment roller 112 is a roller with a high adhesiveness or coefficient of friction on its outer surface around which the stretch laminate sheet L is wound. Specifically, the adhesiveness or coefficient of friction on the outer surface of the speed adjustment roller 112 is greater than the adhesiveness or coefficient of friction on the outer surface of the guide roller 120 (an example of a first roller) around which the stretch laminate sheet L is wound. The guide roller 120 is disposed between the lamination joining mechanism 48 and the adjustment unit 110 in the transport path of the stretch laminate sheet L, and guides the wound stretch laminate sheet L. The roller is, for example, a rotatable roller.

[0099] The adhesiveness of the outer surface of the speed adjustment roller 112 can be achieved, for example, by attaching an adhesive material such as rubber to the outer surface of the speed adjustment roller 112. Furthermore, a relatively large coefficient of friction of the outer surface of the speed adjustment roller 112 can be achieved, for example, by attaching a member with a large coefficient of friction to the outer surface of the speed adjustment roller 112 or by roughening the outer surface of the speed adjustment roller 112.

[0100] The adjustment unit 110 changes the conveying speed of the stretchable laminate sheet L in the adjustment unit 110 by changing the rotation speed of the speed adjustment roller 112, which has an outer surface with a relatively high adhesiveness or coefficient of friction, and as a result, changes the conveying speed of the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60.

[0101] The adjusting unit 110 may not be configured to use a single speed adjusting roller 112, but may be configured to sandwich the elastic laminate sheet L between two rollers to adjust the conveying speed of the elastic laminate sheet L.

[0102] The adjustment of the conveying speed of the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 by the adjustment unit 110 and the resulting adjustment of the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 will be described below.

[0103] For example, it is assumed that the conveying mechanism 70 conveys the elastic laminate sheet L at a conveying speed V, and the adjusting unit 110 also conveys the elastic laminate sheet L at the conveying speed V.

[0104] Under these conditions, let us assume that the conveying speed V of the stretch laminate sheet L by the conveying mechanism 70 is not changed, but the rotational speed of the speed adjustment motor 114 is reduced, and the rotational speed of the speed adjustment roller 112 is reduced. In this case, the adjuster 110 conveys the stretch laminate sheet L at a relatively low speed, and the conveying mechanism 70 conveys the stretch laminate sheet L at a relatively high speed, so that the tension acting on the stretch laminate sheet L between the adjuster 110 and the conveying mechanism 70 becomes large. As a result, the tension acting on the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 becomes smaller than the tension acting on the stretch laminate sheet L conveyed from the lamination joining mechanism 48 to the adjuster 110.

[0105] Conversely, under the condition that the conveying mechanism 70 conveys the stretch laminate sheet L at a conveying speed V and the adjusting unit 110 also conveys the stretch laminate sheet L at a conveying speed V, the rotational speed of the speed adjustment motor 114 is increased and the rotational speed of the speed adjustment roller 112 is increased without changing the conveying speed V of the stretch laminate sheet L by the conveying mechanism 70. In this case, the adjusting unit 110 conveys the stretch laminate sheet L at a relatively high speed and the conveying mechanism 70 conveys the stretch laminate sheet L at a relatively low speed, so the tension acting on the stretch laminate sheet L between the adjusting unit 110 and the conveying mechanism 70 is reduced. As a result, the tension acting on the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 is greater than the tension acting on the stretch laminate sheet L conveyed from the laminate joining mechanism 48 to the adjusting unit 110.

[0106] The manner in which the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 is controlled during operation of the manufacturing apparatus 100A will be described.

[0107] First, when the manufacturing apparatus 100A starts operating or when it stops operating, the conveying speed of the film F and the stretch laminate sheet L is slower than during steady operation. Note that steady operation refers to a state in which a predetermined period of time has passed since the start of operation of the manufacturing apparatus 100A and the conveying speed of the film F and the stretch laminate sheet L is constant. Therefore, when the manufacturing apparatus 100A starts operating or when it stops operating, the tension acting on the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 is reduced, and there is a risk that only relatively small openings will be formed in the stretch laminate sheet L.

[0108] Therefore, it is preferable that the control device 90 as a speed control unit controls the operation of the adjustment unit 110 (more specifically, the operation of the speed adjustment motor 114) when operation starts or stops, thereby slowing down the conveying speed of the stretchable laminate sheet L in the adjustment unit 110, thereby increasing the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 relative to the tension acting on the stretchable laminate sheet L conveyed from the laminate joining mechanism 48 to the adjustment unit 110.

[0109] On the other hand, during steady-state operation of the manufacturing apparatus 100A, the conveying speed of the film F and the stretchable laminate sheet L becomes relatively high, and the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 becomes too large, which may result in the opening formed in the stretchable laminate sheet L becoming too large or the stretchable laminate sheet L being damaged.

[0110] Therefore, it is preferable that the control device 90 as a speed control unit controls the operation of the adjustment unit 110 (more specifically, the operation of the speed adjustment motor 114) when operation starts or stops, thereby increasing the conveying speed of the stretchable laminate sheet L in the adjustment unit 110, thereby reducing the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 relative to the tension acting on the stretchable laminate sheet L conveyed from the laminate joining mechanism 48 to the adjustment unit 110.

[0111] Preferably, the control device 90 as a speed control section controls the operation of the adjustment section 110 (more specifically, the operation of the speed adjustment motor 114) to always keep the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 constant.

[0112] (1-2) Configuration b The above configuration b will now be described.

[0113] If the stretch laminate sheet L is at a low temperature during gear stretching in the laminate sheet stretching mechanism 60, the thermoplastic film F of the stretch laminate sheet L may harden, making it difficult to stretch.

[0114] Therefore, a heater 66 is provided on at least one of the pair of gear rolls 62, 64 (in this embodiment, at least the gear roll 64) to heat the gear rolls 62, 64 to a predetermined temperature. By heating the gear rolls 62, 64 with the heater 66, the stretchable laminate sheet L in contact therewith is also heated, making it easier for the stretchable laminate sheet L to stretch.

[0115] In order to facilitate heating of the stretch laminate sheet L, it is preferable that the stretch laminate sheet L be in contact for a predetermined length with the outer peripheral surface of one of the pair of gear rolls 62, 64 (here, the gear roll 64) that is heated by the heater 66, and then be guided between the pair of gear rolls 62, 64. Although the numerical value is not limited, for example, the stretch laminate sheet L is in contact with the outer peripheral surface of the gear roll 64 by 5% or more of the outer peripheral length of the gear roll 64, and then be guided between the pair of gear rolls 62, 64.

[0116] In order to bring the stretch laminate sheet L into contact with the outer circumferential surface of the gear roll 64 before guiding the stretch laminate sheet L between the pair of gear rolls 62, 64, the stretch laminate sheet L conveyed from the adjustment unit 110 (or the stretch laminate sheet L conveyed from the laminate sheet stretching mechanism 60 if the adjustment unit 110 is not provided) is not guided directly between the gear rolls 62, 64. Specifically, as shown in FIG. 12 , the stretch laminate sheet L conveyed from the adjustment unit 110 (or the stretch laminate sheet L conveyed from the laminate sheet stretching mechanism 60 if the adjustment unit 110 is not provided) is guided by a guide roller 130, and the stretch laminate sheet L is wrapped around the outer circumferential surface of the gear roll 64, and then led between the gear rolls 62, 64.

[0117] (1-3) Configuration c The above configuration c will now be described.

[0118] First, the reason for providing the configuration c will be explained.

[0119] The size of the opening required for the stretch laminate sheet L is not always constant and may vary depending on the worn article 200, 300, 400, etc. in which the stretch laminate sheet L is used. To change the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 according to the size of the opening required for the stretch laminate sheet L, it is preferable to change the settings of the gear rolls 62, 64 of the laminate sheet stretching mechanism 60, for example. The settings of the gear rolls 62, 64 refer to, for example, the tooth depth of the gear rolls 62, 64 (the distance from the tooth bottom to the tooth tip; in this case, the distance between the peak and valley of the tooth 62a) and the distance between the axial center of the gear roll 62 and the axial center of the gear roll 64. The larger the tooth depth of the gear rolls 62, 64, the larger the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60. The smaller the distance between the axial center of the gear roll 62 and the axial center of the gear roll 64, the larger the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60.

[0120] However, the settings of the gear rolls 62, 64 are not limited to those exemplified, and may be characteristics of each gear roll 62, 64 or characteristics related to the correlation between the gear roll 62 and the gear roll 64 that change the amount of stretching by the stretch laminate sheet L. The settings of the gear rolls 62, 64 may be changed by trial and error by the operator of the manufacturing apparatus 100A, but in this case, it may take some time before the settings can be changed.

[0121] Therefore, it is preferable that the control device 90 of the manufacturing apparatus 100A determines the settings of the gear rolls 62, 64 in the laminated sheet stretching mechanism 60 based on information regarding the size of the opening that the laminated sheet stretching mechanism 60 forms in the stretchable laminated sheet L. Therefore, the control device 90 of the manufacturing apparatus 100A has the above-mentioned configuration c.

[0122] Configuration c will be specifically described.

[0123] The manufacturing apparatus 100A has a receiving unit 92 that receives information regarding the size of the openings that the laminate sheet stretching mechanism 60 forms in the stretch laminate sheet L. The receiving unit 92 is, for example, a switch or a touch panel that receives information input by an operator of the manufacturing apparatus 100A. The receiving unit 92 may also be a communication device that receives information transmitted via a network such as the Internet from a terminal operated by the operator of the manufacturing apparatus 100A (for example, a computer that serves as a management device that manages the manufacturing apparatus 100A or a mobile terminal carried by the operator).

[0124] The information regarding the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 is, for example, a numerical value indicating the ratio of the desired opening size to the seal area where the laminate joining mechanism 48 welds the nonwoven fabric sheets S1, S2 and the film F. The information regarding the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 may also be, for example, the numerical value of the desired opening size itself. The information regarding the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 may also be a relative index indicating the desired opening size, such as "large," "medium," or "small."

[0125] The control device 90 of the manufacturing apparatus 100A functions as a determination unit in the claims, and determines the settings of the gear rolls 62, 64 in the laminated sheet stretching mechanism 60 based on information regarding the size of the opening that the laminated sheet stretching mechanism 60 will form in the stretchable laminated sheet L, which is received by the receiving unit 92.

[0126] To achieve this, for example, the memory of the control device 90 stores related information that associates the size of the openings formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 with the settings of the gear rolls 62, 64. The related information is information based on test results obtained by using the testing device of the manufacturing apparatus 100A to perform gear stretching of the stretch laminate sheet L while changing the settings of the gear rolls 62, 64, and measuring the openings formed by gear stretching. The related information is also information calculated from theory or obtained by computer simulation regarding the correlation between the settings of the gear rolls 62, 64 and the openings formed by gear stretching.

[0127] The control device 90 refers to the related information and determines the settings of the gear rolls 62 , 64 corresponding to the information received by the receiving unit 92 regarding the size of the opening to be formed in the stretchable laminate sheet L by the laminate sheet stretching mechanism 60 .

[0128] The manufacturing apparatus 100A may have, for example, a display serving as the output unit 94, and the control device 90 may display the settings of the gear rolls 62, 64 determined by the manufacturing apparatus 100A on the display serving as the output unit 94. Alternatively, the manufacturing apparatus 100A may have, for example, a communication device serving as the output unit 94, and the control device 90 may transmit the settings of the gear rolls 62, 64 determined by the manufacturing apparatus 100A to a terminal operated by an operator of the manufacturing apparatus 100A (for example, a computer serving as a management device that manages the manufacturing apparatus 100A, or a mobile terminal carried by the operator).

[0129] By configuring the manufacturing apparatus 100A in this manner, the operator of the manufacturing apparatus 100A can replace the gear rolls 62, 64 used in the laminated sheet stretching mechanism 60, or adjust the distance between the axis of the gear roll 62 and the axis of the gear roll 64, based on the settings of the gear rolls 62, 64 output by the control device 90 from the output section 94.

[0130] (2) Features The manufacturing apparatus 100A of the second embodiment has the following features in addition to the features described in (4) Features of the manufacturing apparatus 100 of the first embodiment.

[0131] (2-1) The manufacturing apparatus 100A for the stretch laminate sheet L includes an adjustment unit 110 and a control device 90 as a speed control unit. The adjustment unit 110 is disposed between the lamination joining mechanism 48 and the laminate sheet stretching mechanism 60 in the conveyance path of the stretch laminate sheet L, and adjusts the conveyance speed of the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60. The control device 90 controls the operation of the adjustment unit 110.

[0132] In the manufacturing apparatus 100A for the stretch laminate sheet L, the conveying speed of the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 is controlled, and as a result, the tension acting on the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 is controlled. This makes it possible to prevent problems such as excessive tension acting on the stretch laminate sheet L in the laminate sheet stretching mechanism 60, causing damage to the stretch laminate sheet L, or the size of the opening formed in the stretch laminate sheet L in the laminate sheet stretching mechanism 60 deviating from the desired size.

[0133] (2-2) In the manufacturing apparatus 100A for the stretchable laminated sheet L, the control device 90 controls the operation of the adjustment unit 110, for example, during steady-state operation, to reduce the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 relative to the tension acting on the stretchable laminated sheet L transported from the lamination joining mechanism 48 to the adjustment unit 110.

[0134] In the manufacturing apparatus 100A for the stretch laminate sheet L, during steady operation, the laminate sheet stretching mechanism 60 can prevent excessive tension from acting on the stretch laminate sheet L, thereby preventing the stretch laminate sheet L from being damaged.

[0135] (2-3) In the manufacturing apparatus 100A for the stretchable laminated sheet L, the control device 90 controls the operation of the adjustment unit 110, for example, at the start or stop of operation, to increase the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 relative to the tension acting on the stretchable laminated sheet L transported from the lamination joining mechanism 48 to the adjustment unit 110.

[0136] Assume that the operation of the adjusting unit 110 is not controlled. When the manufacturing apparatus 100A for the stretch laminate sheet L starts or stops operation, the tension acting on the stretch laminate sheet L supplied to the laminate sheet stretching mechanism 60 is smaller than during steady operation, and the size of the openings formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 may be smaller than during steady operation. If the openings are too small, the stretch laminate sheet L will not have the desired breathability, and there is a risk that the stretch laminate sheet L in the portions with the too-small openings cannot be used for the worn article (will be wasted).

[0137] In contrast, the manufacturing apparatus 100A for the stretchable laminate sheet L controls the operation of the adjustment unit 110 to increase the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60, so that an opening of an appropriate size can be formed in the stretchable laminate sheet L in the laminate sheet stretching mechanism 60 even when the manufacturing apparatus 100A for the stretchable laminate sheet L starts or stops operating.

[0138] (2-4) In the manufacturing apparatus 100A for the stretchable laminated sheet L, the control device 90 controls the operation of the adjusting unit 110 to keep the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 constant.

[0139] In the manufacturing apparatus 100A for the stretchable laminate sheet L, the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 is constant, so that openings of approximately the same size are likely to always be formed in the stretchable laminate sheet L.

[0140] (2-5) The manufacturing apparatus 100A for the stretch laminate sheet L includes a guide roller 120 as an example of a first roller. The guide roller 120 is disposed between the lamination joining mechanism 48 and the adjustment unit 110 on the conveyance path, and guides the stretch laminate sheet L wound around the guide roller 120. The adjustment unit 110 includes a speed adjustment roller 112 as an example of a second roller around which the stretch laminate sheet L is wound. The outer surface of the speed adjustment roller 112 has a higher adhesion or coefficient of friction than the outer surface of the guide roller 120.

[0141] In the manufacturing apparatus 100A for the stretchable laminate sheet L, the stretchable laminate sheet L is grasped by the outer surface of the speed adjustment roller 112 in the adjustment section 110, and the conveying speed of the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60 can be adjusted using a single roller.

[0142] However, the adjustment unit 110 may not be configured to use a single speed adjustment roller 112, but may be configured to adjust the conveying speed of the elastic laminate sheet L by sandwiching the elastic laminate sheet L between two rollers.

[0143] (2-6) The manufacturing apparatus 100A for the stretch laminate sheet L includes a heater 66 that heats at least one of the pair of gear rolls 62, 64. In this embodiment, the manufacturing apparatus 100A for the stretch laminate sheet L includes at least the heater 66 that heats the gear roll 64.

[0144] In the manufacturing apparatus 100A for the stretch laminate sheet L, the stretch laminate sheet L can be stretched after being heated, so that the stretch laminate sheet L can be easily stretched in the laminate sheet stretching mechanism 60.

[0145] (2-7) In the manufacturing apparatus 100A for the stretch laminate sheet L, the stretch laminate sheet L comes into contact with the outer peripheral surface of one of the pair of gear rolls 62, 64 heated by the heater 66 for a predetermined length, and then is guided between the pair of gear rolls 62, 64. In this embodiment, the stretch laminate sheet L comes into contact with the outer peripheral surface of one of the gear rolls 64 heated by the heater 66 for a predetermined length, and then is guided between the pair of gear rolls 62, 64.

[0146] In the manufacturing apparatus 100A for the stretch laminate sheet L, the stretch laminate sheet L is easily heated sufficiently, and the stretch laminate sheet L is easily stretched sufficiently in the laminate sheet stretching mechanism 60.

[0147] (2-8) The manufacturing apparatus 100A for the stretch laminate sheet L includes a receiving unit 92 and a control device 90. The receiving unit 92 receives information regarding the size of the opening to be formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60. The control device 90 determines the settings of the gear rolls 62, 64 in the laminate sheet stretching mechanism 60 based on the information regarding the size of the opening to be formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60.

[0148] In the manufacturing apparatus 100A for the stretchable laminate sheet L, the settings of the gear rolls 62, 64 are determined according to the size of the opening to be provided in the stretchable laminate sheet L, so that the laminate sheet stretching mechanism 60 can easily form an opening of the desired size in the stretchable laminate sheet L.

[0149] <Modification 1> The manufacturing apparatus 100A may have the following configuration instead of the above configuration c.

[0150] As a method for changing the size of the opening formed in the stretchable laminate sheet L by the laminate sheet stretching mechanism 60 according to the size of the opening required in the stretchable laminate sheet L, instead of changing the settings of the gear rolls 62, 64 of the laminate sheet stretching mechanism 60, it is also possible to control the operation of the adjustment unit 110 to change the tension acting on the stretchable laminate sheet L supplied to the laminate sheet stretching mechanism 60.

[0151] Therefore, the control device 90 may determine the control pattern of the adjustment unit 110 in accordance with the size of the opening required for the elastic laminate sheet L, rather than determining the settings of the gear rolls 62, 64.

[0152] An example of a specific configuration for realizing the manufacturing apparatus 100A of the first modified example will be described.

[0153] Similar to the above embodiment, the manufacturing apparatus 100A of the first modified example has a receiving unit 92 that receives information regarding the size of the opening that the laminated sheet stretching mechanism 60 forms in the stretchable laminated sheet L. The receiving unit 92 and the information regarding the size of the opening that the laminated sheet stretching mechanism 60 forms in the stretchable laminated sheet L have already been described in the second embodiment, and therefore will not be described here.

[0154] The control device 90 of the manufacturing apparatus 100A determines a control pattern for the adjusting unit 110 based on information received by the receiving unit 92 regarding the size of the opening to be formed in the stretchable laminated sheet L by the laminated sheet stretching mechanism 60.

[0155] For example, the memory of the control device 90 stores related information that associates the size of the opening formed in the stretch laminate sheet L by the laminate sheet stretching mechanism 60 with the control pattern of the adjustment unit 110 (a method for controlling the rotational speed of the speed adjustment motor 114 at the start of operation, the stop of operation, and steady operation). The related information here is information based on test results obtained by using the test equipment of the manufacturing apparatus 100A to perform gear stretching of the stretch laminate sheet L while changing the control pattern of the adjustment unit 110 and measuring the openings formed by gear stretching. The related information is also information calculated from theory or obtained by computer simulation regarding the correlation between the control pattern of the adjustment unit 110 and the openings formed by gear stretching.

[0156] The control device 90 refers to the related information and determines a control pattern for the adjustment unit 110 corresponding to the information received by the reception unit 92 regarding the size of the opening to be formed in the stretchable laminate sheet L by the laminate sheet stretching mechanism 60 .

[0157] The manufacturing apparatus 100A may output the control pattern of the adjustment unit 110 determined by itself from, for example, an output unit 94 (description of the output unit 94 is omitted). Then, an operator of the manufacturing apparatus 100A may input the control pattern of the adjustment unit 110 to the control device 90. Furthermore, the control device 90 may control the operation of the adjustment unit 110 using the setting of the control pattern of the adjustment unit 110 determined by itself while the manufacturing apparatus 100A is in operation.

[0158] In the manufacturing apparatus 100A for the stretchable laminated sheet L of modified example A, the tension acting on the stretchable laminated sheet L supplied to the laminated sheet stretching mechanism 60 is changed according to information regarding the size of the opening formed in the stretchable laminated sheet L by the laminated sheet stretching mechanism 60.

[0159] Therefore, openings of the desired size can be easily formed in the stretchable laminate sheet L in the laminate sheet stretching mechanism 60 .

[0160] <Modification 2> In the manufacturing apparatus 100A of the second embodiment, it is assumed that an operator of the manufacturing apparatus 100A manually changes the settings of the gear rolls 62, 64 depending on the size of the opening required in the stretch laminate sheet L.

[0161] However, the present invention is not limited to this, and the manufacturing apparatus 100A may automatically change the settings of the gear rolls 62, 64 depending on the size of the opening required in the elastic laminate sheet L.

[0162] A specific configuration for realizing the manufacturing apparatus 100A of Modification 2 will be described with reference to Figures 14 and 15. Figure 14 is a schematic diagram showing the configuration of the manufacturing apparatus 100A of the stretch laminate sheet L of Modification 2, and the molding portion of the film F is not shown. Figure 15 is a control block diagram of the manufacturing apparatus 100A of the stretch laminate sheet L of Modification 2.

[0163] In this example, the setting of the gear rolls 62 and 64 is the setting of the distance between the axis of the gear roll 62 and the axis of the gear roll 64.

[0164] The manufacturing apparatus 100A of the second modification has a drive mechanism 68 that moves at least one of the axial centers of the gear rolls 62 and 64 closer to or farther away from the other gear roll (see FIGS. 14 and 15 ). As shown in FIG. 15 , the manufacturing apparatus 100A of the second modification does not have an output unit 94. However, the present invention is not limited to this, and the manufacturing apparatus 100A may have an output unit 94.

[0165] The manufacturing apparatus 100A of the modified example 2 determines the settings of the gear rolls 62, 64 in the laminated sheet stretching mechanism 60 (here, the distance between the axis of the gear roll 62 and the axis of the gear roll 64) based on information regarding the size of the opening to be formed in the stretchable laminated sheet L by the laminated sheet stretching mechanism 60 received by the receiving section 92 in a manner similar to that of the manufacturing apparatus 100A of the second embodiment.

[0166] Then, instead of outputting the determined settings of the gear rolls 62, 64 from the output unit 94, the control device 90 controls the operation of the drive mechanism 68 to adjust the distance between the axis of the gear roll 62 and the axis of the gear roll 64 to the distance between the axis of the gear roll 62 and the axis of the gear roll 64 that it has determined.

[0167] Finally, the technical ideas that can be understood from the above embodiment will be added below.

[0168] The stretch laminate sheet manufacturing apparatus is an apparatus for manufacturing a stretch laminate sheet in which a base sheet and a stretchable film are arranged one on top of the other, and the base sheet and the film are bonded together. The stretch laminate sheet manufacturing apparatus includes a joining unit and a stretching unit. The joining unit has a first bonding member and a second bonding member. The joining unit sandwiches a laminate in which the base sheet and the stretched film are bonded together between the first bonding member and the second bonding member, and heat-welds the base sheet and the film to form a stretch laminate sheet. The stretching unit has a pair of gear rolls with uneven peripheral surfaces. The stretching unit stretches the stretch laminate sheet as it passes between the pair of gear rolls and is transported.

[0169] In the manufacturing apparatus for a stretchable laminate sheet of the first aspect, a base sheet and a film are heat-sealed to form a stretchable laminate sheet, and then a stretching process is performed using a gear roll having an uneven peripheral surface, thereby forming openings of sufficient area at the heat-sealed points between the base sheet and the film and / or around them, thereby producing a stretchable laminate sheet with good breathability.

[0170] A second aspect of the invention relates to the first aspect of the invention, and the manufacturing apparatus for a stretch laminate sheet includes a forming unit and a film stretching unit. The forming unit forms a film from raw materials. The film stretching unit is disposed between the forming unit and the joining unit in the film transport direction and stretches the film. The elongation rate of the film transported between the film stretching unit and the joining unit relative to its natural length is greater than the elongation rate of the film transported between the forming unit and the film stretching unit relative to its natural length. The elongation rate of the film of the stretch laminate sheet in the stretching unit relative to its natural length is greater than the elongation rate of the film transported between the film stretching unit and the joining unit relative to its natural length.

[0171] In the stretch laminate sheet manufacturing apparatus of the second aspect, the film can be stretched in stages, thereby reducing the film thickness. In particular, in this stretch laminate sheet manufacturing apparatus, after forming a stretch laminate sheet using the film, the film is further stretched, thereby reducing the film thickness while suppressing film breakage.

[0172] A third aspect of the present invention relates to the manufacturing apparatus for a stretch laminate sheet of the first or second aspect, and further includes an adjusting unit and a speed control unit. The adjusting unit is disposed between the joining unit and the stretching unit in the conveying path of the stretch laminate sheet, and adjusts the conveying speed of the stretch laminate sheet supplied to the stretching unit. The speed control unit controls the operation of the adjusting unit.

[0173] In the manufacturing apparatus for a stretch laminate sheet according to the third aspect, the conveying speed of the stretch laminate sheet supplied to the stretching section is controlled, and as a result, the tension acting on the stretch laminate sheet supplied to the stretching section is controlled, thereby preventing problems such as excessive tension acting on the stretch laminate sheet in the stretching section, causing the stretch laminate sheet to break, or preventing the size of the opening formed in the stretch laminate sheet in the stretching section from deviating from the desired size.

[0174] A fourth aspect of the stretch laminate sheet manufacturing apparatus is the stretch laminate sheet manufacturing apparatus of the third aspect, in which the speed control unit controls the operation of the adjustment unit during steady-state operation to reduce the tension acting on the stretch laminate sheet supplied to the stretching unit relative to the tension acting on the stretch laminate sheet transported from the joining unit to the adjustment unit.

[0175] In the manufacturing apparatus for a stretch laminate sheet according to the fourth aspect, during steady operation, it is possible to suppress the occurrence of a problem in which excessive tension acts on the stretch laminate sheet in the stretching section, causing damage to the stretch laminate sheet.

[0176] The manufacturing apparatus for stretchable laminated sheets of the fifth aspect is the manufacturing apparatus for stretchable laminated sheets of the third or fourth aspect, in which the speed control unit controls the operation of the adjustment unit when operation starts or stops, so as to increase the tension acting on the stretchable laminated sheet supplied to the stretching unit relative to the tension acting on the stretchable laminated sheet transported from the joining unit to the adjustment unit.

[0177] Assume that the operation of the adjusting unit is not controlled. When the manufacturing apparatus for a stretch laminate sheet starts or stops operation, the tension acting on the stretch laminate sheet supplied to the stretching unit is smaller than during steady operation, and the size of the openings formed in the stretch laminate sheet by the stretching unit may be smaller than during steady operation. If the openings are too small, the stretch laminate sheet will not have the desired breathability, and the stretch laminate sheet in the portions with the too-small openings may not be usable (or may be wasted) for the worn article.

[0178] In contrast, the stretch laminate sheet manufacturing apparatus of the fifth aspect controls the operation of the adjustment section to increase the tension acting on the stretch laminate sheet supplied to the stretch section, so that an opening of an appropriate size can be formed in the stretch laminate sheet in the stretch section even when the stretch laminate sheet manufacturing apparatus starts or stops operating.

[0179] The sixth aspect of the stretch laminate sheet manufacturing apparatus is the third aspect of the stretch laminate sheet manufacturing apparatus, in which the speed control unit controls the operation of the adjustment unit to keep constant the tension acting on the stretch laminate sheet supplied to the stretch unit.

[0180] In the manufacturing apparatus for a stretchable laminate sheet according to the sixth aspect, the tension acting on the stretchable laminate sheet supplied to the stretching section is constant, so that openings of approximately the same size are likely to always be formed in the stretchable laminate sheet.

[0181] A seventh aspect of the invention relates to the apparatus for manufacturing a stretchable laminate sheet according to any one of the third to sixth aspects, further comprising a first roller. The first roller is disposed between the joint and the adjusting unit on the conveying path, and guides the stretchable laminate sheet wound around the first roller. The adjusting unit includes a second roller around which the stretchable laminate sheet is wound. The outer surface of the second roller has a higher adhesiveness or coefficient of friction than the outer surface of the first roller.

[0182] In the seventh aspect of the stretch laminate sheet manufacturing apparatus, the stretch laminate sheet is gripped by the outer surface of the second roller in the adjustment section, and the conveying speed of the stretch laminate sheet supplied to the stretching section can be adjusted using a single roller.

[0183] An eighth aspect of the invention relates to the stretch laminate sheet manufacturing apparatus of any one of the first to seventh aspects, further comprising a heater for heating at least one of the pair of gear rolls.

[0184] In the manufacturing apparatus for a stretch laminate sheet according to the eighth aspect, the stretch laminate sheet can be stretched after being heated, so that the stretch laminate sheet can be easily stretched in the stretching section.

[0185] The ninth aspect of the stretch laminate sheet manufacturing apparatus is the eighth aspect of the stretch laminate sheet manufacturing apparatus, in which the stretch laminate sheet comes into contact with the outer peripheral surface of one of a pair of gear rolls heated by a heater for a predetermined length, and then is guided between the pair of gear rolls.

[0186] In the manufacturing apparatus for a stretch laminate sheet according to the ninth aspect, the stretch laminate sheet is easily heated sufficiently, and the stretch laminate sheet is easily stretched sufficiently in the stretching section.

[0187] A tenth aspect of the present invention relates to the manufacturing apparatus for a stretchable laminate sheet according to any one of the first to ninth aspects, and further includes a receiving unit and a determining unit. The receiving unit receives information relating to the size of the opening to be formed in the stretchable laminate sheet by the stretching unit. The determining unit determines the setting of the gear roll in the stretching unit based on the information relating to the size of the opening to be formed in the stretchable laminate sheet by the stretching unit.

[0188] In the stretch laminate sheet manufacturing apparatus of the tenth aspect, the gear roll settings are determined according to the size of the opening to be provided in the stretch laminate sheet, so that openings of the desired size are easily formed in the stretch laminate sheet in the stretch section.

[0189] An eleventh aspect of the present invention relates to the apparatus for manufacturing a stretchable laminate sheet according to any one of the first to ninth aspects, further comprising a receiving unit. The receiving unit receives information relating to the size of the opening to be formed in the stretchable laminate sheet by the stretching unit. The tension applied to the stretchable laminate sheet and supplied to the stretching unit is changed in accordance with the information relating to the size of the opening to be formed in the stretchable laminate sheet by the stretching unit.

[0190] In the stretch laminate sheet manufacturing apparatus of the eleventh aspect, the tension of the stretch laminate sheet supplied to the stretching section is changed according to the size of the opening to be provided in the stretch laminate sheet, so that an opening of the desired size is easily formed in the stretch laminate sheet in the stretching section.

[0191] A twelfth aspect of the present invention relates to a method for producing a stretch laminate sheet, in which a base sheet and a stretchable film are arranged one on top of the other, and the pair of base sheet and film are joined together. The method for producing a stretch laminate sheet includes a welding step and a stretching step. In the welding step, the base sheet and the stretched film are thermally welded to form a stretch laminate sheet. In the stretching step, the stretch laminate sheet is transported between a pair of gear rolls having irregularities on their peripheral surfaces, and is stretched by the pair of gear rolls.

[0192] In the method for producing a stretchable laminate sheet of the twelfth aspect, a base sheet and a film are heat-welded to form a stretchable laminate sheet, and then the sheet is stretched using a gear roll having an uneven peripheral surface, thereby forming openings of sufficient area at the heat-welded points between the base sheet and the film and / or in the surrounding area (see Figures 9 and 11), thereby producing a stretchable laminate sheet with good breathability.

[0193] A wearing article according to a thirteenth aspect includes a waist member and an absorbent. The waist member is placed around the waist of a wearer when worn. The absorbent is joined to the waist member and placed in the wearer's crotch area when worn. The waist member includes a waist portion that is placed at the upper end of the waist member and placed around the wearer's waist when worn. The waist portion uses a stretchable laminate sheet manufactured by the manufacturing method according to the twelfth aspect.

[0194] A fourteenth aspect of the present invention provides a wearing article comprising a waistband member and an absorbent. The waistband member is placed around the waist of a wearer when worn. The absorbent is joined to the waistband member and placed in the wearer's crotch when worn. The waistband member includes a waist portion and a lower waist portion. The waist portion is placed at the upper end of the waistband member and placed around the wearer's waist when worn. The lower waist portion is placed below the waist stretch portion when worn. The lower waist portion uses a stretchable laminate sheet manufactured by the manufacturing method of the twelfth aspect.

[0195] A wearing article according to a fifteenth aspect includes a waist member, an absorbent, and a fastening member. The waist member is placed around the waist of a wearer when worn. The absorbent is joined to the waist member and placed in the wearer's crotch when worn. The fastening member is attached to a fastening member attachment portion provided on at least one of the left and right ends of the waist member. The fastening member is attached to a portion of the waist member to be fastened when worn. The fastening member attachment portion or the portion to be fastened is made of a stretchable laminate sheet manufactured by the manufacturing method according to the twelfth aspect.

[0196] A sixteenth aspect of the present invention provides a wearing article comprising a waist member, an absorbent, and a fastening member. The waist member is placed around the waist of a wearer when worn. The absorbent is joined to the waist member and placed in the wearer's crotch when worn. The fastening member is attached to a fastening member attachment portion provided on at least one of the left and right ends of the waist member. The fastening member is fastened to a portion of the waist member to be fastened when worn. The fastening member is made of a stretchable laminate sheet manufactured by the manufacturing method of the twelfth aspect.

[0197] In the wearing articles of the thirteenth to sixteenth aspects, the stretchable laminate sheet provides a wearing article with good breathability.

[0198] A seventeenth aspect of the wearing article comprises a waist member, an absorbent, and a fastening member. The waist member is placed around the waist of the wearer when worn. The absorbent is joined to the waist member and placed in the wearer's crotch when worn. The fastening member is attached to a fastening member attachment portion provided on at least one of the left and right ends of the waist member. The fastening member is joined to a portion to be joined of the waist member when worn. At least one of the waist member and the fastening member uses a stretchable laminate sheet in which a base sheet and a stretchable film are joined together in an overlapping state, with openings formed at the joints between the base sheet and the film.

[0199] In the wearing article of the seventeenth aspect, the stretchable laminate sheet is used in which openings are formed at the joining portions between the base sheet and the film, thereby realizing a wearing article with good breathability.

[0200] DESCRIPTION OF SYMBOLS 20 Discharge mechanism (forming section) 30 Cooling roll (forming section) 38 Film stretching mechanism (film stretching section) 48 Lamination and joining mechanism (joining section) 60 Laminated sheet stretching mechanism (stretching section) 62, 64 Gear roll 66 Heater 68 Shaft drive mechanism 90 Control device (speed control section, determination section) 92 Receiving section 94 Output section 100, 100A Stretchable laminated sheet manufacturing apparatus 110 Adjustment section 112 Speed ​​adjustment roller (second roller) 120 Guide roller (first roller) 300 Wearing article 310 Waistband member 312 Waistband section 314 Lower waistband section 320 Absorbent body 400 Wearing article 410 Front waistband section (waistband member) 412 Waistband section 414 Lower waistband section 416 Attachment section (connecting member attachment section) 420 Rear torso portion (waistline member) 422 Waist-surrounding portion 424 Lower waistline portion 426 Loop portion (joining portion) 430 Crotch portion (absorbent body) 440 Absorbent article (absorbent body) 450 Fastening tape (joining member) B Laminated body F Film L Stretchable laminated sheet S1 First nonwoven fabric sheet (base sheet) S2 Second nonwoven fabric sheet (base sheet)

Claims

1. A waistband member to be placed around the waist of a wearer; an absorbent body joined to the waistband member and placed in the crotch area of ​​the wearer; Equipped with The waistband member is provided with a stretchable laminated sheet in which a base sheet and a stretchable film are joined in a superimposed state, and an opening is formed at the joining point between the base sheet and the film. Wearable items.

2. The waistband member includes a waistband portion that is disposed at an upper end of the waistband member and is disposed around the waist of the wearer when worn, The stretchable laminate sheet is used in the waist area. The wearing article according to claim 1 .

3. The waistband member includes a waist portion that is disposed at the upper end of the waistband member and disposed around the waist of the wearer when worn, and a lower waist portion that is disposed below the waist portion, The stretchable laminate sheet is used for the lower waistband portion, The wearing article according to claim 1 .

4. The garment further comprises a connecting member attached to a connecting member attachment portion provided on at least one of the left and right ends of the waistband member, and connected to the connected portion of the waistband member when worn; The stretchable laminated sheet is used for the joining member mounting portion or the joined portion, The wearing article according to claim 1 .

5. The garment further comprises a connecting member attached to a connecting member attachment portion provided on at least one of the left and right ends of the waistband member, and which is connected to the connecting portion of the waistband member when worn; The stretchable laminate sheet is used for the connecting member, The wearing article according to claim 1 .

6. The joint between the base sheet and the film has a shape extending in a direction perpendicular to the stretch direction of the stretchable laminate sheet as the longitudinal direction. The wearing article according to claim 1 .