Manufacturing device and manufacturing method for absorbent article

Abstract

Provided are a manufacturing device and a manufacturing method for an absorbent article that are capable of detecting, at an early stage, a failure in which a continuous material for forming an absorbent article is not cut at a desired position. A manufacturing device (100) for a diaper (1) is provided with a first drum (200), a second drum (300), a cutting device (500), and a control device (700). The first drum conveys a continuous material. The second drum receives the continuous material conveyed by the first drum and conveys the continuous material further. The cutting device is disposed to face the second drum and cuts a predetermined portion of the continuous material to form the diaper. The control device detects a cutting position of the continuous material being conveyed by the first drum or the second drum, the cutting position being upstream of the cutting location of the continuous material by the cutting device in the conveyance direction of the continuous material.

Description

Absorbent article manufacturing device and manufacturing method

[0001] The present invention relates to an apparatus and method for manufacturing absorbent articles.

[0002] As disclosed in Patent Document 1 (WO 2018 / 212092), an apparatus and method for manufacturing absorbent articles are known, in which a continuous material that is stretchable in the conveying direction is conveyed while tension is applied in the conveying direction, and the conveyed continuous material is cut to form individual absorbent articles.

[0003] In particular, the manufacturing apparatus disclosed in Patent Document 1 (International Publication No. 2018 / 212092) can adjust the amount of expansion and contraction of the continuous material by changing the tension applied to the continuous material being transported, thereby accommodating changes in product size, thereby reducing the work required when changing the size of the product.

[0004] International Publication No. 2018 / 212092

[0005] However, when such a stretchable continuous material is used, if the continuous material stretches beyond the desired length for some reason, the continuous material may be cut at a position other than the intended cutting point during the cutting process to cut the continuous material to a length appropriate for the size of the absorbent article, and the desired shape of the product may not be obtained. Such problems may not be detected immediately when they occur.

[0006] An absorbent article manufacturing apparatus according to one embodiment of the present invention comprises a first drum, a second drum, a cutting device, and a detection device. The first drum transports a continuous material. The second drum receives the continuous material transported by the first drum and further transports the continuous material. The cutting device is disposed opposite the second drum and cuts a predetermined portion of the continuous material to form an absorbent article. The detection device detects the cut portion of the continuous material transported by the first drum or the second drum upstream of the location where the cutting device cuts the continuous material in the transport direction of the continuous material.

[0007] A method for manufacturing absorbent articles according to one embodiment of the present invention comprises a first conveying step, a second conveying step, a cutting step, and a detection step. In the first conveying step, the continuous material is conveyed by a first drum. In the second conveying step, the continuous material conveyed by the first drum is further conveyed by a second drum. In the cutting step, a predetermined portion of the continuous material is cut by a cutting device disposed opposite the second drum to form an absorbent article. In the detection step, a detection device detects the cut portion of the continuous material conveyed by the first drum or the second drum, upstream of the location where the continuous material is cut by the cutting device in the conveying direction of the continuous material.

[0008] The absorbent article manufacturing device and manufacturing method of the present invention can detect misalignment of the cutting portion (misalignment of the portion to be cut at the detection location or misalignment of the portion actually cut by the cutting device) early on based on the image.

[0009] 4A is a schematic front view of a disposable diaper, which is an example of an absorbent article manufactured by the absorbent article manufacturing apparatus of the present invention. FIG. 5 is a diagram illustrating the disposable diaper of FIG. 1 in a state where a side seal portion is unfolded. FIG. 6 is a block diagram illustrating an absorbent article manufacturing apparatus according to an embodiment of the present invention, along with a process flow. FIG. 7 is a schematic process diagram illustrating a part of a process of a manufacturing method for a wearing article of an embodiment, the process being a continuation of the process shown in FIG. 4A. FIG. 8 is a schematic process diagram illustrating a part of a process of a manufacturing method for a wearing article of an embodiment, the process being a continuation of the process shown in FIG. 4B. FIG. 9 is a side view illustrating a part of the manufacturing apparatus of FIG. 3 (first drum, second drum, imaging device, and cutting device). FIG. 10 is an enlarged view of the periphery of the cutting device of FIG. 10. FIG. 11 is an enlarged view of the cutting device, and one of the auxiliary suction members and anvils of the second drum. The upper part is a view of the second drum (the main suction member and auxiliary suction member of the second drum) viewed along the radial direction of the second drum, and the lower part is a view of the continuous material and diapers transported by the second drum depicted in the upper part, viewed along the radial direction of the second drum.

[0010] Hereinafter, an embodiment of an apparatus and method for manufacturing an absorbent article according to the present invention will be described with reference to the drawings.

[0011] It should be noted that the embodiment described below is merely an example of the present invention and does not limit the scope of the present invention. Those skilled in the art will understand that various modifications can be made to the following embodiment without departing from the spirit and scope of the present invention as defined in the claims.

[0012] (1) Absorbent Article An example of an absorbent article manufactured by the manufacturing apparatus 100 according to one embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG.

[0013] Fig. 1 is a schematic front view of a disposable diaper 1 (hereinafter simply referred to as diaper 1) according to an example of an absorbent article manufactured by the manufacturing apparatus 100. Fig. 2 is a diagram illustrating the diaper 1 with a side seal portion 5 (described later) unfolded.

[0014] In this embodiment, the absorbent article will be described using a disposable diaper 1 as an example. However, the absorbent article is not limited to a disposable diaper, as long as it is a wearing article that has a liquid-absorbing member such as an absorbent core described below and is formed by cutting a conveyed continuous material.

[0015] The diaper 1 will now be described in detail.

[0016] In the following description, expressions such as "front," "back," "left," and "right" may be used, but unless otherwise specified, these expressions refer to the direction as seen by the wearer when the diaper 1 is worn by the wearer.

[0017] The diaper 1 has a bilaterally symmetrical structure as shown in Fig. 1. The diaper 1 mainly comprises an absorbent body 2, a front torso section 3, and a rear torso section 4 as shown in Fig. 2.

[0018] As shown in Fig. 2, the absorbent body 2 is a member that extends between the front torso section 3 and the rear torso section 4 and covers the crotch area of ​​the wearer. The front torso section 3 is a member that covers the front side of the wearer's torso, and the rear torso section 4 is a member that covers the back side of the wearer's torso.

[0019] The absorbent body 2, the front torso section 3, and the rear torso section 4 that constitute the diaper 1 will now be described in detail.

[0020] In the following description, the direction extending around the waist of the wearer when wearing the absorbent article (the left-right direction in Figures 1 and 2) may be referred to as the waist direction X1, and the longitudinal direction of the absorbent body 2, that is, the direction perpendicular to the waist direction X1, may be referred to as the vertical direction X2.

[0021] The diaper 1 here is a pants-type diaper. However, the type of diaper is not limited to pants-type, and may be a tape-type diaper in which the front and rear torso sections are separate (not joined by the side seals 5) and fastened together with tape when worn.

[0022] In the pants-type diaper 1 of this embodiment, in the finished state (as shown in Fig. 1), the absorbent body 2 is folded in two at the middle in the longitudinal direction X2, and the left and right ends on both sides of the front torso section 3 in the waist-circumference direction X1 overlap with the left and right ends on both sides of the rear torso section 4 in the waist-circumference direction X1, as shown in Fig. 1. The end of the front torso section 3 in the waist-circumference direction X1 and the end of the rear torso section 4 in the waist-circumference direction X1 are joined at the side seal portion 5 (see Fig. 1).

[0023] The absorbent body 2 includes a top sheet, a back sheet, and an absorbent core disposed between the top sheet and the back sheet (not shown). Note that the structure of the absorbent body 2 shown here is merely an example, and the absorbent body 2 may include components other than the top sheet, back sheet, and absorbent core. The top sheet is a liquid-permeable sheet that is disposed on the wearer's skin side when worn. The back sheet is a liquid-impermeable sheet that is disposed on the opposite side of the top sheet (the outer side that does not face the wearer's skin). The absorbent core is made of pulverized pulp or a mixture of pulverized pulp and a superabsorbent polymer. The absorbent core absorbs bodily fluids such as urine from the wearer.

[0024] As shown in Fig. 2, the absorbent body 2 is a substantially rectangular member. The absorbent body 2 has a longitudinal direction in the vertical direction X2 and extends between the front torso section 3 and the rear torso section 4. The absorbent body 2 is joined to the front torso section 3 at a central portion of the front torso section 3 in the waist-circumferential direction X1, and is joined to the rear torso section 4 at a central portion of the rear torso section 4 in the waist-circumferential direction X1.

[0025] The front torso section 3 and the rear torso section 4 have an inner sheet S1 that faces the wearer's skin and an outer sheet S2 that does not face the wearer's skin (that is, that is positioned on the outside when the wearer wears the garment). The inner sheet S1 and the outer sheet S2 are laminated. The outer sheet S2 not only constitutes the front torso section 3 and the rear torso section 4, but also extends continuously to connect the front torso section 3 and the rear torso section 4. The outer sheet S2, which is positioned between the front torso section 3 and the rear torso section 4 in the longitudinal direction X2, forms leg hole portions. As shown in FIG. 2 , the absorbent body 2 is positioned on the outer sheet S2, which is positioned between the front torso section 3 and the rear torso section 4 in the longitudinal direction X2.

[0026] Elastic members F are arranged in the front torso section 3 and the rear torso section 4 to fit the diaper 1 to the wearer. In the front torso section 3 and the rear torso section 4, the elastic members F are arranged between the inner sheet S1 and the outer sheet S2, and the inner sheet S1 and the outer sheet S2 are joined in this state. The elastic members F are also joined to at least one of the inner sheet S1 and the outer sheet S2. The elastic members F may be made of, for example, multiple rubber threads, flat rubber, or a material containing a thermoplastic resin. Note that the structures of the front torso section 3 and the rear torso section 4 shown here are merely examples, and the front torso section 3 and the rear torso section 4 may include members other than the inner sheet S1, the outer sheet S2, and the elastic members F.

[0027] (2) Overview of the manufacturing apparatus and manufacturing method for absorbent articles An overview of the manufacturing apparatus 100 and manufacturing method for the diaper 1 will be described with reference to Fig. 3 and Figs. 4A to 4C. Fig. 3 is a block diagram showing the manufacturing apparatus 100 for the diaper 1 together with the process flow. Figs. 4A to 4C are each a schematic process diagram showing part of the process of the manufacturing method for the diaper 1. Fig. 4B shows a continuation of the process in Fig. 4A, and Fig. 4C shows a continuation of the process in Fig. 4B. Note that the process described below is merely an example and may be modified as appropriate.

[0028] As shown in FIG. 3, the manufacturing apparatus 100 mainly includes a sheet dividing and conveying device 110, an outer sheet band conveying device 120, an elastic member supplying device 130, a joining device 140, an elastic member disabling device 150, an absorbent body joining device 160, a leg hole forming device 170, a folding device 180, a sheet joining device 190, a first drum 200, a second drum 300, an imaging device 400, a cutting device 500, a diaper conveying device 650, a discharge device 600, and a control device 700.

[0029] The control device 700 is a computer having a CPU (not shown), memories such as ROM and RAM, auxiliary storage devices, input / output devices, various electric and electronic components, etc. The control device 700 does not have to be a single device, and multiple devices may work together to function as the control device 700.

[0030] The control device 700 is electrically connected to the sheet dividing and conveying device 110, the outer sheet band conveying device 120, the elastic member supplying device 130, the joining device 140, the elastic member disabling device 150, the absorbent body joining device 160, the leg hole forming device 170, the folding device 180, the sheet joining device 190, the first drum 200, the second drum 300, the imaging device 400, the cutting device 500, the diaper conveying device 650, and the discharge device 600. The control device 700 has a CPU that executes programs stored in memory to control the operations of the sheet dividing and conveying device 110, the outer sheet band conveying device 120, the elastic member supplying device 130, the joining device 140, the elastic member nullifying device 150, the absorbent body main body joining device 160, the leg hole forming device 170, the folding device 180, the sheet joining device 190, the first drum 200, the second drum 300, the imaging device 400, the cutting device 500, the diaper conveying device 650, and the discharging device 600. The control device 700 also functions as a detection device within the scope of the claims.

[0031] Here, we will explain an example in which the control device 700 is a computer, but as long as it is possible to cause the various devices 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 300, 400, 500, 600, and 650 to perform the operations described below or to execute the processes described below, the control device 700 may be realized by hardware (various electric circuits and electronic circuits) or by a combination of software and hardware.

[0032] The sheet dividing and conveying device 110 divides a continuously conveyed sheet, which is unwound from a wound sheet roll (not shown), into two pieces in a direction perpendicular to the conveying direction using a blade (not shown) to form a sheet-like inner sheet band S1a (step P1 in FIG. 4A). Hereinafter, the conveying direction of the sheet will be referred to as the "conveying direction Z1." The direction perpendicular to the "conveying direction Z1" will be referred to as the "width direction Z2." The inner sheet band S1a is a sheet band formed by continuously joining together the inner sheets S1 that will form the front torso section 3 when the diaper 1 is formed, or a sheet band formed by continuously joining together the inner sheets S1 that will form the rear torso section 4 when the diaper 1 is formed. The sheet dividing and conveying device 110 conveys two inner sheet bands S1a formed by dividing a single sheet in the same conveying direction Z1, spaced a predetermined distance apart in the width direction Z2. The sheet dividing and conveying device 110 conveys the stretchable inner sheet band S1a while applying a predetermined tension in the conveying direction Z1.

[0033] The outer sheet band conveying device 120 conveys the sheet-like outer sheet band S2a (a continuous sheet that will become the outer sheet S2 when formed into the diaper 1) unwound from a sheet roll (not shown) in the same direction (conveying direction Z1) as the two rows of inner sheet bands S1a (see step P2 in FIG. 4A). The outer sheet band conveying device 120 conveys the stretchable outer sheet band S2a while applying a predetermined tension in the conveying direction Z1.

[0034] The two rows of inner sheet bands S1a transported by the sheet dividing and transporting device 110 are aligned so that one end (outer edge) of the inner sheet band S1a in the width direction Z2 overlaps with each of the two end portions of the outer sheet band S2a in the width direction Z2.

[0035] In another embodiment, the two rows of inner sheet strips S1a conveyed by the sheet dividing and conveying device 110 may be positioned such that the end (outer edge) in the width direction Z2 of each inner sheet strip S1a is positioned inside the end (outer edge) in the width direction Z2 of the outer sheet strip S2a. The end (portion positioned outside the inner sheet strip S1a in the width direction Z2) of the outer sheet strip S2a in the width direction Z2 may be folded back inward to overlap the absorbent body 2 in a later process to form a structure that prevents bodily fluids and the like from leaking from the torso portion of the diaper 1. A detailed description of this embodiment will be omitted.

[0036] The elastic member supplying device 130 supplies the elastic member F stretched in the longitudinal direction between the inner sheet band S1a and the outer sheet band S2a (see step P3 in FIG. 4A). The elastic member supplying device 130 arranges the elastic member F between the inner sheet band S1a and the outer sheet band S2a along the conveying direction Z1.

[0037] For convenience, the manufacturing apparatus 100 is described here in the order of the outer sheet band conveying device 120 and the elastic member supplying device 130, but in reality, the elastic member F is supplied to the inner sheet band S1a or the outer sheet band S2a first, and then the other sheet band S2a, S1a is supplied, so that the elastic member F is sandwiched between the inner sheet band S1a and the outer sheet band S2a.

[0038] The joining device 140 joins the elastic member F, the inner sheet strip S1a, and the outer sheet strip S2a at predetermined positions to form a continuous sheet 3a that will become the front torso section 3 when the diaper 1 is formed, and a continuous sheet 4a that will become the rear torso section 4 when the diaper 1 is formed (see step P4 in FIG. 4A ). For example, but not limited to, means such as heat welding, ultrasonic welding, or adhesives may be used for joining. The continuous sheet 3a is a sheet strip formed by continuously joining the front torso section 3 in the longitudinal direction, and the continuous sheet 4a is a sheet strip formed by continuously joining the front torso section 3 in the longitudinal direction.

[0039] The elastic member nullifying device 150 performs a nullifying process of cutting a part of the elastic member F at the location of the continuous sheets 3 a, 4 a where the absorbent body 2 is to be disposed (see step P5 in FIG. 4A ). The elastic member F may be cut using, for example, a blade or by fusing with heat.

[0040] The absorbent body joining device 160 positions the absorbent body 2 so as to straddle the continuous sheets 3a and 4a at the location where the elastic member nullifying device 150 nullified the elastic members F, and joins the continuous sheets 3a and 4a to the absorbent body 2 (see step P6 in FIG. 4B ). For joining, means such as heat welding, ultrasonic welding, adhesives, etc. may be used, but are not limited to these.

[0041] The leg hole forming device 170 sandwiches the continuous sheets 3a, 4a and the absorbent body 2, which have been integrated by the absorbent body joining device 160, between, for example, an anvil roll and a die-cut roll, and forms oblong holes H in the outer sheet band S2a, which will become leg holes of the diaper 1 (see step P7 in Figure 4B).

[0042] After the holes H are formed in the outer sheet bands S2a, the folding device 180 folds the absorbent body 2 at the center in the width direction Z2 to overlap the continuous sheets 3a and 4a (see step P8 in FIG. 4B ). Note that for convenience of illustration in FIG. 4B , the sheet is depicted as being discontinuous before and after folding by the folding device 180, but in reality, the sheet is not cut along the width direction Z2 at this point, and the sheet is continuous.

[0043] The sheet joining device 190 joins the continuous sheets 3a and 4a in the width direction Z2 of the laminated sheet (integrated continuous sheets 3a, 4a, and outer sheet band S2a) formed by the folded continuous sheets 3a and 4a conveyed by the folding device 180 in a folded state, near positions that will define both ends of the front torso section 3 and both ends of the rear torso section 4 when the diaper 1 is formed, to form side seal portions 5 (side seal portions 5 of each diaper 1) (see step P9 in FIG. 4B ). In FIG. 4B , the areas where the side seal portions 5 are formed are indicated by hatching. For example, thermal welding, ultrasonic welding, and other methods may be used for joining. Hereinafter, the continuous sheets 3a, 4a, and outer sheet band S2a, to which the absorbent body 2 is attached at a predetermined interval and joined at the side seal portions 5, are referred to as a continuous material C.

[0044] The cutting device 500, which will be described later, cuts the continuous material C at a midpoint in the conveyance direction Z1 between two adjacent side seal portions 5 (sandwiched between two adjacent absorbent bodies 2 in the conveyance direction Z1). Hereinafter, for ease of explanation, the portion of the continuous material C that is to be cut by the cutting device 500 will be referred to as the planned cutting portion Y. In Figures 4B and 4C, the planned cutting portion Y is depicted with a dashed line. Note that the dashed lines depicted in Figures 4B and 4C are imaginary lines and are not actually lines on the continuous material C.

[0045] The first drum 200 is a device that conveys the continuous material C by rotating around a rotation axis.

[0046] In particular, here, the first drum 200 is equipped with a plurality of suction members 210, 220 (see Figure 5), each having an suction surface capable of suctioning the continuous material C, a holding mechanism (not shown) that holds the plurality of suction members 210, 220 rotatably around a first axis, a drive device (not shown) that has a rotating shaft (not shown) that can rotate around a second axis parallel to the first axis and a connecting mechanism (not shown) that connects the rotating shaft to the suction members 210, 220, and a support mechanism (not shown) that supports the holding mechanism and the drive device, and the connecting mechanism is connected to the plurality of suction members 210, 220 in a state in which the plurality of suction members 210, 220 can move in the radial direction of a circle centered on the first axis, and the support mechanism is a sheet conveying device that supports the holding mechanism and the drive device so that the holding mechanism and the drive device can move relatively in a direction perpendicular to the first axis. Specifically, the first drum 200 is a device similar to the sheet conveying device disclosed in Patent Document 1 (WO 2018 / 212092).

[0047] The first drum 200 conveys the continuous material C in the conveying direction Z1 by rotating in the direction of the arrow (clockwise in FIG. 5 ) while sucking the continuous material C onto the suction surfaces (outer peripheral surfaces) of the suction members 210, 220. The first drum 200 stretches and contracts the continuous material C while conveying it so that the cutting device 500 can cut the continuous material C at the same pitch (at the same intervals) regardless of the size of the diaper 1 in a subsequent process. In other words, the first drum 200 adjusts the length of the conveyed continuous material C in the conveying direction Z1 so that the intervals between the planned cutting positions Y in the continuous material C are a predetermined length regardless of the size of the diaper 1 to be manufactured. In other words, the first drum 200 changes the tension acting on the continuous material C in the conveying direction Z1 while conveying the continuous material C. By using such a first drum 200 that can adjust the amount of expansion and contraction of the continuous material C, even if the size of the diaper 1 to be manufactured changes (for example, even when M-size, L-size, and XL-size diapers 1 are manufactured using a single manufacturing device 100), there is no need to perform tasks such as replacing the second drum in the subsequent stage to match the size of the diaper 1.

[0048] For example, as shown in Figure 4C, the first drum 200 shrinks the continuous material C, which has a distance A between adjacent planned cutting points Y, to shrink the distance B between adjacent planned cutting points Y (see step P10 in Figure 4C).

[0049] The second drum 300 rotates about a rotation axis to transport the continuous material C. When viewed along the rotation axis O1 (the rotation axis that rotates the main suction member 310 and the sub suction member 320, which will be described later), the second drum 300 has a generally circular outer shape (see FIG. 5).

[0050] The second drum 300 receives the continuous material C (here, the continuous material C having a distance B between adjacent planned cutting portions Y) conveyed by the first drum 200 with the main suction member 310 and the auxiliary suction member 320 (see FIG. 5), and while sucking the continuous material C with the suction surface 312 (outer peripheral surface) of the main suction member 310 and the suction surface 322 (outer peripheral surface) of the auxiliary suction member 320 (see FIG. 6), rotates the main suction member 310 and the auxiliary suction member 320 about the rotation axis O1, thereby further conveying the continuous material C. Note that the continuous material C conveyed by the second drum 300 is cut at the planned cutting portions Y by a cutting device 500 during conveyance, and individual diapers 1 are formed (see step P12 in FIG. 4C). It should be noted that the expression "diaper 1 is molded" is not limited to the case where diaper 1 is in a finished state, but does not exclude, for example, the case where some accessories are attached to diaper 1 molded from continuous material C in a later process, or some processing is performed on diaper 1.

[0051] The formed diaper 1 is further conveyed in the conveying direction Z1 by the rotation of the main suction member 310 and the auxiliary suction member 320 about the rotation axis O1. Furthermore, while conveying the diaper 1, the second drum 300 rotates the diaper 1, which was conveyed with the waist-circumference direction X1 aligned with the conveying direction Z1, by 90° to align the longitudinal direction X2 with the conveying direction Z1 (see step P13 in FIG. 4C ). The second drum 300 then conveys the diaper 1, with the longitudinal direction X2 aligned with the conveying direction Z1, further in the conveying direction Z1 and delivers it to the diaper conveying device 650. The second drum 300 will be described in detail later.

[0052] The imaging device 400 is, for example, a camera that captures video. It images the continuous material C in the conveying direction Z1 of the continuous material C upstream of the cutting location of the continuous material C by the cutting device 500 (described later) (see process P11 in FIG. 4C ). In this embodiment, the control device 700, as an example of a detection device, detects the cutting location (planned cutting location Y) of the continuous material C based on the image captured by the imaging device 400. Note that the detection here is not limited to the case where the cutting device 500 detects the cutting location (planned cutting location Y) of the continuous material C itself, but may also detect a location (e.g., the side seal portion 5 described later) from which the cutting device 500 can identify the cutting location (planned cutting location) of the continuous material C. Preferably, the imaging device 400 images the continuous material C being conveyed by the second drum 300, as shown in FIG. 5 . For example, the imaging device 400 is installed at a position opposite the second drum 300 with its lens facing the second drum 300 and captures an image of the continuous material C being transported by the second drum 300.

[0053] Furthermore, the imaging device 400 may capture an image of the continuous material C being transported by the first drum 200. For example, the imaging device 400 is installed at a position opposite the first drum 200 with its lens facing the first drum 200, and captures an image of the continuous material C being transported by the first drum 200. In this case, it is preferable that the imaging device 400 captures an image of the continuous material C after the tension has been changed in the first drum 200 (in this embodiment, after the distance between adjacent planned cutting portions Y has been changed to B).

[0054] It is preferable that the imaging device 400 captures at least an image of the cutting portion (planned cutting portion Y) of the continuous material C where the cutting device 500 will cut. Specifically, the imaging device 400 captures an image of the cutting portion (planned cutting portion Y) of the continuous material C where the cutting device 500 will cut the continuous material C and a pair of side seal portions 5 located on either side of the cutting portion, for example, in the conveying direction Z1 of the continuous material C. Note that the imaging device 400 may capture an image of the entire continuous material C passing in front of the lens of the imaging device 400. Alternatively, the imaging device 400 may capture an image of only a portion of the side seal portions 5 in the width direction Z2.

[0055] The cutting device 500 is disposed opposite the second drum 300 and is a device that cuts a predetermined portion (a planned cutting portion Y) of the continuous material C to form a diaper 1 as an example of an absorbent article.

[0056] Although not intended to be limiting in structure, the cutting device 500 may include, for example, one or more cutting members 510, a rotation mechanism 520 that rotates the one or more cutting members 510 about a rotation axis, and a drive unit 530 that drives the rotation mechanism 520 (see FIGS. 3 and 6 ). The drive unit 530 is, for example, a motor, and drives the rotation mechanism 520 independently of the rotation of the second drum 300 (independently of a first drive unit 340 of the second drum 300, which will be described later). The cutting member 510 is rotated by the rotation mechanism 520 to move between a position where it comes into contact with the continuous material C being transported by the second drum 300 and a position where it does not come into contact with the continuous material C being transported by the second drum 300. The control device 700, which will be described later, controls the operation of the drive unit 530 of the cutting device 500, thereby bringing the cutting member 510 into contact with the continuous material C so as to sandwich the continuous material C between the cutting member 510 and an anvil 330 (see FIG. 7), which will be described later, of the second drum 300, thereby cutting the continuous material C. The control device 700 controls the operation of the cutting device 500 based on images captured by the imaging device 400. The control of the operation of the cutting device 500 by the control device 700 will be described later.

[0057] In addition, the cutting device 500 may be a device that moves the cutting member 510 back and forth so that the cutting member 510 approaches the second drum 300 and moves away from the second drum 300, instead of rotating the cutting member 510 around the rotation axis.

[0058] The diaper transport device 650 transports the diaper 1 received from the second drum 300 to a subsequent process.

[0059] However, if the diaper 1 is defective, the control device 700 causes the discharge device 600, which is disposed downstream of the second drum 300 in the conveying direction Z1 of the diapers 1, to discharge the defective diaper 1 to the outside (outside the manufacturing process). For example, if the control device 700 determines that the cutting device 500 has not cut the continuous material C at the intended cutting point Y, the control device 700 operates the discharge device 600 to remove the diapers 1 upstream and downstream of the cutting position by the cutting device 500 from the diaper conveying device 650. Note that the discharge device 600 may, for example, be a device that physically contacts the diaper 1 with a member to discharge the diaper 1 to the outside, a device that blows air or the like onto the diaper 1 to discharge the diaper 1 to the outside, or a device that guides the defective diaper 1 to a path different from that of the normal diapers 1 to discharge the diaper 1 to the outside.

[0060] The manufacturing apparatus and manufacturing process for the diaper 1 described here are merely examples and can be modified as appropriate.

[0061] For example, in the above description, the sheet dividing and conveying device 110 divides a continuously conveyed sheet into two pieces in a direction perpendicular to the conveying direction using a blade (not shown) to form the sheet-like inner sheet band S1a. However, this is not limited to this. The inner sheet band S1a for the continuous sheet 3a and the inner sheet band S1a for the continuous sheet 4a may be fed from two separate sheet rolls. Furthermore, for example, the manufacturing process of the diaper 1 may include a step of attaching components other than those described above to the diaper 1 or performing some other processing on the diaper 1. Furthermore, for example, the manufacturing apparatus 100 for the diaper 1 may include a device for notifying the occurrence of defective diapers 1, instead of the discharge device 600 for the diaper 1.

[0062] (3) Second Drum The second drum 300 will be described in detail with reference to FIGS. 5 to 8 . FIG. 5 is a side view of a portion of the manufacturing apparatus 100 (the first drum 200, the second drum 300, the imaging device 400, and the cutting device 500). FIG. 6 is an enlarged view of the cutting device 500 and its surroundings. FIG. 7 is an enlarged view of the cutting device 500 and one of the auxiliary suction members 320 and anvils 330 of the second drum 300. In FIG. 8 , the upper part is a view of the second drum 300 (the main suction member 310 and the auxiliary suction member 320 of the second drum 300) viewed along the radial direction of the second drum 300 (the direction extending perpendicularly from the rotation axis O1 to the rotation axis O1). The lower part is a view of the continuous material C and diapers 1 being transported by the second drum 300 depicted in the upper part, viewed along the radial direction of the second drum 300.

[0063] The second drum 300 mainly includes a plurality of main suction members 310, a plurality of auxiliary suction members 320, a plurality of anvils 330, a first drive unit 340 that rotates the main suction members 310, the auxiliary suction members 320, and the anvils 330 around a rotation axis O1, and a second drive unit 350 that rotates the main suction members 310 around a rotation axis O2 that extends in the radial direction of the second drum 300 (see FIGS. 3 and 5 to 8).

[0064] The main suction members 310 and the auxiliary suction members 320 are alternately arranged in the circumferential direction around the rotation axis O1 (see FIG. 5). The anvils 330 are arranged side by side in the circumferential direction around the rotation axis O1 of the second drum 300. Specifically, each anvil 330 is arranged in the center of each auxiliary suction member 320 in the circumferential direction around the rotation axis O1 (see FIG. 7). In other words, the anvils 330 and the main suction members 310 are alternately arranged in the circumferential direction around the rotation axis O1, and auxiliary suction members 320, which serve as an example of a support portion for supporting the continuous material C, are provided on both sides of the anvils 330 in the circumferential direction of the second drum 300 around the rotation axis O1 (see FIGS. 6 and 7).

[0065] (3-1) Main and Sub-Suction Members The main suction member 310 has an suction surface 312 (on the outer circumferential surface) on the side opposite to the rotation axis O1 (see FIGS. 6 and 8). The suction surface 312 has a plurality of suction holes 314 formed therein for sucking air (see FIG. 8).

[0066] The auxiliary suction member 320 has an suction surface 322 (on the outer circumferential surface) on the side opposite to the rotation axis O1 (see FIGS. 6 and 8). The suction surface 322 has a plurality of suction holes 324 formed therein for sucking air (see FIG. 8).

[0067] The main suction member 310 suctions and holds the continuous material C transferred from the first drum 200 to the suction surface 312 by a suction device (not shown) arranged inside the second drum 300 sucking air through suction holes 314 in the suction surface 312. The auxiliary suction member 320 suctions and holds the continuous material C transferred from the first drum 200 to the suction surface 322 by a suction device (not shown) arranged inside the second drum 300 sucking air through suction holes 324 in the suction surface 322. Specifically, the suction surface 312 of the main suction member 310 suctions and holds the absorbent body 2 and the portions of the continuous sheet 3a and continuous sheet 4a to which the absorbent body 2 is attached and the surrounding areas of the absorbent body 2 (see FIG. 8 ). In other words, the suction surface 312 of the main suction member 310 suctions and holds the center portion in the waist circumference direction X1 of the diaper 1 to be formed from the continuous material C. The suction surface 322 of the auxiliary suction member 320 suction-holds the continuous material C in the vicinity of the intended cutting location Y (see FIG. 8 ). In other words, the suction surface 322 of the auxiliary suction member 320 suction-holds the end portion in the waist circumference direction X1 of the diaper 1 to be formed from the continuous material C.

[0068] (3-2) Anvil The anvil 330 is a support member for the cutting member 510, which clamps the continuous material C (particularly the intended cutting portion Y of the continuous sheets 3a, 4a) between its outer surface 332 and the cutting member 510 of the cutting device 500 during the cutting process of the continuous material C by the cutting device 500.

[0069] It is preferable that the outer surface 332 of the anvil 330 be positioned radially outward from the suction surface 312 of the main suction member 310 and the suction surface 322 of the auxiliary suction member 320 (on the side where the cutting device 500 is positioned relative to the second drum 300) in the radial direction centered on the rotation axis O1 so that the continuous material C can be easily clamped between the anvil 330 and the cutting member 510 (see Figure 7).

[0070] Furthermore, it is preferable that the width L (see FIG. 7) of the anvil 330 in the circumferential direction (conveying direction Z1 of the continuous material C) about the rotation axis O1 is longer than the width E between adjacent side seal portions 5 of the continuous material C being conveyed on the second drum 300 (the distance between a pair of adjacent side seal portions 5 arranged to sandwich the planned cutting point Y of 1; see FIG. 8). With this configuration, even if there is a slight deviation between the center of the outer circumferential surface 332 of the anvil 330 in the circumferential direction about the rotation axis O1 and the position of the planned cutting point Y of the continuous material C, the planned cutting point Y of the continuous material can be sandwiched between the cutting member 510 and the anvil 330 when the cutting device 500 cuts the continuous material C.

[0071] (3-3) First drive unit and second drive unit The first drive unit 340 transports the continuous material C in the transport direction Z1 by rotating the main suction member 310 and the auxiliary suction member 320, which adsorb and hold the continuous material C, around the rotation axis O1.

[0072] When the auxiliary suction member 320 (the continuous material C suction-held by the auxiliary suction member 320) reaches a position facing the cutting device 500, the rotation mechanism 520 of the drive unit 530 of the cutting device 500 rotates the cutting member 510, causing the cutting member 510 to protrude toward the continuous material C. The cutting member 510 of the cutting device 500 then clamps the continuous material C (more specifically, the intended cutting portion Y of the continuous material C) between itself and the anvil 330, and cuts the diaper 1 from the continuous material C located upstream in the conveying direction Z1, thereby forming the diaper 1. How the control device 700 drives the drive unit 530 of the cutting device 500 so that the cutting member 510 contacts the intended cutting portion Y of the continuous material C will be described later.

[0073] The first drive unit 340 rotates the main suction member 310 and the auxiliary suction member 320, which suction and hold not only the continuous material C but also the diaper 1 cut and shaped by the cutting device 500, around the rotation axis O1, thereby transporting the diaper 1 in the transport direction Z1.

[0074] When the diaper 1 is conveyed to a predetermined position by the first driving unit 340, the auxiliary suction member 320 supporting the end of the diaper 1 in the waist circumference direction X1 stops suctioning air through the suction holes 324 of the suction surface 322 and releases suction from the diaper 1. As a result, the diaper 1 is now held by suction only by the main suction member 310. In this state, the second driving unit 350 rotates the main suction member 310 by 90° around a rotation axis O2 (see FIG. 8 ) extending radially of the second drum 300, thereby aligning the longitudinal direction X2 of the diaper 1 with the conveying direction Z1.

[0075] In this transport state, the first drive unit 340 rotates the main suction member 310, which is suction-holding the diaper 1, about the rotation axis O1, thereby further transporting the diaper 1 in the transport direction Z1. Then, at the timing when the diaper 1 is transferred from the second drum 300 to the diaper transport device 650, the main suction member 310 stops suctioning air through the suction holes 314 of the suction surface 312, thereby releasing the suction-holding of the diaper 1.

[0076] (4) Control of the cutting device and the discharge device As described above, when the auxiliary suction member 320 (the continuous material C adsorbed and held by the auxiliary suction member 320) reaches a location opposite the cutting device 500 (referred to as the cutting location), the cutting device 500 protrudes the cutting member 510 toward the continuous material C, clamps the intended cutting location Y of the continuous material C between the cutting member 510 and the anvil 330, and cuts off the diaper 1 from the continuous material C located upstream in the conveying direction Z1, thereby forming the diaper 1.

[0077] Assuming that, in an ideal state, there is absolutely no positional deviation of the intended cutting point Y of the continuous material C, the intended cutting point Y of the continuous material C is designed to always be located at the center of the anvil 330 in the circumferential direction of the second drum 300 centered on the rotation axis O1. In this state, if the second drum 300 rotates at a constant speed, and the cutting member 510 of the cutting device 500 is always brought into contact with the continuous material C at constant time intervals (time intervals corresponding to the rotation speed of the second drum 300), the continuous material C should always be cut at the intended cutting point Y.

[0078] However, in reality, for example, due to a difference in the amount of expansion and contraction of the continuous material C on the first drum 200, the intended cutting point Y of the continuous material C may shift from the center position of the anvil 330 in the circumferential direction of the second drum 300 centered on the rotation axis O1.

[0079] Therefore, here, the control device 700 detects the intended cutting point Y of the continuous material C based on the image captured by the imaging device 400, and controls the operation of the cutting device 500 (the timing at which the cutting device 500 clamps the continuous material C between the cutting member 510 and the anvil 330 of the second drum 300) based on this detection result.

[0080] Specifically, the imaging device 400 captures an image of the continuous material C immediately before it is cut by the cutting device 500 (the continuous material C being transported by the second drum 300 before it is cut by the cutting device 500, or the continuous material C being transported by the first drum 200 after the tension has been adjusted (after the amount of stretching has been adjusted) by the first drum 200). The control device 700 applies general image recognition technology to the image captured by the imaging device 400 to detect a reference portion of the continuous material C that can be used to identify the planned cutting location Y, and determines the timing at which the reference portion of the position passes in front of the imaging device 400 (the timing (time) at which the reference portion of the position in the continuous material C is captured).

[0081] Furthermore, the control device 700 is aware of the conveying speed of the continuous material C on the first drum 200 and the second drum 300, the distance in the conveying direction Z1 between the reference position of the continuous material C and the intended cutting location Y, and the distance in the conveying direction Z1 from the location where the image of the continuous material C is captured by the imaging device 400 to the cutting location by the cutting device 500. For example, this information is input into the control device 700 in advance. Furthermore, if the conveying speed of the continuous material C on the first drum 200 and the second drum 300 is a quantity that can be detected by a sensor, the control device 700 may acquire this quantity using the sensor.

[0082] The control device 700 then calculates the timing (time) at which the intended cutting point Y of the continuous material C will reach the cutting point by the cutting device 500 based on the timing (time) at which the position reference point on the continuous material C is imaged, the conveying speed of the continuous material C on the first drum 200 and the second drum 300, the distance in the conveying direction Z1 between the position reference point on the continuous material C and the intended cutting point Y, and the distance in the conveying direction Z1 from the location at which the image of the continuous material C is captured by the imaging device 400 to the cutting point by the cutting device 500, and controls the operation of the drive unit 530 of the cutting device 500 to adjust the rotation speed of the cutting member 510 by the rotation mechanism 520 so that the cutting member 510 comes into contact with the continuous material C at this timing. As a result of being configured in this manner, even if the intended cutting point Y of the continuous material C shifts from the center position of the anvil 330 in the circumferential direction of the second drum 300 centered on the rotation axis O1 due to a difference in the amount of expansion and contraction of the continuous material C on the first drum 200, the cutting device 500 can cut the continuous material C at the intended cutting point Y or very close to the intended cutting point Y (a position where the shift does not adversely affect the quality of the diaper 1).

[0083] It is preferable that the reference positional portion of the continuous material C be, for example, a pair of side seal portions 5 arranged on either side of the planned cutting location Y. Since the side seal portions 5 are located close to the planned cutting location Y, by using the side seal portions 5 as the reference positional portion of the continuous material C, the continuous material C can be cut accurately at the appropriate location.

[0084] However, the portion of the continuous material C that serves as a reference for positioning is not limited to the side seal portion 5, and may be, for example, a pattern provided on the continuous sheet 3a or the continuous sheet 4a, or the edge of the absorbent body 2 in the conveying direction Z1. Furthermore, if the diaper is a tape-type diaper rather than a pants-type diaper, a fixing tape attached to the continuous material C may be used as a portion of the continuous material C that serves as a reference for positioning.

[0085] Furthermore, the control device 700 may detect the planned cutting portion Y of the continuous material C itself as a reference portion for identifying the position of the planned cutting portion Y on the continuous material C.

[0086] In addition, if, for some reason, adjusting the rotation speed of the rotation mechanism 520 is not able to accommodate the misalignment of the intended cutting point Y and the continuous material C cannot be cut at or near the intended cutting point Y, the control device 700 will discharge the defective diaper 1 to the outside (outside the manufacturing process) using the discharge device 600, which is located downstream of the second drum 300 in the conveying direction Z1 of the diaper 1.

[0087] (5) Features (5-1) A manufacturing apparatus 100 for a diaper 1, which is an example of an absorbent article, includes a first drum 200, a second drum 300, a cutting device 500, and a control device 700, which is an example of a detection device. The first drum 200 conveys the continuous material C. The second drum 300 receives the continuous material C conveyed by the first drum 200 and further conveys the continuous material C. The cutting device 500 is disposed opposite the second drum 300 and cuts a predetermined portion of the continuous material C to form the diaper 1. The control device 700 detects a cutting portion (planned cutting portion Y) of the continuous material C conveyed by the first drum 200 or the second drum 300, upstream of a cutting location of the continuous material C by the cutting device 500 in the conveying direction of the continuous material C.

[0088] This manufacturing apparatus 100 can detect early positional deviation of the cutting portion (positional deviation of the intended cutting portion Y at the detection location, or positional deviation of the portion that will actually be cut by the cutting apparatus 500).

[0089] (5-2) The diaper 1 manufacturing apparatus 100 includes an imaging device 400 that captures an image of the continuous material C. The control device 700 detects the cutting portion (planned cutting portion Y) of the continuous material C based on the image captured by the imaging device 400.

[0090] This manufacturing device can detect misalignment of the cutting portion at an early stage based on the image.

[0091] (5-3) The manufacturing apparatus 100 for the diaper 1 includes the control device 700 as an example of a first control unit that controls the operation of the cutting device 500 based on the detection of the control device 700.

[0092] Here, the control device 700 functions as both a detection device and a first control unit, but this is not limited to this; a first device may function as a detection device, and a second device separate from the first device may function as the first control unit.

[0093] In this manufacturing apparatus 100, positional deviation of the cutting portion of the continuous material C can be suppressed.

[0094] For example, the diaper 1 manufacturing apparatus 100 preferably includes an imaging device 400 that captures an image of side seal portions 5, which are an example of a pair of seal portions, provided on the continuous material C on either side of a cutting location (planned cutting location Y) in the conveying direction Z1 of the continuous material C. The control device 700 detects the cutting location (planned cutting location Y) from the detection result of the side seal portions 5. The control device 700 controls the operation of the cutting device 500 based on the timing at which the side seal portions 5 are imaged.

[0095] In such a diaper 1 manufacturing device, the side seal portion 5, which is relatively easy to detect, is used as a standard for detecting misalignment of the cutting point (planned cutting point Y), so that the misalignment of the cutting point (planned cutting point Y) of the continuous material C at the imaging location can be accurately detected, thereby enabling the cutting point of the continuous material C to be accurately controlled.

[0096] Furthermore, since the side seal portion 5 is close to the intended cutting point Y, by using the side seal portion 5 as a reference, it is possible to detect with particular accuracy any misalignment of the cutting point (intended cutting point Y) of the continuous material C at the imaging location, thereby enabling the cutting point of the continuous material C to be controlled with high accuracy.

[0097] (5-4) In the diaper 1 manufacturing apparatus 100, the second drum 300 has a plurality of anvils 330 arranged in a row in the circumferential direction of the second drum 300. The cutting device 500 has a cutting member 510. The cutting device 500 cuts the continuous material C by sandwiching it between the cutting member 510 and the anvils 330 of the second drum 300. The width L of each anvil 330 in the circumferential direction of the second drum 300 (the circumferential direction centered on the rotation axis O1) is wider than the width E between a pair of side seal portions 5 provided on the continuous material C across the intended cutting location Y.

[0098] In this manufacturing apparatus 100, the width L of the anvil 330 is set wider than the width E of a pair of side seal portions 5 that are arranged on either side of the cutting point (planned cutting point Y) on the continuous material C, so that the planned cutting point Y can be sandwiched and cut between the cutting member 510 and the anvil 330 even if the cutting timing of the cutting device 500 is slightly shifted to match the positional misalignment.

[0099] (5-5) In the diaper 1 manufacturing apparatus 100 of this embodiment, the second drum 300 has auxiliary suction members 320 as an example of a support portion for supporting the continuous material C, which are provided on both sides of each anvil 330 in the circumferential direction centered on the rotation axis O1 of the second drum 300.

[0100] In particular, here, the auxiliary suction member 320 not only supports the continuous material C but also suction-holds it.

[0101] In this manufacturing apparatus 100, the continuous material C is supported by auxiliary suction members 320 provided on both sides of the anvil 330 in the circumferential direction centered on the rotation axis O1 of the second drum 300, thereby preventing problems such as the continuous material C wrinkling and shifting position when cut.

[0102] (5-6) The manufacturing apparatus 100 for the diaper 1 of this embodiment includes a discharge device 600. The discharge device 600 is disposed downstream of the second drum 300 in the conveying direction of the continuous material C, and discharges the diapers 1 to the outside (outside the manufacturing process by the manufacturing apparatus 100). A control device 700, which is an example of a second control unit, controls the operation of the discharge device 600. The control device 700 controls the operation of the discharge device 600 to discharge defective diapers 1 (for example, diapers 1 that were not cut at the intended cutting portion Y) to the outside.

[0103] Here, the control device 700 functions as a detection device, a first control unit, and a second control unit, but is not limited to this. For example, a first device may function as a detection device, a second device separate from the first device may function as the first control unit, and a third device separate from the first and second devices may function as the second control unit.

[0104] In this manufacturing apparatus 100, even if the continuous material C is not cut at an appropriate position, the resulting defective diapers 1 can be automatically discharged to the outside.

[0105] (5-7) In the diaper 1 manufacturing apparatus 100 of this embodiment, the first drum 200 changes the tension acting on the continuous material C in the conveying direction Z1 of the continuous material C while the continuous material C is being conveyed. The control device 700 detects the cutting point (planned cutting point Y) of the continuous material C after the tension has been changed on the first drum 200.

[0106] In the manufacturing apparatus 100 of this embodiment, tension adjustment is performed on the first drum 200, allowing diapers 1 of different sizes to be manufactured using a single apparatus without the need for complex adjustments, but without any countermeasures, the continuous material C may expand or contract relative to the desired length when tension adjustment is performed, which could result in the continuous material C being cut at a position different from the intended cutting point Y during the cutting process, resulting in an undesired product. However, in this embodiment, the control device 700 functions as a detection device and can detect misalignment of the intended cutting point Y at the detection location and misalignment of the portion actually cut by the cutting device 500, thereby detecting and preventing such problems from occurring.

[0107] (6) Modifications Modifications of the above embodiment are shown below. The following modifications may be combined as appropriate as long as they do not contradict each other.

[0108] (6-1) Modification A In the above embodiment, an example is described in which the first drum 200 changes the tension acting on the continuous material C in the conveying direction Z1 while conveying the continuous material C. However, this is not limited to this, and the first drum 200 that supplies the continuous material C to the second drum 300 may be a conveying device that does not change the tension (adjust the amount of expansion and contraction) in this way.

[0109] Even in such a case, if there is a possibility that the intended cutting point Y of the continuous material C, which is stretchable in the conveying direction Z1, may be misaligned for some reason, it is useful to control the operation of the cutting device 500 using a detection device that detects the cutting point of the continuous material C.

[0110] (6-2) Modification B In the above embodiment, an example is described in which the detection result of the control device 700 is used to control the operation of the cutting device 500. However, the detection result of the control device 700 may be used for purposes other than controlling the operation of the cutting device 500.

[0111] For example, even if the control device 700 always operates the cutting device 500 at a fixed time interval (a time interval corresponding to the rotation speed of the second drum 300), the control device 700 can detect a positional shift of the intended cutting point Y in the continuous material C from the detection results of the control device 700 as a detection device, thereby being able to detect early on that a defective diaper 1 has been formed.

[0112] When the detection results of the control device 700 are used for such purposes, the control device 700 may, for example, notify the manager of the manufacturing device 100 by some means that a defective diaper 1 has been formed, or may stop the operation of the manufacturing device 100.

[0113] (6-3) Modification C In the above embodiment, an example is described in which the detection result of the control device 700 is used to control the operation of the cutting device 500. However, the detection result of the control device 700 may also be used to control the operation of the second drum 300 (control of the conveying speed of the second drum 300).

[0114] However, since the second drum 300 is generally a large piece of equipment, it is often preferable to control the operation of the relatively small cutting device 500 based on the detection results of the control device 700 rather than controlling the operation of the second drum 300 based on the detection results of the control device 700.

[0115] (6-3) Variation D In the above embodiment, the control device 700 as a detection device detects the cutting point (planned cutting point Y) of the continuous material C based on the image captured by the imaging device 400, but the control device 700 as a detection device may also detect the cutting point (planned cutting point Y) of the continuous material C using other means.

[0116] For example, the diaper 1 manufacturing apparatus 100 may have a sensor that detects the thickness of the continuous material C instead of the imaging device 400. In this case, the control device 700 as a detection device may, for example, detect a side seal portion 5 that has a different thickness from other portions based on the detection result of the sensor, and may detect the center of two adjacent side seal portions 5 as the cutting portion (planned cutting portion Y).

[0117] Furthermore, the side seal portion 5 and the like may be detected using ultraviolet light, changes in reflected light depending on the material, or ultrasonic waves.

[0118] <Additional Notes> Finally, the following additional notes will be added regarding the technical ideas that can be understood from the above-described embodiments.

[0119] A first aspect of the absorbent article manufacturing apparatus includes a first drum, a second drum, a cutting device, and a detection device. The first drum transports the continuous material. The second drum receives the continuous material transported by the first drum and further transports the continuous material. The cutting device is disposed opposite the second drum and cuts a predetermined portion of the continuous material to form an absorbent article. The detection device detects the cut portion of the continuous material transported by the first drum or the second drum upstream of the location where the cutting device cuts the continuous material in the transport direction of the continuous material.

[0120] In the manufacturing apparatus according to the first aspect, it is possible to detect early positional deviation of the cutting portion (positional deviation of the portion to be cut at the detection location, or positional deviation of the portion actually cut by the cutting device).

[0121] The absorbent article manufacturing apparatus according to a second aspect is the absorbent article manufacturing apparatus according to the first aspect, further comprising an imaging device that images the continuous material, and a detection device that detects a cut portion of the continuous material based on an image captured by the imaging device.

[0122] In the manufacturing apparatus according to the second aspect, misalignment of the cutting portion can be detected early based on the image.

[0123] The absorbent article manufacturing apparatus of a third aspect is the absorbent article manufacturing apparatus of the second aspect, wherein the imaging device images at least the cutting portion where the continuous material is cut by the cutting device.

[0124] An absorbent article manufacturing apparatus according to a fourth aspect is an absorbent article manufacturing apparatus according to any one of the first to third aspects, further comprising a first control unit that controls the operation of the cutting device based on the detection result of the detection device.

[0125] In the manufacturing device of the fourth aspect, the positional deviation of the cutting point (planned cutting point) of the continuous material at the detection location is detected based on the detection results of the detection device, and the operation of the cutting device is controlled based on this, thereby suppressing the positional deviation of the cutting point of the continuous material.

[0126] The absorbent article manufacturing apparatus of a fifth aspect is the absorbent article manufacturing apparatus of the second or third aspect, further comprising a first control unit that controls the operation of the cutting device based on the detection result of the detection device. The imaging device images a pair of seal portions provided on the continuous material on either side of the cutting location in the conveying direction of the continuous material. The first control unit controls the operation of the cutting device based on the timing at which the seal portions are imaged.

[0127] Here, the sealed portion means the portion where multiple sheets that make up the continuous material are joined together.

[0128] In the manufacturing apparatus of the fifth aspect, the sealing portion, which is relatively easy to detect, is used as the basis for detecting misalignment of the cutting point (planned cutting point), so that the misalignment of the cutting point (planned cutting point) of the continuous material at the imaging location can be accurately detected, thereby enabling the cutting point of the continuous material to be accurately controlled.

[0129] An absorbent article manufacturing apparatus according to a sixth aspect is the absorbent article manufacturing apparatus according to any one of the first to fifth aspects, wherein the second drum has a plurality of anvils arranged in a circumferential direction of the second drum. The cutting device has a cutting member. The cutting device cuts the continuous material by clamping it between the cutting member and the anvils of the second drum. The width of each anvil in the circumferential direction of the second drum is wider than the width between a pair of seal portions provided on the continuous material on either side of the cut point.

[0130] In the manufacturing apparatus of the sixth aspect, the width of the anvil is set wider than the width of a pair of sealing portions that are arranged on either side of the cutting point (the point to be cut) on the continuous material, so that the point to be cut can be sandwiched and cut between the cutting member and the anvil even if the cutting timing of the cutting device is slightly shifted to match the positional misalignment.

[0131] The absorbent article manufacturing apparatus of the seventh aspect is the absorbent article manufacturing apparatus of the sixth aspect, wherein the second drum has support portions provided on both sides of each anvil in the circumferential direction of the second drum and which support the continuous material.

[0132] In the manufacturing apparatus of the seventh aspect, the continuous material is supported by support portions provided on both sides of the anvil in the circumferential direction of the second drum, thereby preventing problems such as the continuous material wrinkling and shifting position when cut.

[0133] An absorbent article manufacturing apparatus according to an eighth aspect is the absorbent article manufacturing apparatus according to the first to seventh aspects, further comprising a discharge device and a second control unit. The discharge device is disposed downstream of the second drum in the conveying direction of the continuous material, and discharges the absorbent articles to the outside. The second control unit controls the operation of the discharge device. The second control unit controls the operation of the discharge device to discharge defective absorbent articles to the outside.

[0134] In the manufacturing apparatus of the eighth aspect, even if the continuous material is not cut at an appropriate position, the resulting defective absorbent articles can be automatically discharged to the outside.

[0135] The absorbent article manufacturing apparatus of a ninth aspect is the absorbent article manufacturing apparatus of the first aspect to the eighth aspect, wherein the first drum changes the tension acting on the continuous material in the conveying direction while the continuous material is being conveyed, and the detection device detects a cut point in the continuous material after the tension on the first drum has been changed.

[0136] In the manufacturing apparatus of the ninth aspect, by adjusting the tension on the first drum, it is possible to manufacture absorbent articles of different sizes using a single apparatus without performing complex adjustments, but if no countermeasures are taken, the continuous material may expand or contract relative to the desired length when the tension is adjusted, and the continuous material may be cut at a position different from the intended cutting point during the cutting process, resulting in an undesirable product. However, by providing a detection device here, it is possible to detect misalignment of the intended cutting point at the detection location and misalignment of the point actually cut by the cutting device, thereby detecting and preventing the occurrence of such problems.

[0137] A tenth aspect of the method for manufacturing absorbent articles comprises a first conveying step, a second conveying step, a cutting step, and a detection step. In the first conveying step, the continuous material is conveyed by a first drum. In the second conveying step, the continuous material conveyed by the first drum is further conveyed by a second drum. In the cutting step, a predetermined portion of the continuous material is cut by a cutting device arranged opposite the second drum to form an absorbent article. In the detection step, a detection device detects the cut portion of the continuous material conveyed by the first drum or the second drum upstream of the location where the continuous material is cut by the cutting device in the conveying direction of the continuous material.

[0138] In the manufacturing method of the tenth aspect, positional deviation of the cutting location (positional deviation of the planned cutting location at the detection location or positional deviation of the location actually cut by the cutting device) can be detected early based on the detection results of the detection device.

[0139] The method for manufacturing absorbent articles according to an eleventh aspect is the method for manufacturing absorbent articles according to the tenth aspect, further comprising an imaging step of imaging the continuous material with an imaging device. In the detection step, a cut portion of the continuous material is detected based on the image captured by the imaging device.

[0140] In the manufacturing apparatus according to the eleventh aspect, misalignment of the cutting portion can be detected early on based on the image.

[0141] A twelfth aspect of the present invention relates to the method for manufacturing absorbent articles of the eleventh aspect, and in the imaging step, the imaging device images a pair of seal portions provided on the continuous material on either side of the cutting location in the conveying direction of the continuous material. In the cutting step, the first control unit controls the operation of the cutting device based on the timing at which the seal portions are imaged.

[0142] Here, the sealed portion means the portion where multiple sheets that make up the continuous material are joined together.

[0143] In the manufacturing method of the twelfth aspect, the positional deviation of the cutting point (planned cutting point) of the continuous material at the imaging location is detected based on the image captured by the imaging device, and the operation of the cutting device is controlled based on this, thereby suppressing the positional deviation of the cutting point of the continuous material.

[0144] In particular, here, the seal portion, which is relatively easy to detect, is used as the basis for detecting misalignment of the cutting point (planned cutting point), so that the misalignment of the cutting point (planned cutting point) of the continuous material at the imaging location can be accurately detected, thereby enabling the cutting point of the continuous material to be accurately controlled.

[0145] A thirteenth aspect of the method for manufacturing absorbent articles is the method for manufacturing absorbent articles of any one of the tenth to twelfth aspects, further comprising a discharging step, in which the second control unit operates a discharging device disposed downstream of the second drum in the conveying direction of the continuous material, to discharge defective absorbent articles to the outside.

[0146] In the manufacturing method of the thirteenth aspect, even if the continuous material is not cut at an appropriate position, any defective absorbent articles that are produced can be automatically discharged to the outside.

[0147] A fourteenth aspect of the present invention relates to a method for manufacturing absorbent articles according to any one of the tenth to thirteenth aspects, wherein in the first conveying step, the tension acting in the conveying direction of the continuous material is changed while the continuous material is being conveyed, and in the detecting step, a cut point in the continuous material after the tension has been changed in the first conveying step is detected.

[0148] In the manufacturing method of the fourteenth aspect, the tension is adjusted in the first drum, so that absorbent articles of different sizes can be manufactured using a single device without the need for complex adjustments, etc. However, if no countermeasures are taken, the continuous material may expand or contract relative to the desired length when the tension is adjusted, and the continuous material may be cut at a position different from the intended cutting point during the cutting process, resulting in an undesirable product. However, by providing a detection device here, it is possible to detect misalignment of the intended cutting point at the detection location and misalignment of the point actually cut by the cutting device, thereby making it possible to detect and prevent such problems from occurring.

[0149] DESCRIPTION OF SYMBOLS 1 Diaper (absorbent article) 5 Side seal portion (seal portion) 200 First drum (first drum) 300 Second drum (second drum) 320 Auxiliary suction member (support portion) 330 Anvil 400 Imaging device 500 Cutting device 510 Cutting member 600 Discharge device 700 Control device (detection device, first control unit, second control unit) C Continuous material E Width between side seal portions (width between seal portions) L Width of anvil Y Planned cutting location (cutting location)

Claims

1. An absorbent article manufacturing apparatus comprising: a first drum for transporting a continuous material; a second drum for receiving the continuous material transported by the first drum and further transporting the continuous material; a cutting device disposed opposite the second drum for cutting a predetermined portion of the continuous material to form an absorbent article; and a detection device for detecting the cut portion of the continuous material transported by the first drum or the second drum, upstream of a location where the continuous material is cut by the cutting device in the transport direction of the continuous material.

2. The absorbent article manufacturing apparatus of claim 1, further comprising an imaging device that images the continuous material, and the detection device detects the cut portion of the continuous material based on the image captured by the imaging device.

3. The absorbent article manufacturing apparatus according to claim 2, wherein the imaging device images at least the cutting portion of the continuous material cut by the cutting device.

4. The absorbent article manufacturing apparatus according to any one of claims 1 to 3, further comprising a first control unit that controls the operation of the cutting device based on a detection result of the detection device.

5. An absorbent article manufacturing apparatus as described in claim 2 or 3, further comprising a first control unit that controls the operation of the cutting device based on the detection result of the detection device, wherein the imaging device images a pair of seal portions provided on the continuous material in the conveying direction of the continuous material, on either side of the cutting point of the continuous material where the cutting device cuts the continuous material, and the first control unit controls the operation of the cutting device based on the timing at which the seal portions are imaged.

6. An absorbent article manufacturing apparatus as described in any one of claims 1 to 5, wherein the second drum has a plurality of anvils arranged in a line in the circumferential direction of the second drum, the cutting device has a cutting member and cuts the continuous material by clamping it between the cutting member and the anvils of the second drum, and the width of each of the anvils in the circumferential direction of the second drum is wider than the width between a pair of seal portions provided on the continuous material on either side of the cut point.

7. The absorbent article manufacturing apparatus according to claim 6, wherein the second drum has support portions provided adjacent to each of the anvils in the circumferential direction of the second drum for supporting the continuous material.

8. An absorbent article manufacturing apparatus as described in any one of claims 1 to 7, further comprising: a discharge device arranged downstream of the second drum in the conveying direction of the absorbent articles, which discharges the absorbent articles to the outside; and a second control unit which controls the operation of the discharge device, wherein the second control unit controls the operation of the discharge device to discharge defective absorbent articles to the outside.

9. An absorbent article manufacturing apparatus as described in any one of claims 1 to 8, wherein the first drum changes the tension acting in the conveying direction of the continuous material while the continuous material is being conveyed, and the detection device detects the cut point of the continuous material after the tension has been changed on the first drum.

10. A method for manufacturing absorbent articles, comprising: a first conveying step of conveying a continuous material by a first drum; a second conveying step of further conveying the continuous material conveyed by the first drum by a second drum; a cutting step of cutting a predetermined portion of the continuous material by a cutting device arranged opposite the second drum to form an absorbent article; and a detection step of detecting the cut portion of the continuous material conveyed by the first drum or the second drum by a detection device upstream of the place where the continuous material is cut by the cutting device in the conveying direction of the continuous material.

11. A method for manufacturing absorbent articles as described in claim 10, further comprising an imaging step of imaging the continuous material with an imaging device, wherein in the detection step, the cut portion of the continuous material is detected based on the image captured by the imaging device.

12. A method for manufacturing absorbent articles as described in claim 11, wherein, in the imaging process, the imaging device images a pair of seal portions provided on the continuous material on either side of the cut point in the conveying direction of the continuous material, and, in the cutting process, a first control unit controls the operation of the cutting device based on the timing at which the seal portions are imaged.

13. A method for manufacturing absorbent articles described in any one of claims 10 to 12, further comprising a discharge step in which the second control unit operates a discharge device located downstream of the second drum in the conveying direction of the continuous material to discharge defective absorbent articles to the outside.

14. A method for manufacturing absorbent articles as described in any one of claims 10 to 13, wherein in the first conveying process, the tension acting in the conveying direction of the continuous material is changed while the continuous material is being conveyed, and in the detection process, the cut point of the continuous material after the tension has been changed in the first conveying process is detected.

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