Laminated sheet for wearable article, manufacturing method for laminated sheet for wearable article, and manufacturing system for laminated sheet for wearable article

Abstract

Provided is a laminated sheet having a low basis weight and a high elongation rate, and a manufacturing method and a manufacturing system for the laminated sheet. The manufacturing method for the laminated sheet for a wearable article includes: a film generation step (P1), a cooling step (P2), a layering step (P4), and a fusing step (P5). In the film generation step, melted raw material is extruded to form a film. In the cooling step, the extruded film is cooled. In the layering step, the following are layered: a nonwoven fabric sheet in a natural length state; and the film that is being conveyed, is elastic, and is in a natural length state or is elongated in the conveyance direction with an elongation rate of 15% or less. In the fusing step, a laminated sheet is generated by fusing the film and the non-woven fabric sheet which were layered and conveyed.

Description

Laminated sheet for worn article, manufacturing method of laminated sheet for worn article, and manufacturing system of laminated sheet for worn article

[0001] The present invention relates to a laminated sheet for a worn article, and a method and system for manufacturing a laminated sheet for a worn article.

[0002] Conventionally, methods and apparatuses for manufacturing stretchable laminated sheets by laminating nonwoven fabric and a film-like elastic material have been known, such as those disclosed in Patent Document 1 (JP Patent Publication No. 2018-513043) and Patent Document 2 (JP Patent Publication No. 7267498).

[0003] In the manufacturing process of the laminated sheet of Patent Document 1 (JP 2018-513043 A), the nonwoven element portion of the laminate is distorted and at least partially deformed via an activation unit, thereby activating the laminated web to make it stretchable.

[0004] In the method for producing a laminated sheet disclosed in Patent Document 2 (Japanese Patent No. 7267498), an elastic film is stretched and laminated on a nonwoven fabric to produce a laminated sheet.

[0005] Special table publication No. 2018-513043 Publication Patent No. 7267498 Publication

[0006] However, in the process of Patent Document 1 (JP 2018-513043 A), the elongation rate of the laminated web depends on the amount of deformation of the nonwoven element portion, which is difficult to stretch, making it difficult to obtain a laminated sheet with a high elongation rate.

[0007] In addition, in the manufacturing method of Patent Document 2 (Japanese Patent No. 7267498), the elongation percentage of the laminated sheet depends on the elongation percentage of the elastic film before lamination, and in order to obtain a sheet with a high elongation percentage, it is necessary to laminate the elastic film in a highly elongated state with the nonwoven fabric. However, when attempting to obtain a high elongation percentage, the amount of nonwoven fabric used per unit area of ​​the laminated sheet increases, and it is not easy to manufacture a laminated sheet with a high elongation percentage and a low basis weight.

[0008] An object of the present invention is to provide a laminate sheet having a low basis weight and a high elongation percentage, and a method and system for manufacturing this laminate sheet.

[0009] The method for manufacturing a laminated sheet for a wearing article of the present invention includes a film producing step, a cooling step, a laminating step, and a welding step. In the film producing step, a molten raw material is extruded to produce a film. In the cooling step, the extruded film is cooled. In the laminating step, a nonwoven fabric in its natural length is laminated with an elastic film in its natural length that is being transported. Alternatively, in the laminating step, a nonwoven fabric in its natural length is laminated with an elastic film that is being transported and stretched in the transport direction with an elongation rate of 15% or less. In the welding step, the film and nonwoven fabric that are being transported in a layered state are welded to produce a laminated sheet.

[0010] The manufacturing system for a laminated sheet for a worn article of the present invention includes a film producing device, a cooling device, a laminating device, and a welding device. The film producing device extrudes molten raw material to produce a film. The cooling device cools the extruded film. The laminating device laminates a nonwoven fabric in its natural length with an elastic film in its natural length that is being transported. Alternatively, the laminating device laminates a nonwoven fabric in its natural length with an elastic film that is being transported and stretched in the transport direction with an elongation rate of 15% or less. The welding device welds the film and nonwoven fabric that are being stacked and transported to produce a laminated sheet.

[0011] The laminated sheet for a worn article of the present invention comprises an elastic film and a nonwoven fabric laminated together. The film and the nonwoven fabric are integrated by welding. When the nonwoven fabric is in its natural length, no tension acts on the film.

[0012] The laminate sheet manufacturing method and manufacturing system of the present invention can manufacture a laminate sheet with a low basis weight (low weight of nonwoven fabric per unit area) and a high elongation percentage.

[0013] The laminated sheet of the present invention has a low basis weight (a low weight of nonwoven fabric per unit area) and a high elongation rate.

[0014] 1 is a schematic diagram showing the overall configuration of a laminate sheet manufacturing system according to one embodiment of the present invention; FIG. 2 is a schematic cross-sectional view of a laminate sheet in which a film is in an unstretched state; FIG. 3 is a schematic diagram of a wearing article using the laminate sheet; FIG. 4 is a control block diagram of the laminate sheet manufacturing system of FIG. 1; FIG. 5 is a schematic flow diagram of a laminate sheet manufacturing method according to one embodiment of the present invention; FIG. 6 is a schematic enlarged view of a stretching roll and a horn of the laminate sheet manufacturing system of FIG. 1; FIG. 7 is a diagram illustrating the arrangement of protrusions formed on the surface of the stretching roll of the laminate sheet manufacturing system of FIG. 1; FIG. 8 is a diagram showing an example of the arrangement of welded portions formed on a laminate sheet; FIG. 9 is a schematic partial enlarged plan view of a laminate sheet before gear stretching, and a schematic cross-sectional view taken along the X1-X1 arrows in the schematic partial enlarged plan view; FIG. 10 is a schematic partial enlarged plan view of a laminate sheet after gear stretching, and a schematic cross-sectional view taken along the X2-X2 arrows in the schematic partial enlarged plan view; FIG. 11 is a diagram showing another example of the arrangement of welded portions formed on a laminate sheet; FIG. 12 is a diagram showing yet another example of the arrangement of welded portions formed on a laminate sheet; FIG. 13 is a diagram showing yet another example of the arrangement of welded portions formed on a laminate sheet; FIG. 14 is a diagram showing yet another example of the shape of welded portions formed on a laminate sheet; 13 is a diagram showing yet another example of the shape of a welded portion formed in a laminated sheet. FIG. 14 is a schematic diagram of a laminated sheet stretching mechanism that stretches a laminated sheet in a direction perpendicular to the conveying direction of the laminated sheet. FIG. 15 is a schematic flow diagram of a laminated sheet manufacturing method according to another example. FIG. 16 is a schematic diagram illustrating a stretching step in the laminated sheet manufacturing method of FIG. 13.

[0015] A laminated sheet and a manufacturing system and method for the laminated sheet according to one embodiment of the present invention will be described with reference to the drawings.

[0016] (1) Laminated Sheet The laminated sheet L is a sheet used in a worn article.

[0017] The laminate sheet L is a stretchable sheet formed by laminating multiple sheets / films. As shown in FIG. 2 , the laminate sheet L includes an elastic (stretchable) film F, a first nonwoven fabric sheet S1, and a second nonwoven fabric sheet S2. In the laminate sheet L, the film F is disposed between the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2. In the laminate sheet L, the first nonwoven fabric sheet S1 and the film F, and the second nonwoven fabric sheet S2 and the film F are intermittently welded at welded portions J. In other words, in the laminate sheet L, the film F and the nonwoven fabrics (here, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2) are integrated by welding.

[0018] Although the description here is given taking as an example a three-layer structure of the first nonwoven fabric sheet S1, the second nonwoven fabric sheet S2, and the film F, the laminated sheet L may include sheets / films other than the film F and the nonwoven fabric sheets S1 and S2, and may be a laminate of four or more sheets / films. The laminated sheet may also have a two-layer structure of the film F and one of the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2.

[0019] The laminated sheet L of this embodiment is manufactured by stacking natural length nonwoven fabric (here, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2) and an elastic film F in a natural length state, and welding them together.

[0020] Alternatively, the laminated sheet L of this embodiment is produced by laminating a natural-length nonwoven fabric and an elastic film F that is not substantially elongated in the conveying direction A. Specifically, the laminated sheet L of this embodiment is produced by laminating a natural-length nonwoven fabric and an elastic film F that is being conveyed and stretched in the conveying direction A with an elongation rate of 15% or less, and welding them together. More preferably, the laminated sheet L of this embodiment is produced by laminating a natural-length nonwoven fabric and an elastic film F that is being conveyed and stretched in the conveying direction A with an elongation rate of 10% or less, and welding them together.

[0021] In the above description, the term "natural length" for the nonwoven fabric or film F does not necessarily mean that the nonwoven fabric is in its completely natural length, but also means that the nonwoven fabric is in its substantially natural length (for example, when it is slightly stretched due to tension).

[0022] Because the laminate sheet L is manufactured by the above-described method, when no force is applied to the laminate sheet L, the nonwoven fabric (here, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2) and the film F are generally parallel, as shown in FIG. 2 . In other words, when no force is applied to the laminate sheet L, the laminate sheet L is generally flat. Furthermore, when the nonwoven fabric of the laminate sheet L is at its natural length (when no tension is applied to the laminate sheet L), no tension acts on the film F. Note that when the nonwoven fabric of the laminate sheet L is at its natural length, no tension acts on the film F includes the case where the tension acting on the film F is generally zero.

[0023] The laminate sheet L of the present invention is used in a wearing article. Specifically, for example, a sheet piece cut from the laminate sheet L in a direction perpendicular to the conveying direction A (described later) is used in the wearing article. Here, the sheet piece cut from the laminate sheet L is also simply referred to as the laminate sheet L. While not limiting the type of wearing article in which the laminate sheet L is used, examples of the wearing article include disposable diapers and disposable medical gowns. Furthermore, while not limiting the use of the laminate sheet L, the laminate sheet L can be widely used in wearing articles, for example, as a waistband member worn around the waist of a wearer, a cuff member worn around the wrists of a wearer, or a hem member worn around the ankles of a wearer.

[0024] As an example, a disposable diaper as a wearing article 200 in which the laminated sheet L is used will be described with reference to FIG.

[0025] As shown in Fig. 3, 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).

[0026] In the wearing article 200, the laminated sheet L is used in the front torso section 210 and the rear torso section 220. The laminated 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.

[0027] (2) Overview of the Laminated Sheet Manufacturing System and Manufacturing Method The laminated sheet L manufacturing system 100 and the laminated sheet L manufacturing method can be summarized as follows.

[0028] The manufacturing system 100 produces a stretchable film F from a predetermined raw material. The manufacturing system 100 conveys the produced film F, merges a pair of nonwoven fabric sheets S1, S2 with the conveyed film F, and welds the pair of nonwoven fabric sheets S1, S2 to the film F in a state where the film F is disposed between the pair of nonwoven fabric sheets S1, S2 (in a state where the film F and the nonwoven fabric sheets S1, S2 are laminated), thereby producing a laminated sheet L. In the manufacturing system 100, when the film F and the nonwoven fabric sheets S1, S2 are laminated, the nonwoven fabric sheets S1, S2 in their natural lengths and the elastic film F in their natural length are laminated. Alternatively, in the manufacturing system 100, natural length nonwoven fabric sheets S1, S2 are laminated with an elastic film F that is stretched in the conveying direction A and has an elongation rate of 15% or less.Furthermore, the manufacturing system 100 stretches (gear stretching) the laminated sheet L using gear rolls 62, 64 to improve the breathability of the laminated sheet L (specifically, the breathability of the film F of the laminated sheet L) and the elasticity of the laminated sheet L.

[0029] The manufacturing system 100 and manufacturing method for the laminated sheet L will be described in detail later.

[0030] (3) Details of the laminated sheet manufacturing system As shown in Figures 1 and 4, the manufacturing system 100 mainly includes a discharge mechanism 20, a cooling roll 30, a film stretching mechanism 38, a laminate joining mechanism 48, a laminated sheet stretching mechanism 60, and a control device 90.

[0031] (3-1) Discharge Mechanism The discharge mechanism 20 is an example of a film production device within the scope of the claims. The discharge mechanism 20 is a device that produces a film (more specifically, a film before it has stabilized in terms of stretchability) from a raw resin material. Here, the term "film F" includes a film before it has stabilized in terms of stretchability. The meaning of the expression "stable stretchability" will be explained later. 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 extrudes the molten resin material from the discharge port 24 to produce the film F. The film F produced 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.

[0032] 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 (WO 2019 / 150801), although not limited thereto, a thermoplastic elastomer specified in JIS K 6418:2007 (ISO 18064:2003) is used as the resin material.

[0033] For example, the resin material may be a mixture of multiple resins that have different conditions for stabilizing elasticity. For example, the resin material may be a mixture of two resins, with a styrene-based resin as the first resin and an olefin-based resin as the second resin. Here, the first resin (styrene-based resin) is a resin that reaches a stable elasticity state at an earlier stage than the second resin (olefin-based resin) (in other words, at a higher temperature than the olefin-based resin). Note that "stable elasticity" means that the resin material is deformed by applying a slight external force (without causing plastic deformation beyond the range of elastic deformation) and then returns to its original state when the external force is removed (in other words, it means that the resin material is elastically deformed).

[0034] For example, when two types of resins are used, the resin material may consist solely of a styrene-based resin as the first resin and an olefin-based resin as the second resin. Alternatively, the resin material may consist of a styrene-based resin as the first resin, an olefin-based resin as the second resin, and other components. For example, when the resin material uses a styrene-based resin as the first resin and an olefin-based resin as the second resin, the total content of the first and second resins is preferably 90% by weight or more. The other components may include, for example, fatty acid amides, waxes, antioxidants, tackifier resins, softeners, antibacterial agents, light stabilizers, UV absorbers, dyes, lubricants, pigments, etc.

[0035] A specific example of the content of each resin material when a styrene-based resin is used as the first resin and an olefin-based resin is used as the second resin will be described.

[0036] The content of the styrene resin is 0 to 85% by weight. From the viewpoint of further improving moldability and the elasticity and stress relaxation properties of the resulting elastic member, the content of the styrene resin is preferably 40 to 80% by weight, more preferably 50 to 80% by weight, even more preferably 60 to 80% by weight, and particularly preferably 65 to 75% by weight.

[0037] The content of the olefin resin is 15 to 100% by weight. From the viewpoint of further improving the moldability and the stretchability of the resulting stretchable material, the content of the olefin resin is preferably 20 to 60% by weight, more preferably 20 to 50% by weight, even more preferably 20 to 40% by weight, and particularly preferably 25 to 35% by weight.

[0038] The preferred weight ratio of the styrene resin to the olefin resin is 1:0.33 to 0.54, and the content of the styrene resin and the olefin resin in the entire resin material is 90% by weight or more.

[0039] (3-2) Chilling Roll The chilling roll 30 is an example of a cooling device in the claims. The chilling roll 30 cools the film F.

[0040] 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 film F flows.

[0041] The film F produced by the discharge mechanism 20 is supplied to the cooling roll 30. The film F discharged from the discharge port 24 of the discharge mechanism 20 is stretched in a first section 80 (see FIG. 1 ) before reaching the cooling roll 30. To achieve this, the cooling roll 30 rotates at a peripheral speed greater 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 F until the thickness of the film F reaches a predetermined value.

[0042] The cooling roll 30 is driven to rotate by a drive device, and the film F is transported along the outer circumferential surface of the cooling roll 30. The cooling roll 30 cools the film F to a first temperature in a second section 82 where the film F is in contact with the outer circumferential surface of the cooling roll 30. The first temperature is a temperature at which the elasticity of at least a portion of the resins used as raw materials for the film F becomes stable. For example, if the raw material is a mixture of a styrene-based resin and an olefin-based resin, the first temperature is a temperature at which the elasticity of the olefin-based resin does not become stable, but the elasticity of the styrene-based resin becomes stable. For example, if the raw material is a mixture of three or more types of resins, the first temperature is a temperature at which at least some types of resin become stable, but the remaining types of resins do not become stable.

[0043] The first temperature may be, for example, a temperature that is determined theoretically, or may be a temperature that is determined by experiment or simulation.

[0044] In addition, since the stability of the elasticity of the resin is also affected by the time after the resin material has melted, the conveying speed and conveying distance of the film F by the cooling roll 30 (diameter of the cooling roll 30) may be designed so that the elasticity of at least a portion of the resin that is the raw material of the film F is stable.

[0045] The film F cooled by the cooling roll 30 passes through the guide roll 32 and is sent to the film stretching mechanism 38. Note that, although it is assumed here that the film F is cooled only by the cooling roll 30, this is not limitative, and the guide roll 32 may also be provided with a cooling function, so that the film F is cooled by both the cooling roll 30 and the guide roll 32.

[0046] (3-3) Film Stretching Mechanism The film stretching mechanism 38 is an example of a stretching device in the claims. The film stretching mechanism 38 stretches the film F to reduce its thickness. The cooling roll 30 supplies the film F, some of whose resin is still in a state where its stretchability is not yet stable, to the film stretching mechanism 38.

[0047] 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).

[0048] 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.

[0049] The film F is stretched by the film stretching mechanism 38 in a third section 84 between the pull-out roll 34 and the pinch roll 36 and 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. The film stretching mechanism 38 stretches the film F at an elongation ratio of, for example, 130% or less, although the numerical value is not limited thereto. Note that, since the film F stretched by the film stretching mechanism 38 is in a state where some resins are not yet stable in terms of elasticity, the stretched film F does not undergo elastic deformation (does not deform so as to return to its original state when the application of force is stopped), but is stretched to reduce its thickness.

[0050] The elongation rate of the film F in the film stretching mechanism 38 (how much it is stretched) is determined according to the resin components of the raw material. For example, if the raw material is a mixture of a styrene-based resin and an olefin-based resin, the higher the blend ratio of the olefin-based resin, the higher the elongation rate is set. In other words, if the raw material is a mixture of a styrene-based resin and an olefin-based resin, the higher the blend ratio of the resin (olefin-based resin) that has not yet reached a stable state in terms of stretchability, the higher the elongation rate is set. If the raw material uses a type of resin other than a mixture of a styrene-based resin and an olefin-based resin, or if three or more types of resins are used, the higher the blend ratio of the resin that has not yet reached a stable state in terms of stretchability in the film F supplied to the film stretching mechanism 38, the higher the elongation rate is set.

[0051] The film stretching mechanism 38 may be omitted, and the stretching step of the film F may be omitted. However, by stretching the film F to reduce its thickness, a laminated sheet L with a low basis weight (here, a low weight of the film F per unit area) can be produced, and the amount of material used can be reduced.

[0052] (3-4) Lamination and Joining Mechanism The lamination and joining mechanism 48 is an example of a lamination device and a welding device in the claims. In this embodiment, the lamination and joining mechanism 48 functions as a lamination device and a welding device (particularly, here, the extension roll 40 functions as a part of the extension device, a part of the lamination device, and a part of the welding device). However, the lamination device and the welding device may be independent devices.

[0053] Generally speaking, the layer joining mechanism 48 stacks the nonwoven fabric sheets S1, S2 and the film F to form the laminate B. In particular, in this embodiment, the layer joining mechanism 48 forms the laminate B in which the film F is disposed between the pair of nonwoven fabric sheets S1, S2.

[0054] In one example, the lamination and joining mechanism 48 as a lamination device laminates the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 in their natural lengths (including almost their natural lengths) and the elastic film F in their natural lengths (including almost their natural lengths). In another example, the lamination and joining mechanism 48 laminates the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 in their natural lengths (including almost their natural lengths) and the elastic film F during transport that is stretched in the transport direction and has an elongation rate of 15% or less.

[0055] Furthermore, the lamination and joining mechanism 48 welds the laminate B (the film F and the nonwoven fabric sheets S1, S2 that are stacked and transported) together to produce a laminated sheet L. The lamination and joining mechanism 48 presses the horn 43 of the ultrasonic joining device 42 against the extension roll 40 that functions as an anvil roll to weld the film F and the nonwoven fabric sheets S1, S2 together.

[0056] <Function of the layering and joining mechanism 48 as a stacking device> A continuous first nonwoven fabric sheet S1 unwound from a raw fabric roll (not shown) is supplied to the stretching roll 40 of the layering and joining mechanism 48 via a guide roll 50. In addition, 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, 54. In the layering and joining mechanism 48, a 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 in which the film F is disposed between the pair of nonwoven fabric sheets S1, S2 is formed.

[0057] When the laminated 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 laminated joining mechanism 48 via a guide roll 50. Then, in the laminated joining mechanism 48, the 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 laminated body B.

[0058] <Function of the Laminated Joining Mechanism 48 as a Welding Device> The laminated joining mechanism 48 moves with the rotation of the extension roll 40 and welds the laminated body B passing between the extension roll 40 (an example of a first member in the claims) functioning as an anvil roll and the horn 43 (an example of a second member in the claims) of the ultrasonic joining device 42. When the laminated joining mechanism 48 welds the laminated body B, the elasticity of some of the resins in the film F may not have reached a stable state. For example, if the raw material of the film F is a mixture of a styrene-based resin and an olefin-based resin, the elasticity of the olefin-based resin may not have reached a stable state. This configuration eliminates the need to wait for the elasticity of all components of the molten raw material to reach a stable state. This eliminates the need to lengthen the transport path of the film F for cooling or transport the film F at a slow speed for cooling, allowing the laminated sheet L to be efficiently produced using relatively compact equipment.

[0059] Specifically, the surface of the stretching roll 40, which functions as an anvil roll, is provided with a plurality of convex portions 40a arranged along the axial direction of the stretching roll 40 (a first direction D1 intersecting (particularly perpendicular here) to the conveying direction A (circumferential direction) of the film F and nonwoven fabric sheets S1, S2) and along the circumferential direction of the stretching roll 40 (see FIGS. 6A and 6B ). The horn 43 is ultrasonically vibrated by an ultrasonic oscillator (not shown). The laminate joining mechanism 48 ultrasonically welds the nonwoven fabric sheets S1, S2 and the film F, which are being conveyed in a stacked state, by vibrating the horn 43 with the ultrasonic oscillator while the film F and the nonwoven fabric sheets S1, S2 (laminate B) are sandwiched between the horn 43 and the convex portions 40a of the stretching roll 40. The nonwoven fabric sheets S1, S2 and the film F are ultrasonically welded together to form a laminated sheet L in which the pair of nonwoven fabric sheets S1, S2 and the film F are intermittently joined at welded portions J.

[0060] More specifically, the layer joining mechanism 48 welds the film F and the nonwoven fabric sheets S1, S2 at a plurality of welds J aligned along a first direction D1 that intersects (particularly orthogonal in this case) with the conveyance direction A of the film F and the nonwoven fabric sheets S1, S2 (the conveyance direction A of the laminate B). While not limiting the shape, the welds J have a rectangular shape with the longitudinal direction being the first direction D1 that intersects (particularly orthogonal in this case) with the conveyance direction A of the film F and the nonwoven fabric sheets S1, S2 (the conveyance direction A of the laminate B). In other words, when the convex portions 40a of the extension roll 40 are viewed radially toward the center of rotation of the extension roll 40, the convex portions 40a have a rectangular shape with the longitudinal direction being the direction of the rotation axis of the extension roll 40.

[0061] It is preferable that a first group of protrusions 401 and a second group of protrusions 402 are provided on the surface of the stretching roll 40 of the layer joining mechanism 48. Both the first group of protrusions 401 and the second group of protrusions 402 include a plurality of protrusions 40a arranged at equal intervals along the first direction D1 (here, the direction of the rotation axis of the stretching roll 40). The first group of protrusions 401 and the second group of protrusions 402 are arranged on the surface of the stretching roll 40 with a circumferential offset. In particular, here, the first group of protrusions 401 and the second group of protrusions 402 are arranged alternately in the circumferential direction on the surface of the stretching roll 40 (see FIG. 6B ). Note that, in the first group of protrusions 401 and the second group of protrusions 402, the protrusions 40a are arranged at different positions in the first direction D1, as shown in FIG. 6B . For example, in the first direction D1, adjacent convex portions 40a of the second convex portion group 402 are arranged between adjacent convex portions 40a of the first convex portion group 401, and adjacent convex portions 40a of the first convex portion group 401 are arranged between adjacent convex portions 40a of the second convex portion group 402.

[0062] The first protrusion group 401 as an example of a first portion in the claims forms a first welded portion group J1 including a plurality of welded portions J arranged at predetermined intervals along the first direction D1 on the film F and the nonwoven fabric sheets S1, S2 (in other words, on the laminated sheet L formed by welding the film F and the nonwoven fabric sheets S1, S2 together) (see FIG. 7 ). The second protrusion group 402 as an example of a second portion in the claims forms a second welded portion group J2 including a plurality of welded portions J arranged at predetermined intervals along the first direction D1 on the film F and the nonwoven fabric sheets S1, S2, at a position offset from the first welded portion group J1 in a second direction D2 (here, the conveying direction A of the film F and the nonwoven fabric sheets S1, S2) perpendicular to the first direction D1 (see FIG. 7 ). In addition, since the convex portions 40a are arranged at different positions in the first direction D1 in the first convex portion group 401 and the second convex portion group 402, the welded portions J in the second welded portion group J2 are arranged at different positions in the first direction D1 from the first welded portion group J1 (see Figure 7).

[0063] 6 , the first convex portion group 401 and the second convex portion group 402 are alternately arranged on the surface of the extension roll 40, and therefore the first welded portion group J1 and the second welded portion group J2 are alternately arranged on the laminated sheet L in the second direction D2 (conveying direction A). Furthermore, in this embodiment, the convex portions 40 a in the first convex portion group 401 and the second convex portion group 402 are arranged at equal intervals in the first direction D1, and adjacent convex portions 40 a in the second convex portion group 402 are arranged between adjacent convex portions 40 a in the first convex portion group 401, and adjacent convex portions 40 a in the first convex portion group 401 are arranged between adjacent convex portions 40 a in the second convex portion group 402. As a result, the welded portions J are arranged in a staggered pattern on the laminated sheet L as shown in FIG.

[0064] The arrangement of the protrusions 40a on the stretching roll 40 is not limited to the embodiment shown in FIG. 6B . For example, instead of the first protrusion group 401 and the second protrusion group 402 being alternately arranged on the stretching roll 40, only groups of protrusions 40a corresponding to the first protrusion group 401 (or the second protrusion group 402) in FIG. 6B may be arranged in a circumferential direction. In this case, as shown in FIG. 10A , a row of welded portions J, in which the welded portions J are arranged at the same position in the first direction D1, is formed on the laminated sheet L in a state aligned along the second direction D2 (conveying direction A). Furthermore, for example, the stretching roll 40 may have three or more protrusion groups (groups of protrusions 40a in which the protrusions 40a are arranged at different positions from each other in the first direction D1) arranged in a circumferential direction. For example, when there are three protrusion groups, the laminated sheet L is formed with welded portions J arranged, for example, as shown in FIG. 10B . Furthermore, for example, the extension roll 40 may have the convex portion groups 401, 402 arranged such that one first convex portion group 401 and two second convex portion groups 402 are provided in the circumferential direction, rather than the first convex portion group 401 and the second convex portion group 402 being alternately arranged in the circumferential direction. For example, when the convex portion groups 401, 402 are present in this manner, the laminated sheet L has a welded portion J formed in an arrangement as shown in FIG. 10C .

[0065] In this way, by changing the arrangement of the welded parts J, the manufacturing system 100 can easily manufacture laminated sheets L with different elongation rates depending on the application, etc. Furthermore, by changing not only the arrangement of the welded parts J but also the density at which the welded parts J are formed, it is possible to easily manufacture laminated sheets L with different elongation rates depending on the application, etc.

[0066] Although the lamination and joining mechanism 48, which is an example of a welding device, has been described here as ultrasonically welding the nonwoven fabric sheets S1, S2 and the film F, the welding method is not limited to ultrasonic welding. For example, the lamination and joining mechanism 48 may be a mechanism that sandwiches the laminate B between two rollers equipped with heaters inside, and heat-seals the nonwoven fabric sheets S1, S2 and the film F.

[0067] (3-5) Laminated Sheet Stretching Mechanism The laminated sheet stretching mechanism 60 is an example of a stretching device in the claims. The laminated sheet stretching mechanism 60 stretches the laminated sheet L (gear stretching) using gear rolls 62, 64 to improve the stretchability and breathability of the laminated sheet L.

[0068] 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 alternating tooth portions 62a and valley portions 62b along the circumferential direction of the gear roll 62, like a spur gear. The gear roll 64 also has a plurality of alternating tooth portions 64a and valley portions 64b 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 tooth portions 62a of the gear roll 62 and the valley portions 64b of the gear roll 64 mesh with each other, and the valley portions 62b of the gear roll 62 and the tooth portions 64a of the gear roll 64 mesh with each other. The laminated sheet L transported from the laminate joining mechanism 48 along the transport direction A is supplied to the meshing portion between the gear rolls 62 and 64 and stretched.

[0069] Then, the laminated sheet stretching mechanism 60 stretches the laminated sheet L (in other words, the film F and nonwoven fabric sheets S1, S2 that are integrated by welding and transported) using the laminated sheet stretching mechanism 60 to form an opening Op at the welded portion J between the film F and the nonwoven fabric sheets S1, S2 and / or around the welded portion J, and / or widen the opening Op.

[0070] Specifically, when the laminate sheet L is stretched in the conveying direction A before being stretched by the laminate sheet stretching mechanism 60, openings Op are formed by the action of heat at the welded portions J (the dotted portions) of the laminate sheet L and around them, as shown in FIG. 8 . Note that FIG. 8 is a schematic diagram and does not limit the actual shape, size, position, etc. of the openings Op. When openings Op are formed in the laminate sheet L, the nonwoven fabric sheets S1 and S2 become more easily deformed (compared to when there are no openings Op), thereby improving the stretchability of the laminate sheet L. In particular, when the welded portions J are arranged in a staggered pattern as shown in FIG. 8 , the stretchability of the laminate sheet L is more likely to be improved. Furthermore, when openings Op are formed in the laminate sheet L, the breathability of the laminate sheet L is improved (compared to when there are no openings Op).

[0071] However, since such openings Op are relatively small, there is a risk that the openings Op may not have a sufficient area to ensure the breathability and stretchability of the laminated sheet L.

[0072] In contrast, by performing stretching using the laminated sheet stretching mechanism 60, the film F is cut, for example, at a part of the welded portion J of the laminated sheet L or at a location other than the opening Op around the welded portion J. For example, in the example of FIG. 9, the film F is cut at the welded portion J of the laminated sheet L by stretching, and an opening Op is formed. Also, in the example of FIG. 9, a force is applied to the already existing opening Op, resulting in an increase in the width of the opening Op. Note that FIG. 9 is a schematic diagram and does not limit the shape, size, position, etc. of the actual opening Op.

[0073] In this way, by the laminated sheet stretching mechanism 60 stretching the laminated sheet L, as shown in Fig. 9, relatively large openings are formed in the laminated sheet L. As a result, the breathability and stretchability of the laminated sheet L are improved.

[0074] Here, the laminate sheet stretching mechanism 60 stretches the laminate sheet L in the conveying direction A. In this case, the laminate sheet L is provided with stretchability, particularly along the conveying direction A, making it more likely to stretch along the conveying direction A. In particular, since the laminate sheet L has welded portions J whose longitudinal direction is the first direction D1 perpendicular to the conveying direction A of the laminate sheet L, stretching the laminate sheet L in the conveying direction A by the laminate sheet stretching mechanism 60 makes it more likely to be provided with high stretchability along the conveying direction A. In FIG. 7 , the welded portions J have a rectangular shape whose longitudinal direction is the first direction D1, but the shape of the welded portions J is not limited to a rectangular shape. For example, the welded portions J may have an elliptical shape whose longitudinal direction is the first direction D1, as shown in FIG. 11A .

[0075] The laminated sheet stretching mechanism 60' may be a device having a pair of rollers 62', 64' as described below, which stretches the laminated sheet L in a direction perpendicular to the conveying direction A (first direction D1).

[0076] The pair of rollers 62', 64' extend perpendicular to the conveying direction A of the laminated sheet L. As shown in FIG. 12 , roller 62', one of the pair of rollers, has a plurality of circumferentially continuous teeth 62a' formed along the rotation axis of roller 62'. Furthermore, roller 64', the other of the pair of rollers, has a plurality of circumferentially continuous teeth 64a' formed along the rotation axis of roller 64'. The teeth 62a' and 64a' are arranged such that the teeth 62a' fit into gaps between the teeth 64a', and the teeth 64a' fit into gaps between the teeth 62a'. By sandwiching the laminated sheet L between these rollers 62', 64' and conveying the laminated sheet L in the conveying direction A, the laminated sheet L is stretched in a direction (first direction D1) perpendicular to the conveying direction A.

[0077] Although not shown, when the laminate sheet L is stretched in a direction (first direction D1) perpendicular to the conveying direction A, the welded portion J may have a shape whose longitudinal direction is the conveying direction A perpendicular to the first direction D1. By selecting such a shape for the welded portion J, the laminate sheet L is likely to be given high stretchability along the first direction D1.

[0078] Furthermore, the shape of the welded portion J may be a square shape having a side extending in the conveying direction A and a side extending in the first direction D1, or a circle (see FIGS. 11B and 11C ). For example, when the square shape and the circle shape of the welded portion J are employed and the laminated sheet L is stretched using the laminated sheet stretching mechanism 60 and the laminated sheet stretching mechanism 60′, the laminated sheet L can be realized to have high stretchability in both the conveying direction A and the first direction D1.

[0079] (3-6) 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.

[0080] 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.

[0081] 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.

[0082] (4) Manufacturing Method of Laminated Sheet The manufacturing method of the laminated sheet L will be described again with reference to FIG.

[0083] The film F is produced in the discharge mechanism 20. Specifically, in the discharge mechanism 20, a resin material that is elastic at room temperature as a raw material is heated and melted, and extruded from the discharge port 24 to produce the film F (step P1).

[0084] The extruded film F is sent to the cooling roll 30. At the cooling roll 30, the film F is cooled to a first temperature (step P2). For example, if the raw material is a mixture of a styrene-based resin and an olefin-based resin, the film F is cooled to the first temperature at which the elasticity of the olefin-based resin does not reach a stable state, but the elasticity of the styrene-based resin does reach a stable state.

[0085] The film F pulled out from the cooling roll 30 is sent to the film stretching mechanism 38, where it is stretched to reduce its thickness (step P3). The stretching rate of the film F in the film stretching mechanism 38 is determined, for example, depending on the resin components of the raw material. For example, if the raw material is a mixture of a styrene-based resin and an olefin-based resin, the higher the blending rate of the olefin-based resin, the higher the stretching rate is set.

[0086] The film F stretched by the film stretching mechanism 38 is sent to the laminating and joining mechanism 48 and laminated with the nonwoven fabric sheets S1 and S2 (step P4). In particular, in this embodiment, the film F and the nonwoven fabric sheets S1 and S2 are laminated between the pair of nonwoven fabric sheets S1 and S2 (to form a laminate B).

[0087] In the lamination, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 are laminated in their natural lengths (including almost their natural lengths) and the elastic film F is laminated in its natural length (including almost its natural length). Alternatively, the first nonwoven fabric sheet S1 and the second nonwoven fabric sheet S2 are laminated in their natural lengths (including almost their natural lengths) stretched in the conveyance direction A and the elastic film F being conveyed and stretched in the conveyance direction A with an elongation rate of 15% or less may be laminated.

[0088] Furthermore, in the laminate joining mechanism 48, the film F and nonwoven fabric sheets S1, S2 that are stacked and transported (in other words, the transported laminate B) are sandwiched between the extension roll 40 and the horn 43 of the ultrasonic joining device 42, and the pair of stacked nonwoven fabric sheets S1, S2 and the film F are welded together to produce a laminate sheet L.

[0089] The film F and nonwoven fabric sheets S1, S2 (i.e., laminated sheet L) that are transported and integrated by welding are sent to the laminated sheet stretching mechanism 60 and stretched (step P6). As a result, openings Op are formed at the welded portions J between the film F and the nonwoven fabric sheets S1, S2 and / or around the welded portions J. Furthermore, as a result of stretching the laminated sheet L, the openings Op that were formed at the welded portions J and around them during welding are widened. As a result, the stretchability and breathability of the laminated sheet L are improved.

[0090] As mentioned above, the laminated sheet L may be stretched in the conveying direction A, or in a first direction D1 perpendicular to the conveying direction A, or in both the conveying direction A and the first direction D1.

[0091] The manufacturing method of the laminated sheet L described here is merely an example, and may be modified as appropriate, as mentioned in the description of the manufacturing system 100. For example, the stretching step of step P3 may be omitted. Also, the elongation step of step P6 may be omitted.

[0092] Furthermore, for example, the manufactured laminate sheet L may not be sent directly to a manufacturing line for a worn article. Instead, as shown in FIG. 13 , when the laminate sheet L is produced in step P5, the laminate sheet L may be temporarily wound around a core (not shown) (step P5a) ​​to form a roll R around the laminate sheet L. The laminate sheet L may then be transported in the form of the wound roll R to a factory where it will actually be used (step P5b). Alternatively, although not shown, the wound roll R of the laminate sheet L may be temporarily stored in a warehouse or the like (rather than transported to another location). Then, when actually used, the laminate sheet L may be unwound from the roll R and stretched using a device such as a laminate sheet stretching mechanism 60, 60′ (step P6), and the stretch-activated laminate sheet L may be used to manufacture a worn article (see FIG. 14 ).

[0093] In this way, the laminated sheet L manufactured by the manufacturing apparatus and manufacturing method described above in steps P1 to P5 is temporarily wound up into a roll R after step P5, and then (after a certain time has passed) the laminated sheet L is unwound from the roll R and stretched using an apparatus such as the laminated sheet stretching mechanism 60, 60', and the advantages of using the stretchable laminated sheet L in the manufacture of worn articles will be explained.

[0094] In the manufacture of a worn article, all steps related to the manufacture of the worn article are not carried out continuously, and for example, a laminate sheet L manufactured at another location or by another company may be used.

[0095] In this case, the manufactured laminated sheet L is packaged, transported, and stored. Considering the stability of the packaging operation, productivity, handling of the packaged body, transport efficiency of the packaged body, and storage of the packaged body, roll packaging in which the laminated sheet L is wound around a core material and packaged in a roll shape is preferred.

[0096] However, if the laminate sheet L is stretched using an apparatus such as the laminate sheet stretching mechanism 60, 60', and then the laminate sheet L (hereinafter, for simplicity of description, the laminate sheet L after stretching using an apparatus such as the laminate sheet stretching mechanism 60, 60' will be referred to as a stretched laminate sheet) is wound around a core material while under tension, and this roll is stored for a long period of time, the laminate sheet L may become too stretched and may no longer be usable as the laminate sheet L.

[0097] Therefore, when packaging, transporting, and storing the stretched laminated sheet, it is conceivable to adopt a packaging method in which the laminated sheet L is folded and packed in a laminated state (without applying tension). However, the package of the stretched laminated sheet obtained by this method is poor in handleability and bulky, resulting in poor transport efficiency and storage properties.

[0098] Another possible method for packaging stretched laminated sheets is to apply a weak tension to the stretched laminated sheet so that the sheet is not fully stretched and wound around a core to form a roll. However, in such a package in which the stretched laminated sheet is loosely wound, the stretched laminated sheet is prone to shifting, and the length of the elastic member that can be packed per roll is reduced, resulting in increased roll replacement frequency and a workload in the manufacturing process of worn articles.

[0099] However, as described above, when the laminated sheet L before stretching using a device such as the laminated sheet stretching mechanism 60, 60' is first wound around a core material to form a roll R, and then the laminated sheet L is unwound from the roll R, the elasticity of the laminated sheet L is activated when stretched by the laminated sheet stretching mechanism 60, 60', so that the elastic laminated sheet L can be used in worn articles even when the laminated sheet L is wound around a core material with a certain amount of tension applied to it.

[0100] Furthermore, in the present invention, by producing a laminate sheet using the above-described production apparatus and production method, it is possible to produce a laminate sheet L using a small amount of nonwoven fabric per unit area, and therefore the thickness of the laminate sheet L is unlikely to be large. Therefore, assuming that the sheet is wrapped around the core material so that the outer diameter is the same, the length of the laminate sheet that can be packaged per roll is longer when the laminate sheet L is used than when a laminate sheet using a large amount of nonwoven fabric is used. Therefore, the laminate sheet L of this embodiment also provides effects such as improved transportability and storability when formed into a roll R and reduced frequency of replacing the roll R when manufacturing worn articles.

[0101] Furthermore, the inventors of the present application have discovered that the elasticity of the laminated sheet L can also be improved by waiting a certain amount of time (first winding the laminated sheet L around a core material to form a roll R, which is then transported and stored in that state) before stretching the laminated sheet L using the laminated sheet stretching mechanisms 60, 60', rather than immediately stretching the laminated sheet L using the laminated sheet stretching mechanisms 60, 60' after the welding process of step P5.

[0102] Specifically, when a mixture of styrene resin and olefin resin is used as the resin material as described above, the elasticity of the olefin resin may not be completely stable immediately after the welding process in step P5. If the laminated sheet is stretched in this state by the laminated sheet stretching mechanism 60, 60', the film F constituting the laminated sheet L will be partially plastically deformed, and such plastically deformed portions will not contribute to the elasticity of the laminated sheet L.

[0103] In contrast, if, after step P5, the laminate sheet L is temporarily wound around a core material to form a roll R, and then stretched by the laminate sheet stretching mechanism 60, 60' after a certain amount of time has passed, the elasticity of the olefin-based resin is also stable, so the film F that constitutes the laminate sheet L is less likely to undergo plastic deformation, and the resulting laminate sheet L has high elasticity.

[0104] (5) Features (5-1) A method for producing a laminated sheet L for a wearing article includes a film producing step P1, a cooling step P2, a laminating step P4, and a welding step P5. In the film producing step P1, a molten raw material is extruded to produce a film F. In the cooling step P2, the extruded film F is cooled. In the laminating step P4, nonwoven fabric sheets S1, S2 in their natural length are laminated with an elastic film F in their natural length that is being transported. Alternatively, in the laminating step P4, nonwoven fabric sheets S1, S2 in their natural length are laminated with an elastic film F in the transport that is stretched in the transport direction A and has an elongation rate of 15% or less. In the welding step P5, the film F and the nonwoven fabric sheets S1, S2 that are being transported in a stacked state are welded to produce a laminated sheet L.

[0105] This method for manufacturing the laminated sheet L allows the production of a laminated sheet L with a low basis weight (a low weight of the nonwoven fabric sheets S1 and S2 per unit area) compared to when the laminated sheet L is formed by stacking a film F in a highly stretched state with the nonwoven fabric sheets S1 and S2.

[0106] Furthermore, in this manufacturing method of the laminate sheet L, the film F and the nonwoven fabric sheets S1, S2 are welded together, and an opening Op is formed at or around the welded portion J during welding. The formation of the opening Op also makes the nonwoven fabric sheets S1, S2 more likely to deform, so this manufacturing method of the laminate sheet L can manufacture a laminate sheet L with a high elongation rate. Furthermore, because this manufacturing method forms the opening Op, it can manufacture a laminate sheet L with good breathability.

[0107] (5-2) The method for producing the laminated sheet L of this embodiment includes a stretching step P6 in which the film F and the nonwoven fabric sheets S1, S2, which are transported while being integrated by welding, are stretched to form openings Op at the welded portions J between the film F and the nonwoven fabric sheets S1, S2 and / or around the welded portions J, and / or to widen the openings Op.

[0108] By providing the stretching step P6, it is possible to produce a laminated sheet L that has a particularly high elongation rate and good breathability.

[0109] (5-3) The method for producing the laminated sheet L of this embodiment includes a stretching step P3 of stretching the film F to reduce its thickness after the cooling step P2 and before the laminating step P4.

[0110] By providing the stretching step P3 and reducing the thickness of the film F constituting the laminate sheet L, it is possible to produce a laminate sheet L that is easily deformed with a relatively small force and that is less likely to cause a strong feeling of tightness to the wearer of the worn article. Furthermore, by reducing the thickness of the film F constituting the laminate sheet L, it is possible to produce a laminate sheet L with a low basis weight (here, a low weight of the film F per unit area).

[0111] (5-4) In the method for producing the laminate sheet L of this embodiment, the melted raw material contains a first resin and a second resin that have different conditions for stabilizing the stretchability. In the cooling step P2, the film F is cooled to a first temperature at which the stretchability of the first resin is stabilized but the stretchability of the second resin is not stabilized.

[0112] Although not limited thereto, the first resin is, for example, a styrene-based resin, and the second resin is, for example, an olefin-based resin.

[0113] For example, when a styrene-based resin and an olefin-based resin are used as the resin material, the weight ratio of the styrene-based resin to the olefin-based resin is 1:0.33 to 0.54, and the content of the styrene-based resin and the olefin-based resin in the entire raw material is 90% by weight or more.

[0114] In this method for producing the laminated sheet L, the film F and the nonwoven fabric sheets S1 and S2 can be laminated and integrated, rather than using raw materials that are not completely stable in terms of stretchability, and at least one component of the film F has stabilized stretchability. On the other hand, because it is not necessary to wait for all components of the molten raw materials to reach a stable stretchability, the laminated sheet L can be produced efficiently using relatively compact equipment without having to lengthen the transport path of the film F for cooling or transport the film F at a low speed for cooling.

[0115] Although the above embodiment has been described mainly with reference to an example in which the raw material contains two types of resin, the raw material may contain three or more types of resin. In this case, the cooling step P2 may cool the film F to a temperature at which the stretchability of at least one type of resin becomes stable, but the stretchability of the other resins does not become stable.

[0116] (5-5) In the manufacturing method of the laminated sheet L of this embodiment, when two types of resins, a first resin and a second resin, are used, it is preferable that the stretching ratio of the film F in the stretching process P3 be set according to the blending ratio of the second resin, the elasticity of which does not reach a stable state in the cooling process P2.

[0117] In the manufacturing method of the laminated sheet L, the elongation ratio of the film F, in other words, the thickness of the film F produced, can be appropriately adjusted by changing the compounding ratio of the second resin according to the application of the laminated sheet L, etc.

[0118] In addition, when the raw material contains three or more types of resin, the stretching ratio of the film in the stretching step P3 may be set according to the blending ratio of the resin that does not reach a stable state by the cooling step P2.

[0119] (5-6) In the manufacturing method of the laminated sheet L of this embodiment, the film F and the nonwoven fabric sheets S1 and S2 are welded at a plurality of welds J in the welding step P5.

[0120] For example, the multiple welded portions J are aligned along a first direction D1 that intersects (particularly, is perpendicular to) the conveyance direction A of the film F and the nonwoven fabric sheets S1 and S2.

[0121] Each welded portion J has a shape whose longitudinal direction is a first direction D1 that intersects (particularly in this case, is perpendicular to) the conveying direction A of the film F and the nonwoven fabric sheets S1, S2. When configured in this manner, a laminated sheet L having high stretchability in the direction perpendicular to the first direction D1 can be produced.

[0122] Alternatively, each welded portion J may have a shape whose longitudinal direction is, for example, a second direction D2 perpendicular to the first direction D1 (particularly, in this embodiment, the conveying direction A of the laminated sheet L). When configured in this manner, a laminated sheet L having high stretchability in the first direction D1 can be manufactured.

[0123] Alternatively, each welded portion J may have a square or circular shape. When configured in this manner, a laminated sheet L having high stretchability in the first direction D1 as well as in a direction perpendicular to the first direction D1 can be manufactured.

[0124] In this way, by appropriately selecting the shape of the welded portion J, the stretchability of the laminated sheet L in a desired direction can be increased.

[0125] (5-7) In the manufacturing method of the laminated sheet L of this embodiment, a plurality of welds J arranged at predetermined intervals along a first direction D1 that intersects with (particularly orthogonal in this case) the conveyance direction A of the film F and nonwoven fabric sheets S1, S2 constitute one weld group. The weld group includes a first weld group J1 and a second weld group J2 that is positioned away from the first weld group J1 in a second direction D2 (particularly, the conveyance direction A in the above embodiment) that intersects with the first direction D1. In the second weld group J2, the welds J are positioned at a different position in the first direction D1 from the first weld group J1.

[0126] In this manufacturing method of the laminated sheet L, by providing a first group of welded portions J1 and a second group of welded portions J2, it is possible to manufacture a laminated sheet L with higher elasticity than when the welded portions J are arranged in the second direction D2 without changing their positions.

[0127] Preferably, the first welded portion groups J1 and the second welded portion groups J2 are arranged alternately in the second direction D2, and the welded portions J are arranged in a staggered pattern in the laminated sheet L.

[0128] By arranging the welded portions J in a staggered pattern, a laminated sheet L having high stretchability can be produced.

[0129] (5-8) In the stretching step P6, the laminate sheet L is stretched in the machine direction A to produce a laminate sheet L having high stretchability in the machine direction A.

[0130] Alternatively, in the stretching process P6, the laminated sheet L may be stretched in a direction perpendicular to the conveying direction A in order to produce a laminated sheet L having high elasticity in a direction perpendicular to the conveying direction A (in the above embodiment, the first direction D1).

[0131] (5-9) The method for producing the laminate sheet L of this embodiment may include a winding step after the welding step P5 and before the stretching step P6, in which the laminate sheet L is wound up to form a roll R of the laminate sheet L. In the stretching step P6, the film F and the nonwoven fabric sheets S1 and S2 of the laminate sheet L that are unwound from the roll R and transported are stretched.

[0132] By configuring the laminated sheet L in this manner, even if the laminated sheet L is wound around a core material while a certain degree of tension is applied to the laminated sheet L to form a roll R, and the roll R is transported, stored, etc., the laminated sheet L can be activated in the stretching process P6 to produce a highly elastic laminated sheet L.

[0133] Furthermore, by being configured in this manner, as described above, when, for example, a mixture of styrene-based resin and olefin-based resin is used as the resin material (raw material for the film), plastic deformation of the olefin-based resin during the stretching process can be suppressed, and a highly elastic laminated sheet L can be produced.

[0134] (5-10) A manufacturing system 100 for a laminated sheet L for a worn article includes a discharge mechanism 20 as an example of a film producing device, a cooling roll 30 as an example of a cooling device, and a layering and joining mechanism 48 as an example of a laminating device and a welding device. The discharge mechanism 20 extrudes molten raw material to produce a film F. The cooling roll 30 cools the extruded film F. The layering and joining mechanism 48 layers nonwoven fabric sheets S1, S2 in a natural length state and an elastic film F in a natural length state that is being transported. Alternatively, the layering and joining mechanism 48 layers nonwoven fabric sheets S1, S2 in a natural length state and an elastic film F in a transported state that is stretched in the transport direction A and has an elongation rate of 15% or less. The layering and joining mechanism 48 welds the film F and nonwoven fabric sheets S1, S2 that are being transported in a stacked state to produce the laminated sheet L.

[0135] This manufacturing system 100 can produce a laminated sheet L with a low basis weight (a low weight of the nonwoven fabric sheets S1, S2 per unit area). Also, this manufacturing system 100 can produce a laminated sheet L with a high elongation rate and good breathability.

[0136] (5-11) The manufacturing system 100 for the laminated sheet L includes a film stretching mechanism 38 as an example of a stretching device that stretches the film F to reduce its thickness after cooling by the cooling roll 30 (and before laminating the film F and the nonwoven fabric sheets S1 and S2).

[0137] This manufacturing system 100 can manufacture a laminated sheet L having a low basis weight (here, a low weight of the film F per unit area).

[0138] (5-12) In the laminated sheet L manufacturing system 100, the laminate joining mechanism 48 sandwiches the film F and the nonwoven fabric sheets S1, S2 between an extension roll 40 (anvil roll) as an example of a first member and a horn 43 as an example of a second member, and welds them at a plurality of welds J aligned along a first direction D1 that intersects with (is orthogonal to in this embodiment) the conveyance direction A of the film F and the nonwoven fabric sheets S1, S2. The extension roll 40 includes a first group of protrusions 401 as an example of a first portion, and a second group of protrusions 402 as an example of a second portion. The first group of protrusions 401 forms a first group of welds J1 in the film F and the nonwoven fabric sheets S1, S2, including a plurality of welds J aligned at predetermined intervals along the first direction D1. The second protrusion group 402 forms a second welded portion group J2 on the film F and the nonwoven fabric sheets S1, S2, including a plurality of welded portions J arranged at predetermined intervals along the first direction D1, at a position offset from the first welded portion group J1 in a second direction D2 (here, the conveying direction A) perpendicular to the first direction D1. In the second welded portion group J2, the welded portions J are arranged at a different position in the first direction D1 from the first welded portion group J1.

[0139] This manufacturing system 100 can manufacture a laminated sheet L having high elasticity.

[0140] (5-13) The manufacturing system 100 for the laminated sheet L includes a laminated sheet stretching mechanism 60 as an example of a stretching device. The laminated sheet stretching mechanism 60 stretches the film F and the nonwoven fabric sheets S1, S2 (the laminated sheet L), which are transported while being integrated by welding, in the transport direction A of the film F and the nonwoven fabric sheets S1, S2 or in a direction perpendicular to the transport direction A, to form an opening Op at a welded portion J between the film F and the nonwoven fabric sheets S1, S2 and / or around the welded portion J, and / or to widen the opening Op.

[0141] This manufacturing system 100 can manufacture a laminated sheet L that has a particularly high elongation rate and good breathability.

[0142] (5-14) In the laminated sheet L for a worn article, an elastic film F and nonwoven fabric sheets S1, S2 are laminated together. The film F and the nonwoven fabric sheets S1, S2 are integrated by welding. When the nonwoven fabric sheets S1, S2 are at their natural lengths, no tension acts on the film F.

[0143] (5-15) The laminate sheet L is welded at a plurality of welds J arranged along a first direction (here, the first direction D1 during the manufacture of the laminate sheet L). A plurality of welds J arranged at a predetermined interval along the first direction D1 constitute one weld group. The weld group includes a first weld group J1 and a second weld group J2 that is positioned away from the first weld group J1 in a second direction D2 that is perpendicular to the first direction D1. In the second weld group J2, the welds J are arranged in a different position from the first weld group J1 in the first direction D1.

[0144] (5-16) In the laminate sheet L, the film F and the nonwoven fabric sheets S1 and S2 are welded at a plurality of welds J arranged along the first direction D1. Each weld J has a shape with the first direction D1 as its longitudinal direction. Alternatively, each weld J has a square or circular shape.

[0145] <Additional Notes> Finally, the following additional notes will be added regarding the technical ideas that can be understood from the above-described embodiments.

[0146] A first aspect of the method for producing a laminated sheet for a wearing article includes a film producing step, a cooling step, a laminating step, and a welding step. In the film producing step, a molten raw material is extruded to produce a film. In the cooling step, the extruded film is cooled. In the laminating step, a nonwoven fabric in a natural length state and an elastic film in a natural length state that is being transported are laminated. Alternatively, in the laminating step, a nonwoven fabric in a natural length state and an elastic film that is being transported and stretched in the transport direction with an elongation rate of 15% or less are laminated. In the welding step, the film and nonwoven fabric that are being transported in a layered state are welded to produce a laminated sheet.

[0147] In the method for manufacturing a laminated sheet according to the first aspect, a nonwoven fabric in its natural length is laminated with a film in its natural length or a film with an elongation rate of 15% or less (stretched by 15% or less from its natural length), and therefore a laminated sheet with a low basis weight (less weight of nonwoven fabric per unit area) can be manufactured compared to when a laminated sheet is formed by laminating a film in a highly stretched state with a nonwoven fabric.

[0148] In addition, in the laminate sheet manufacturing method of the first aspect, by welding the film and the nonwoven fabric, openings are formed at or around the welded portion during welding. Since the formation of openings makes the nonwoven fabric more likely to deform, this laminate sheet manufacturing method can manufacture a laminate sheet with high extensibility. Furthermore, since openings are formed in this manufacturing method, a laminate sheet with good breathability can be manufactured.

[0149] The method for manufacturing a laminated sheet according to a second aspect is the method for manufacturing a laminated sheet according to the first aspect, and further comprises a stretching step of stretching the film and nonwoven fabric that are transported while being integrated by welding, to form openings at the welded portions between the film and nonwoven fabric and / or around the welded portions, and / or to widen the openings.

[0150] In the method for producing a laminated sheet according to the second aspect, a laminated sheet having a particularly high elongation rate and good breathability can be produced.

[0151] A method for producing a laminate sheet according to a third aspect is the method for producing a laminate sheet according to the first or second aspect, further comprising a stretching step of stretching the film to reduce its thickness after the cooling step and before the laminating step.

[0152] In the method for producing a laminate sheet according to the third aspect, by reducing the thickness of the films constituting the laminate sheet, it is possible to produce a laminate sheet that is easily deformed by a relatively small force and that is less likely to cause a strong feeling of tightness to the wearer of the worn article. Furthermore, by reducing the thickness of the films constituting the laminate sheet, it is possible to produce a laminate sheet with a low basis weight (here, a low weight of film per unit area).

[0153] A fourth aspect of the present invention relates to a method for producing a laminate sheet according to any one of the first to third aspects, wherein the melted raw material contains a first resin and a second resin, the first and second resins having different conditions for stabilizing the stretchability. In the cooling step, the film is cooled to a first temperature at which the stretchability of the first resin is stabilized but the stretchability of the second resin is not stabilized.

[0154] In the method for producing a laminated sheet according to the fourth aspect, a film and a nonwoven fabric in which the stretchability of at least one component has been stabilized can be laminated and integrated. Meanwhile, since it is not necessary to wait for the stretchability of all components of the molten raw material to be stabilized, the laminated sheet can be produced efficiently using relatively compact equipment without having to lengthen the film transport path for cooling or transport the film at a low speed for cooling.

[0155] A fifth aspect of the present invention relates to the method for producing a laminate sheet according to the fourth aspect, and further includes a stretching step of stretching the film to reduce its thickness after the cooling step and before the laminating step. The stretching ratio of the film in the stretching step is set according to the blending ratio of the second resin.

[0156] In the method for producing a laminate sheet according to the fifth aspect, the blending ratio of the second resin can be changed according to the application of the laminate sheet, thereby making it possible to appropriately adjust the stretching ratio of the film in the stretching step, in other words, the thickness of the film produced.

[0157] A sixth aspect of the present invention relates to the method for producing a laminate sheet according to the fourth or fifth aspect, in which the first resin is a styrene-based resin and the second resin is an olefin-based resin.

[0158] A seventh aspect of the present invention relates to a method for producing a laminate sheet according to the sixth aspect, wherein the weight ratio of the first resin to the second resin is 1:0.33 to 0.54, and the content ratio of the first resin to the second resin in the raw materials is 90% by weight or more.

[0159] A laminated sheet manufacturing method according to an eighth aspect is the laminated sheet manufacturing method according to any one of the first to seventh aspects, wherein the welding step involves welding at a plurality of welding portions, each of which has a shape whose longitudinal direction is in a direction intersecting the transport direction of the film and nonwoven fabric.

[0160] In the method for producing a laminated sheet according to the eighth aspect, it is possible to produce a laminated sheet that has high stretchability in a direction perpendicular to the longitudinal direction of the welded portions.

[0161] A ninth aspect of the present invention relates to the method for producing a laminate sheet according to any one of the first to seventh aspects, wherein in the welding step, the film and the nonwoven fabric are welded at a plurality of welds, each of which has a square or circular shape.

[0162] In the laminate sheet manufacturing method of the ninth aspect, it is possible to manufacture a laminate sheet that has high stretchability both in the conveying direction and in a direction perpendicular to the conveying direction.

[0163] A tenth aspect of the present invention relates to a method for manufacturing a laminate sheet according to any one of the first to ninth aspects, wherein a plurality of welds aligned along a first direction intersecting the conveyance direction of the film and the nonwoven fabric constitute one weld group. The weld group includes a first weld group and a second weld group positioned at a position offset from the first weld group in a second direction orthogonal to the first direction. In the second weld group, the welds are positioned at a different position in the first direction from the first weld group.

[0164] In the method for producing a laminate sheet according to the tenth aspect, by providing the first group of welded portions and the second group of welded portions, a laminate sheet having high stretchability can be produced.

[0165] A method for manufacturing a laminated sheet according to an eleventh aspect is the method for manufacturing a laminated sheet according to the tenth aspect, wherein the first groups of welded portions and the second groups of welded portions are arranged alternately in the second direction. In the laminated sheet, the welded portions are arranged in a staggered pattern.

[0166] In the method for producing a laminate sheet according to the eleventh aspect, by providing the welded portions in a staggered pattern, a laminate sheet having high stretchability can be produced.

[0167] A twelfth aspect of the present invention relates to the method for producing a laminate sheet according to the second aspect, wherein the laminate sheet is stretched in the conveyance direction in the stretching step.

[0168] In the method for producing a laminate sheet according to the twelfth aspect, a laminate sheet having high stretchability in the conveyance direction can be produced.

[0169] A thirteenth aspect of the present invention relates to the method for producing a laminate sheet according to the second or twelfth aspect, wherein in the stretching step, the laminate sheet is stretched in a direction perpendicular to the conveyance direction.

[0170] In the method for producing a laminated sheet according to the thirteenth aspect, a laminated sheet having high stretchability in the conveyance direction can be produced.

[0171] A fourteenth aspect of the present invention relates to the method for producing a laminate sheet L of the second, twelfth or thirteenth aspect, and further includes a winding step of winding the laminate sheet to form a roll of the laminate sheet after the welding step and before the stretching step. In the stretching step, the film and nonwoven fabric sheet of the laminate sheet that are unwound from the roll and transported are stretched.

[0172] In the method for manufacturing a laminated sheet of the fourteenth aspect, a laminated sheet is wound around a core material while a certain degree of tension is applied to the laminated sheet to form a roll, and even if the roll is transported, stored, etc., a highly elastic laminated sheet can be manufactured by activating the laminated sheet in the stretching process.

[0173] Furthermore, in the method for producing a laminate sheet according to the fourteenth aspect, for example, when a mixture of a styrene-based resin and an olefin-based resin is used as a raw material, plastic deformation of the olefin-based resin during stretching in the stretching step can be suppressed, thereby producing a highly elastic laminate sheet.

[0174] A fifteenth aspect of the present invention provides a system for manufacturing a laminated sheet for a worn article, the system comprising a film producing device, a cooling device, a laminating device, and a welding device. The film producing device extrudes molten raw material to produce a film. The cooling device cools the extruded film. The laminating device laminates a nonwoven fabric in a natural length state and an elastic film in a natural length state that is being transported. Alternatively, the laminating device laminates a nonwoven fabric in a natural length state and an elastic film that is being transported and stretched in the transport direction with an elongation rate of 15% or less. The welding device welds the film and nonwoven fabric that are being stacked and transported to produce a laminated sheet.

[0175] In the laminated sheet manufacturing system of the fifteenth aspect, a nonwoven fabric in its natural length and a film in its natural length, or a film with an elongation rate of 15% or less (stretched by 15% or less from its natural length) are laminated together, so that a laminated sheet with a low basis weight (less weight of nonwoven fabric per unit area) can be manufactured compared to when a laminated sheet is formed by laminating a film in a highly stretched state and a nonwoven fabric.

[0176] In addition, in the laminate sheet manufacturing system of the fifteenth aspect, by welding the film and the nonwoven fabric, openings are formed at or around the welded portion during welding. Since the formation of openings makes the nonwoven fabric more easily deformable, this laminate sheet manufacturing method can manufacture a laminate sheet with high extensibility. Furthermore, since openings are formed in this manufacturing method, a laminate sheet with good breathability can be manufactured.

[0177] A laminated sheet manufacturing system according to a sixteenth aspect is the manufacturing system according to the fifteenth aspect, further including a stretching device that stretches the film to reduce its thickness after cooling by the cooling device.

[0178] In the laminate sheet manufacturing system of the sixteenth aspect, by reducing the thickness of the elastic film constituting the laminate sheet, it is possible to manufacture a laminate sheet that is easily deformed by a relatively small force and that is less likely to cause a strong feeling of tightness to a wearer of the worn article. Furthermore, by reducing the thickness of the film constituting the laminate sheet, it is possible to manufacture a laminate sheet with a low basis weight (here, a low weight of film per unit area).

[0179] A seventeenth aspect of the laminated sheet manufacturing system is the manufacturing system of the fifteenth or sixteenth aspect, in which the welding device sandwiches the film and nonwoven fabric between a first member and a second member and welds them at a plurality of welds. The first member includes a first portion and a second portion. The first portion forms a first group of welds in the film and nonwoven fabric, the first group including a plurality of welds aligned along a first direction intersecting a conveyance direction of the film and nonwoven fabric. The second portion forms a second group of welds in the film and nonwoven fabric, the second group including a plurality of welds aligned along the first direction, at a position offset from the first group of welds in a second direction perpendicular to the first direction. In the second group of welds, the welds are arranged at a different position in the first direction from the first group of welds.

[0180] In the laminate sheet manufacturing system of the seventeenth aspect, a laminate sheet having high stretchability can be manufactured.

[0181] A laminated sheet manufacturing system according to an eighteenth aspect is the manufacturing system according to any one of the fifteenth to seventeenth aspects, further comprising a stretching device. The stretching device stretches the film and nonwoven fabric, which are conveyed while being integrated by welding, in the conveying direction of the film and nonwoven fabric or in a direction perpendicular to the conveying direction, to form openings at the welded portions between the film and nonwoven fabric and / or around the welded portions, and / or to widen the openings.

[0182] In the laminated sheet manufacturing system of the eighteenth aspect, a laminated sheet having a particularly high elongation rate and good breathability can be manufactured.

[0183] In a nineteenth aspect of the present invention, a laminate sheet for a wearing article includes an elastic film and a nonwoven fabric laminated together. The film and the nonwoven fabric are integrated by welding. When the nonwoven fabric is in its natural length, no tension acts on the film.

[0184] In the laminate sheet of the nineteenth aspect, when the nonwoven fabric is at its natural length, no tension acts on the film, so the amount of nonwoven fabric used per unit area can be reduced. Furthermore, in the laminate sheet of the nineteenth aspect, openings are formed at or around the welded portion when the film and nonwoven fabric are welded, which makes the nonwoven fabric more likely to deform, resulting in a laminate sheet with a high elongation rate. Furthermore, air can pass through the openings, resulting in a laminate sheet with high breathability.

[0185] A laminate sheet according to a twentieth aspect is the laminate sheet according to the nineteenth aspect, wherein the film and the nonwoven fabric are welded at a plurality of welds aligned along a first direction. The plurality of welds aligned along the first direction constitute one weld group. The weld group includes a first weld group and a second weld group positioned at a position offset from the first weld group in a second direction perpendicular to the first direction. In the second weld group, the welds are positioned at a different position in the first direction from the first weld group.

[0186] In the laminate sheet of the twentieth aspect, by providing the first group of welded portions and the second group of welded portions, a laminate sheet having high stretchability can be manufactured.

[0187] A laminate sheet according to a twenty-first aspect is the laminate sheet according to the nineteenth or twentieth aspect, wherein the film and the nonwoven fabric are welded at a plurality of welds aligned along the first direction, and each weld has a shape whose longitudinal direction is the first direction, or a square or circular shape.

[0188] In the laminate sheet of the twenty-first aspect, it is possible to produce a laminate sheet that has high stretchability in a direction perpendicular to the first direction, or in both the direction perpendicular to the first direction and the first direction.

[0189] DESCRIPTION OF SYMBOLS 20 Discharge mechanism (film producing device) 30 Cooling roll (cooling device) 38 Film stretching mechanism (stretching device) 40 Stretching roll (first member) 401 First convex portion (first part) 402 Second convex portion (second part) 43 Horn (second member) 48 Lamination joining mechanism (laminating device, welding device) 60 Laminated sheet stretching mechanism (stretching device) A Conveying direction D1 First direction D2 Second direction F Film J Welded portion J1 First welded portion group J2 Second welded portion group L Laminated sheet S1 First nonwoven fabric sheet (nonwoven fabric) S2 Second nonwoven fabric sheet (nonwoven fabric) Op Opening P1 Film producing process P2 Cooling process P3 Stretching process P4 Laminating process P5 Welding process P6 Stretching process R Roll

Claims

1. A method for manufacturing a laminated sheet for a wearing article, comprising: a film forming step of extruding a molten raw material to form a film; a cooling step of cooling the extruded film; a laminating step of laminating a nonwoven fabric in a natural length state and the elastic film in a natural length state, or laminating a nonwoven fabric in a natural length state and the elastic film being conveyed and stretched in the conveying direction with an elongation rate of 15% or less; and a welding step of welding the laminated and conveyed film and nonwoven fabric to form a laminated sheet.

2. The method for manufacturing a laminated sheet according to claim 1, further comprising a stretching step of stretching the film and the nonwoven fabric integrated and conveyed by welding to form an opening in the welded portion of the film and the nonwoven fabric and / or around the welded portion, and / or widening the opening.

3. The method for manufacturing a laminated sheet according to claim 1 or 2, further including a stretching step of stretching the film after the cooling step and before the laminating step to reduce the thickness.

4. The raw material includes a first resin and a second resin having different conditions for stabilizing stretchability. In the cooling step, the film is cooled to a first temperature at which the stretchability of the second resin does not reach a stable state while the stretchability of the first resin reaches a stable state. The method for manufacturing a laminated sheet according to any one of claims 1 to 3.

5. The method for manufacturing a laminated sheet according to claim 4, further including a stretching step of stretching the film after the cooling step and before the laminating step to reduce the thickness, and the stretching rate of the film in the stretching step is set according to the blending ratio of the second resin.

6. The first resin is a styrene-based resin and the second resin is an olefin-based resin. The method for manufacturing a laminated sheet according to claim 4 or 5.

7. The weight ratio of the first resin to the second resin is 1:0.33 to 0.54, and the content ratio of the first resin and the second resin in the raw material is 90% by weight or more. The method for manufacturing a laminated sheet according to claim 6.

8. In the welding step, the film and the nonwoven fabric are welded at a plurality of welded portions, and each welded portion has a shape with a longitudinal direction intersecting the conveying direction of the film and the nonwoven fabric. The method for manufacturing a laminated sheet according to any one of claims 1 to 7.

9. In the welding step, the film and the nonwoven fabric are welded at a plurality of welding portions, and each of the welding portions has a square shape or a circular shape. A method for manufacturing a laminated sheet according to any one of claims 1 to 7.

10. A plurality of the welding portions arranged along a first direction intersecting the conveyance direction of the film and the nonwoven fabric constitute one welding portion group. The welding portion group includes a first welding portion group and a second welding portion group. The second welding portion group is arranged at a position shifted from the first welding portion group in a second direction orthogonal to the first direction, and the welding portions are arranged at positions different from the first welding portion group in the first direction. A method for manufacturing a laminated sheet according to any one of claims 1 to 9.

11. In the second direction, the first welding portion group and the second welding portion group are alternately arranged. In the laminated sheet, the welding portions are arranged in a staggered pattern. A method for manufacturing a laminated sheet according to claim 10.

12. In the stretching step, the laminated sheet is stretched in the conveyance direction. A method for manufacturing a laminated sheet according to claim 2.

13. In the stretching step, the laminated sheet is stretched in a direction orthogonal to the conveyance direction. A method for manufacturing a laminated sheet according to claim 2 or 12.

14. Further including a winding step of winding the laminated sheet after the welding step and before the stretching step to form a roll around which the laminated sheet is wound. In the stretching step, the film and the nonwoven fabric of the laminated sheet fed out from the roll and conveyed are stretched. A method for manufacturing a laminated sheet according to claim 2, 12 or 13.

15. A manufacturing system for a laminated sheet for a wearing article, including a film generating device that extrudes a molten raw material to generate a film, a cooling device that cools the extruded film, a nonwoven fabric in a natural length state, and the film having elasticity in a natural length state, or a nonwoven fabric in a natural length state and the film having elasticity in a conveying state that is stretched in the conveyance direction and has an elongation rate of 15% or less, a laminating device that laminates them, and a welding device that welds the laminated and conveyed film and nonwoven fabric to generate a laminated sheet. A manufacturing system for a laminated sheet.

16. Further including a stretching device that stretches the film to reduce its thickness after cooling by the cooling device. A manufacturing system for a laminated sheet according to claim 15.

17. The welding device sandwiches the film and the nonwoven fabric between a first member and a second member and welds them at a plurality of welding portions. The first member includes a first portion that forms a first welding portion group including a plurality of the welding portions arranged along a first direction intersecting the conveyance direction of the film and the nonwoven fabric, and a second portion that forms a second welding portion group including a plurality of the welding portions arranged along the first direction at a position shifted from the first welding portion group in a second direction orthogonal to the first direction. In the second welding portion group, the welding portions are arranged at positions different from those of the first welding portion group in the first direction. The manufacturing system for a laminated sheet according to claim 15 or 16.

18. The manufacturing system for a laminated sheet according to any one of claims 15 to 17, further comprising a stretching device that stretches the film and the nonwoven fabric integrated and conveyed by welding in the conveyance direction of the film and the nonwoven fabric or in a direction orthogonal to the conveyance direction to form an opening at and / or around the welding portion of the film and the nonwoven fabric and / or widen the opening.

19. A laminated sheet for a wearable article in which an elastic film and a nonwoven fabric are laminated, the film and the nonwoven fabric being integrated by welding, and no tension acting on the film when the nonwoven fabric is at its natural length.

20. The film and the nonwoven fabric are welded at a plurality of welding portions arranged along a first direction. The plurality of the welding portions arranged along the first direction constitute one welding portion group. The welding portion group includes a first welding portion group and a second welding portion group, the second welding portion group being arranged at a position shifted from the first welding portion group in a second direction orthogonal to the first direction, and the welding portions being arranged at positions different from those of the first welding portion group in the first direction. The laminated sheet according to claim 19.

21. The film and the nonwoven fabric are welded at a plurality of welding portions arranged along a first direction. Each of the welding portions has a shape having the first direction as its longitudinal direction, or a square shape or a circular shape. The laminated sheet according to claim 19 or 20.

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