JP6212489B2 - 吸収性物品における超音波接合方法、吸収性物品の超音波接合装置および吸収性物品 - Google Patents
吸収性物品における超音波接合方法、吸収性物品の超音波接合装置および吸収性物品 Download PDFInfo
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- JP6212489B2 JP6212489B2 JP2014523662A JP2014523662A JP6212489B2 JP 6212489 B2 JP6212489 B2 JP 6212489B2 JP 2014523662 A JP2014523662 A JP 2014523662A JP 2014523662 A JP2014523662 A JP 2014523662A JP 6212489 B2 JP6212489 B2 JP 6212489B2
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- horn
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- B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
- B29C66/92451—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power using joining tools having different pressure zones or using several joining tools with different pressures
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- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/539—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers
- A61F2013/53991—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers by ultrasonic method
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
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- B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
- B29C66/83431—Roller, cylinder or drum types; Band or belt types; Ball types rollers, cylinders or drums cooperating with bands or belts
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Epidemiology (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- Vascular Medicine (AREA)
- Life Sciences & Earth Sciences (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
- Public Health (AREA)
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- Textile Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Absorbent Articles And Supports Therefor (AREA)
Description
低強度接合部のみで両基材シートを接合すると、吸収性物品の周縁から、体液の漏れが生じたり、あるいは、前記周縁の接合部の面積を大きくする必要がある。
また、本発明の目的は、かかる吸収性物品の製造方法および装置を提供することである。
前記粒状体が配置されていない部位のうちの一部について前記2枚の不織布に超音波エネルギーを付与することで前記2枚の不織布の第1部を接合して、前記2枚の不織布を引き剥がす力により前記不織布同士が前記第1部において互いに分離しない少なくとも1つの高強度接合部を形成する工程と、
前記粒状体が配置されていない前記部位のうちの別の一部について前記2枚の不織布に超音波エネルギーを付与することで前記2枚の不織布の第2部を接合して、前記2枚の不織布を引き剥がす力により前記第2部において前記不織布同士が互いに分離することが可能な状態の少なくとも1つの低強度接合部を形成する工程とを備える。
前記2枚の不織布が重なり合った状態で、前記2枚の不織布を搬送するアンビルロールと、
前記アンビルロールに形成され前記アンビルロールの径方向の外方に向かって突出する複数の突部と、
前記突部上の不織布に前記粒状体が配置されるのを抑制する配置装置と、
超音波振動することにより前記複数の突部との間で前記2枚の不織布を接合して接合部を形成するホーンとを備え、ここにおいて前記突部は、
前記ホーンに最接近した時の前記ホーンまで第1距離を隔てて離れ、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離しない少なくとも1つの高強度接合部を形成するための少なくとも1つの第1突部と、
前記ホーンに最接近した時の前記ホーンまでの第2距離が前記第1距離よりも大きく、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離する少なくとも1つの低強度接合部を形成するための少なくとも1つの第2突部とを備える。
前記2枚の不織布が重なり合った状態で、前記2枚の不織布を搬送するアンビルロールと、
前記アンビルロールに形成され前記アンビルロールの径方向の外方に向かって突出する複数の突部と、
前記突部上の不織布に前記粒状体が配置されるのを抑制する配置装置と、
超音波振動することにより前記複数の突部との間で前記2枚の不織布を接合して接合部を形成するホーンとを備え、ここにおいて前記突部は、
前記ホーンに最接近した時の前記ホーンまで第1距離を隔てて離れ、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離しない少なくとも1つの高強度接合部を形成するための少なくとも1つの第1突部と、
前記ホーンに最接近した時の前記ホーンまでの第2距離が前記第1距離よりも大きく、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離する少なくとも1つの低強度接合部を形成するための少なくとも1つの第2突部とを備える。
前記低強度接合部を形成する工程は前記アンビルロールにおける前記低強度接合部を形成するための第2突部と超音波振動する前記ホーンとの間を前記2枚の不織布が通過することにより実行され、
前記第1突部と前記ホーンとが前記アンビルロールの法線上で対面した時のこれらの両者の間の第1距離に比べ、前記第2突部と前記ホーンとが前記法線上で対面した時のこれらの両者の間の第2距離の方が大きい。
この場合、前記内側領域において低強度接合部と低強度接合部との間の位置に高強度接合部が配置されるのが好ましい。
このような理由から前記距離の差は不織布の目付が10〜20g/m2の場合、10μm〜30μmが更に好ましく、12μm〜16μmが最も好ましい。
以下、本発明の実施例1が図面にしたがって説明される。
図1〜図7は実施例1を示す。
図1に示すように、本実施例の着用物品100は、吸収性本体(吸収性物品の一例)200、前胴回り部301および後胴回り部302を備えている。前記吸収性物品200は、着用者の前胴を覆うフロント部201、着用者の後胴を覆うバック部202、ならびに、前記フロント部201とバック部202との間の股間を覆う股部203を有している。
また、吸収性物品200には、着用者の脚部に沿って括れた脚回り部を形成してもよい。
なお、各図において溶着部位はxxや小さな黒い長方形で示される。
なお、各図において粒状体3は多数の微細なドットで示される。
また、各溶着ラインLは完全に連なっている必要はなく、各集合グループ30の粒状体3が他の集合グループ30に移動しにくい程度に溶着部位が断続的に形成されていてもよい。
本実施例においては、図3Aに示すように、前記溶着ラインLは、第1高強度接合部W1,第2高強度接合部W2および低強度接合部W3を包含する。
なお、製造方法を分り易くするため、前記第1高強度接合部W1が示される各図において、前記長方形状の溶着部位同士の間隔は胴回り方向Xおよび縦方向Yに若干離れて示されているが、実際には同溶着部位同士の間隔は両方向Y,Xにおいて殆ど隙間なく千鳥配列されて実質的に連続している。
すなわち、たとえば図1に示すように、第1高強度接合部W1に囲まれた前記内側領域Aの中央において前記縦方向Yに2列に延びるように形成されてもよい。
この第2高強度接合部W2は図中において黒く塗り潰した長方形で表示されている。
すなわち、第1高強度接合部W1および第2高強度接合部W2において、トップシート21とカバーシート22とを引き剥がす力を付与すると、両者21,22は分離せずに破断ないし一方の不織布に孔が明く程の大きな溶着力で溶着されている。
換言すれば、第1高強度接合部W1および第2高強度接合部W2自体の強度は、トップシート21やカバーシート22の素材よりも大きな強度であり、両シート21,22に外力が負荷されると応力集中により第1高強度接合部W1,第2高強度接合部W2の近傍においてトップシート21またはカバーシート22が破断する。
すなわち、低強度接合部W3における不織布21,22の溶着力は、第1および第2高強度接合部W1,W2における溶着力よりも小さい。
これにより、使用前の吸収性本体200の厚さが小さくても、多量の体液を吸収することができる。
すなわち、前記第1高強度接合部W1と第2高強度接合部W2とで定義される領域内に膨潤した粒状体3が拘束される。
したがって、内側領域Aにおいて粒状体3が著しく大きく片寄った(偏った)配置となるのを防止し得るだろう。
また、前記物品200の周縁に設けられた第1高強度接合部W1の内側に隣接する前記低強度接合部W3が設けられていない場合は、前記第1高強度接合部W1と低強度接合部W3とで配置エリアDが囲まれていてもよい。あるいは、前記配置エリアDは前記第1高強度接合部W1、第2高強度接合部W2および低強度接合部W3で囲まれていてもよい。
図4Aに示すように、本装置はアンビルロール4のまわりに、供給装置5、第1、第2導入ロール71,72および超音波ホーン81を備える。
前記吸収性物品200における前記トップシート21およびカバーシート22(図2)は、それぞれ、前記キャリアウエブ1およびカバーウエブ2から生成される。
前記無数の粒状体3の供給はキャリアウエブ1の単位面積当りにつき所定量ずつ断続的ないし連続的に供給される。
前記吸引孔40および吸引エリア1Bは複数設けられ、所定のパターンで配置される図1の複数の配置エリアDを定義するように設けられている。前記複数の配置エリアDは前記粒状体の集合を区画して配置するためのエリアである。
前記第1突部44Aには吐出孔42が形成されていなくてもよい。なぜならば、供給装置5から供給される粒状体3の供給幅が吸収性物品200における粒状体3の配置幅とほぼ同じ幅で供給される場合、キャリアウエブ1の周縁には粒状体3が殆ど供給されないため、吐出孔42の形成は不要となる。
なお、前記第1突部44Aに、第1突部44Bおよび第2突部45と同様の前記吐出孔42が形成されていてもよい。
図4Aに示すように、前記供給装置5から前記キャリアウエブ1上に供給された粒状体3は配置装置(吸引孔40および吐出孔42)により前記キャリアウエブ1が下流へ搬送されるにしたがい各集合グループ30に互いに区画される。
こうしてアンビルロール4は前記サンドイッチ構造体20を搬送する。
なお、図6Bのアンビルロール4の吸引孔40に吸引される第1エアα1により、前記第2面12および粒状体3上に導入された前記カバーウエブ2はアンビルロール4の内側に向って凹んでいる。
なお、図7Bにおいて構造を分り易くするため、前記第1突部44Bが前記第2突部45よりも大きく突出している様子を誇張して示している。
図6Aのアンビル4Rの外周面の周方向に直交する幅方向において、第2突部45が存在する場合、いずれか少なくとも1つの箇所または複数の箇所には第1突部44A,44Bが配置されていてもよい。このような配置により、ホーン81はウエブ1,2(図7B)を介して第1突部44A,44Bに強く当接し、一方、第2突部45に弱く当接する。そのため、図1の高強度接合部W1,W2および低強度接合部W3について所期の接合強度が得易いだろう。
したがって、図1の物品100においては、低強度接合部W3が存在する縦方向Yの同じ位置には少なくとも1つの又は複数の高強度接合部W1,W2が存在するのが好ましい。
なお、図4Bにおいて、アンビルロール4に形成された各突部44,45とホーン81との関係を分り易くするため、各要素が誇張されて示されている。
前記第1距離Δ1および第2距離Δ2の設定は、溶着する不織布の目付け、ホーンのアンビルへの押し付け荷重、並びに、溶着機の能力等の様々な条件に基づいて決定されるべきである。たとえば、一例を挙げると、不織布21の目付が10g/m2で、不織布22の目付が10g/m2の場合、前記第1距離Δ1は50μm程度に設定され、前記第2距離Δ2は65μm程度に設定されてもよい。
なお、一般に両距離Δ1,Δ2の差Δは12μm〜16μm程度に設定されてもよい。
一方、図1の前記内側領域Aに前記第2高強度接合部W2を形成するために、図6Aの第1突部44Bが前記アンビルロール4に配置されている。
図1の前記低強度接合部W3が前記第1高強度接合部W1に囲まれた内側領域Aに形成されるように、図6Aの前記第2突部45が前記アンビルロール4に配置されている。
図4Aに示すように、第1導入ロール71によりキャリアウエブ1がアンビルロール4に導入されキャリアウエブ1の第1面11がアンビルロール4の搬送面41で吸着保持されながら、前記キャリアウエブ1が所定の搬送経路つまり前記搬送ドラム4の搬送面41に沿って搬送される。
図6Bに示されるアンビル4Rに形成された前記吸引孔40に向かって第1エアα1が吸引されることで、前記供給された粒状体3は前記キャリアウエブ1上に吸着保持される。
なお、第1エアα1の少なくとも一部にキャリアウエブ1の前記第2面12に沿う方向の流れの成分を付与する気流偏向体がキャリアウエブ1の第2面12に対向して設けられてもよい。(PCT/JP2012/52371)
粒状体3の層の厚さはアンビルロール4の軸方向において中央が両端よりも厚くてもよい。また、粒状体3の層の厚さは、1つの吸収性本体200(図1)の周縁において薄く、かつ、中央やその近傍において厚くてもよい。
一方、前記第1エアα1の吸引を行いながら、前記搬送面41の前記突部44Bおよび45を含む非吸引エリア4Aにおいて開口する吐出孔42から前記キャリアウエブ1の第2面12に向って第2エアα2が吐出される。
すなわち、前記非吸引エリア1Aにおける一部の粒状体3は、前記吸引エリア1Bにおいて吸引保持されている別の粒状体3に向って移動する。その結果、図1に示すように、所定のパターンで互いに区画された前記配置エリアDごとに、複数の粒状体3からなる各集合グループ30がキャリアウエブ1上に配置される。
図7Bの前記超音波溶着の際に、前記ホーン81と前記第1突部44A,44B(図6B)との第1距離Δ1は小さく、そのため、溶着エネルギーが大きく、不織布同士(トップシート21およびカバーシート22)が互いに前記分離力で分離しない第1および第2高強度接合部W1,W2(図3B)が形成される。
なお、前述のとおり、製造方法を分かり易くするため、前記第1高強度接合部W1を示す黒い長方形同士の間隔は誇張して大きく図示されている。
一方、第2高強度接合部W2は各配置エリアDを区画することなく、胴回り方向Xおよび/または縦方向Yに部分的に延びるように設けられてもよい。たとえば、図9Aのように、胴回り方向Xに延びる高強度接合部W2と縦方向Yに延びる高強度接合部W2とがT字状に配置されてもよい。
更に、高強度接合部W2および低強度接合部W3の配置について、図1と図9A〜図9Bとを組み合わせた配置であってもよい。
なお、第2高強度接合部W2は不連続である方が、ゴワツキが小さく、着用感が良いだろうし、また、配置エリアD間の圧力調整にも役立つだろう。
たとえば、本物品においては、トップシート21とカバーシート22との接合方法として、超音波溶着の他に、たとえばヒートシールなどの熱溶着による接合方法が用いられてもよい。
また、本発明における「複数の粒状体」とは、粒状の材料の集合体のみからなる場合の他に、複数の粒状体に粉状の材料が混合されている場合も含む概念である。
したがって、そのような変更および修正は、請求の範囲から定まる本発明の範囲内のものと解釈される。
2:カバーウエブ、20:サンドイッチ構造体、21:トップシート(不織布) 、22:カバーシート(不織布) 、23:コア、24:バックシート
3:粒状体、30:集合グループ、D:配置エリア
4:アンビルロール、4A:非吸引エリア、4B:吸引エリア、40:吸引孔、41:搬送面、42:吐出孔(配置装置の一例)、4R:アンビル、43:ロール本体、44A,44B:第1突部、45:第2突部
5:供給装置
71:第1導入ロール、72:第2導入ロール
81:超音波ホーン
100:着用物品、200:吸収性本体(吸収性物品)、201:フロント部、202:バック部、203:股部、301:前胴回り部、302:後胴回り部
A:内側領域
α1:第1エア、α2:第2エア
X:胴回り方向、Y:縦方向、NL:法線
W1:第1高強度接合部、W2:第2高強度接合部、W3:低強度接合部
Δ1:第1距離、Δ2:第2距離
Claims (4)
- 2枚の互いに対面する透液性の不織布の間に、体液を吸液して膨潤する複数の粒状体を有する吸収性物品における超音波接合方法であって、
前記粒状体が配置されていない部位のうちの一部について前記2枚の不織布に超音波エネルギーを付与することで前記2枚の不織布の第1部を接合して、前記2枚の不織布を引き剥がす力により前記不織布同士が前記第1部において互いに分離しない複数の高強度接合部を形成する工程と、
前記粒状体が配置されていない前記部位のうちの別の一部について前記2枚の不織布に超音波エネルギーを付与することで前記2枚の不織布の第2部を接合して、前記2枚の不織布を引き剥がす力により前記第2部において前記不織布同士が互いに分離することが可能な状態の複数の低強度接合部を形成する工程とを備え、
ここにおいて、前記高強度接合部を形成する工程はアンビルロールにおける前記高強度接合部を形成するための第1突部と超音波振動するホーンとの間を前記2枚の不織布が通過することにより実行され、
前記低強度接合部を形成する工程は前記アンビルロールにおける前記低強度接合部を形成するための第2突部と超音波振動する前記ホーンとの間を前記2枚の不織布が通過することにより実行され、
前記第1突部と前記ホーンとが前記アンビルロールの法線上で対面した時のこれらの両者の間の第1距離に比べ、前記第2突部と前記ホーンとが前記法線上で対面した時のこれらの両者の間の第2距離の方が大きく、
ここにおいて、前記高強度接合部は、
前記物品にループ状に形成され、かつ、複数列で千鳥配列されて互いに接近した状態で連続的に形成された第1高強度接合部W1と、
前記第1高強度接合部W1に囲まれた内側領域において、膨潤して重くなった前記粒状体が自由に移動するのを拘束するために、前記物品の縦方向Yおよび/または胴回り方向Xに完全に連ならないように断続的に延びる第2高強度接合部W2とを包含し、
前記第1高強度接合部W1と前記第2高強度接合部W2とで前記物品が複数の領域に区画され、
前記低強度接合部は前記区画された領域に形成されている、ことを特徴とする超音波接合方法。 - 請求項1の方法において、前記低強度接合部および/または高強度接合部は所定のパターンで区画された複数の各配置エリアを定義し、前記各配置エリアごとに複数の前記粒状体が配置されるように、前記低強度接合部および/または高強度接合部が形成される、超音波接合方法。
- 2枚の互いに対面する透液性の不織布の間に、体液を吸液して膨潤する複数の粒状体を有する吸収性物品の超音波接合装置であって、
前記2枚の不織布が重なり合った状態で、前記2枚の不織布を搬送するアンビルロールと、
前記アンビルロールに形成され前記アンビルロールの径方向の外方に向かって突出する複数の突部と、
前記突部上の不織布に前記粒状体が配置されるのを抑制する配置装置と、
超音波振動することにより前記複数の突部との間で前記2枚の不織布を接合して接合部を形成するホーンとを備え、ここにおいて前記突部は、
前記ホーンに最接近した時の前記ホーンまで第1距離を隔てて離れ、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離しない高強度接合部を形成するための複数の第1突部と、
前記ホーンに最接近した時の前記ホーンまでの第2距離が前記第1距離よりも大きく、前記接合部において前記不織布同士を互いに引き剥がす力により前記不織布同士が互いに分離する低強度接合部を形成するための複数の第2突部とを備え、
ここにおいて、前記第1距離と前記第2距離との差が3μm〜60μmであり、
ここにおいて、前記高強度接合部のうち、前記物品にループ状に形成され、かつ、複数列で千鳥配列されて互いに接近した状態で連続的に形成された第1高強度接合部W1が前記物品に形成されるように前記第1突部が前記アンビルロールに配置され、
ここにおいて、前記高強度接合部のうち、前記第1高強度接合部W1に囲まれた内側領域において、膨潤して重くなった前記粒状体が自由に移動するのを拘束するために、前記物品の縦方向Yおよび/または胴回り方向Xに完全に連ならないように断続的に伸びる第2高強度接合部W2を形成するための前記第1突部が前記アンビルロールに配置され、
前記第1高強度接合部W1と前記第2高強度接合部W2とで前記物品が複数の領域に区画され、
前記低強度接合部は前記区画された領域に形成されるように前記第2突部が前記アンビルロールに配置されている、ことを特徴とする超音波接合装置。 - 請求項3の超音波接合装置において、前記低強度接合部および/または高強度接合部が所定のパターンで区画された複数の各配置エリアを定義するように前記第1突部および/または第2突部が設けられ、
前記配置装置が前記各配置エリアごとに複数の前記粒状体を配置する、ことを特徴とする超音波接合装置。
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CN104379102B (zh) | 2016-08-24 |
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