Disclosure of Invention
The invention provides a manufacturing device and a manufacturing method of an elastic composite sheet, which are used for solving the technical problems that the flatness of the elastic composite sheet formed by a plurality of layers of sheets of an outer coating layer of a disposable sanitary article is not high, the coating property is poor, the softness and comfort level are poor, and the appearance cannot achieve an ideal effect.
The technical scheme provided by the invention is as follows:
an object of the present invention is to provide an elastic composite sheet manufacturing apparatus for manufacturing an elastic composite sheet of an outer cover of disposable diaper, the manufacturing apparatus including an elastic body supply unit, a sizing unit, a nip composite roller, and an ultrasonic heat-sealing unit arranged in a flow direction;
the elastic body supply unit comprises a first supply unit, a second supply unit and an elastic material supply unit which are arranged in parallel along the flow path, wherein the elastic material supply unit is positioned between the first supply unit and the second supply unit;
the first feeding unit is used for continuously conveying a first sheet and a fourth sheet which are parallel in the direction perpendicular to the flow direction along the flow direction; the second feeding unit is used for continuously conveying a second sheet and a third sheet which are parallel in the direction perpendicular to the flow direction along the flow direction;
The elastic material supply unit is used for continuously conveying a plurality of elastic materials along the flow direction; the elastic material supply unit comprises a plurality of tension sensors, wherein each tension sensor corresponds to one elastic material;
wherein, in a direction perpendicular to a flow direction, the first sheet corresponds to the second sheet position, and the fourth sheet corresponds to the third sheet position; the first sheet and the second sheet are positioned on one side of a flow center line, and the third sheet and the fourth sheet are positioned on the other side of the flow center line;
the process center line refers to a datum line which is used as a process design for processing the disposable diaper in manufacturing equipment of the disposable diaper;
the sizing unit is used for coating an adhesive on the surface of each elastic material;
the clamping and pressing composite roller is used for compositing the elastic material extending along the flow direction between the first sheet and the second sheet on one side of the flow center line to form a first elastic composite semi-finished product, and compositing the elastic material extending along the flow direction between the third sheet and the fourth sheet on the other side of the flow center line to form a second elastic composite semi-finished product;
The ultrasonic heat sealing unit is used for respectively and simultaneously carrying out ultrasonic compounding on the outer layer sheet material and the first elastic composite semi-finished product and the second elastic composite semi-finished product so as to form a first joint part and a second joint part between the outer layer sheet material and the sheet material of the first elastic composite semi-finished product and the sheet material of the second elastic composite semi-finished product, thereby forming the elastic composite sheet material.
In a preferred embodiment, the manufacturing apparatus further includes a cutter unit disposed on an upstream side of the nip composite roller, for cutting the inner sheet, and sequentially forming a first sheet, a second sheet, a third sheet, and a fourth sheet from one side to the other side perpendicular to the flow direction, wherein there is no gap between adjacent sheets.
In a preferred embodiment, the manufacturing apparatus further includes a shifting unit including a first shifting unit and a second shifting unit which are simultaneously disposed on the downstream side of the cutter unit and are disposed in parallel in the flow path;
the first displacement unit is used for displacing the first sheet and the fourth sheet with the interval distance in the direction perpendicular to the flow direction, so that the distance between the first sheet and the fourth sheet after displacement reaches a preset distance;
The second displacement unit is used for displacing the second sheet and the third sheet which are adjacent and close to each other in the direction perpendicular to the flow direction, so that the distance between the second sheet and the third sheet after displacement reaches a preset distance;
the first sheet after being displaced by the first displacement unit corresponds to the second sheet after being displaced by the second displacement unit along the direction perpendicular to the flow direction; the fourth sheet displaced by the first displacement unit corresponds to the third sheet displaced by the second displacement unit.
In a preferred embodiment, the cutter unit comprises a bottom roller and a cutter assembly,
the bed roll includes first, second and third bed knives that are axially spaced apart and are all circular, and is configured to: simultaneously driving the first bed knife, the second bed knife and the third bed knife to rotate;
the cutter assembly includes first, second and third blades that are axially spaced apart and each circular, and the first, second and third blades are each configured to: can freely rotate;
In an axial direction, the first blade corresponds to the first bed knife, the second blade corresponds to the second bed knife, and the third blade corresponds to the third bed knife;
when the inner sheet is guided into the cutter unit, the first bed knife, the second bed knife and the third bed knife rotate and respectively drive the first blade, the second blade and the third blade to rotate, the first blade, the second blade and the third blade cut the inner sheet, and the first sheet, the second sheet, the third sheet and the fourth sheet are sequentially formed from one side to the other side along the direction perpendicular to the flow.
In a preferred embodiment, the bottom roller further comprises a rotating shaft, a linkage roller and a drum;
the linkage roller is fixed on the outer side of the circumference of the rotating shaft, and the first bed knife, the second bed knife and the third bed knife are sleeved and fixed on the linkage roller in parallel along the axial direction;
the roller is sleeved and fixed on the linkage roller along the axial direction, and separates the first bed knife, the second bed knife and the third bed knife.
In a preferred embodiment, the end surfaces of the first bed knife, the second bed knife and the third bed knife are provided with steps, and a first groove, a second groove and a third groove are respectively formed with the adjacent roller; the first groove, the second groove and the third groove correspond to the axial positions of the first bed knife, the second bed knife and the third bed knife respectively;
When the inner sheet is guided into the cutter unit, the first blade, the second blade and the third blade are respectively embedded into the first groove, the second groove and the third groove, the rotating shaft drives the linkage roller to drive the first bed knife, the second bed knife, the third bed knife and the roller to rotate, the first blade, the second blade and the third blade cut the inner sheet, and the first sheet, the second sheet, the third sheet and the fourth sheet are sequentially formed from one side to the other side along the direction perpendicular to the flow.
In a preferred embodiment, the cutter assembly further comprises a mount on which the first, second and third blades are mounted in an axially adjustable manner such that the first, second and third blades are aligned with the first, second and third grooves, respectively.
In a preferred embodiment, the manufacturing apparatus further includes an elastic material cutting unit disposed on an upstream side of the ultrasonic heat sealing unit;
the elastic material cutting unit is used for cutting the elastic material in the corresponding first elastic composite semi-finished product and the corresponding second elastic composite semi-finished product in the position area of the outer covering layer of the disposable diaper corresponding to the composite inner sheet, so that elastic weakening areas are respectively formed in the first elastic composite semi-finished product and the second elastic composite semi-finished product; wherein, the inner piece of the disposable diaper is arranged inside the outer coating layer.
In a preferred embodiment, the manufacturing apparatus further comprises a first driving unit disposed between the cutter unit and the index unit,
the first sheet and the fourth sheet are guided to the first displacement unit via the first driving unit, and the second sheet and the third sheet are guided to the second displacement unit via the first driving unit.
In a preferred embodiment, the first sheet and the second sheet are equidistant from the process centerline and the third sheet and the fourth sheet are equidistant from the process centerline.
In a preferred embodiment, the first displacement unit comprises a mounting frame, and a first rotating assembly and a second rotating assembly which are symmetrically distributed on two sides of a flow center line, and the first rotating assembly and the second rotating assembly are connected to the mounting frame in a rotating manner;
the second deflection unit comprises a support frame, and a third rotating assembly and a fourth rotating assembly which are symmetrically distributed on two sides of a flow center line, and the third rotating assembly and the fourth rotating assembly are connected to the support frame in a rotating manner;
The first sheet and the fourth sheet being led into the first displacement unit to form a first path, the first sheet being displaced on the first rotating assembly, the fourth sheet being displaced on the second rotating assembly;
the second sheet and the third sheet are led into the second shifting unit to form a second path, the second sheet is shifted on the third rotating assembly, and the third sheet is shifted on the fourth rotating assembly.
In a preferred embodiment, the first rotating assembly includes a first lead-in roller, a first lead-out roller, and a first carriage;
the first leading-in roller and the first leading-out roller are fixed on the first bracket, a first arc-shaped groove is arranged at the bottom of the first bracket, the first rotating component is connected to the mounting frame through the first arc-shaped groove,
the first bracket drives the first rotating assembly to swing relative to the mounting frame through the first arc-shaped groove so as to adjust the angle of the first rotating assembly relative to the flow center line;
the second rotating assembly comprises a second leading-in roller, a second leading-out roller and a second bracket;
the second leading-in roller and the second leading-out roller are fixed on the second bracket, a second arc-shaped groove is arranged at the bottom of the second bracket, the second rotating component is connected to the mounting frame through the second arc-shaped groove,
And the second bracket drives the second rotating assembly to swing relative to the mounting frame through the second arc-shaped groove so as to adjust the angle of the second rotating assembly relative to the flow center line.
In a preferred embodiment, the third rotating assembly includes a third lead-in roller, a third lead-out roller, and a third carriage;
the third leading-in roller and the third leading-out roller are fixed on the third bracket, the bottom of the third bracket is provided with a first hole and a third arc-shaped groove taking the center of the first hole as the center of the circle,
the third bracket rotates and swings around the center of the first hole through a third annular groove to drive the third rotating assembly to swing on the supporting frame so as to adjust the angle of the third rotating assembly relative to the flow center line;
the fourth rotating assembly comprises a fourth leading-in roller, a fourth leading-out roller and a fourth bracket;
the fourth leading-in roller and the fourth leading-out roller are fixed on the fourth bracket, the bottom of the fourth bracket is provided with a second hole and a fourth arc-shaped groove taking the center of the second hole as the center of the circle,
the fourth bracket rotates and swings around the center of the second hole through the fourth arc-shaped groove, so that the fourth rotating assembly is driven to swing on the supporting frame, and the angle of the fourth rotating assembly relative to the flow center line is adjusted.
In a preferred embodiment, the manufacturing apparatus further comprises a first deviation rectifying unit and a second deviation rectifying unit,
after the first sheet and the fourth sheet are shifted by the first shifting unit, the first sheet and the fourth sheet are conveyed to the first deviation rectifying unit along a first path, and deviation rectification is carried out on the first sheet and the fourth sheet respectively;
and after the second sheet and the third sheet are shifted by the second shifting unit, the second sheet and the third sheet are conveyed to the second deviation rectifying unit along a second path, and deviation rectification is carried out on the second sheet and the third sheet respectively.
In a preferred embodiment, the nip composite roller comprises a drive roller and a nip roller which are oppositely arranged,
the first sheet, the second sheet and the elastic material arranged between the first sheet and the second sheet are subjected to clamping driving through a driving roller and a clamping pressing roller, so that a first elastic composite semi-finished product is formed; and simultaneously carrying out clamping driving on the third sheet, the fourth sheet and the elastic material arranged between the third sheet and the fourth sheet at the other side of the flow center line, so as to form the second elastic composite semi-finished product.
In a preferred embodiment, the manufacturing apparatus further comprises a second driving unit disposed between the elastic material cutting unit and the ultrasonic heat-sealing unit,
and leading the first elastic composite semi-finished product and the second elastic composite semi-finished product which are obtained by cutting the elastic material at preset positions into the ultrasonic heat sealing unit through the second driving unit.
In a preferred embodiment, the ultrasonic heat-sealing unit comprises a first ultrasonic horn, a second ultrasonic horn and an ultrasonic bottom roller,
the first ultrasonic welding head and the second ultrasonic welding head are axially arranged in parallel and are simultaneously arranged opposite to the ultrasonic bottom roller;
when the first elastic composite semi-finished product and the outer sheet are transmitted between the first ultrasonic welding head and the ultrasonic bottom roller, the outer sheet and the sheet of the first elastic composite semi-finished product are welded to form the first joint part;
and simultaneously, when the second elastic composite semi-finished product and the outer sheet are transmitted between the second ultrasonic welding head and the ultrasonic bottom roller, the outer sheet and the sheet of the second elastic composite semi-finished product are welded to form the second joint part.
In a preferred embodiment, a plurality of engaging flower-shaped parts are arranged at intervals along the circumferential surface of the ultrasonic bottom roller, and the engaging flower-shaped parts are arranged along the axial direction;
the engagement pattern portion includes a base portion and a convex portion connected, the base portion and the convex portion are disposed at an interval, and the convex portion is higher than the base portion, and a pattern is disposed on a surface of the convex portion.
In a preferred embodiment, the second and third sheets or the first and fourth sheets are disposed below the sizing unit.
In a preferred embodiment, the first feeding unit includes a first free roller provided in the flow for guiding the first sheet and the fourth sheet;
the second feeding unit includes a second free roller provided in the flow path for guiding the second sheet and the third sheet;
the elastic material supply unit further comprises a guide wheel arranged on the flow path for guiding the elastic material.
Another object of the present invention is to provide a method for manufacturing an elastic composite sheet, which is to manufacture an elastic composite sheet of an outer cover layer of a disposable diaper using the manufacturing apparatus of an elastic composite sheet provided by the present invention, the manufacturing method comprising the following method steps:
Elastomer supply step: the method comprises a first feeding process, a second feeding process and an elastic material feeding process which are arranged in parallel along a flow, wherein the elastic material feeding process is positioned between the first feeding process and the second feeding process;
a first supply step: continuously conveying a first sheet and a fourth sheet which are parallel in the direction perpendicular to the flow direction along the flow direction;
a second supply step: continuously conveying the second sheet and the third sheet which are parallel in the direction perpendicular to the flow direction along the flow direction;
an elastic material supply step: continuously conveying a plurality of elastic materials along the flow direction;
wherein the first sheet corresponds to the second sheet in position along a direction perpendicular to the flow direction; the fourth sheet corresponds to the third sheet position; the first sheet and the second sheet are positioned on one side of a flow center line, and the third sheet and the fourth sheet are positioned on the other side of the flow center line;
sizing: coating an adhesive on the surface of each elastic material by using a sizing unit;
compounding: compounding the elastic material extending along the flow direction between the first sheet and the second sheet on one side of the flow center line by using a clamping and pressing compounding roller to form a first elastic compound semi-finished product; compounding the elastic material extending along the flow direction between the third sheet and the fourth sheet on the other side of the flow center line to form a second elastic composite semi-finished product;
An outer sheet feeding step: continuously conveying the outer sheet material along the flow direction after uncoiling;
ultrasonic wave compounding procedure: and respectively carrying out ultrasonic compositing on the outer layer sheet and the first elastic composite semi-finished product and the second elastic composite semi-finished product by utilizing an ultrasonic heat sealing unit so as to form a first joint part between the outer layer sheet and the sheet of the first elastic composite semi-finished product and form a second joint part between the outer layer sheet and the sheet of the second elastic composite semi-finished product, thereby forming the elastic composite sheet.
In a preferred embodiment, the manufacturing method further includes an inside sheet pretreatment process before the elastomer supply process; the inside sheet pretreatment process includes, in a flow direction:
an inner sheet feeding step: continuously conveying the inner layer sheet after uncoiling;
cutting: the cutter unit cuts the inner layer sheet, and sequentially forms a first sheet, a second sheet, a third sheet and a fourth sheet from one side to the other side in the direction perpendicular to the flow direction, wherein no gap exists between the adjacent sheets;
a displacement procedure: a first displacement unit displaces the first sheet and the fourth sheet with a spacing distance in a direction perpendicular to a flow direction, so that a distance between the first sheet and the fourth sheet after displacement reaches a preset distance, and a second displacement unit displaces the second sheet and the third sheet which are adjacent and next to each other in the direction perpendicular to the flow direction, so that a distance between the second sheet and the third sheet after displacement reaches a preset distance;
The position of the shifted first sheet corresponds to the position of the shifted second sheet along the direction perpendicular to the flow direction; the fourth sheet after displacement corresponds to the third sheet after displacement in position;
and the first sheet and the second sheet are positioned on one side of the flow center line, and the third sheet and the fourth sheet are positioned on the other side of the flow center line.
In a preferred embodiment, the manufacturing method further includes an elastic material cutting process located at a downstream side of the compounding process:
in the position area of the outer covering layer of the disposable diaper corresponding to the composite inner sheet, the elastic materials in the corresponding first elastic composite semi-finished product and second elastic composite semi-finished product are cut, so that elastic weakening areas are respectively formed in the first elastic composite semi-finished product and the second elastic composite semi-finished product.
In a preferred embodiment, the manufacturing method further includes a deviation rectifying process on a downstream side of the displacing process:
correcting the deviation of the first sheet and the fourth sheet after the displacement, and correcting the deviation of the second sheet and the third sheet after the displacement.
Compared with the prior art, the technical scheme of the invention has at least the following beneficial effects:
The invention provides a manufacturing device and a manufacturing method of an elastic composite sheet, which are used for only sizing an elastic material, enabling the elastic material to be positioned between a first sheet and a second sheet and forming a first elastic composite semi-finished product, and enabling the elastic material to be positioned between a third sheet and a fourth sheet and forming a second elastic composite semi-finished product. Since the first and second/third and fourth sheets are not sized, the elastic material is secured while also improving the soft comfort of the elastic composite sheet. And then, respectively compositing the first elastic composite semi-finished product and the second elastic composite semi-finished product with the outer layer sheet in an ultrasonic mode to finally form the elastic composite sheet of the outer coating layer of the disposable diaper. The composite of the outer layer sheet material can increase the flatness of the elastic composite sheet material and reduce rib marks of the elastic material on a human body when the elastic composite sheet material is worn. And the ultrasonic heat sealing unit is adopted to realize the joint between a plurality of sheets, the ultrasonic bottom roller is provided with adjacent base parts and convex parts, and flower patterns are arranged on the convex parts so as to obtain joint parts on the elastic composite sheets, so that the sheets can be fixed, regular folds are formed on the outer sides of the elastic composite sheets in a contracted state of the elastic composite sheets, and the attractiveness of the elastic composite sheets is improved. The elastic composite sheet formed by the multilayer sheet adopts a mode of combining sizing and ultrasonic waves, so that the outer coating layer of the disposable sanitary product has high flatness, good wrapping property, good softness and comfort and attractive appearance.
The invention provides a manufacturing device and a manufacturing method of an elastic composite sheet, wherein 3 blades and 3 bed knives which are arranged corresponding to the blades are arranged in a cutter unit, and grooves for inserting the blades along the axial direction are arranged on the bed knives and are used for dividing an inner layer sheet into four materials, namely a first sheet, a second sheet, a third sheet and a fourth sheet. The first deflection unit adopts an arc-shaped groove adjusting structure to realize deflection of a first sheet and a fourth sheet which are originally provided with distances, and the second deflection unit adopts a structure which is adjusted along a certain point at the arc-shaped groove to realize deflection of a second sheet and a third sheet which are not spaced after cutting.
The invention provides a manufacturing device and a manufacturing method of an elastic composite sheet, which enable a first sheet and a second sheet on one side of a flow center line to be positioned at the same position and to be composited with an elastic material to form a first elastic composite semi-finished product, and enable a third sheet and a fourth sheet on the other side of the flow center line to be positioned at the same position and to be composited with the elastic material in a compositing process to form a second elastic composite semi-finished product. The first sheet, the second sheet, the third sheet and the fourth sheet can be obtained by uncoiling one layer of inner sheet, cutting the inner sheet into four layers along the direction perpendicular to the flow direction by using a cutter unit in the slitting process, realizing the deflection of the first sheet and the fourth sheet on the outer side along the direction perpendicular to the flow direction by using a first deflection unit in the deflection process, realizing the deflection of the second sheet and the third sheet in the middle position along the direction perpendicular to the flow direction by using a second deflection unit, and realizing the position deflection of the first sheet and the second sheet along the direction perpendicular to the flow direction by using the two different modes, wherein the fourth sheet corresponds to the third sheet in position, thereby providing the precondition of the positions for the first elastic composite semi-finished product and the second elastic composite semi-finished product. The first elastic composite semi-finished product, the second elastic composite semi-finished product and the outer layer sheet are compounded by adopting an ultrasonic heat sealing unit in an ultrasonic compounding procedure, so that the elastic composite sheet with a 3-layer composite structure is realized. The outer coating layer of the disposable diaper manufactured by the manufacturing method has the characteristics of good flatness, good wrapping property, good softness and comfort, good wearing experience and attractive appearance.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. It will be apparent that the described embodiments are some, but not all, embodiments of the invention. All other embodiments, which can be made by a person skilled in the art without creative efforts, based on the described embodiments of the present invention fall within the protection scope of the present invention.
Unless defined otherwise, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this invention belongs. The terms "first," "second," and the like, as used herein, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Likewise, the terms "a," "an," or "the" and similar terms do not denote a limitation of quantity, but rather denote the presence of at least one. The word "comprising" or "comprises", and the like, means that elements or items preceding the word are included in the element or item listed after the word and equivalents thereof, but does not exclude other elements or items. The terms "connected" or "connected," and the like, are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect.
It should be noted that "upper", "lower", "left", "right", "front", "rear", and the like are used in the present invention only to indicate a relative positional relationship, and when the absolute position of the object to be described is changed, the relative positional relationship may be changed accordingly.
Fig. 1 is a schematic view showing a structure of a disposable diaper manufactured according to the present invention in an unfolded state, fig. 2 is a sectional view in a U-U direction of fig. 1, fig. 3 is a sectional view in a P-P direction of fig. 1, and fig. 3 is a schematic view showing an elastic material in a contracted state. The disposable diaper S has a longitudinal direction, a width direction and a thickness direction which are orthogonal to each other. Since the direction of the manufacturing equipment can be aligned, the width direction of the disposable diaper S corresponds to the width direction of the manufacturing equipment, and the length direction corresponds to the flow direction of the manufacturing equipment.
The disposable diaper S comprises an outer cover layer S1 and an inner sheet S2 provided inside the outer cover layer S1, wherein the inner sheet S2 is an absorbent core structure mainly absorbing excrement, and the outer cover layer S1 is an elastic composite sheet and has an abdomen side S11 corresponding to the abdomen position of a human body and a hip side S12 corresponding to the hip position of the human body.
On the abdomen side S11, as seen from the non-skin side in the thickness direction toward the skin side, the sheet comprises an outer layer sheet W2, a second sheet W12, an elastic material T, and a first sheet W11, wherein the elastic material T is provided between the first sheet W11 and the second sheet W12 so as to extend in the longitudinal direction. The first sheet W11, the second sheet W12, and the outer sheet W2 are nonwoven materials, and may be specifically a release nonwoven or a heat-seal nonwoven. In this embodiment, the elastic material T is spandex filaments (rubber strings), and the number and positions of the elastic material T can be specifically set according to the product of the disposable diaper S.
In order to enable the elastic material T to be joined between the first sheet W11 and the second sheet W12, an adhesive is applied to the elastic material T, the elastic material T and the first sheet W11 and the second sheet W12 are combined to form a thin elastic sheet, and only the elastic material T is glued, and the first sheet W11 and the second sheet W12 are not glued, so that the elastic material T is fixed, and meanwhile, the softness and comfort of the elastic sheet are improved. The elastic sheet and the outer layer sheet W2 are then formed into a first joint F' between the sheets by an ultrasonic process, and the combination of 3 sheets is achieved to form an elastic composite sheet.
As shown in fig. 3, the elastic composite sheet is at the abdomen side S11 such that in the contracted state of the elastic material T, the elastic material T is adhered between the first sheet W11 and the second sheet W12, whereby the first sheet W11 and the second sheet W12 each form irregular small wrinkles at both sides of the elastic material T. The outer sheet W2 forms the first joint F 'between the sheets by using an ultrasonic process, and since the first joint F' is a regular pattern, the outer sheet W2 forms regular large wrinkles on the outer side (non-skin side), the formation of the large wrinkles improves the aesthetic degree of the elastic composite sheet, and the ultrasonic process is adopted to make the first sheet W11, the second sheet W12 and the outer sheet W2 adhesive-free, so that the elastic composite sheet is hardened due to a large amount of adhesive in the traditional sizing manner and is not environment-friendly, thereby greatly improving the soft comfort of the elastic composite sheet of the outer coating layer S1 of the disposable diaper S. Wherein the first joining portion F' is joined only between the outer layer sheet W2, the first sheet W11 and the second sheet W12, and is not joined with the elastic material T.
Similarly, on the buttocks side S12, as viewed from the non-skin side to the skin side in the thickness direction, the outer layer sheet W2, the third sheet W13, the elastic material T, and the fourth sheet W14 are included, wherein the elastic material T is disposed between the third sheet W13 and the fourth sheet W14 so as to extend in the longitudinal direction. The third sheet W13 and the fourth sheet W14 are nonwoven materials, and may be specifically a release nonwoven or a heat-seal nonwoven.
In order to enable the elastic material T to be joined between the third and fourth sheets W13 and W14, an adhesive is applied to the elastic material T, the elastic material T and the third and fourth sheets W13 and W14 are combined to form a thin elastic sheet, and only the elastic material T is glued, and the third and fourth sheets W13 and W14 are not glued, so that the elastic material T is fixed and the softness and comfort of the elastic sheet are improved. The elastic sheet and the outer layer sheet W2 are then ultrasonically bonded together to form a second bond F "between the sheets, thereby forming an elastic composite sheet by compositing the 3 sheets.
The elastic composite sheet is in the contracted state of the elastic material T on the hip side S12 and the contracted state of the elastic material T on the abdomen side S11, and thus will not be described in detail.
The invention provides a manufacturing device and a manufacturing method of an elastic composite sheet, which are used for manufacturing the elastic composite sheet of an outer coating layer S1 of disposable diaper S.
Fig. 4 is a schematic layout view of an apparatus for manufacturing an elastic composite sheet according to an embodiment of the present invention, and an apparatus for manufacturing an elastic composite sheet for manufacturing an outer cover of a disposable diaper according to an embodiment of the present invention is provided.
The manufacturing device of the elastic composite sheet comprises a cutter unit 2, a first driving unit E ', a deflection unit, a deviation correcting unit, an elastic body feeding unit G, a sizing unit H, a clamping composite roller 6, an elastic material cutting unit 8, a second driving unit E' and an ultrasonic heat sealing unit 9 which are arranged along the flow direction.
The shifting unit comprises a first shifting unit 3 and a second shifting unit 4 which are simultaneously arranged on the downstream side of the cutter unit 2 and are arranged in parallel in the flow. The deviation rectifying unit comprises a first deviation rectifying unit 5 and a second deviation rectifying unit 7 which are arranged in parallel in the flow.
The cutter unit 2 is configured to cut the inner sheet W1, in this embodiment, the cutter unit 2 cuts the inner sheet W1 into four sheets, and sequentially forms a first sheet W11, a second sheet W12, a third sheet W13, and a fourth sheet W14 from one side to the other side perpendicular to the flow direction, with no gap between adjacent sheets. The cutter unit 2 may cut the number of sheets according to the need, not limited to 4 materials cut in the present embodiment.
Specifically, the inner sheet W1 is continuously conveyed after being unwound, is conveyed to the cutter unit 2 via the guide free roller 1 provided on the flow path, is cut into four by the cutter unit 2, and sequentially forms a first sheet W11, a second sheet W12, a third sheet W13, and a fourth sheet W14 along one side to the other side perpendicular to the flow direction, as shown in fig. 11 and 12.
Fig. 5 shows a schematic structure of a cutter unit according to the present invention, which includes a bottom roller 21 and a cutter assembly 22. The bed roll 21 includes first, second, and third bed knives 213, 214, 215, which are all circular, spaced apart in the axial direction, and the bed roll 21 is configured to: simultaneously, the first bed knife 213, the second bed knife 214 and the third bed knife 215 are driven to rotate.
The cutter assembly 22 includes first, second and third blades 221, 222 and 223 that are axially spaced apart and each circular, and the first, second and third blades 221, 222 and 223 are respectively configured to: can rotate freely.
In the axial direction, the first blade 221 corresponds to the first bed knife 213, the second blade 222 corresponds to the second bed knife 214, and the third blade 223 corresponds to the third bed knife 215.
When the inner sheet W1 is introduced into the cutter unit 2 via the free roller 1, the first, second, and third bed knives 213, 214, and 215 rotate and drive the first, second, and third blades 221, 222, and 223 to rotate, respectively, the first, second, and third blades 221, 222, and 223 cut the inner sheet W1, and the first, second, third, and fourth sheets W11, W12, W13, and W14 are formed in order from one side to the other side in a direction perpendicular to the flow direction.
Further, according to an embodiment of the present invention, the bottom roller 21 further includes a rotation shaft 211, a linkage roller 212, and a drum 216. The linkage roller 212 is fixed on the outer side of the circumference of the rotating shaft 211, and the first bed knife 213, the second bed knife 214 and the third bed knife 215 are sleeved and fixed on the linkage roller 212 in parallel along the axial direction. The drum 216 is axially sleeved and fixed on the linkage roller 212 to separate the first bed knife 213, the second bed knife 214 and the third bed knife 215, that is, the first bed knife 213, the second bed knife 214 and the third bed knife 215 are sequentially sleeved on the outer circumferential side of the linkage shaft 212, and the drum 216 is sleeved on the outer circumferential side of the linkage shaft 212 to separate the first bed knife 213, the second bed knife 214 and the third bed knife 215.
The end surfaces of the first, second and third bed knives 213, 214 and 215 are stepped to form the first, second and third grooves 2131, 2141 and 2151 with the adjacent roller 216, respectively, i.e., the end surface of the first bed knife 213 is stepped to form the first groove 2131 with the adjacent roller 216, the end surface of the second bed knife 214 is stepped to form the second groove 2141 with the adjacent roller 216, and the end surface of the third bed knife 215 is stepped to form the third groove 2151 with the adjacent roller 216. The first recess 2131, the second recess 2131 and the third recess 2151 correspond to the positions of the first bottom blade 213, the second bottom blade 214 and the third bottom blade 215, respectively, in the axial direction.
When the inner sheet W1 is introduced into the cutter unit via the free roller 1, the first blade 221, the second blade 222, and the third blade 223 are respectively fitted into the first groove 2131, the second groove 2141, and the third groove 2151. The rotating shaft 211 is connected to a driving motor, and drives the linkage roller 212 to drive the first bottom cutter 213, the second bottom cutter 214, the third bottom cutter 215 and the roller 216 to rotate, and the first blade 221, the second blade 222 and the third blade 223 cut the inner sheet W1, so that a first sheet W11, a second sheet W12, a third sheet W13 and a fourth sheet W14 are sequentially formed from one side to the other side in the direction perpendicular to the flow direction.
Still further, the cutter assembly 22 further includes a holder 23, and the first, second and third blades 221, 222 and 223 are axially adjustably mounted on the holder 23 such that the first, second and third blades 221, 222 and 223 are aligned with the first, second and third grooves 2131, 2141 and 2151, respectively.
The first, second and third blades 221, 222 and 223 are respectively axially adjustable with respect to the mount 23. The axial positions of the first blade 221 (first groove 2131), the second blade 222 (second groove 2141), and the third blade 223 (third groove 2151) are set according to the size of the inner sheet W1 to be cut.
When the inner sheet W1 is introduced into the cutter unit 2 to be cut, the first blade 221, the second blade 222, and the third blade 223 enter the first groove 2131, the second groove 2141, and the third groove 2151 of the bottom roller 21, respectively, to cut the inner sheet W1, thereby forming a first sheet W11, a second sheet W12, a third sheet W13, and a fourth sheet W14 from one side to the other side in the direction perpendicular to the flow direction, as shown in fig. 11 and 12. The center line of the inner sheet W1 is the flow center line L of the process of processing the elastic composite sheet. The flow center line L is a reference line for a flow design for processing the disposable diaper in the manufacturing facility of the disposable diaper.
As shown in fig. 4, a first driving unit E ' is disposed between the cutter unit 2 and the displacement unit, and the first sheet W11, the second sheet W12, the third sheet W13, and the fourth sheet W14 separated by the cutter unit 2 are guided into the first driving unit E ' by the guide of the free roller 1, and the first driving unit E ' is connected to a driving motor to drive the first sheet W11, the second sheet W12, the third sheet W13, and the fourth sheet W14 to travel toward the downstream side in the flow direction. The first driving unit E' can adjust the running speed of the sheet in real time as needed.
At this time, the arrangement order of the cut first, second, third and fourth sheets W11, W12, W13 and W14 in the axial direction is left to right, and it is worth noting that the first, second, third and fourth sheets W11, W12, W13 and W14 are adjacent to each other, that is, only the inner sheet W1 is cut into four sheets by the cutter unit 2, and there is no change in distance, as shown in fig. 12.
The cut first, second, third, and fourth sheets W11, W12, W13, and W14 are required to be displaced to a predetermined position to be combined with the downstream side material. The first sheet W11 and the fourth sheet W14 farthest from each other are fed into the first displacement unit 3, and the second sheet W12 and the third sheet W3 adjacent and next to each other are fed into the second displacement unit 4.
Specifically, the first sheet W11 and the fourth sheet W14 are guided to the first displacement unit 3 via the first driving unit E ', and the second sheet W12 and the third sheet W13 are guided to the second displacement unit 4 via the first driving unit E'.
According to the embodiment of the present invention, the first displacement unit 3 is configured to displace the first sheet W11 and the fourth sheet W14 having the separation distance in the direction perpendicular to the flow direction so that the pitch of the displaced first sheet W11 and fourth sheet W14 reaches a predetermined distance. The direction perpendicular to the flow direction refers to the width direction, and is also the width direction of the disposable diaper S.
As shown in fig. 6, the first displacement unit 3 of the present invention includes a mounting frame 31, and a first rotating assembly 32 and a second rotating assembly 33 symmetrically distributed on both sides of a flow center line L, wherein the first rotating assembly 32 and the second rotating assembly 33 are rotatably connected to the mounting frame 31.
The first sheet W11 and the fourth sheet W14 are introduced into the shift unit 3 to form a first path R1, the first sheet W11 is shifted on the first rotating member 32, and the fourth sheet W14 is shifted on the second rotating member 33.
Further, the first rotating assembly 32 includes a first introduction roller 321, a first discharge roller 322, and a first bracket 323. The first introducing roller 321 and the first discharging roller 322 are fixed to a first bracket 323, wherein the first introducing roller 321 is located at the introducing side and the first discharging roller 322 is located at the discharging side.
The bottom of the first bracket 323 is provided with a first arc groove 3231, the first rotating assembly 32 is connected to the mounting frame 31 through the first arc groove 3231, and the first bracket 323 drives the first rotating assembly 32 to rotate and swing relative to the mounting frame 31 through the first arc groove 3231 so as to adjust the angle of the first rotating assembly 32 relative to the process center line L, thereby changing the position of the first sheet W11 on the leading-out side of the first leading-out roller 322 relative to the leading-in side of the first leading-in roller 321.
Also, the second rotating assembly 33 includes a second introduction roller 331, a second discharge roller 332, and a second bracket 333. The second introducing roller 331 and the second discharging roller 332 are fixed to a second bracket 333, wherein the second introducing roller 331 is located on the introducing side and the second discharging roller 332 is located on the discharging side.
The bottom of the second bracket 333 is provided with a second arc-shaped groove 3331, the second rotating assembly 33 is connected to the mounting frame 31 through the second arc-shaped groove 3331, and the second bracket 333 drives the second rotating assembly 33 to rotate and swing relative to the mounting frame 31 through the second arc-shaped groove 3331 so as to adjust the angle of the second rotating assembly 33 relative to the process center line L, thereby changing the position of the fourth sheet W14 on the leading-out side of the second leading-out roller 332 relative to the leading-in side of the second leading-in roller 331.
According to the embodiment of the present invention, the second shifting unit 4 is configured to shift the adjacent and next second sheet W12 and third sheet W13 in the direction perpendicular to the flow direction so that the pitch of the shifted second sheet W12 and third sheet W13 reaches a predetermined distance. The direction perpendicular to the flow direction refers to the width direction, and is also the width direction of the disposable diaper S.
As shown in fig. 7, the second shifting unit 4 of the present invention includes a supporting frame 41, and a third rotating assembly 42 and a fourth rotating assembly 43 symmetrically distributed on both sides of a process center line L, wherein the third rotating assembly 42 and the fourth rotating assembly 43 are rotatably connected to the supporting frame 43.
The second sheet W12 and the third sheet W13 are introduced into the second displacement unit 4 to form a second path R2, the second sheet W12 is displaced on the third rotating group 42, and the third sheet W13 is displaced on the fourth rotating group 43.
Further, the third rotating assembly 42 includes a third introduction roller 421, a third discharge roller 422, and a third bracket 423. The third introduction roller 421 and the third discharge roller 422 are fixed to a third bracket 423, wherein the third introduction roller 421 is located on the introduction side and the third discharge roller 422 is located on the discharge side.
The bottom of the third bracket 423 is provided with a first hole a1 and a third arc-shaped groove 4231 taking the center of the first hole a1 as a center, and the third bracket 423 rotates and swings around the center of the first hole a1 through a third annular groove 4231 to drive the third rotating assembly 42 to swing on the supporting frame 41 so as to adjust the angle of the third rotating assembly 42 relative to the process center line L, thereby changing the position of the second sheet W12 on the leading-out side of the third leading-out roller 422 relative to the leading-in side of the third leading-in roller 421.
Also, the fourth rotating assembly 43 includes a fourth introduction roller 431, a fourth discharge roller 432, and a fourth carriage 433. The fourth introducing roller 431 and the fourth discharging roller 432 are fixed to the fourth carriage 433, wherein the fourth introducing roller 431 is located at the introducing side and the fourth discharging roller 432 is located at the discharging side.
The bottom of the fourth bracket 433 is provided with a second hole a2 and a fourth arc-shaped groove 4331 centering on the center of the second hole a2, and the fourth bracket 433 swings around the center of the second hole a2 through the fourth arc-shaped groove 4331, thereby driving the fourth rotating assembly 43 to swing on the supporting frame 41 to adjust the angle of the fourth rotating assembly 43 relative to the process center line L, thereby changing the position of the third sheet W13 on the leading-out side of the fourth leading-out roller 432 relative to the leading-in side of the fourth leading-in roller 431.
Referring to fig. 6 and 7, in the embodiment of the present invention, the first deflection unit 3 and the second deflection unit 4 fix the mounting frame 31 and the supporting frame 41 through the mounting plate M, respectively, the mounting plate M has a reference line K, and the reference line K of the mounting plate M is parallel to the flow center line L. The flow center line L is a reference line for a flow design for processing the disposable diaper in the manufacturing facility of the disposable diaper.
According to the embodiment of the present invention, the first sheet W11 displaced by the first displacement unit 3 corresponds to the position of the second sheet 2 displaced by the second displacement unit 4 in the direction perpendicular to the flow direction. The fourth sheet W14 displaced by the first displacement unit 3 corresponds to the position of the third sheet W13 displaced by the second displacement unit 4, and the first sheet W11 and the second sheet W12 are located on one side of the flow center line L, and the third sheet W13 and the fourth sheet W14 are located on the other side of the flow center line L, as shown in fig. 13.
In a further embodiment, the first and second sheets W11 and W12 are equidistant from the flow center line L and the third and fourth sheets W13 and W14 are equidistant from the flow center line L.
As shown in fig. 4, after the first sheet W11, the second sheet W12, the third sheet W13, and the fourth sheet W14 are displaced by the first displacement unit 3 and the second displacement unit 4, the first sheet W11 and the fourth sheet W14 are conveyed along the first path R1 under the guidance of the guide free roller 1.
Since the first sheet W11 and the fourth sheet W14 are two separate sheets, it is necessary to make the respective conveyance path lengths of the first sheet W11 and the fourth sheet W14 before entering the first displacement unit 3 the same as those before entering the first deviation correcting unit 5 in the conveyance process so as not to cause inconsistency to affect the post-composite effect. As shown in fig. 4, the length of the first sheet W11 is longer than the length of the fourth sheet W14 on the first displacement unit 3, and therefore, on the upstream side of the first deviation correcting unit 5, the fourth sheet W14 needs to be routed longer than the first sheet W11 in the flow, that is, the fourth sheet W14 needs to be fed back on the downstream side at a distance behind the first displacement unit 3.
After being shifted by the first shifting unit 3, the first sheet W11 and the fourth sheet W14 are conveyed to the first rectifying unit 5 along the first path R1, and the first sheet W11 and the fourth sheet W14 are respectively subjected to precise rectifying, so that the first sheet W11 and the fourth sheet W14 can accurately reach a predetermined position, and preparation is made for downstream-side compounding.
Also, the second sheet W12 and the third sheet W13 are conveyed along the second path R2 under the guide of the guide free roller.
Since the second sheet W12 and the third sheet W13 are also two separated sheets, it is also necessary to make the respective conveyance path lengths of the second sheet W12 and the third sheet W13 before entering the second displacement unit 4 the same as those before entering the second deviation correcting unit 7 during conveyance so as not to cause inconsistency to affect the post-composite effect. As shown in fig. 4, the length of the third sheet W13 is longer than the length of the second sheet W12 on the second displacement unit 4, and therefore, on the upstream side of the second deviation correcting unit 7, the length of the second sheet W12 to be routed in the flow path needs to be longer than the length of the third sheet W13, that is, the distance of the second sheet W12 behind the second displacement unit 4 needs to be fed back on the downstream side.
After being shifted by the second shifting unit 4, the second sheet W12 and the third sheet W13 are conveyed to the second deviation correcting unit 7 along the second path R2, and the second sheet W12 and the third sheet W13 are precisely corrected, respectively, so that the second sheet W12 and the third sheet W13 can accurately reach a predetermined position, and preparation is also made for downstream-side compounding.
As shown in fig. 4, the first and fourth sheets W11 and W14 after the correction are continuously conveyed downstream along the first path R1. The second web W12 and the third web W13 after the correction also continue to be conveyed downstream along the second path R2.
In order to reduce the cost and space of the manufacturing apparatus, the first and fourth sheets W11 and W14, the second and third sheets W12 and W13 are obtained by cutting one inner sheet W1 by the cutter unit 2.
In some embodiments, the first and fourth sheets W11 and W14, the second and third sheets W12 and W13 may be obtained by arranging 4 rolls of material to unwind.
As shown in fig. 4, the elastic body supply unit G includes a first supply unit G1, a second supply unit G2, and an elastic material supply unit G3, which are disposed in parallel along the flow. The elastic material supply unit G3 is located between the first supply unit G1 and the second supply unit G2.
The first feeding unit G1 is configured to continuously convey a first sheet W11 and a fourth sheet W14 parallel in a direction perpendicular to the flow direction in the flow direction. The first feeding unit G1 includes a first free roller 1 'provided in the flow for guiding the first sheet W11 and the fourth sheet W14, the first free roller 1' being laid along the flow path of the sheets.
The second feeding unit G2 is for continuously conveying the second sheet W12 and the third sheet W13 parallel in the flow direction perpendicular to the flow direction. The second feeding unit G2 includes a second free roller 1″ provided in the flow for guiding the second sheet W12 and the third sheet W13, the second free roller 1″ being laid along the flow path of the sheets.
The direction perpendicular to the flow direction refers to the width direction, and is also the width direction of the disposable diaper S.
The elastic material feeding unit G3 continuously conveys the plurality of elastic materials T in the flow direction, and the elastic material feeding unit G3 includes a plurality of tension sensors J and guide rollers D provided in the flow for guiding the elastic materials T.
Because the elastic material T has elasticity, the tension of the elastic material T directly influences the final forming state of the elastic composite sheet W, a tension sensor J is needed, and each tension sensor J corresponds to one elastic material T and is used for monitoring the tension of each elastic material T, so that the tension of the elastic material T is adjusted in real time, and a condition that the tension is stable is provided for the composition of the downstream side and the sheet. The elastic material T is conveyed under the guide of the guide wheel D.
In the embodiment of the present invention, the elastic material T is a plurality of spandex filaments (rubber strings), the number and positions of which are set according to the product. In order to fix the elastic material T well between the first sheet W11 and the second sheet W12 and to fix the elastic material T well between the fourth sheet W14 and the third sheet W13, the manufacturing apparatus further includes an application unit H provided on the upstream side of the nip-composite roller 6 for applying the adhesive N on the surface of each elastic material T, as shown in fig. 14. The elastic material T is applied with an adhesive N by means of an application unit H before it enters the nip-composite roll 6. In this embodiment, the elastic material T is a plurality of spandex filaments, and the sizing unit H sizes each of the spandex filaments, where the binder N wraps the outer periphery of the spandex filaments.
Since the elastic material feeding unit G3 is located between the first feeding unit G1 and the second feeding unit G2, that is, the elastic material T is located between the first sheet W11 and the fourth sheet of the first feeding unit G1 and the second sheet W12 and the third sheet of the second feeding unit G2, as shown in fig. 4 and 14. Since the sizing unit H causes a phenomenon of hot melt adhesive flying yarn during sizing (since the glue gun is provided with blowing hot air at the time of sizing), in order to avoid contamination of equipment by glue, the second sheet W12 and the third sheet W13 or the first sheet W11 and the fourth sheet W14 are provided below the sizing unit H, and the second sheet W12 and the third sheet W13 are provided below the sizing unit H in this embodiment. The hot melt adhesive of the flying silk is taken away by the sheet material by the arrangement, so that the sheet material can be fixed, and the clean and tidy manufacturing equipment can be maintained.
The first sheet W11, the elastic material T, the second sheet W12 are taken as one group, and the fourth sheet W14, the elastic material T, the third sheet W13 are taken as another group, while being conveyed to the nip composite roller 6. The nip-press composite roller 6 composites the elastic material T extending in the flow direction between the first sheet W11 and the second sheet W12 on one side of the flow center line L to form a first elastic composite semifinished product W', and composites the elastic material T extending in the flow direction between the fourth sheet W14 and the third sheet W13 on the other side of the flow center line to form a second elastic composite semifinished product w″ as shown in fig. 15.
Further, the pinch-and-compound roller 6 includes a driving roller and a pinch roller which are disposed opposite to each other, and pinch-drives the first sheet W11, the second sheet W12, and the elastic material T disposed between the first sheet W11 and the second sheet W12 on the side of the flow center line L by the driving roller and the pinch roller, thereby forming a first elastic composite semifinished product W'; and simultaneously nip-driving the third sheet W13, the fourth sheet W14, and the elastic material T provided between the third sheet W13 and the fourth sheet on the other side of the flow center line L, thereby forming a second elastic composite semifinished product W. The nip roller provided in the nip composite roller 6 increases the adhesive force between the first sheet W11, the elastic material T, and the second sheet W13, and increases the adhesive force between the third sheet W13, the elastic material T, and the fourth sheet W14. The driving roller is connected with the driving motor, and the speed adjustment of the composite material of the first elastic composite semi-finished product W 'and the second elastic composite semi-finished product W' of the station is realized by controlling and adjusting the driving motor.
As shown in fig. 4, the first elastic composite semifinished product W' and the second elastic composite semifinished product w″ formed by the compounding by the nip compounding roller 6 enter the elastic material cutting unit 8 to cut the elastic material T.
According to an embodiment of the present invention, the manufacturing apparatus further includes an elastic material cutting unit 8 provided on the upstream side of the ultrasonic heat sealing unit 9.
The elastic material cutting unit 8 is configured to cut the elastic material T in the corresponding first elastic composite semi-finished product W 'and second elastic composite semi-finished product W "in a position area of the outer cover layer S1 of the disposable diaper S corresponding to the composite inner cover sheet S2, so that elastic weakened areas are formed in the first elastic composite semi-finished product W' and the second elastic composite semi-finished product W", respectively, and the inner cover sheet S2 in the disposable diaper S is better and flatly combined in the outer cover layer S1.
As shown in fig. 16, in the outer cover layer S1 of the disposable diaper S, the elastic material T in the first elastic composite semi-finished product W' and the second elastic composite semi-finished product w″ is cut in the location areas corresponding to the composite inner sheet S2, i.e., the first area K1 and the second area K2, so that the elastic material T is completely or partially inelastic, and shrinkage is prevented from being caused in the first area K1 and the second area K2 after the inner sheet S2 is compounded, thereby affecting the flatness of the compounding and reducing the quality of the product.
As shown in fig. 4, according to an embodiment of the present invention, a second driving unit E "is disposed between the elastic material cutting unit 8 and the ultrasonic heat-sealing unit 9, and the first elastic composite semifinished product W' and the second elastic composite semifinished product W" after cutting the elastic material T at predetermined positions are introduced into the ultrasonic heat-sealing unit 9 via the second driving unit E ". The second driving unit e″ is connected to the driving motor to drive the first and second elastic composite semi-finished products W' and w″ to move downstream after cutting the elastic material T at a predetermined position. The second driving unit e″ can adjust the running speeds of the first and second elastic composite semi-finished products W' and w″ in real time as needed.
As shown in fig. 4, the cut first elastic composite semifinished product W' and second elastic composite semifinished product w″ are conveyed to the downstream side. The outer sheet W2 is fed under the guide of the guide free roller 1 after being unwound. The cut first elastic composite semifinished product W' and second elastic composite semifinished product w″ and the outer layer web W2 are simultaneously conveyed to the ultrasonic heat-sealing unit 9, as shown in fig. 17.
An ultrasonic heat-sealing unit 9 for ultrasonically compositing the outer-layer sheet W2 extending in the flow direction simultaneously with the first elastic composite semifinished product W ' and the second elastic composite semifinished product W ", respectively, to form a first joint F ' and a second joint F" between the outer-layer sheet W2 and the sheets of the first elastic composite semifinished product W ', the second elastic composite semifinished product W ", respectively, thereby forming the elastic composite sheet W.
Specifically, on one side of the flow center line L, the first elastic composite semifinished product W' is composited with the outer sheet W2, and on the other side of the flow center line L, the second elastic composite semifinished product w″ is composited with the outer sheet W2, as shown in fig. 18.
Fig. 8 is a schematic view showing the structure of an ultrasonic heat-sealing unit according to the present invention, fig. 9 is a schematic view showing the development of an ultrasonic bottom roller according to the present invention in the circumferential direction, and fig. 10 is a sectional view showing the direction V-V in fig. 9, the ultrasonic heat-sealing unit 9 including a first ultrasonic horn 91, a second ultrasonic horn 93 and an ultrasonic bottom roller 92 according to an embodiment of the present invention.
The first ultrasonic horn 91 and the second ultrasonic horn 93 are disposed in parallel in the axial direction while being opposed to the ultrasonic bottom roller 92. The first ultrasonic horn 91 corresponds to the position of the first elastic composite semifinished product W', and the second ultrasonic horn 93 corresponds to the position of the second elastic composite semifinished product W ".
When the first elastic composite semi-finished product W ' and the outer sheet W2 are transferred between the first ultrasonic horn 91 and the ultrasonic bottom roller 92, the outer sheet W2 and the sheet of the first elastic composite semi-finished product W ' are welded to form a first joint F ', as shown in fig. 19.
Meanwhile, when the second elastic composite semifinished product w″ and the outer layer sheet W2 are transferred between the second ultrasonic horn 93 and the ultrasonic bottom roller 92, the outer layer sheet W2 and the sheet of the second elastic composite semifinished product w″ are welded to form a second joint f″ as shown in fig. 19.
Specifically, the first ultrasonic horn 91 and the second ultrasonic horn 93 emit ultrasonic energy, and heat and melt the first sheet W11, the second sheet W12, and the outer sheet W2 in the first elastic composite semifinished product W 'through the energy converter, thereby forming a first joint F' of the fixed sheets; similarly, the third sheet W13, the fourth sheet W14, and the outer sheet W2 in the second elastic composite semifinished product w″ are heated and melted to form a second joined portion f″ of the fixing sheet, as shown in fig. 18 and 19.
Further, according to the embodiment of the present invention, the ultrasonic foot roller 92 is provided with a plurality of engaging flower sections 921 arranged to extend in the axial direction at intervals on the circumferential surface. The engaging flower 921 includes a base 9211 and a convex 9212 connected, the base 9211 and the convex 9212 are spaced apart, and the convex 9212 is higher than the base 9211.
The engaging pattern portions 921 are arranged at regular intervals on the circumferential surface of the ultrasonic back roller 92 and extend in the axial direction of the ultrasonic back roller 92, and the surface of the convex portion 9212 is provided with a pattern corresponding to the pattern of the first engaging portion F' and the second engaging portion f″. The flower-shaped pattern may be a circle, a square, a rectangle, a triangle, a trapezoid, etc. and combinations of patterns thereof, and the flower-shaped pattern is a rectangle in this embodiment, so the patterns of the first joint portion F' and the second joint portion f″ are also rectangular.
As shown in fig. 4, after the first elastic composite semifinished product W' and the second elastic composite semifinished product w″ are ultrasonically combined with the outer sheet W2 by the ultrasonic heat sealing unit 9, an elastic composite sheet W is formed, and the processing is continued downstream by the conveyance of the output roller 10 to form the outer cover layer S1, and finally, the inner sheet S2 is combined with the outer cover layer S1 and processed by the downstream process, thereby forming the disposable diaper S.
The present invention provides a method for manufacturing an elastic composite sheet, and a method for manufacturing an elastic composite sheet according to the present invention will be described with reference to fig. 4 and 11 to 19.
According to an embodiment of the present invention, a method for manufacturing an elastic composite sheet, an elastic composite sheet W for manufacturing an outer cover layer S1 of a disposable diaper S using the manufacturing apparatus of an elastic composite sheet provided by the present invention, comprises the following method steps:
inner sheet feeding step A1:
as shown in fig. 4 and 11, the inner sheet W1 is continuously conveyed in the flow direction after being unwound. The inner sheet W1 is fed to the cutter unit 2 via a guide free roller 1 provided on the flow path after being unwound.
Slitting process A2:
as shown in fig. 4 and 12, the cutter unit 2 cuts the inner sheet W1, and forms a first sheet W11, a second sheet W12, a third sheet W13, and a fourth sheet W14 in this order from one side to the other side in the direction perpendicular to the flow direction, wherein there is no gap between adjacent sheets.
A displacement process A3:
as shown in fig. 4 and 13, the first displacement unit 3 displaces the first sheet W11 and the fourth sheet W14 having the separation distance in the direction perpendicular to the flow direction so that the pitch of the displaced first sheet W11 and fourth sheet W14 reaches a predetermined distance.
The second displacement unit 4 displaces the adjacent and adjacent second and third sheets W12 and W13 in the direction perpendicular to the flow direction so that the pitch of the displaced second and third sheets W12 and W13 reaches a predetermined distance.
Along the direction perpendicular to the flow direction, the shifted first sheet W11 corresponds in position to the shifted second sheet W12, the shifted fourth sheet W14 corresponds in position to the shifted third sheet W13, and the first sheet W11 and the second sheet W12 are located on one side of the flow center line L, and the fourth sheet W14 and the third sheet W13 are located on the other side of the flow center line L.
The distance between the first sheet W11 and the second sheet W12 and the process center line L is equal to the distance between the third sheet W13 and the fourth sheet W14 and the process center line L.
The inner sheet feeding step A1, the slitting step A2, and the displacement step A3 are defined as inner sheet pretreatment steps for processing the inner sheet W1, that is, slitting the inner sheet W1 into a first sheet W11, a second sheet W12, a third sheet W13, and a fourth sheet W14, and then displacing the inner sheet.
The downstream side of the displacement step A3 further includes a correction step of correcting the first sheet W11 and the fourth sheet W14 after displacement, respectively, and correcting the second sheet W12 and the third sheet W13 after displacement, respectively.
Elastomer supply step A4:
referring to fig. 4, the elastic body supply process A4 includes a first supply process a41, a second supply process a42, and an elastic material supply process a43 that are arranged in parallel along the flow, wherein the elastic material supply process a43 is located between the first supply process a41 and the second supply process a 42.
First supply step a41:
the first sheet W11 and the fourth sheet W14 parallel in the direction perpendicular to the flow direction are continuously conveyed in the flow direction by the first feeding unit G1.
Second supply step a42:
the second sheet W12 and the third sheet W13 parallel in the direction perpendicular to the flow direction are continuously conveyed in the flow direction by the first feeding unit G2.
Elastic material supply step a43:
the elastic material supply unit G3 continuously conveys the plurality of elastic materials T in the flow direction.
Along a direction perpendicular to the flow direction, the first sheet W11 corresponds in position to the second sheet W12; the fourth web W14 corresponds in position to the third web W13; the first web W11 and the second web W12 are located on one side of the flow center line L, and the third web W13 and the fourth web W14 are located on the other side of the flow center line L.
In some embodiments, the elastomer supply process A4 may be obtained by unwinding 4 rolls of directly joined first, second, third and fourth sheets W11, W12, W13 and W14.
In this embodiment, the elastic body supply step A4 is performed downstream of the slitting step A2 and the displacement step A3, and the first sheet W11, the second sheet W12, the third sheet W13, and the fourth sheet W14 are obtained after slitting in the slitting step A2, and the displacement step A3 displaces the first sheet W11, the second sheet W12, the third sheet W13, and the fourth sheet W14 to predetermined positions for compounding.
Sizing process A5:
as shown in fig. 4 and 14, an adhesive N is coated on the surface of each elastic material T using an application unit H. After the elastic material T is continuously fed through the elastic material feeding step a43, the adhesive N is applied to the elastic material T so as to be fixed between the two sheets. In this embodiment, the elastic material T is a plurality of spandex filaments, and the sizing unit H sizes each of the spandex filaments, where the binder N wraps the outer periphery of the spandex filaments.
Compounding procedure A6:
as shown in fig. 4, 14, and 15, the first sheet W11, the elastic material T, the second sheet W12, and the fourth sheet W14, the elastic material T, and the third sheet W13 are conveyed to the nip composite roller 6. The elastic material T extending in the flow direction is compounded between the first sheet W11 and the second sheet W12 on one side of the flow center line L by the nip compounding roller 6 to form a first elastic composite semifinished product W'. The elastic material T extending in the flow direction is compounded between the fourth sheet W14 and the third sheet W13 on the other side of the flow center line L to form a second elastic compound semifinished product W.
Elastic material cutting process A7:
as shown in fig. 4 and 16, the elastic material T in the corresponding first elastic composite semi-finished product W 'and second elastic composite semi-finished product W "is cut by the elastic material cutting unit 8 in the position region of the outer cover layer S1 of the disposable diaper S corresponding to the composite inner sheet S2, thereby forming elastic weakened areas in the first elastic composite semi-finished product W' and second elastic composite semi-finished product W", respectively.
Namely, in the first region K1 and the second region K2, the elastic material T in the first elastic composite semi-finished product W' and the second elastic composite semi-finished product w″ is cut off to completely or partially lose elasticity, so that shrinkage is prevented from being caused in the first region K1 and the second region K2 after the inner sheet S2 is compounded, the flatness of the compounded product is affected, and the product quality is reduced.
Outer sheet feeding step A8:
as shown in fig. 4 and 17, the outer sheet W2 is continuously conveyed in the flow direction after being unwound, specifically, the outer sheet W2 is conveyed under the guide of the guide free roller 1.
Ultrasonic wave compounding process A9:
as shown in fig. 4, 17, 18, and 19, the cut first elastic composite semifinished product W' and second elastic composite semifinished product w″ and the outer sheet W2 are conveyed to the ultrasonic heat sealing unit 9. The outer sheet W2 extending in the flow direction is ultrasonically compounded with the first elastic composite semifinished product W ' and the second elastic composite semifinished product W ", respectively, by the ultrasonic heat-sealing unit 9 to form a first joint F ' between the outer sheet W2 and the sheet of the first elastic composite semifinished product W ', and a second joint f″ between the outer sheet W2 and the sheet of the second elastic composite semifinished product W", thereby forming the elastic composite sheet W.
Specifically, the first sheet W11, the second sheet W12, and the outer sheet W2 in the first elastic composite semi-finished product W 'are heated and melted to form a first joint F', and the third sheet W13, the fourth sheet W14, and the outer sheet W2 in the second elastic composite semi-finished product w″ are heated and melted to form a second joint F ".
The following points need to be described:
(1) The drawings of the embodiments of the present invention relate only to the structures related to the embodiments of the present invention, and other structures may refer to the general designs.
(2) In the drawings for describing embodiments of the present invention, the thickness of layers or regions is exaggerated or reduced for clarity, i.e., the drawings are not drawn to actual scale. It will be understood that when an element such as a layer, film, region or substrate is referred to as being "on" or "under" another element, it can be "directly on" or "under" the other element or intervening elements may be present.
(3) The embodiments of the invention and the features of the embodiments can be combined with each other to give new embodiments without conflict.
The present invention is not limited to the above embodiments, but the scope of the invention is defined by the claims.