阅读说明：本技术 弹性片的制造方法和制造装置、伸缩性复合片的制造方法和制造装置、以及伸缩性复合片 (Method and apparatus for producing elastic sheet, method and apparatus for producing stretchable composite sheet, and stretchable composite sheet ) 是由 腰岛美和 中村秀幸 于 2019-01-23 设计创作，主要内容包括：本发明提供一种具有优异透气性的弹性片制造方法和制造装置、以及复合伸缩性片制造方法和制造装置、以及伸缩性复合片。本发明将以热塑性弹性树脂为主要成分的弹性树脂材料加热至高于弹性树脂材料发生弹性变形的温度范围,并熔融；再将熔融的弹性树脂材料以纤维状或线状排出；将排出的弹性树脂材料(中间体(2))以网状涂敷至冷却构件(30),将涂敷的弹性树脂材料用冷却构件(30)冷却至弹性树脂材料发生弹性变形的温度范围,并固化,从而获得弹性片(3)；将弹性片(3)和无纺布(4,6)层压接合,获得伸缩性复合片(8)。(The invention provides a method and a device for manufacturing an elastic sheet with excellent air permeability, a method and a device for manufacturing a composite elastic sheet, and an elastic composite sheet. The present invention heats an elastic resin material containing a thermoplastic elastic resin as a main component to a temperature range higher than a temperature at which the elastic resin material is elastically deformed, and melts the elastic resin material; discharging the molten elastic resin material in a fibrous or linear form; applying the discharged elastic resin material (intermediate (2)) to a cooling member (30) in a web form, cooling the applied elastic resin material with the cooling member (30) to a temperature range in which the elastic resin material is elastically deformed, and curing to obtain an elastic sheet (3); the elastic sheet (3) and the nonwoven fabrics (4, 6) are laminated and joined to obtain a stretchable composite sheet (8).)

1. A method of making an elastic sheet, comprising: the method comprises the following steps:

the first step is as follows: a first elastic resin material containing a first thermoplastic elastic resin as a main component is heated to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, and is melted;

the second step is as follows: discharging the molten first elastic resin material in a fiber or thread form from a first discharge port;

the third step: the first elastic resin material discharged from the first discharge port is applied to the cooling member in a mesh shape, and the applied first elastic resin material is cooled to a first temperature range by the cooling member and solidified.

2. The elastic sheet manufacturing method according to claim 1, wherein:

in the second step, the first elastic resin material is discharged in a linear shape;

in the third step, the first elastic resin material discharged in a linear shape is applied to the cooling member in a zigzag or spiral shape.

3. The elastic sheet manufacturing method according to claim 1 or 2, characterized in that:

in the second step, the first elastic resin material is discharged from a plurality of first discharge ports;

in the third step, the first elastic resin material discharged from each first discharge port is applied to the cooling member in a manner to partially overlap with each other.

4. A method of manufacturing an elastic sheet according to claim 3, wherein:

in the second step, the first elastic resin material is discharged from the plurality of first discharge ports, and the discharge amount of the first elastic resin material is changed in accordance with the first discharge ports.

5. The elastic sheet manufacturing method according to any one of claims 1 to 4, characterized in that: in the second step, the discharge amount of the first elastic resin material is periodically changed.

6. The elastic sheet manufacturing method according to any one of claims 1 to 5, characterized in that:

the first step comprises a first substep of: a second elastic resin material containing the second thermoplastic elastic resin as a main component is heated to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, and is melted;

the second step comprises a second substep of: the melted second elastic resin material is discharged in a linear shape from a plurality of second discharge ports;

the third step comprises a third substep of: applying the second elastic resin material discharged from the second discharge port to the cooling member in parallel and linearly so as to overlap the first elastic resin material applied to the cooling member; and the applied second elastic resin material is cooled to a second temperature range with a cooling member and cured.

7. The elastic sheet manufacturing method according to any one of claims 1 to 5, characterized in that:

the first step comprises a first substep of: a second elastic resin material containing the second thermoplastic elastic resin as a main component is heated to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, and is melted;

The second step comprises a second substep of: the molten second elastic resin material is discharged from the second discharge port in a linear or fibrous form;

the third step comprises a third substep of: drawing the first elastic resin material, which is cooled to the first temperature range and solidified, out of the cooling member, through the additional cooling member; and coating the second elastic resin material discharged from the second discharge port on the additional cooling member in a linear or web shape; so as to overlap with the first elastic resin material along a portion of the additional cooling member; and cooling the coated second elastic resin material to a second temperature range with an additional cooling member and solidifying.

8. A method for manufacturing a stretchable composite sheet, comprising: an elastic sheet manufactured by the method according to any one of claims 1 to 7, which is laminated and joined to the first nonwoven fabric.

9. A method for manufacturing a stretchable composite sheet, comprising: an elastic sheet manufactured by the elastic sheet manufacturing method according to any one of claims 1 to 5, laminated and joined with a first nonwoven fabric;

the method for manufacturing the elastic sheet comprises the following steps:

the first step comprises a first substep of: a second elastic resin material containing a second thermoplastic elastic resin as a main component is heated to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, and is melted;

The second step includes a second substep of: the molten second elastic resin material is discharged from the second discharge port in a linear or fibrous form;

the third step includes a third substep of: drawing the first elastic resin material, which is cooled to the first temperature range and solidified, out of the cooling member, through the additional cooling member; and coating the second elastic resin material discharged from the second discharge port on the additional cooling member in a linear or web shape; so as to overlap with the first elastic resin material along a portion of the additional cooling member; and cooling the coated second elastic resin material to a second temperature range with an additional cooling member and solidifying.

10. A method of manufacturing a stretchable composite sheet according to claim 8 or 9, characterized in that: laminating the second nonwoven fabric with the elastic sheet and the first nonwoven fabric; a second nonwoven fabric bonded to at least one of the elastic sheet and the first nonwoven fabric; so that the elastic sheet is sandwiched between the first nonwoven fabric and the second nonwoven fabric.

11. A method of manufacturing a stretchable composite sheet according to claim 8 or 9, characterized in that: the elastic sheet and the first nonwoven fabric are ultrasonically bonded at a plurality of locations separated from each other.

12. A method of manufacturing a stretchable composite sheet according to claim 8 or 9, characterized in that: stretching the elastic sheet, and laminating and joining the stretched elastic sheet to the first nonwoven.

13. A method of manufacturing a stretchable composite sheet according to claim 8 or 9, characterized in that: after the elastic sheet and the first nonwoven fabric are laminated and joined, the elastic sheet and the first nonwoven fabric are stretched together.

14. A method of manufacturing a stretchable composite sheet according to claim 12 or 13, characterized in that: and laminating and bonding the elastic sheet and the first nonwoven fabric stretched in at least one direction so that one direction of the first nonwoven fabric is perpendicular to the stretching direction of the elastic sheet.

15. An elastic sheet manufacturing apparatus characterized in that: it includes:

a coating mechanism provided with a first discharge mechanism; and a cooling member disposed below the first discharge mechanism; wherein

The first discharge mechanism has a first discharge port for heating a first elastic resin material containing a first thermoplastic elastic resin as a main component to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, melting the first elastic resin material, and discharging the first elastic resin material in a fibrous or linear form;

The coating mechanism is used for coating the first elastic resin material discharged from the first discharge port to the cooling component in a net shape;

the cooling member cools the first elastic resin material applied to the cooling member to a first temperature range and solidifies.

16. An apparatus for manufacturing an elastic sheet according to claim 15, wherein:

the coating mechanism is provided with a second discharge mechanism; the cooling component is arranged below the second discharge mechanism; wherein the content of the first and second substances,

a second discharge mechanism having a plurality of second discharge ports for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the melted second elastic resin material in a linear shape;

the coating mechanism is parallel to the cooling member and linearly coats the cooling member so that the second elastic resin material discharged from the second discharge port overlaps the first elastic resin material coated on the cooling member;

the cooling member cools the second elastic resin material applied to the cooling member to a second temperature range and solidifies.

17. An apparatus for manufacturing an elastic sheet according to claim 15, wherein: further having an additional cooling member applied to the cooling member and cooled to a first temperature range and solidified; passing the first elastic resin material through the additional cooling member after being drawn out of the cooling member;

The coating mechanism is provided with a second discharge mechanism;

the additional cooling component is arranged below the second discharge mechanism;

the second discharge mechanism has a second discharge port for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear or fibrous form;

the coating mechanism is coated to the additional cooling member in a linear or net shape so that the second elastic resin material discharged from the second discharge port overlaps with the first elastic resin material along a portion of the additional cooling member;

the additional cooling member cools the second elastic resin material applied to the additional cooling member to a second temperature range and solidifies.

18. The utility model provides a compound piece manufacturing installation of elasticity which characterized in that: it includes: a coating mechanism provided with a first discharge mechanism; a cooling member disposed below the first discharge mechanism; and a laminating mechanism; wherein the content of the first and second substances,

the first discharge mechanism has a first discharge port for heating a first elastic resin material containing a first thermoplastic elastic resin as a main component to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, melting the first elastic resin material, and discharging the first elastic resin material in a fibrous or linear form;

The coating mechanism is used for coating the first elastic resin material discharged from the first discharge port to the cooling component in a net shape;

the cooling member is used for cooling the first elastic resin material applied to the cooling member to a first temperature range and solidifying the first elastic resin material to form a reticular elastic sheet;

the laminating mechanism laminates and bonds the elastic sheet to the non-woven fabric.

19. The apparatus for manufacturing an extensible composite sheet according to claim 18, wherein:

the coating mechanism is provided with a second discharge mechanism;

the cooling component is arranged below the second discharge mechanism;

a second discharge mechanism having a plurality of second discharge ports for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the melted second elastic resin material in a linear shape;

the coating mechanism is parallel to the cooling member and linearly coats the cooling member so that the second elastic resin material discharged from the second discharge port overlaps the first elastic resin material coated on the cooling member;

the cooling member cools the second elastic resin material applied to the cooling member to a second temperature range and solidifies.

20. The apparatus for manufacturing an extensible composite sheet according to claim 18, wherein: an additional cooling member through which the elastic sheet drawn out from the cooling member passes; the coating mechanism is provided with a second discharge mechanism; wherein the content of the first and second substances,

the additional cooling component is arranged below the second discharge mechanism;

a second discharge mechanism having a second discharge port for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear or fibrous form;

the coating mechanism is used for coating the second elastic resin material discharged from the second discharge port to the additional cooling member in a linear or net shape;

the additional cooling member cools the second elastic resin material applied to the additional cooling member to a second temperature range and solidifies.

21. The apparatus for manufacturing a stretchable composite sheet according to any one of claims 18 to 20, wherein: also has a stretching mechanism for stretching the elastic sheet; the laminating mechanism joins the stretched elastic sheet to the nonwoven.

22. A stretchable composite sheet characterized by: it includes:

a first nonwoven fabric; and

a net-like elastic sheet mainly composed of a thermoplastic elastic resin and having a fibrous or linear structure partially overlapped with each other;

the net-like elastic sheet and the first nonwoven fabric are joined at a plurality of locations separated from each other.

23. The stretchable composite sheet of claim 22, wherein:

also comprises a second non-woven fabric;

the second nonwoven fabric is laminated with the elastic sheet and the first nonwoven fabric and joined with at least one of the elastic sheet and the first nonwoven fabric at a plurality of locations separated from each other such that the elastic sheet is sandwiched between the first nonwoven fabric and the second nonwoven fabric.

Technical Field

The present invention relates to a method and an apparatus for manufacturing an elastic sheet, a method and an apparatus for manufacturing an elastic composite sheet, and an elastic composite sheet. More particularly, the present invention relates to a method and an apparatus for producing an elastic sheet, a method and an apparatus for producing an extensible composite sheet, and an extensible composite sheet, which are suitable for use in disposable wearing articles and the like.

Background

The stretchable composite sheet having excellent elasticity is useful as a backsheet for a disposable diaper. Fig. 9 is a schematic view of a process for making a stretchable composite sheet. As shown in fig. 9, the thermoplastic elastic resin is extruded from the T-die 111 to form a film 103' in a molten state. Then, the film 103' is cooled with a cooling roller 120. Then, the cooled film 103' is sandwiched between two continuous nonwoven fabrics 102, and simultaneously subjected to embossing treatment. In the embossing process, the embossing roller 112 and the backup roller 113 having a plurality of dot-shaped protrusions 112a formed on the surface thereof are pressed and nipped. The layers of the stretch sheet 101 are joined to each other by embossing to form a single unit, and are wound around a winding roll 116. The nonwoven fabric 102 used can be subjected to stretch bonding at least in the left-right direction (the direction perpendicular to the flow direction and the thickness direction of the nonwoven fabric 102) (see, for example, patent document 1).

Patent document 1 japanese patent No. 3054930.

For example, it may be desirable to use a stretchable composite sheet having excellent breathability for a disposable wearing article.

However, the stretchable composite sheet 101 manufactured by the method of fig. 9 includes the film-like material 103', and thus it is difficult to provide breathability.

Disclosure of Invention

The invention aims to provide a method and a device for manufacturing an elastic sheet, which can manufacture an elastic sheet with excellent air permeability; also provided are a method and an apparatus for producing a composite stretchable sheet; it is also possible to produce a composite stretchable sheet having excellent air permeability and a stretchable composite sheet having excellent air permeability.

The technical scheme of the invention is as follows:

in order to solve the above-described technical problem, the present invention provides a method of manufacturing an elastic sheet configured as follows.

A method of making an elastic sheet comprising:

(i) the first step is as follows: a first elastic resin material containing a first thermoplastic elastic resin as a main component is heated to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, and is melted;

(ii) the second step is as follows: discharging the molten first elastic resin material in a fiber or thread form from a first discharge port;

(iii) the third step: the first elastic resin material discharged from the first discharge port is applied to the cooling member in a mesh shape, and the applied first elastic resin material is cooled to a first temperature range by the cooling member and solidified.

By the above method, a net-like elastic sheet made of the cooled and solidified first elastic resin material can be obtained, and therefore an elastic sheet having excellent air permeability can be produced. Further, an elastic sheet stretched in all directions can be manufactured.

Preferably, in the second step, the first elastic resin material is discharged in a linear shape. In the third step, the first elastic resin material discharged in the form of a wire is applied to the cooling member in a zigzag or spiral shape.

In this case, the first elastic resin material can be easily applied in a net shape.

Preferably, in the second step, the first elastic resin material is discharged from the plurality of first discharge ports. In the third step, the first elastic resin material discharged from each of the first discharge ports is applied to the cooling member in such a manner as to partially overlap each other.

In this case, the wide-mesh elastic sheet can be easily manufactured.

Preferably, in the second step, the first elastic resin material is discharged from the plurality of first discharge ports, and the discharge amount of the first elastic resin material is different according to the first discharge ports.

In this case, elastic sheets having different stretch characteristics can be manufactured according to the position in the width direction, i.e., the direction perpendicular to the flow direction of the elastic sheet and the thickness direction of the elastic sheet during the manufacturing process.

Preferably, in the second step, the discharge amount of the first elastic resin material may be periodically changed.

In this case, elastic sheets having different stretch characteristics can be manufactured according to the position in the flow direction, i.e., the direction perpendicular to the width direction and the thickness direction.

Preferably, the first step comprises a first sub-step of: a second elastic resin material containing a second thermoplastic elastic resin as a main component is heated to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, and is melted. The second step comprises a second sub-step of: the melted second elastic resin material is discharged in a linear shape from the plurality of second discharge ports. The third step comprises a third sub-step of: the second elastic resin materials discharged from the second discharge port are applied to the cooling member in parallel and linearly to overlap with the first elastic resin materials applied to the cooling member, and the applied second elastic resin materials are cooled to the second temperature range with the cooling member and solidified.

In this case, a net-like elastic sheet made of the cooled and solidified first and second elastic resin materials can be obtained. By changing the amount (thickness or number) of the first elastic resin material and the application pattern, the stretching stress in the width direction of the elastic sheet can be mainly adjusted. By changing the amount (thickness or amount) of the second elastic resin material, the expansion and contraction stress in the flow direction of the elastic sheet (the direction perpendicular to the width direction and the thickness direction of the elastic sheet) during the manufacturing process can be mainly adjusted. Therefore, the flow direction and the width direction of the elastic sheet can be easily adjusted in the expansion and contraction stress.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

Preferably, the first step comprises a first sub-step of: a second elastic resin material containing a second thermoplastic elastic resin as a main component is heated to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, and is melted. The second step comprises a second sub-step of: the molten second elastic resin material is discharged from the second discharge port in a linear or fibrous shape. The third step comprises a third sub-step of: the first elastic resin material cooled to the first temperature range and solidified is pulled out from the cooling member, passes through the additional cooling member, and the second elastic resin material discharged from the second discharge port is coated on the additional cooling member in a linear or web shape so as to overlap with the first elastic resin material along a portion of the additional cooling member, and the coated second elastic resin material is cooled to the second temperature range with the additional cooling member and solidified.

In this case, the flow direction and the width direction of the elastic sheet can be easily adjusted in the expansion and contraction stress. Further, since the first and second elastic resin materials are cooled and cured, respectively, it is easier to provide a difference in the stretch ratio than when the first and second elastic resin materials are cooled and cured simultaneously.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

The present invention also provides a method for manufacturing a stretchable composite sheet configured as follows.

In the method for producing a stretchable composite sheet, the elastic sheet produced by any one of the above-described elastic sheet production methods is laminated and joined to the first nonwoven fabric.

By the above method, the elastic sheet having excellent air permeability and the first nonwoven fabric can be joined to produce the stretchable composite sheet having excellent air permeability.

When the first and second elastic resin materials are used, the second elastic resin material discharged from the second discharge port may be coated on the additional cooling member in a linear or web shape so as not to overlap with the first elastic resin material along a portion of the additional cooling member.

Preferably, the second nonwoven fabric is laminated with the elastic sheet and the first nonwoven fabric such that the second nonwoven fabric is joined to at least one of the elastic sheet and the first nonwoven fabric with the elastic sheet sandwiched between the first nonwoven fabric and the second nonwoven fabric.

In this case, a stretchable composite sheet can be produced in which an elastic sheet is sandwiched between the first nonwoven fabric and the second nonwoven fabric.

Preferably, the elastic sheet and the first nonwoven fabric are ultrasonically bonded at a plurality of locations separated from each other.

When the elastic resin material of the elastic sheet has bondability (for example, hot melt), the elastic sheet and the first nonwoven fabric can be easily bonded. Further, the joining of the elastic sheet and the first nonwoven fabric, and the joining of the first nonwoven fabric and the second nonwoven fabric can be easily performed.

Preferably, the elastic sheet is stretched, and the elastic sheet in the stretched state is laminate-joined with the first nonwoven fabric.

In this case, by releasing the stretched elastic sheet, a stretchable composite sheet having irregularities formed on the surface of the first nonwoven fabric can be obtained.

Preferably, after the elastic sheet is laminated and joined with the first nonwoven, the elastic sheet is stretched together with the first nonwoven.

In this case, a stretchable composite sheet in which the surface of the first nonwoven fabric is kept substantially flat even when the stretch of the elastic sheet is released can be obtained.

Preferably, the elastic sheet is laminated and joined with a first nonwoven stretchable in at least one direction such that one direction of the first nonwoven is perpendicular to the elastic sheet stretching direction.

In this case, a stretchable composite sheet which is stretchable in all directions can be produced.

Further, the present invention provides an elastic sheet manufacturing apparatus configured as follows to solve the above-described technical problems.

An elastic sheet manufacturing apparatus comprising: (a) a coating mechanism provided with a first discharge mechanism; and (b) a cooling member disposed below the first discharge mechanism. Wherein the first discharge mechanism has a first discharge port for heating a first elastic resin material containing a first thermoplastic elastic resin as a main component to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, melting, and discharging in a fibrous or linear form; the coating mechanism is used for coating the first elastic resin material discharged from the first discharge port to the cooling component in a net shape; the cooling member cools the first elastic resin material applied to the cooling member to a first temperature range and solidifies.

According to the above configuration, a net-like elastic sheet can be obtained, and therefore an elastic sheet having excellent air permeability can be manufactured. Further, an elastic sheet stretched in all directions can be manufactured.

Preferably, the coating mechanism is provided with a second discharge mechanism; the cooling member is disposed below the second discharge mechanism. Wherein the second discharge mechanism has a plurality of second discharge ports for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear form; the coating mechanism is parallel to the cooling member and linearly coats the cooling member so that the second elastic resin material discharged from the second discharge port overlaps the first elastic resin material coated on the cooling member; the cooling member cools the second elastic resin material applied to the cooling member to a second temperature range, and solidifies.

In this case, a net-like elastic sheet made of the cooled and solidified first and second elastic resin materials can be obtained. By changing the amount (thickness or number) of the first elastic resin material and the application pattern, the stretching stress in the width direction of the elastic sheet can be mainly adjusted. By changing the amount (thickness or amount) of the second elastic resin material, the stretching stress in the flow direction of the elastic sheet in the manufacturing process can be mainly adjusted. Therefore, the flow direction and the width direction of the elastic sheet can be easily adjusted in the expansion and contraction stress.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

Preferably, the elastic sheet manufacturing apparatus further has an additional cooling member to be applied to the cooling member, and cooled to the first temperature range and solidified; the first elastic resin material is drawn out of the cooling member and then passed through the additional cooling member. The coating mechanism is provided with a second discharge mechanism. The additional cooling member is disposed below the second discharge mechanism. The second discharge mechanism has a second discharge port for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear or fibrous form. The coating mechanism is coated to the additional cooling member in a linear or web shape such that the second elastic resin material discharged from the second discharge port overlaps with the first elastic resin material along a portion of the additional cooling member. The additional cooling member cools the second elastic resin material applied to the additional cooling member to a second temperature range, and solidifies.

In this case, the flow direction and the width direction of the elastic sheet can be easily adjusted in the expansion and contraction stress. Further, the first and second elastic resin materials are cooled and cured, respectively, and therefore, a difference in the stretch ratio is more easily provided than the case where the first and second elastic resin materials are cooled and cured simultaneously.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

In order to solve the above-described problems, the present invention also provides an apparatus for manufacturing an elastic composite sheet, which is configured as follows.

An apparatus for manufacturing a stretchable composite sheet, comprising: (a) a coating mechanism provided with a first discharge mechanism; and (b) a cooling member disposed below the first discharge mechanism; and (c) a lamination mechanism. Wherein the first discharge mechanism has a first discharge port for heating a first elastic resin material containing a first thermoplastic elastic resin as a main component to a temperature higher than a first temperature range in which the first elastic resin material is elastically deformed, melting the first elastic resin material, and discharging the first elastic resin material in a fibrous or linear form; the coating mechanism is used for coating the first elastic resin material discharged from the first discharge port to the cooling component in a net shape; the cooling member is used for cooling the first elastic resin material applied to the cooling member to a first temperature range and solidifying the first elastic resin material to form a reticular elastic sheet; the lamination mechanism laminates and bonds the elastic sheet to the nonwoven.

With the above configuration, the elastic sheet excellent in air permeability and the nonwoven fabric can be joined together, thereby producing a stretchable composite sheet excellent in air permeability.

Preferably, the coating mechanism is provided with a second discharge mechanism; the cooling member is disposed below the second discharge mechanism. Wherein the second discharge mechanism has a plurality of second discharge ports for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear shape; the coating mechanism is parallel to the cooling member and linearly coats the cooling member such that the second elastic resin material discharged from the second discharge port overlaps the first elastic resin material coated to the cooling member; the cooling member cools the second elastic resin material applied to the cooling member to a second temperature range, and solidifies.

In this case, a net-like elastic sheet made of the cooled and solidified first and second elastic resin materials can be obtained. By changing the amount (thickness or number) of the first elastic resin material and the application pattern, the stretching stress in the width direction of the elastic sheet can be mainly adjusted. By changing the amount (thickness or amount) of the second elastic resin material, the stretching stress in the flow direction of the elastic sheet in the manufacturing process can be mainly adjusted. Therefore, the flow direction and the width direction of the elastic sheet can be easily adjusted.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

Preferably, the apparatus for manufacturing a stretchable composite sheet further has an additional cooling member through which the elastic sheet drawn out from the cooling member passes; the coating mechanism is provided with a second discharge mechanism; the additional cooling member is disposed below the second discharge mechanism. Wherein the second discharge mechanism has a second discharge port for heating a second elastic resin material containing a second thermoplastic elastic resin as a main component to a temperature higher than a second temperature range in which the second elastic resin material is elastically deformed, melting the second elastic resin material, and discharging the second elastic resin material in a linear or fibrous form; the coating mechanism coats the second elastic resin material discharged from the second discharge port to the additional cooling member in a linear or net shape; the additional cooling member cools the second elastic resin material applied to the additional cooling member to a second temperature range, and solidifies.

In this case, the flow direction and the width direction of the elastic sheet can be easily adjusted in the expansion and contraction stress. Further, the first and second elastic resin materials are cooled and cured, respectively, and therefore, a difference in the stretch ratio is more easily provided than when the first and second elastic resin materials are cooled and cured simultaneously.

The first and second thermoplastic elastomer resins may be the same or different. The first and second thermoplastic elastomer resins may be the same, and the first and second elastomer resin materials may be the same or different.

Preferably, there is also a stretching mechanism for stretching the elastic sheet. The laminating mechanism joins the stretched elastic sheet to the nonwoven.

In this case, by releasing the stretched elastic sheet, a stretchable composite sheet having irregularities formed on the surface of the first nonwoven fabric can be obtained.

In order to solve the above-described problems, the present invention also provides a stretchable composite sheet constructed as follows.

A stretchable composite sheet comprising: (a) a first nonwoven fabric; and (b) a net-like elastic sheet mainly composed of a thermoplastic elastic resin and having a fibrous or linear structure partially overlapped with each other. The net-like elastic sheet and the first nonwoven fabric are joined at a plurality of locations separated from each other.

According to the above configuration, the elastic sheet having excellent air permeability and the nonwoven fabric are joined together, and therefore, the produced stretchable composite sheet has excellent air permeability.

Preferably, the stretchable composite sheet further comprises (c) a second nonwoven fabric. The second nonwoven fabric is laminated with the elastic sheet and the first nonwoven fabric and joined with at least one of the elastic sheet and the first nonwoven fabric at a plurality of locations separated from each other such that the elastic sheet is sandwiched between the first nonwoven fabric and the second nonwoven fabric.

In this case, in the stretchable composite sheet, the elastic sheet is sandwiched between the first nonwoven fabric and the second nonwoven fabric.

The present invention can produce an elastic sheet having excellent air permeability, a composite stretchable sheet having excellent air permeability, and a stretchable composite sheet having excellent air permeability.

Drawings

FIG. 1 is a schematic view showing the overall configuration of an apparatus for producing an extensible composite sheet according to an embodiment 1 of the present invention.

FIG. 2 is a schematic view of the coating pattern in example 1 of the present invention.

FIG. 3 is a schematic view of the coating pattern in example 1 of the present invention.

Fig. 4(a) is a cross-sectional view of a stretchable composite sheet in which an elastic sheet is stretched in example 1 of the present invention.

Fig. 4(b) is a sectional view of the stretchable composite sheet released in tension in example 1 of the present invention.

FIG. 5 is a schematic view showing the overall structure of an apparatus for producing a stretchable composite sheet according to example 2 of the present invention.

FIG. 6 is an explanatory view of the coating pattern in example 2 of the present invention.

FIG. 7 is a schematic view showing the overall structure of an apparatus for producing a stretchable composite sheet according to example 3 of the present invention.

FIG. 8 is a schematic view showing the structure of the essential part of an apparatus for producing a stretchable composite sheet according to example 3 of the present invention.

Fig. 9 is a schematic view of a conventional process for manufacturing a stretchable composite sheet according to example 1.

Detailed Description

The present invention will be further described with reference to the accompanying drawings and examples.