Method and apparatus for producing wearing article, and wearing article

The method comprises the steps of: preparing a first suction-holding section and a second suction-holding section; positioning the first suction-holding section and the second suction-holding section in such a manner that respective surfaces of the first suction-holding section and the second suction-holding section are aligned side-by-side while facing the same side; suction-holding a forward surface of a main body of an developed module by the first suction-holding section, and suction-holding a rearward surface of the main body of the developed module by the second suction-holding section; closing the first suction-holding section and the second suction-holding section to fold the main body in half; and releasably joining superimposed portions of the developed module half-folded by the half-folding step.

TECHNICAL FIELD

The present invention relates to a method and apparatus for producing a wearing article.

BACKGROUND ART

Heretofore, there has been known a wearing article which comprises a main body adapted to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and a side panel for covering a lateral surface of a waist region of the wearer.

As this type of wearing article, an absorbent garment of Japanese Examined Patent Publication No. H08-017792B is known, for example. The absorbent garment of Japanese Examined Patent Publication No. H08-017792B comprises a waste containment section (main body) adapted to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and a side panel provided on each of laterally opposite sides of the waste containment section.

The absorbent garment of Japanese Examined Patent Publication No. H08-017792B is produced in the following manner. Firstly, an developed module is produced which comprises an absorbent assembly corresponding to the waste containment section, and four side panels a respective two of which extend from a respective one of front and rear end portions of the absorbent assembly, laterally in respective opposite directions. Then, the developed module is folded in half by pressing a tucker bar against a longitudinally central position of the absorbent assembly.

However, in the production method of Japanese Examined Patent Publication No. H08-017792B, in order to half-fold the absorbent assembly, a strong pressing force from the tucker bar is applied to only a portion of the absorbent assembly corresponding to a bend line. This is likely to cause damage to the absorbent assembly. Moreover, in the production method of Japanese Examined Patent Publication No. H08-017792B, the absorbent assembly, which encloses an absorbent body and an elastic member and thereby has a non-uniform thickness, is half-folded on the basis of the pressing position of the tucker bar. This also causes a problem that a folding line of the absorbent assembly becomes positionally unstable, resulting in poor accuracy of the half-folding.

Therefore, as an apparatus for accurately half-folding a workpiece while suppressing damage of the workpiece, a folding apparatus of the following Japanese Unexamined Patent Publication No. H07-205943A is known, for example.FIGS. 26 to 28are schematic diagrams of a folding operation using the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A.

As illustrated inFIG. 26, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A comprises a suction-holding section102for sucking and holding one of two regions of a workpiece101, and a suction-holding section103for sucking and holding the other region of the workpiece101. The suction-holding sections102,103are adapted to be relatively displaceable between a state illustrated inFIG. 26, in which the first suction-holding section102and the second suction-holding section103are opened, and a state illustrated inFIG. 27, in which the first suction-holding section102and the second suction-holding section103are closed. Thus, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A is operable to close the suction-holding section102holding one of the two regions of the workpiece101to be folded in half, and the suction-holding section103holding the other region, to thereby half-fold the workpiece101. Then, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A is operable, after half-folding the workpiece101, to re-open the suction-holding sections102,103as illustrated inFIG. 28, and transfer the half-folded workpiece101to a transfer conveyer located downstream of the folding apparatus, while sucking and holding the half-folded workpiece101by one102of the suction-holding sections.

However, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A has a problem that a folded position of the workpiece101is undesirably displaced after the half-folding operation. More specifically, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A can apply a suction-holding force from the suction-holding section102directly to the one region of the half-folded workpiece101, as illustrated inFIG. 28. On the other hand, it is impossible to sufficiently apply the suction-holding force from the suction-holding section102to the other region of the half-folded workpiece101, because the other region is located on a side opposite to the suction-holding section102across the one region.

Thus, the folding apparatus of Japanese Unexamined Patent Publication No. H07-205943A has difficulty in reliably maintaining the folded position of the workpiece101after the half-folding operation.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a method and apparatus, for producing a wearing article, capable of accurately folding a main body in half while suppressing damage of the main body, and maintaining a folded position of the main body after the half-folding step, and a wearing article produced thereby.

In order to solve the above problems, the present invention provides a method for producing a wearing article which comprises a main body adapted to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and a side panel for covering a lateral surface of a waist region of the wearer. The method comprises: an developed module preparing step of preparing an developed module which comprises the main body, and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respective opposite directions; a suction-holding section preparing step of preparing a first suction-holding section having a first suction-holding surface capable of suction-holding a forward surface of the main body in the developed module, and a second suction-holding section having a second suction-holding surface capable of suction-holding a rearward surface of the main body in the developed module; a suction-holding section positioning step of positioning the first suction-holding section and the second suction-holding section in such a manner that the first suction-holding surface and the second suction-holding surface are aligned side-by-side while facing a same side; a suction-holding step of, after the suction-holding section positioning step, suction-holding the forward surface of the main body in the developed module by the first suction-holding surface, and suction-holding the rearward surface of the main body in the developed module by the second suction-holding surface; a half-folding step of, after the suction-holding step, closing the first suction-holding section and the second suction-holding section in such a manner that the first suction-holding surface and the second suction-holding surface are located in opposed relation to each other, thereby folding the main body in half; and a temporarily joining step of externally heating and/or pressing superimposed portions of the developed module half-folded by the half-folding step, thereby releasably joining the superimposed portions of the developed module.

The present invention also provides an apparatus for producing a wearing article using an developed module which comprises a main body, and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respective opposite directions, wherein the wearing article is capable of being worn in a state in which the main body extends from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and the side panel segments cover a lateral surface of a waist region of the wearer. The apparatus comprises: a first suction-holding section having a first suction-holding surface capable of suction-holding a forward surface of the main body in the developed module; a second suction-holding section having a second suction-holding surface capable of suction-holding a rearward surface of the main body in the developed module; a support member supporting the first suction-holding section and the second suction-holding section in such a manner that they are relatively displaceable between an open position where the first suction-holding surface and the second suction-holding surface are aligned side-by-side while facing a same side, and a closed position where the first suction-holding surface and the second suction-holding surface are located in opposed relation to each other; and a temporarily joining portion provided in at least one of the first suction-holding section and the second suction-holding section, and adapted to externally heat and/or press superimposed portions of the developed module half-folded between the first and second suction-holding surfaces at the closed position, thereby releasably joining the superimposed portions together.

Further, the present invention provides a wearing article including an developed module which comprises a main body and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respectively opposite directions, wherein the main body is folded in half, the wearing article comprising a temporarily jointed area where superimposed portions of the developed module are releasably joined together.

The present invention makes it possible to accurately fold the main body in half while suppressing damage of the main body, and maintain a folded position of the main body after the half-folding step.

DESCRIPTION OF EMBODIMENTS

With reference to the accompanying drawings, an embodiment of the present invention will now be described. It should be understood that the following embodiment is a specific example of the present invention, and is not intended to restrict a technical scope of the present invention.

FIG. 1is a front view illustrating a disposable diaper according to a first embodiment of the present invention.FIG. 2is a plan view illustrating the disposable diaper inFIG. 1in a state in which side sealed areas thereof are developed.

Referring toFIGS. 1 and 2, the disposable diaper1A according to this embodiment, as one example of a wearing article, is a so-called pant-type diaper. More specifically, the disposable diaper1A comprises a main body2adapted to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and four side panel segments3,3,4,4for covering a lateral surface of a waist region of the wearer. The disposable diaper1A is formed as a pant-type by, after folding the main body2in half, joining the pair of side panel segments3,3together through a side sealed area5, and joining the pair of side panel segments4,4together through a side sealed area6.

The disposable diaper1A according to this embodiment further comprises a pair of temporarily joined areas7,7each releasably joining the side panel segments3,3together, and a pair of temporarily joined areas8,8each releasably joining the side panel segments4,4together. A positional relationship between the side panel segments3,3and a positional relationship between the side panel segments4,4are maintained by the temporarily joined areas7,8. This makes it possible to keep a half-folded state of the main body2. Further, each of the temporarily joined areas7,8releasably joins a respective pair of the side panel segments3,3and the side panel segments4,4. Thus, a wearer can wear the disposable diaper1A by releasing the joined state of the temporarily joined areas7,8.

With reference toFIGS. 1 to 5, a specific configuration of the disposable diaper1A will be described below.

FIG. 3,FIG. 4andFIG. 5are, respectively, a sectional view taken along the line III-III inFIG. 2, a sectional view taken along the line IV-IV inFIG. 2, and a sectional view taken along the line V-V inFIG. 2.

The main body2is capable of absorbing bodily waste (e.g., urine) of a wearer, and has flexibility (stretchability and contractibility) in a desired position. More specifically, the main body2comprises: an absorbent body11capable of absorbing bodily waste of a wearer; a plurality of leg elastic members12,12each provided at a position corresponding to a crotch region of the wearer; a pair of waist elastic members14,14provided at respective positions corresponding to a front abdominal region and a rear dorsal region of the wearer; and an inner sheet9and an outer sheet10which sandwich therebetween the absorbent body11, the leg elastic members12,12and the waist elastic members14,14.

The inner sheet9is an approximately rectangular-shaped sheet which is disposed to face toward a body surface of the wearer during use or wearing of the disposable diaper, and has liquid-permeability. More specifically, as the inner sheet9, it is possible to employ a nonwoven sheet or mesh sheet having liquid-permeability.

The outer sheet10is a sheet which is disposed to face outwardly with respect to the wearer during use or wearing of the disposable diaper, and has liquid-impermeability. More specifically, as the outer sheet10, it is possible to employ a polyethylene film, or a nonwoven fabric having water repellency and breathability. Further, the outer sheet10is an approximately rectangular-shaped sheet formed in a size substantially equal to that of the inner sheet9.

The absorbent body11is adapted to absorb liquid passing through the inner sheet9. More specifically, the absorbent body11is formed by laminating and molding pulverized pulp or a mixture of pulverized pulp and highly-absorbent polymer. The absorbent body11is formed in an approximately rectangular or hourglass shape having a longitudinal dimension less than that of each of the sheets9,10and a width dimension less than that of each of the sheets9,10. The absorbent body11is disposed between the two sheets9,10to leave a non-installation zone along longitudinally opposite edge regions of each of the sheets9,10and width-directionally (laterally) opposite edge regions of each of the sheets9,10. Then, as illustrated inFIG. 3, the absorbent body11is joined to the inner sheet9and the outer sheet10while being sandwiched between the two sheets9,10.

The leg elastic members12,12are adapted to pull the main body2upwardly toward the crotch region of the wearer during the wearing to allow the main body2to be brought into close contact with the crotch region so as to suppress leakage of bodily waste from a gap between the main body2and the body surface of the wearer. More specifically, at least a portion of each of the leg elastic members12,12is provided at a respective one of laterally opposite positions outside of the absorbent body11and between the side panel segments3,3or between the side panel segments4,4. Each of the leg elastic members12,12is attached to the main body2in a stretched state in a longitudinal direction of the main body2. In this embodiment, as illustrated inFIG. 4, each of the leg elastic members12,12is joined to the inner sheet9and the outer sheet10while being sandwiched between the two sheets9,10. As the leg elastic members12,12, it is possible to employ a sheet or thread made of polyurethane, natural rubber or thermoplastic resin.

Each of the waist elastic members14,14is adapted to cause the main body2to be tightened against the front abdominal region or the rear dorsal region of the wearer, during the wearing so as to suppress slip-down of the disposable diaper1A. More specifically, each of the waist elastic members14,14is provided at a respective one of opposite positions longitudinally outward of the absorbent body11, and attached to the main body2in a stretched state in a width or lateral direction of the main body2. In this embodiment, as illustrated inFIG. 5, each of the waist elastic members14,14is joined to the inner sheet9and the outer sheet10while being sandwiched between the two sheets9,10. As the waist elastic members14,14, it is possible to employ a sheet or thread made of polyurethane, natural rubber or thermoplastic resin.

Each of the side panel segments3,3extends from a respective one of longitudinally (front-rear directionally) opposite end portions of the main body2, laterally in one direction (rightwardly inFIGS. 1 and 2), and has flexibility in the lateral direction. The side panel segments3,3are disposed to define a leg-hole space3atherebetween. The leg-hole space3ais used as a lag hole by joining together right edge portions of the side panel segments3,3by the side sealed area5. The side panel segments3,3are formed with a pair of temporarily joined areas7,7each releasably joining the side panel segments3,3together. Each of the temporarily joined areas7,7is formed by externally heating and/or pressing superimposed portions of the side panel segments3,3, as described in detailed later. In this embodiment, as illustrated inFIG. 3, each of the side panel segments3,3is joined to the inner sheet9and the outer sheet10while being sandwiched between the two sheets9,10at a position rightward of the absorbent body11. As the side panel segments3,3, it is possible to employ: a stretchable film made of one or a mixture of at least two selected from the group consisting of polystyrene based block copolymer, polyisoprene based block copolymer, polybutadiene based block copolymer, ethylene based copolymer, natural rubber and urethane; a stretchable nonwoven fabric; a laminate of the stretchable film and the stretchable nonwoven fabric; or a laminate of rubber thread and the stretchable nonwoven fabric.

Each of the side panel segments4,4extends from a respective one of longitudinally (front-rear directionally) opposite end portions of the main body2, laterally in one direction (leftwardly inFIGS. 1 and 2), has flexibility in the lateral direction. The side panel segments4,4are disposed to define a leg-hole space4atherebetween. The leg-hole space4ais used as a lag hole by joining together left edge portions of the side panel segments4,4by the side sealed area6. The side panel segments4,4are formed with a pair of temporarily joined areas8,8each releasably joining the side panel segments4,4together. Each of the temporarily joined areas8,8is formed by externally heating and/or pressing superimposed portions of the side panel segments4,4, as described in detailed later. In this embodiment, as illustrated inFIG. 3, each of the side panel segments4,4is joined to the inner sheet9and the outer sheet10while being sandwiched between the two sheets9,10at a position leftward of the absorbent body11. As the side panel segments4,4, it is possible to employ: a stretchable film made of one or a mixture of at least two selected from the group consisting of polystyrene based block copolymer, polyisoprene based block copolymer, polybutadiene based block copolymer, ethylene based copolymer, natural rubber and urethane; a stretchable nonwoven fabric; a laminate of the stretchable film and the stretchable nonwoven fabric; or a laminate of rubber thread and the stretchable nonwoven fabric.

With reference toFIGS. 6 and 7, a production method for the above disposable diaper1A will be described below.

FIG. 6is a process chart of a production method for the disposable diaper inFIG. 1.FIG. 7is a process chart of the production method for the disposable diaper inFIG. 1, which illustrates a process following the process inFIG. 6.

The production method for the disposable diaper1A primarily comprises the following steps S1to S10.

In Step S1, an outer sheet strip10A for forming the outer sheet10is continuously conveyed in a longitudinal direction of the outer sheet strip10A.

In Step S2, the waist elastic members14is joined onto the outer sheet strip10A which is continuously being conveyed. More specifically, in the Step S2, a plurality of pairs of the waist elastic members14are disposed on the outer sheet strip10A at intervals of a distance corresponding to a longitudinal dimension of the absorbent body11, on a pair-by-pair basis. In this process, each of the waist elastic members14is attached onto the outer sheet strip10A in a state in which it is stretched in a width direction of the outer sheet strip10A. Further, the waist elastic members14in a pair to be attached in the Step S2are disposed in spaced-apart relation to each other in the longitudinal direction of the outer sheet strip10A.

In Step S3, the absorbent body11is joined onto the outer sheet strip10A which is continuously being conveyed. More specifically, the absorbent body11is disposed between adjacent two of the pairs of waist elastic members14in a posture where the longitudinal direction thereof is oriented along the longitudinal direction of the outer sheet strip10A.

In Step S4, a pair of the leg elastic members12is joined onto the outer sheet strip10A which is continuously being conveyed. More specifically, in the Step S4, the leg elastic members12in the pair are disposed at a longitudinally central position of the absorbent body11on the outer sheet strip10A and are one-by-one disposed at respective laterally opposite positions outside of the absorbent body11. Each of the leg elastic members12is attached onto the outer sheet strip10A in a state in which it is stretched in the longitudinal direction of the outer sheet strip10A.

In Step S5, a side panel strip3A for forming the side panel segment3, and a side panel strip4A for forming the side panel segment4, are joined onto the outer sheet strip10A which is continuously being conveyed. More specifically, each of the side panel strips3A,4A is continuously fed in a posture where a longitudinal direction thereof is oriented along the longitudinal direction of the outer sheet strip10A, and joined onto a respective one of opposite edge portions of the outer sheet strip10A outside of the leg elastic members12. That is, each of the side panel strips3A,4A is joined to the outer sheet strip10A while protruding from the outer sheet strip10A.

In Step S6, an inner sheet strip9A for forming the inner sheet9is joined onto the outer sheet strip10A which is continuously being conveyed. More specifically, the inner sheet strip9A is continuously fed in a posture where a longitudinal direction thereof is oriented along the longitudinal direction of the outer sheet strip10A, and joined to the outer sheet strip10A in a state in which a position of the inner sheet strip9A in the width direction is adjusted to a position of the outer sheet strip10A in the width direction. By the Step S6, the elastic members12,14and the absorbent body11are entirely sandwiched between the sheet strips9A,10A, and an edge portion of each of the side panel strips3A,4A is sandwiched between the sheet strips9A,10A.

In Step S7, each of the side panel strips3A,4A is partially cut away to form a respective one of the spaces3a,4a. More specifically, each of the side panel strips3A,4A is cut away over a predetermined range in the longitudinal direction of the side panel strips3A,4A, including the longitudinally central position of the absorbent body11.

In Step S8, the sheet strips9A,10A and the side panel strips3A,4A are cut off to form an developed module1Z of a disposable diaper. Specifically, the sheet strips9A,10A and the side panel strips3A,4A are cut at a position between the pair of adjacent waist elastic members14. By the Step S8, the developed module1Z is formed in which the side panel strips3A,4A are segmentalized into the four side panel segments3,3,4,4.

Referring toFIG. 7, in Step S9, the main body2of the developed module1Z is folded in half along a longitudinally central position thereof, and kept in a half-folded state. More specifically, by use of an after-mentioned production apparatus, the main body2is folded in half, and temporarily joined areas7,8are formed in respective ones of the pairs of side panel segments3,3and side panel segments4,4superimposed by the half-folding.

In Step S10, a side sealed area5is formed along edge portions of the side panel segments3,3, and a side sealed area6is formed along edge portions of the side panel segments4,4, thereby completing the disposable diaper1A.

As described above, in the production apparatus according to this embodiment, the developed module1Z can be produced by the Steps S1to S8(developed module preparing step), and the disposable diaper1A can be produced by subjecting the developed module1Z to the Steps S9and S10. In the production method according to this embodiment, the following production apparatus20(particularly, aftermentioned folding unit22and conveying and sealing unit23) are prepared (suction-holding section preparing step) so as to perform the Steps S9and S10.

A production apparatus for performing the Steps S8to S10will be described below.

FIG. 8is a schematic diagram illustrating a general configuration of the production apparatus for performing the Steps S8to S10inFIGS. 6 and 7.

Referring toFIG. 8, the production apparatus20comprises a cutting unit21for performing the Step S8, a folding unit22for performing the Step S9, and a conveying and sealing unit23for performing the Step S10.

The cutting unit21is adapted to cut the inner sheet strip9A, the outer sheet strip10A and the side panel strips3A,4A to form the developed module1Z. More specifically, the cutting unit21comprises a rotary cutter24, and a vacuum roll25disposed in opposed relation to the rotary cutter24. The rotary cutter24has a cutting blade capable of cutting the side panel strips3A,4A by nipping the side panel strips3A,4A and the sheet strips9A,10A between the vacuum roll25and the rotary cutter24. The vacuum roll25has a body wall capable of suction-holding the side panel strips3A,4A and the sheet strips9A,10A. The developed module1Z after the cutting by the rotary cutter24is transferred to the folding unit22by rotating the vacuum roll25while suction-holding the developed module1Z by the body wall of the vacuum roll25.

The folding unit22comprises a camshaft26, a drum (support member)27disposed around the camshaft26to rotationally drive about a rotary shaft27a, and ten folding sub-units28supported around the drum. The camshaft26has an outer surface in which a circular cylindrical surface26bconcentric with the rotary shaft27aof the drum27, and a cam surface26amore inclined toward the rotary shaft27athan the circular cylindrical surface26bare continuously formed. The drum27covers over the entire outer periphery of the camshaft26from the outside of the camshaft26, and supports each of the folding sub-units28in such a manner that each of the folding sub-units28protrudes outwardly. Each of the folding sub-units28is adapted, with respect to the developed module1Z transferred from the cutting unit21, to fold the main body2in half, and form the temporarily joined areas7,8(seeFIG. 1) in the side panel segments3,3,4,4. More specifically, the folding sub-unit28is adapted, after receiving the developed module1Z from the cutting unit21at a rotational position P1around the rotary shaft27a, to gradually fold the main body2of the developed module1Z along with a counterclockwise (inFIG. 9) rotation of the drum27from the rotational position P1, and finally fold the main body2in half at a rotational position P2. Further, the folding sub-unit28is adapted to transfer the half-folded developed module1Z to the conveying and sealing unit23at a rotational position P3where the drum27is further rotated from the rotational position P2in the counterclockwise (inFIG. 9) direction.

With reference toFIGS. 9 and 10, a specific configuration of the folding sub-unit28will be described below.FIG. 10is a schematic diagram enlargedly illustrating the folding sub-units28, which are, respectively, at the rotational positions P1, P2inFIG. 9.

The folding sub-unit28comprises: a base29fixed to an outer surface of the drum27; a pair of support plates30a,30beach standingly provided on the base29; a pair of sliding shafts31a,31beach provided to penetrate through the base29and the drum27; a slider32fixed to an inner end of each of the sliding shafts31a,31blocated inside the drum27; a mounting member33fixed to an outer end of each of the sliding shafts31a,31blocated outside the drum27; a first suction-holding section34aand a second suction-holding section34beach attached to the mounting member33swingably about an axis parallel to the rotary shaft27a; and a pair of links35each coupling one of the suction-holding sections34a,34band a corresponding one of the support plates30a,30btogether. InFIG. 10, the suction-holding sections34bat the rotational position P1, and the suction-holding sections34aat the rotational position P2are omitted.

Each of the sliding shafts31a,31bis biased toward the rotary shaft27aby a non-illustrated biasing member. Thus, the slider32fixed to the inner end of each of the sliding shafts31a,31bis continually pressed against the outer surface of the camshaft26. Therefore, when the slider32is slidingly moved along the outer surface of the camshaft26along with rotation of the drum27, each of the sliding shafts31a,31bis displaced in a radial direction of the drum27. Each of the links35has a first end attached to a respective one of the suction-holding sections34a,34brotatably about an axis parallel to the rotary shaft27a, and a second end attached to a respective one of the support plates30a,30brotatably about an axis parallel to the rotary shaft27a. Thus, when the sliding shafts31a,31bare displaced radially in a direction away from a center of the drum27, the suction-holding sections34a,34bare swingingly moved with respect to the mounting member33and the support plates30a,30bvia the links35. This allows the suction-holding sections34a,34bto be opened in such a manner that respective surfaces of the suction-holding sections34a,34bare aligned side-by-side while facing the same side (the suction-holding section positioning step). On the other hand, when the sliding shafts31a,31bare displaced radially in a direction approaching the center of the drum27, the suction-holding sections34a,34bare swingingly moved with respect to the mounting member33and the support plates30a,30bvia the links35. This allows the suction-holding sections34a,34bto be closed in such a manner that the respective surfaces of the suction-holding sections34a,34bface each other (the half-folding step).

Referring toFIG. 11, the first suction-holding section34ais adapted to suction-hold a forward surface of the developed module1Z (a region of a surface of the developed module1Z forward of a folding line). More specifically, the first suction-holding section34acomprises a section body36ahaving a planar T shape corresponding a shape of a combination of the front end portion of the main body2and the two side panel segments3,4in the developed module1Z, and a plurality of suction holes37aformed in a surface (first suction-holding surface) of the section body36a. The first suction-holding section34ais adapted to suck air from the suction holes37aaccording to a non-illustrated suction source, thereby suction-holding a forward portion of the developed module1Z by the surface of the section body36a.

Similarly, the second suction-holding section34bis adapted to suction-hold a rearward surface of the developed module1Z (a region of a surface of the developed module1Z rearward of the folding line). More specifically, the suction-holding section34bcomprises a section body36bhaving a planar T shape corresponding a shape of a combination of the rear end portion of the main body2and the two side panel segments3,4in the developed module1Z, and a plurality of suction holes37bformed in a surface (second suction-holding surface) of the section body36b. The second suction-holding section34bis adapted to suck air from the suction holes37baccording to a non-illustrated suction source, thereby suction-holding the rearward surface of the developed module1Z by the surface of the section body36b.

The suction-holding section34ain this embodiment further comprises a protruding element38awhich protrudes from the surface (first suction-holding surface) of the section body36aand is capable of compressing superimposed portions of the developed module1Z in cooperation with the second suction-holding section34b.FIG. 12is a sectional view taken along the line XII-XII inFIG. 11.

Referring toFIG. 12, the protruding element38ais composed of a columnar screw member having an external thread formed in an outer peripheral surface thereof. This protruding element38ais screwed with a screw hole formed in the section body36a. Thus, a level of screw-in of the protruding element38awith respect to the section body36acan be changed so as to adjust an amount of protrusion of the protruding element38afrom the section body36a.

On the other hand, the suction-holding section34bin this embodiment further comprises a recess38bwhich is concaved from the surface of the section body36band capable of allowing the protruding element38ato be engaged thereinto while interposing the superimposed portions of the developed module1Z therebetween.FIG. 13is a sectional view taken along the line XIII-XIII inFIG. 11.FIG. 14is a sectional view illustrating a state in which the developed module IZ is compressed between the suction-holding sections34a,34b.

With reference toFIGS. 13 and 14, the recess38bis formed in a size which allows a predetermined gap to be defined with respect to the protruding element38awhen the protruding element38ais inserted thereinto. More specifically, each of a distance D1between a distal edge face of the protruding element38aand a bottom surface of the recess38b, and a distance D2between the outer peripheral surface of the protruding element38aand an inner peripheral surface of the recess38b, in the closed state of the suction-holding sections34a,34b, is set to be less than a thickness dimension of the superimposed portions of the developed module1Z.

Thus, the superimposed portions (side panel segment pairs3,4) of the developed module1Z are compressed between an outer surface of the protruding element38aand an inner surface of the recess38b, and releasably joined together (the temporarily joined areas7,8are formed, respectively, in the side panel segment pairs3,4: the temporarily joining step). A distance D3between the surface of the first suction-holding section34aand the surface of the second suction-holding section34bin the closed state of the suction-holding sections34a,34bis set to be greater than each of the distances D1, D2, more specifically, equal to or slightly greater than the thickness dimension of the superimposed portions of the developed module1Z.

In this embodiment, the first suction-holding section34ais provided with the protruding element38a, and the second suction-holding section34bis provided with the recess38b. Alternatively, the first suction-holding section34ais provided with the recess38b, and the second suction-holding section34bis provided with the protruding element38a. Further, each of the first suction-holding section34aand the second suction-holding section34bmay be provided with the protruding element38aand the recess38bin such a manner that each of the protruding elements38acan be engaged into a counterpart one of the recesses38b.

In this embodiment, each of the temporarily joined areas7,8is formed in the superimposed portions of the developed module1Z by allowing the protruding element38ato be engaged into the recess38b. In the present invention, a mechanism for forming each of the temporarily joined areas7,8is not limited to the combination of the protruding element38aand the recess38b.FIG. 15is a sectional view illustrating an example of modification of the suction-holding sections inFIG. 11. In the modification illustrated inFIG. 15, not only the first suction-holding section34a, but also the second suction-holding section34bis provided with a protruding element38b2. In this case, when the suction-holding sections34a,34bare closed, the distal edge face of the protruding element38aand a distal edge face of the protruding element38b2are disposed in opposed, spaced-apart relation to each other by a distance D4. This distance D4is set to be less than the thickness of the superimposed portions of the developed module1Z. Thus, the superimposed portions of the developed module1Z are compressed between the protruding element38aand the protruding element38b2, and releasably joined together. In the modification inFIG. 15, the developed module1Z is compressed between the protruding elements38a,38b2. Alternatively, only one of the suction-holding sections34a,34bmay be provided with a protruding element, while omitting a protruding element for the other suction-holding section, wherein the superimposed portions of the developed module1Z are compressed between the protruding element and a surface of the other suction-holding section.

In this embodiment, each of the temporarily joined areas7,8is formed by compressing the superimposed portions of the developed module1Z. Alternatively or additionally, the temporarily joined areas7,8may be formed by heating the superimposed portions of the developed module1Z. More specifically, at least one of the suction-holding sections34a,34bmay be provided with a heater for heating at least one of the inner surfaces of the protruding element38aand the recess38b.

In this embodiment, the protruding elements38a,38b2each having a columnar shape are described as an example of the protruding element. Alternatively, a triangular prism-shaped protruding element as illustrated inFIG. 16may be employed. The protruding element illustrated inFIG. 16is disposed in one of the suction-holding sections34a,34bin a posture where a top ridge thereof is oriented toward the other suction-holding section in the closed state of the suction-holding sections34a,34b. When this protruding element is employed, a contact area with respect to the developed module1Z can be reduced as compared to the case where the distal end face of the aforementioned columnar-shaped protruding element is pressed against the developed module1Z. Thus, it becomes possible to more strongly compress the superimposed portions of the developed module1Z.

As above, in the folding unit22, the main body2of the developed module1Z can be folded in half while forming the temporarily joined areas7,8in the side panel segment3,4of the half-folded developed module1Z, by closing the suction-holding sections34a,34bas illustrated at the rotational position P2inFIG. 9. Thus, even when the suction-holding sections34a,34bare opened between the rotational position P2and the rotational position P3, the temporarily joined areas7,8allows the half-folded state of the developed module1Z to be maintained. Then, the half-folded developed module1Z is transferred to the conveying and sealing unit23at the rotational position P3.

Referring toFIG. 8, the conveying and sealing unit23comprises: a first conveyer39for receiving the developed module1Z from the folding unit22; a second conveyer40disposed in opposed relation to a part of the first conveyer39; a side sealing section41for forming the side sealed areas5,6in the side panels3,4of the developed module1Z which is being conveyed by the conveyers39,40; and a third conveyer42for receiving a disposable diaper1A from the second conveyer40.

The first conveyer39is arranged in a loop shape having a portion extending in a tangential direction with respect to each of the folding sub-units28of the folding unit22, and a portion making a U-turn from the tangential portion. The second conveyer40is disposed in opposed to the U-turn portion of the first conveyer39. Thus, the developed module1Z transferred to the first conveyer39is conveyed toward a downstream side while being clamped between the first conveyer39and the second conveyer40. With reference toFIG. 17, specific configurations of the first conveyer39and the second conveyer40will be described below.

FIG. 17is a schematic diagram illustrating a conveyance state of the developed module IZ using the first conveyer39and the second conveyer40.

The first conveyer39has a portion for supporting the half-folded main body2from therebelow, and a portion for supporting superimposed portions of each of the side panel segment pairs3,4from therebelow, and is adapted to be circulated along a predetermined pathway. The second conveyer40has a portion for pressing the side panel segment3,4from thereabove, in such a manner as to clamp the side panel segment3,4in cooperation with the first conveyer39, and is adapted to be circulated along a predetermined pathway. The first conveyer39and the second conveyer40are arranged to vertically clamp the side panel segment3,4in such a manner as to allow lateral edge portions of the side panel segment3,4to be exposed as a side sealing region E1.

As above, the half-folded developed module1Z is conveyed in a state in which superimposed portions of each of the side panel segment pairs3,4are clamped by the conveyers39,40. Thus, the developed module1Z is conveyed to the side sealing section41while being kept in the half-folded state.

FIG. 18is a schematic diagram illustrating a state in which the side panel segment pairs3,4are side-sealed by the side sealing section41.

Referring toFIGS. 8 and 18, the side sealing section41comprises sealing means43for welding together each of the side panel segment pairs3,4, and an opposed roller44disposed in opposed relation to the sealing means43. For example, as the sealing means43, it is possible to employ a horn for ultrasonic-welding each of the side panel segment pairs3,4. The sealing means43and the opposed roller44are arranged to clamp each of the side panel segment pairs3,4in the side sealing region E1. Thus, the side sealed areas5,6are formed along the respective lateral edge portions of the side panel segment pairs3,4(a permanently joining step). Then, the disposable diaper1A formed with the side sealed areas5,6is transferred to the third conveyer42.

As described above, according to the first embodiment, it becomes possible to accurately fold the main body2in half while suppressing damage to the main body2, and maintain a folded position of the main body2after the half-folding step.

More specifically, in the first embodiment, the main body2can be folded in half by closing the first suction-holding section34aand the second suction-holding section34bin a state in which the forward surface and the rearward surface of the main body2located on both sides of a folding line are suction-held by the suction-holding sections34a,34b, respectively. Thus, differently from the case where a half-folding operation is performed by pressing a tucker bar against only a portion corresponding to a folding line as in the conventional technique, the production method according to the first embodiment can fold the main body2in half while holding two regions to be half-folded. This makes it possible to accurately fold the main body2in half while suppressing damage to the main body2. Further, in the production method, the superimposed portions of the half-folded developed module1Z are releasably joined together. Thus, the temporarily joined areas7,8allow a folded state of the main body2after the half-folding step to be maintained. The temporarily joined areas7,8are releasable, so that a wearer can wear the wearing article by releasing the joined state of the temporarily joined areas7,8.

In the first embodiment, each of the temporarily joined areas7,8can be formed by compressing the superimposed portions of the developed module1Z between the protruding element38a(38b2) and the counterpart suction-holding section. Thus, the temporarily joined areas can be formed in conjunction with the operation of folding the developed module1Z in half. This makes it possible to more reliably maintain the folded state of the main body2after the half-folding step.

In the first embodiment, each of the temporarily joined areas7,8can be formed in conjunction with the half-folding operation for the main body2, by closing the suction-holding sections34a,34bat least one of which is formed with the protrusion element38a(38b2). However, in the present invention, a mechanism for forming the temporarily joined areas7,8is not limited to the suction-holding sections34a,34b. For example, a mechanism for forming the temporarily joined areas7,8may be provided separately from the suction-holding sections34a,34b, to form the temporarily joined areas7,8just after the half-folding step using the suction-holding sections34a,34b.

In the first embodiment, the protruding element38a(38b2) is so configured as to be able to adjust an amount of protrusion thereof. Thus, a pressing force to be applied to the developed module1Z can be adjusted.

In the first embodiment, the suction-holding section34bhas the recess38bcapable of allowing the protruding element38ato be engaged thereinto while interposing the superimposed portions of the developed module1Z therebetween. Thus, the superimposed portions of the developed module1Z can be compressed not only between the distal edge face of the protruding element38aand the bottom surface of the recess38bbut also between the outer peripheral surface of the protruding element38aand the inner peripheral surface of the recess38b. This makes it possible to more reliably form the temporarily joined areas7,8.

In the first embodiment, the temporarily joined areas7,8are formed in the side panel segments3,4closer to the side sealed areas5,6than the main body2. This makes it possible to more reliably maintain each of the side panel segments3,4in a positional relationship set for forming the side sealed area during the side sealing operation, i.e., in a positional relationship of the superimposed portions obtained when the main body2is property folded in half.

In the first embodiment, during conveyance from the suction-holding sections34a,34bto the side sealing section41, the developed module1Z can be conveyed while being kept in a half-folded state. Thus, it becomes possible to reliably maintain the half-folded state of the developed module even if the developed module receives vibration or the like during conveyance.

The first embodiment has been described based on the disposable diaper1A in which each of the side panel segments3,4is sandwiched between the inner sheet9and the outer sheet10, as illustrated inFIG. 3. Alternatively, each of the side panel segments3,4may be joined onto the inner sheet9, as illustrated inFIG. 19. In this case, the order of the Step S5and the Step S6may be reversed.

FIG. 20is a development diagram illustrating a general configuration of a disposable diaper1B according to a second embodiment of the present invention.FIG. 21is a front view illustrating a state of the disposable diaper inFIG. 20when it is worm by a wearer.FIG. 22is a front view illustrating a state of the disposable diaper inFIG. 20when it is packaged. A difference from the disposable diaper1A according to the first embodiment will be described below.

Referring toFIGS. 20 to 22, the disposable diaper1B is different from the first embodiment in that each of a pair of side panel segments3,3and a pair of side panel segments4,4are not joined together. Further, the disposable diaper1B is different from the first embodiment in that it comprises two detachable members45,46each provided on a respective one of the upper (inFIG. 20) side panel segment3and the upper (inFIG. 20) side panel segment4.

The detachable member45protrudes rightwardly (inFIG. 20) from the side panel3. On the other hand, the detachable member46protrudes leftwardly (inFIG. 20) from the side panel4. Each of the detachable members45,46is a sheet having a detachable surface (surface facing a front side inFIG. 20) detachably attachable with respect to an outer surface (outer sheet10) of the main body2. Specifically, as each of the detachable members45,46, it is possible to employ an adhesive tape or a mechanical fastener (hook and loop fastener), for example. When a mechanical fastener is used as each of the detachable members45,46, it is necessary to use a hook member and a loop member in a paired manner. In the second embodiment, a nonwoven sheet is employed as the outer sheet10of the main body2. Thus, a hook member may be employed as each of the detachable members45,46, and the nonwoven sheet may be utilized as a loop member. Alternatively, a loop member may be additionally provided on the outer sheet10.

When a wearer wears the disposable diaper1B, after the main body2is disposed to extend from a front abdominal region to a rear dorsal region via a crotch region of the wearer, the side panel segments3,4each provided with a respective one of the detachable members45,46are positioned to extend in a front-rear direction to cover a lateral surface of a waist region of the wearer, and the detachable members45,46are fixed onto the outer surface of the main body2, as illustrated inFIG. 21. In this manner, the disposable diaper1B can be worn while covering the lateral surface of the waist region of the wearer by the side panel segments3,3,4,4.

When the disposable diaper1B is packaged in a packaging material as a finished product, the disposable diaper1B in a developed state illustrated inFIG. 20is folded into a state illustrated inFIG. 22. More specifically, each of the side panel segments3,4is folded back toward the main body2in such a manner that the detachable surface of each of the detachable members45,46faces toward the inner sheet9, and the main body2is folded in half in such a manner that each of the fold-back side panel segments3,4is located inside. The disposable diaper1B in the packaged state has four temporarily joined areas47each releasably joining superimposed portions of the main body2together. Thus, the temporarily joined areas47allow a half-folded state of the main body2to be maintained, so that it becomes possible to reliably maintain a half-folded packaged state of the disposable diaper1B.

With reference toFIG. 23, a production method for the disposable diaper1B will be described below.

FIG. 23is a process chart corresponding toFIG. 7, which illustrates a production process for the disposable diaper1B inFIG. 20.

The production method for the disposable diaper1B comprises Steps S1to S8which are identical to the aforementioned Steps S1to S8(seeFIG. 6) in the first embodiment. Subsequently to the Step S8, the following Steps S81and S82are performed.

In Step S81, the detachable members45,46are joined to the side panel segment3and the side panel segment4, respectively.

In Step S82, each of the side panel segments3,3,4,4is folded back toward the main body2in such a manner that the detachable surface (surface facing a front side inFIG. 20) of each of the detachable members45,46faces toward the inner sheet9of the main body2.

Then, after completion of the Step S82, the main body2is folded in half using the folding unit22, and superimposed portions of the main body2are releasably joined together to form the temporarily joined areas47. In this embodiment, each of the temporarily joined areas47is formed at a position offset from the absorbent body11, the detachable members45,46and the elastic members12,14.

InFIG. 22, the point of forming the temporarily joined area47in the superimposed portions of the main body2has been described. However, the temporarily joined area47may be formed in superimposed portions of the side panel segments3,3,4,4(superimposed portions of four sheets).

InFIGS. 20 to 23, the disposable diaper1B having the side panel segments3,3,4,4formed in respective longitudinally opposite end portions of the main body2. Alternatively, the remaining side panel segments3,4other than the side panel segments3,4each provided with a respective one of the detachable members45,46may be omitted. That is, the disposable diaper may be configured to cover a lateral surface of a waist region of a wearer by only a pair of right and left side panel segments3,4.

As described above, according to the second embodiment, the disposable diaper1B can be produced which is capable of being worn by: positioning the main body2to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer; positioning the side panel segments3,3,4,4to extend in a front-rear direction to cover a lateral surface of a waist region of the wearer; and fixing the detachable members45,46onto the outer surface of the main body2.

In the second embodiment, in the Step S82, each of the side panel segments3,3,4,4is folded back toward the main body2. Alternatively, as illustrated inFIG. 24, each of the detachable members45,46may be folded back toward the main body2.FIG. 24is a process chart illustrating an example of modification of the disposable diaper production process inFIG. 23.

In this modified production method, after joining the each of the detachable members45,46in the Step S81, the following Step S821is performed, instead of the Step S82.

In Step S821, each of the detachable members45,46is folded back toward the main body2in such a manner that the detachable surface (surface facing a front side inFIG. 24) of each of the detachable members45,46faces toward the inner sheet9of the main body2.

Then, after completion of the Step S821, the main body2is folded in half in the Step S9using the folding unit22, and resulting superimposed portions of a respective pair of the side panel segments3,3,4,4are releasably joined together to form a temporarily joined area57. In this case, each of the temporarily joined areas47is formed at a position offset from a respective one of the detachable members45,46.

In the second embodiment, in the Step S82or S821, each of the side panel segments3,3,4,4or each of the detachable members45,46is folded back toward the main body2. Alternatively, superimposed portions of the side panel segments3,3,4,4and the detachable members45,46may be folded back. In this case, the detachable surface of each of the detachable members45,46can be positioned to face toward the inner sheet9of the main body2.

In the first and second embodiments, as illustrated inFIG. 6, the side panel segments3,4are formed by cutting the side panel strips3A,4A joined onto the outer sheet strip10A. Alternatively, as illustrated inFIG. 25, side panel segments3,4each cut into a predetermined size may be joined to the outer sheet strip10A.FIG. 25is a process chart of a disposable diaper production method according to a third embodiment of the present invention.

In the embodiment illustrated inFIG. 25, the following Step S51is performed, instead of the Step S5.

In Step S51, the side panel strips3A,4A are cut into individual side panel segments3,4, and the resulting side panel segments3,4are joined onto the outer sheet strip10A. In this case, the pair of side panel segments3,3,4,4are disposed at positions corresponding to longitudinally opposite ends of the absorbent body11, at intervals of a distance equivalent to the leg-hole space3a,4a. Further, a distance between the side panel segments3,3,4,4located between adjacent two of the spaces3a,4ais set to allow the cutting blade to pass through therebetween in the subsequent Step S8.

According to the production method illustrated inFIG. 25, differently from the first and second embodiments, the Step S7(seeFIG. 6) for forming the leg-hole spaces3a,4acan be omitted.

Although, in the Step S51illustrated inFIG. 25, the side panel strips3A,4A are cut into individual side panel segments3,3,4,4, the present invention is not limited thereto. For example, in the Step S51, a first strip having a length of two side panel segments3and a second strip having a length of two side panel segments4may be subjected to the joining. In this case, the first and second strips are arranged at intervals of a distance equivalent to the leg-hole space3a,4a, and cut into two side panel segments3,3,4,4in the subsequent Step S8. This makes it possible to halve the number of components to be subjected to the joining in the Step S51, thereby enhancing efficiency of the operation in the Step S51.

Although the above embodiments have been described based on the disposable diapers1A,1B having the absorbent body11, the temporarily joined areas7,8,47may be formed in a wearing article devoid of the absorbent body11. In this case, the Step S3for joining absorbent body11may be omitted from the production method according to each of the above embodiments.

The above specific embodiments primarily include inventions having the following features.

In order to solve the aforementioned problems, the present invention provides a method for producing a wearing article which comprises a main body adapted to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and a side panel for covering a lateral surface of a waist region of the wearer. The method comprises: an developed module preparing step of preparing an developed module which comprises the main body, and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respective opposite directions; a suction-holding section preparing step of preparing a first suction-holding section having a first suction-holding surface capable of suction-holding a forward surface of the main body in the developed module, and a second suction-holding section having a second suction-holding surface capable of suction-holding a rearward surface of the main body in the developed module; a suction-holding section positioning step of positioning the first suction-holding section and the second suction-holding section in such a manner that the first suction-holding surface and the second suction-holding surface are aligned side-by-side while facing a same side; a suction-holding step of, after the suction-holding section positioning step, suction-holding the forward surface of the main body in the developed module by the first suction-holding surface, and suction-holding the rearward surface of the main body in the developed module by the second suction-holding surface; a half-folding step of, after the suction-holding step, closing the first suction-holding section and the second suction-holding section in such a manner that the first suction-holding surface and the second suction-holding surface face each other, thereby folding the main body in half; and a temporarily joining step of externally heating and/or pressing superimposed portions of the developed module half-folded by the half-folding step, thereby releasably joining the superimposed portions of the developed module.

The present invention further provides an apparatus for producing a wearing article using an developed module which comprises a main body, and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respective opposite directions, wherein the wearing article is capable of being worn in a state in which the main body extends from a front abdominal region to a rear dorsal region via a crotch region of a wearer, and the side panel segments cover a lateral surface of a waist region of the wearer. The apparatus comprises: a first suction-holding section having a first suction-holding surface capable of suction-holding a forward surface of the main body in the developed module; a second suction-holding section having a second suction-holding surface capable of suction-holding a rearward surface of the main body in the developed module; a support member supporting the first suction-holding section and the second suction-holding section in such a manner that the suction-holding sections are relatively displaceable between an open position where the first suction-holding surface and the second suction-holding surface are aligned side-by-side while facing a same side, and a closed position where the first suction-holding surface and the second suction-holding surface face each other; and a temporarily joining portion provided in at least one of the first suction-holding section and the second suction-holding section, and adapted to externally heat and/or press superimposed portions of the developed module half-folded between the first and second suction-holding surfaces at the closed position, thereby releasably joining the superimposed portions together.

In the above method and apparatus of the present invention, it is possible to accurately fold the main body in half while suppressing damage to the main body, and maintain a folded position of the main body after the half-folding step.

More specifically, in the present invention, the main body can be folded in half by closing the first suction-holding section and the second suction-holding section in a state in which the forward surface and the rearward surface of the main body located on both sides of a folding line are suction-held by the two suction-holding sections, respectively. Thus, differently from the case where a half-folding operation is performed by pressing a tucker bar against only a portion corresponding to a folding line as in the conventional technique, the main body can be folded in half while holding two regions (the forward surface and the rearward surface of the main body) to be half-folded, so that it is possible to accurately fold the main body in half while suppressing damage to the main body. Further, in the production method of the present invention, the superimposed portions of the half-folded developed module are releasably joined together. Thus, the temporarily joined area allows a folded state of the main body after the half-folding step to be maintained. The temporarily joined area is releasable, so that a wearer can wear the wearing article by releasing the joined state of the temporarily joined area.

As compared to the case where the developed module is superimposedly joined using an adhesive, the production method of the present invention designed to externally heat and/or press the developed module, thereby temporarily joining the superimposed portions of the developed module, has the following advantageous effects. In the case of using an adhesive, it is necessary to prepare not only the adhesive as consumable supply but also a facility for applying the adhesive. As a result, a product cost of the wearing article is increased. In contrast, the production method of the present invention can suppress a product cost of the wearing article. Moreover in the case of using an adhesive, the applied adhesive is likely to adhere to a production facility and others, causing deterioration in production efficiency. In contrast, the production method of the present invention can avoid such deterioration in production efficiency. Further, in the case of using an adhesive, air permeability of the main body or the side panel is likely to be impaired in a region applied with the adhesive, and skin problems are likely to occur due to contact with the adhesive, depending on wearer's constitution. In contrast, the production method of the present invention can suppress such problems.

As used here, the term “side panel” means a component of a wearing article during use or wearing, wherein opposite ends of the component are coupled to the main body to cover a lateral surface of a waist region of a wearer. The term “side panel segment” means a member constituting the side panel and having at least one end separated from the main body.

Preferably, in the production method of the present invention, in the temporarily joining step, a temporarily joining portion provided in at least one of the first suction-holding section and the second suction-holding section is brought into contact with the superimposed portions of the developed module during a period of performing the half-folding step, thereby releasably joining the superimposed portions of the developed module.

In this method, the temporarily joined area can be formed during the period of performing the half-folding step by the temporarily joining portion provided in at least one of the first and second suction-holding sections. Thus, as compared to the case where the temporarily joining step is performed after the half-folding step, an operation time can be shortened.

Preferably, in the above production method, the temporarily joining portion comprises a protruding element protruding from at least one of the first suction-holding surface and the second suction-holding surface, wherein, in the temporarily joining step, the superimposed portions of the developed module are compressed between the protruding element and the counterpart suction-holding section.

Preferably, in the production apparatus of the present invention, the temporarily joining portion comprises a protruding element protruding from at least one of the first suction-holding surface and the second suction-holding surface, and adapted to compress the superimposed portions of the developed module in cooperation with the counterpart suction-holding section.

In these production method and production apparatus, the temporarily joined area can be formed by compressing the superimposed portions of the developed module between the protruding element and the counterpart suction-holding section. Thus, the temporarily joined area can be formed in conjunction with the operation of folding the developed module in half, so that it is possible to more reliably maintain the folded state of the main body after the half-folding step.

Preferably, in the above production apparatus, the protruding element is so configured as to be able to adjust an amount of protrusion of the protruding element from at least one of the first suction-holding surface and the second suction-holding surface.

In this production apparatus, a joining level of the temporarily joined area can be adjusted by adjusting an amount of protrusion of the protruding element to adjust a pressing force to be applied to the developed module.

Preferably, in the above production method, the temporarily joining portion further comprises a recess formed in a counterpart one of the first suction-holding surface and the second suction-holding surface, with respect to the protruding element, wherein, in the temporarily joining step, the protruding element is engaged into the recess while interposing the superimposed portions of the developed module therebetween, thereby compressing the superimposed portions of the developed module.

Preferably, in the above production apparatus, the temporarily joining portion further comprises a recess formed in a counterpart one of the first suction-holding surface and the second suction-holding surface, with respect to the protruding element, and configured in such a manner that the protruding element can be engaged into the recess while interposing the superimposed portions of the developed module therebetween.

In these production method and production apparatus, the superimposed portions of the developed module can be compressed not only between a distal edge face of the protruding element and a bottom surface of the recess but also between an outer peripheral surface of the protruding element and an inner peripheral surface of the recess. This makes it possible to more reliably form the temporarily joined area.

Preferably, in the production method of the present invention, in the developed module preparing step, the developed module is prepared, the developed module comprising four side panel segments a respective two of which extend from a respective one of the front and rear end portions of the main body, laterally in respective opposite directions, wherein, in the suction-holding section preparing step, a suction-holding surface capable of suction-holding two of the side panel segments extending from the front end portion of the main body in the developed module, laterally in respectively opposite directions, is prepared as the first suction-holding surface, and a suction-holding surface capable of suction-holding two side panel segments extending from the rear end portion of the main body in the developed module, laterally in respective opposite directions, is prepared as the second suction-holding surface, and wherein the method further comprises a permanently joining step of, after the temporarily joining step, joining together lateral edge portions of a respective pair of the side panel segments superimposed by the half-folding step.

Preferably, in the production apparatus of the present invention, the developed module comprises four side panel segments a respective two of which extend from a respective one of the front and rear end portions of the main body, laterally in respective opposite directions, wherein the first suction-holding surface is capable of suction-holding two of the side panel segments extending from the front end portion of the main body in the developed module, laterally in respective opposite directions, wherein the second suction-holding surface is capable of suction-holding two side panel segments extending from the rear end portion of the main body of the developed module, laterally in respective opposite directions, and wherein the apparatus further comprises a permanently joining section for joining together lateral edge portions of a respective pair of the side panel segments superimposed in the developed module half-folded by the first and second suction-holding sections.

In these production method and production apparatus, by using the developed module comprising four side panel segments a respective two of which extend from a respective one of the front and rear end portions of the main body, laterally in respective opposite directions, a pant-type wearing article can be produced by joining together lateral edge portions of the pair of side panel segments superimposed when the main body is folded in half.

Preferably, in the above production method, in the temporarily joining step, the respective pair of side panel segments superimposed by the half-folding step is releasably joined.

Preferably, in the above production apparatus, the temporarily joining portion is adapted to releasably join the respective pair of side panel segments superimposed between the first and second suction-holding sections.

In these production method and production apparatus, the side panel segment pair closer to a permanently joined area than the main body is joined. This makes it possible to more reliably maintain the side panel segment pair in a positional relationship set for permanent joining, i.e., in a positional relationship of the superimposed portions obtained when the main body is property folded in half.

Preferably, the above production method further comprises: an opening step of, after the temporarily joining step, opening the first and second suction-holding sections; and a conveying step of, after the opening step, conveying the half-folded developed module from the first and second suction-holding sections to a position where the permanently joining step is performed, wherein, in the conveying step, the half-folded developed module is conveyed while being kept in a half-folded state by being clamped in a superimposing direction thereof.

Preferably, the above production apparatus further comprises a conveying section capable of receiving the half-folded developed module from the first and second suction-holding sections moved to the open position, and conveying the received developed module to the permanently joining section, wherein the conveying section is adapted to convey the developed module while keeping the developed module in a half-folded state.

In these production method and production apparatus, during conveyance from the suction-holding sections to the position where the permanently joining step is performed (permanently joining section), the developed module can be conveyed while being kept in the half-folded state. Thus, it is possible to reliably maintain the half-folded state of the developed module even if the developed module receives vibration or the like during conveyance.

Preferably, in the above production method, the developed module is conveyed while at least a portion of the superimposed side panel segments is clamped, in the conveying step.

Preferably, in the above production apparatus, the conveying section comprises a first conveyer for conveying the developed module while holding the developed module from therebelow, and a second conveyer for conveying the developed module while clamping at least a portion of the superimposed side panel segments in cooperation with the first conveyer.

In these production method and production apparatus, the developed module can be conveyed while the side panel segment pair located closer to a permanently joined area than the main body is clamped. This makes it possible to more reliably maintain the side panel segment pair in a positional relationship set for permanent joining, during the period of performing the permanently joining step.

Preferably, the production method of the present invention further comprises: an attaching step of attaching at least two detachable members to respective ones of the side panel segments, each of the detachable members having a detachable surface detachably attachable with respect to an outer surface of the main body; and a fold-back step of, prior to the half-folding step, folding back at least one of the side panel segments and the detachable members, onto the main body, in such a manner that the detachable surfaces of the detachable members faces toward an inner surface of the main body, wherein, in the half-folding step, the main body is folded in half in such a manner that the folded-back side panel segments are located inside.

In this method, a wearing article can be produced which is capable of being worn by: positioning the main body to extend from a front abdominal region to a rear dorsal region via a crotch region of a wearer; positioning the side panel segments extending laterally from the main body to extend in a front-rear direction to cover a lateral surface of a waist region of the wearer; and fixing the detachable members onto the outer surface of the main body.

The present invention further provides a wearing article produced by the above production method.

The present invention further provides a wearing article including an developed module which comprises a main body and at least two side panel segments extending from at least one of front and rear end portions of the main body, laterally in respectively opposite directions, wherein the main body is folded in half, the wearing article comprising a temporarily jointed area where superimposed portions of the developed module are releasably joined together.

The wearing article of the present invention can be obtained through a production method capable of accurately folding the main body in half while suppressing damage to the main body, and maintaining a folded position of the main body after the half-folding step.

More specifically, the wearing article of the present invention can be obtained through a production method capable of folding the main body in half by closing the first suction-holding section and the second suction-holding section in a state in which the forward surface and the rearward surface of the main body located on both sides of a folding line are suction-held by the suction-holding sections, respectively. Thus, in the wearing article of the present invention, a production method may be employed which is designed to fold the main body in half while holding two regions (the forward surface and the rearward surface of the main body) to be half-folded, differently from the case where a half-folding operation is performed by pressing a tucker bar against only a portion corresponding to a folding line as in the conventional technique. This makes it possible to accurately fold the main body in half while suppressing damage to the main body. Further, in the wearing article of the present invention, the superimposed portions of the half-folded developed module are releasably joined together. Thus, a folded state of the main body after the half-folding step can be maintained. Further, the temporarily joined area is releasable, so that a wearer can wear the wearing article by releasing the joined state of the temporarily joined area.

Preferably, in the above wearing article, the developed module has four side panel segments a respective two of which extend from a respective one of the front and rear end portions of the main body, laterally in respective opposite directions, wherein the wearing article further comprises a permanently joined area formed by joining together lateral edge portions of a respective pair of the side panel segments superimposed in a state in which the main body is folded in half, and wherein the temporarily joined area is formed by releasably joining the side panel segments superimposed in a state in which the main body is folded in half, at a position other than that of the permanently joined area.

In this wearing article, the temporarily joined area is formed at a position other than that of the permanently joined area. Thus, in comparison between this wearing article and other wearing article, whether or not a wearing article is a type formed by permanently joining side panel segments together in a state in which the side panel segments are accurately positioned can be readily determined by checking a presence or absence of the temporarily joined area.

The present invention makes it possible to accurately fold the main body in half while suppressing damage to the main body, and maintain a folded position of the main body after the half-folding step.