# US 11,992,395 B2 · Method for manufacturing an absorbent article

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- Number: US 11,992,395 B2
- Document ID: US11992395B2
- Status: Granted
- Kind: B2
- Application number: 16/980,687
- Filed: 2019-03-18
- Published: 2021-01-14
- Granted: 2024-05-28
- Earliest claimed: 2018-03-19
- Assignees: Daio Paper Corporation
- Applicants: Daio Paper Corporation
- Inventors: Megumi Yoshiba
- Web page: https://patentgrep.com/patent/US11992395B2

## CPC

- A61F 13/15699: {Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs}
- A61F 13/51108: {the top sheet having corrugations or embossments having one axis relatively longer than the other axis, e.g. forming channels or grooves in a longitudinal direction}
- A61F 13/15617: {Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres}
- A61F 13/15731: {Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing}
- A61F 13/5116: {being formed of multiple layers (A61F13/5123 takes precedence)}
- A61F 2013/15878: {by thermal bonding}
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)

## Abstract

An absorbent article comprising a top-surface sheet, a second sheet, and an absorber interposed between the top-surface sheet and the second sheet. The absorbent article allows a body fluid absorbed by the top-surface sheet to move to a non-skin side without deteriorating a soft touch feeling of cotton. The top-surface sheet 3 has a multi-layer structure including a non-heat fusible layer 10 made of a cellulose fiber and arranged on a skin side and a heat-fusible layer 11 made of a heat-fusible fiber and arranged on the non-skin side. The second sheet 6 made of a heat-fusible fiber is arranged on the non-skin side of the top-surface sheet 3. A large number of compressed parts 15 are formed on the non-skin side of the second sheet 6 by integrally recessing the second sheet 6 and the top-surface sheet 3 toward the skin side.

## Claims

### Claim 1

A method for manufacturing an absorbent article, the absorbent article comprising a top-surface sheet, a back-surface sheet, and an absorber interposed between the top-surface sheet and the back-surface sheet,
wherein the top-surface sheet includes a non-heat fusible layer arranged on a skin side and made of a nonwoven fabric made of 100% by weight of cotton fiber and a heat-fusible layer arranged on a non-skin side and made of a heat-fusible fiber,
a second sheet made of a heat-fusible fiber is arranged on the non-skin side of the top-surface sheet,
the top-surface sheet is formed to have a flat skin-side surface, and a large number of compressed parts are formed on a non-skin side surface of the second sheet by integrally recessing the second sheet and the top-surface sheet toward the skin side by compression from the non-skin side of the second sheet,
the method comprising:
allowing a laminate of the top-surface sheet and the second sheet to pass between a flat roll and a convex roll, the flat roll having a flat surface and not being heated, and the convex roll having a surface formed with a large number of protrusions corresponding to the compressed parts and being heated at least at a time of compression, thereby heat-fusing and joining the second sheet and the heat-fusible fiber of the heat-fusible layer while forming the compressed parts.

### Claim 2

A method for manufacturing an absorbent article, the absorbent article comprising a top-surface sheet, a back-surface sheet, and an absorber interposed between the top-surface sheet and the back-surface sheet,
wherein the top-surface sheet includes a non-heat fusible layer arranged on a skin side and made of a nonwoven fabric made of 100% by weight of cotton fiber and a heat-fusible layer arranged on a non-skin side and made of a heat-fusible fiber,
a second sheet made of a heat-fusible fiber is arranged on the non-skin side of the top-surface sheet,
the top-surface sheet is formed to have a flat skin-side surface, and a large number of compressed parts are formed on a non-skin side surface of the second sheet by integrally recessing the second sheet and the top-surface sheet toward the skin side by compression from the non-skin side of the second sheet,
the method comprising:
allowing the top-surface sheet to pass between a flat roll and a convex roll, the flat roll having a flat surface and not being heated, and the convex roll having a surface formed with a large number of protrusions and being heated at least at a time of compression to form a large number of intermediate compressed parts in a non-skin side surface of the top-surface sheet by integrally recessing the heat-fusible layer and the non-heat fusible layer toward a skin side, and
then in a state in which the second sheet is laminated on the non-skin side of the top-surface sheet, allowing the top-surface sheet to pass between a second flat roll and a second convex roll, the second flat roll having a flat surface and not being heated, and the second convex roll having a surface formed with a large number of protrusions corresponding to the compressed parts and being heated at least at compression time, thereby heat-fusing and joining the second sheet and the heat-fusible fiber of the heat-fusible layer while forming the compressed parts.

### Claim 3 (depends on 1)

The method for manufacturing the absorbent article according to claim 1, wherein a large number of the compressed parts are formed in an intermittent pattern in which the compressed parts are disposed at intervals.

### Claim 4 (depends on 2)

The method for manufacturing the absorbent article according to claim 2, wherein a large number of the compressed parts are formed in an intermittent pattern in which the compressed parts are disposed at intervals.