MANUFACTURING SYSTEM AND MANUFACTURING METHOD FOR SHEET-LIKE STRUCTURE

Abstract

To provide a manufacturing system and a method for manufacturing sheet-like structures. The manufacturing system of sheet-like structures comprises a loosened portion forming apparatus which forms plural loosened portions, which are substantially U-shaped on a cord member, an arranging apparatus which inserts each of the plural loosened portions into each of the plural openings formed on a belt-like member and form plural linear portions in substantial linear form which connect each of the plural loosened portions respectively, a sewing apparatus which sews a belt-like member and each of the plural linear portions together with a thread member, and a belt-like member cutting apparatus which cuts a belt-like member in prescribed forms.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a plan view of the sheet-like structure of Example 1;

FIG. 2 shows a cross section of X-X line of FIG. 1;

FIG. 3 shows a plan view of a conventional sheet-like structure;

FIG. 4 shows a view describing a manufacturing system of the first embodiment of the present invention;

FIG. 5A shows an enlarged view of area A in FIG. 4;

FIG. 5B shows an enlarged view of area A in FIG. 4;

FIG. 6A shows an enlarged view of area B in FIG. 4;

FIG. 6B shows an enlarged view of area B in FIG. 4;

FIG. 7 shows a view describing a manufacturing system of the second embodiment of the present invention;

FIG. 8 shows a view describing manufacture of sheet-like structures in the manufacturing system of the second embodiment of the present invention;

FIG. 9 shows a view describing a manufacturing system of the third embodiment of the present invention;

FIG. 10 shows a view describing a manufacturing system of the fourth embodiment of the present invention;

FIG. 11 shows a view describing manufacture of sheet-like structures in the manufacturing system of the fourth embodiment of the present invention;

FIG. 12 shows a view describing the fifth embodiment;

FIG. 13 shows an enlarged view of area C in FIG. 12; and

FIG. 14A shows a view describing manufacture of sheet-like structures in the manufacturing system of the fifth embodiment;

FIG. 14B shows a view describing manufacture of sheet-like structures in the manufacturing system of the fifth embodiment;

FIG. 14C shows a view describing manufacture of sheet-like structures in the manufacturing system of the fifth embodiment.

Claims

1. A manufacturing system for a sheet-like structure, comprising: a sheet member with a prescribed form; and a cord member sewn onto a predefined surface of the sheet member with a specified thread member, having an extended portion extending from an outer edge of the predefined surface, and on which a non-sewn area without the specified thread member is formed, the manufacturing system comprising: a loosened portion forming apparatus to form plural loosened portions which are substantially U-shaped on a cord member; an inserting portion forming apparatus to form plural cut portions or openings through which the loosened portions can be inserted on the belt-like member with an substantially belt form;an arranging apparatus to insert each of the plural loosened portions from a predefined surface of the belt-like member into each of the plural cut portions or each of the plural openings on an opposite surface of the predefined surface of the belt-like member, and to form plural linear portions formed substantially linearly on a predefined surface to connect each of the plural loosened portions respectively;a sewing apparatus to sew each of the plural linear portions arranged by the arranging apparatus and a belt-like member together using a thread member,a belt-like member cutting apparatus to form plural sheet members by cutting the belt-like member in a prescribed form so that the specified linear portion of the plural linear portions sewn by the sewing apparatus and the linear portions which lie adjacent to the specified linear portion are arranged on the different sheet members;a thread member cutting apparatus to cut thread member connecting portions which are parts of the thread member formed to connect a specified linear portion of the plural linear portions sewn by the sewing apparatus and other linear portions which lie adjacent to the specified linear portion; anda cord member cutting apparatus to cut cord connecting portions, which are parts of the cord member formed to connect a specified linear portion of the plural linear portions sewn by the sewing apparatus and other linear portions which lie adjacent to the specified linear portion at a predetermined position.

2. The manufacturing system for the sheet-like structure according to claim 1, wherein the inserting portion forming apparatus is capable of forming each of the plural cut portions or openings in a substantial center in the width direction of the belt-like member.

3. The manufacturing system for the sheet-like structure according to claim 1, wherein the loosened portions forming apparatus forms plural loosened portions by drawing in plural predetermined portions in the cord member, and the arranging apparatus pushes out each of the plural loosened portions with air and inserts each of the plural loosened portions to each of the plural cut portions or openings from a predefined surface of the belt-like member to an opposite surface of the predefined surface of the belt-like member.

4. The manufacturing system for the sheet-like structure according to claim 1, wherein the arranging apparatus arranges the plural linear portions lined up in substantially linearly, andthe sewing apparatus sews each of the plural linear portions lined up in a substantially linear form by the arranging apparatus continuously onto the belt-like member along a straight line formed by the plural linear portions.

5. The manufacturing system for the sheet-like structure according to claim 4, wherein the sewing apparatus further comprises a primary evacuating apparatus to evacuate each of the plural loosened portions to avoid overlapping the straight line formed by the plural linear portions.

6. The manufacturing system for the sheet-like structure according to claim 1, wherein the belt-like member cutting apparatus comprises a predetermined cutting unit, and a secondary evacuating apparatus to evacuate the cord connecting portion from a cutting position at which the belt-like member is cut by the cutting unit.

7. The manufacturing system for the sheet-like structure according to claim 1, wherein the belt-like member cutting apparatus, the thread member cutting apparatus, and the cord member cutting apparatus are the same cutting unit, andfurther comprising a conveying apparatus for moving the cord connecting portion to the cutting position in the cutting unit.

8. The manufacturing system for the sheet-like structure according to claim 1, wherein the belt-like member is a belt-like absorbing member comprising a predetermined absorbing layer with liquid absorbability coated with a surface material of a thin film form, and further comprisinga belt-like member forming apparatus for covering the absorbing layer with the surface material.

9. A method for manufacturing a sheet-like structure comprising: a sheet member with a prescribed form; and a cord members sewn onto a predefined surface of the sheet member with a specified thread member, and having an extended portion extending from an outer edge of the predefined surface on which a non-sewn area without the specified thread member is formed, the method comprising steps of: forming loosened portion to form plural loosened portions which are substantially U-shaped on a cord member;forming inserting portion to form plural cut portions or openings on the belt-like member with an approximate belt form through which the loosened portions can be inserted;arranging to insert each of the plural loosened portions from a predefined surface of the belt-like member into each of the plural cut portions or each of the plural openings on an opposite surface of the predefined surface of the belt-like member, and to form plural linear portions formed substantially linearly on a predefined surface to connect each of the plural loosened portions respectively;sewing to sew each of the plural linear portions arranged by the arranging apparatus and a belt-like member together using a thread member;cutting a belt-like member to form plural sheet members by cutting the belt-like member in a prescribed form so that the specified linear portion of the plural linear portions sewn by the sewing apparatus and the linear portions which lie adjacent to the specified linear portion are arranged on the different sheet members;cutting a thread member to cut thread member connecting portions which are parts of the thread member formed to connect a specified linear portion of the plural linear portions sewn by the sewing apparatus and other linear portions which lie adjacent to the specified linear portion; andcutting a cord member to cut cord connecting portions, which are parts of the cord member formed to connect a specified linear portion of the plural linear portions sewn by the sewing apparatus and other linear portions which lie adjacent to the specified linear portion at a predetermined position.

10. The method for manufacturing a sheet-like structure according to claim 9, wherein the forming inserting portion step is capable of forming each of the plural cut portions or openings in a substantial center in the width direction of the belt-like member.

11. The method for manufacturing a sheet-like structure according to claim 9, wherein the forming loosened portions step forms plural loosened portions by drawing in plural predetermined portions in the cord member, and the arranging step pushes out each of the plural loosened portions with air and inserts each of the plural loosened portions to each of the plural cut portions or openings from a predefined surface of the belt-like member to an opposite surface of the predefined surface of the belt-like member.

12. The method for manufacturing a sheet-like structure according to claim 9, wherein the arranging step arranges the plural linear portions lined up in substantially linearly, andthe sewing step sews each of the plural linear portions lined up in a substantially linear form by the arranging apparatus continuously onto the belt-like member along a straight line formed by the plural linear portions.

13. The method for manufacturing a sheet-like structure according to claim 12, wherein the sewing step further comprises a primary evacuating apparatus to evacuate each of the plural loosened portions to avoid overlapping the straight line formed by the plural linear portions.

14. The method for manufacturing a sheet-like structure according to claim 9, wherein cutting the belt-like member step comprises a predetermined cutting unit, and a secondary evacuating apparatus to evacuate the cord connecting portion from a cutting position at which the belt-like member is cut by the cutting unit.

15. The method for manufacturing a sheet-like structure according to claim 9, wherein the cutting a belt-like member step, the cutting thread member step and cutting the cord member step are performed by the same cutting unit, and the cord connecting portion is moved to a cutting position in the cutting unit by a predetermined conveying apparatus.

16. The method for manufacturing a sheet-like structure according to claim 9, wherein the belt-like member is a belt-like absorbing member comprising a predetermined absorbing layer with liquid absorbability coated with a surface material of a thin film form, and further comprising a step of forming a belt-like member for covering the absorbing layer with the surface material.