JP7736974B2 - Manufacturing method and manufacturing device for sheet-shaped cushioning material - Google Patents

Description

The present invention relates to a method for manufacturing sheet-type cushioning material. The present invention also relates to an apparatus for manufacturing sheet-type cushioning material. The present invention also relates to sheet-type cushioning material.

Foamed resin cushioning materials, also known as fruit caps, are used for individual packaging of fruit. The following literature is also available regarding cushioning materials:

Patent Document 1 discloses a fruit cushioning material that protects fruit from external impacts and the like, and is made by bonding soft foamed resin strips and hard foamed resin strips made of a foamed resin material in a cross-net pattern.

Patent Document 2 discloses a fruit cap consisting of a mesh-like tubular main body formed by overlapping a large number of foamed polyethylene linear members on the outer layer with a large number of foamed polyethylene linear members on the inner layer, crossing at a certain angle, and fusing the overlapping portions together, with one open end of the tubular main body closed by fusing the foamed polyethylene linear members of the inner and outer layers.

Utility Model Registration No. 3170893 Japanese Patent Application Publication No. 8-301373

Because these cushioning materials are made from foam resin, they are bulky even when not in use and are difficult to store, and their shape makes them difficult to fold. Furthermore, because the resin is extruded into a linear shape and then glued together and cut, they are difficult to mold into anything other than a cylindrical shape. This makes them difficult to hold fruit and other items, and it can be difficult to create cushioning materials shaped to suit different types of fruit. For this reason, new methods of manufacturing cushioning materials are needed.

In light of this situation, the present invention aims to provide a sheet-type cushioning material, as well as an apparatus and method for manufacturing the same.

As a result of extensive research aimed at solving the above problems, the inventors discovered that the following invention meets the above objectives, leading to the completion of the present invention. Specifically, the present invention relates to the following:

<1> A conveying step of continuously conveying a first substrate containing a roll-shaped thermoplastic resin and a second substrate containing a roll-shaped thermoplastic resin to form a laminated material in which the first substrate and the second substrate are superimposed;
a welding step of welding the laminated material to form a welded portion;
A manufacturing method for a sheet-like cushioning material, comprising a cutting processing step of forming staggered cut portions in the laminate material to match the welded portions and processing the cut portions of the sheet-like cushioning material.
<2> The cutting process is a process of punching out a sheet-like cushioning material,
The manufacturing method according to <1>, further comprising a winding step of winding up the waste material around the sheet-like cushioning material.
<3> The manufacturing method according to <1>, wherein the cutting section has a winding step of providing a slit for cutting and winding the sheet-like cushioning material into a strip shape including the sheet-like cushioning material.
<4> The manufacturing method according to any one of <1> to <3>, wherein the first substrate and the second substrate are nonwoven fabrics having a basis weight of 50 g/m ² or more.
<5> A conveying means for continuously conveying a first substrate containing a roll-shaped thermoplastic resin and a second substrate containing a roll-shaped thermoplastic resin, and forming a laminated material by superposing the first substrate and the second substrate;
a welding means for welding the laminated material to form a welded portion;
and a cutting means for forming staggered cuts in the laminated material in accordance with the welded portions, and processing the cut portions of the sheet-like cushioning material.
<6> A laminated material in which a sheet-like first base material and a sheet-like second base material are superimposed,
a welded portion formed by welding the periphery of the laminated material;
A staggered cut portion provided on the inner side of the surface of the welded portion;
and an opening where the welded portion is not provided.

The present invention provides a sheet-like cushioning material, as well as an apparatus and method for manufacturing the same. The sheet-like cushioning material of the present invention can be stored in sheet or roll form, and can be made into a compact sheet. The manufacturing apparatus and method of the present invention are also used to manufacture such cushioning material.

1 is a schematic diagram of an embodiment of a manufacturing apparatus of the present invention. FIG. 1 is a flow diagram of a manufacturing method of the present invention. 1 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 1 is a schematic diagram illustrating an embodiment of a sheet-type cushioning material of the present invention. 1 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 1 is a schematic diagram of an embodiment of a manufacturing apparatus of the present invention. FIG. 1 is a flow diagram of a manufacturing method of the present invention. 1 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 1 is a schematic diagram illustrating an embodiment of a sheet-type cushioning material of the present invention. 1 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 1 is a schematic diagram illustrating an embodiment of a sheet-type cushioning material of the present invention. 1 is an image relating to a manufacturing example of a sheet-like cushioning material of the present invention.

The following describes in detail an embodiment of the present invention. However, the following description of the constituent elements is merely one example (representative example) of an embodiment of the present invention, and the present invention is not limited to the following content unless the gist of the present invention is changed. Note that when the expression "~" is used in this specification, it is used to include the numerical values before and after it.

[Production method of the present invention]
The method for producing a sheet-like cushioning material of the present invention includes a conveying step of continuously conveying a first substrate containing a roll-shaped thermoplastic resin and a second substrate containing a roll-shaped thermoplastic resin to form a laminated material by overlapping the first substrate and the second substrate, a welding step of welding the laminated material to form welded portions, and a cutting step of forming staggered cut portions in the laminated material to match the welded portions and processing the cut portions of the sheet-like cushioning material. The method for producing a sheet-like cushioning material of the present invention may be referred to as the "production method of the present invention."

[Manufacturing apparatus of the present invention]
The sheet-type cushioning material manufacturing apparatus of the present invention comprises: a conveying means for continuously conveying a roll-shaped first substrate containing a thermoplastic resin and a roll-shaped second substrate containing a thermoplastic resin to form a laminated material by overlapping the first substrate and the second substrate; a welding means for welding the laminated material to form welded portions; and a cutting means for cutting staggered cut portions in the laminated material to match the welded portions and process the cut portions of the sheet-type cushioning material. The sheet-type cushioning material manufacturing apparatus of the present invention may be referred to as the "manufacturing apparatus of the present invention."

[Sheet-like cushioning material of the present invention]
The sheet-like cushioning material of the present invention comprises a laminated material formed by overlapping a sheet-like first substrate and a sheet-like second substrate, a welded portion where the periphery of the laminated material is welded, a staggered cut portion provided on the inside of the plane of the welded portion, and an opening where the welded portion is not provided.

In addition, in this application, the manufacturing method of the present invention can also be carried out using the manufacturing apparatus of the present invention, and the sheet-shaped cushioning material of the present invention can also be manufactured using these, and the corresponding configurations in this application can be used interchangeably.

Polyethylene foam cushions have a low specific gravity and tend to be bulky. They are primarily used for packaging fruit, and demand varies depending on geographical and seasonal factors. For this reason, there is a demand for cushioning materials that are efficient to transport and easy to store. The present invention provides a sheet-like cushioning material that is easy to store. This sheet-like cushioning material can be stored in sheet form, stacked on top of each other, or in roll form. When in use, it can be unfolded through the opening to protect fruit or other items inside.

[Manufacturing equipment 101]
FIG. 1 is a schematic diagram of an embodiment of a manufacturing apparatus of the present invention. The manufacturing apparatus 101 is an apparatus for continuously transporting and processing a first substrate 11 and a second substrate 12. The first substrate 11 is transported from a first roll 21 as a substrate wound in a strip shape, and the second substrate 21 is transported from a second roll 22 as a substrate wound in a strip shape. In FIG. 1, the manufacturing apparatus 101 transports substrates and the like from left to right. The transport means transports the substrates in a flow in which the substrates are fed from the first roll 21 or the second roll 22 and wound up by a winder 61. The substrates are transported between these rolls via sequentially arranged drive rolls, free rolls, and the like, and are appropriately processed.

The manufacturing apparatus 101 includes a laminating roll 31, a welding means 41, and a cutting means 51. The laminating roll 31 overlaps a first substrate 11 and a second substrate 12 to form a laminated material 13. The welding means 41 is a device for welding the laminated material 13 to form welded portions. The cutting means 51 is a device for processing cutouts and cut-out portions in the laminated material 13. The container 52 is a container for storing the cut-out sheet-like cushioning material 701. Scrap material 14 is wound onto a winder 61 and collected.

[Manufacturing flow example]
FIG. 2 is a flow diagram of the manufacturing method of the present invention. This manufacturing flow can be performed using manufacturing apparatus 101, etc. In this manufacturing method, first, step S11 is a process of conveying first substrate 11 and second substrate 12. Next, step S21 is a process of partially welding laminated material 13, which is made by overlapping first substrate 11 and second substrate 12, using welding means 41. Next, step S31 is a process of forming staggered slits (notches) in accordance with the welded portions, performing a cutout process to provide cutout portions in accordance with the welded portions, and then punching out the cutout portions. This results in a sheet-like cushioning material. Finally, step S41 is a process of winding up the remaining laminated material 14 on winder 61 after the sheet-like cushioning material has been removed.

[First substrate 11, second substrate 12]
The first substrate and the second substrate are substrates containing a thermoplastic resin. Hereinafter, the first substrate and the second substrate may be simply referred to as "substrates used in the present invention." By containing a thermoplastic resin, processing to form a welded portion by welding means can be performed. In particular, a substrate in which a thermoplastic resin is used as the main material is used for the surface where the first substrate 11 and the second substrate 12 contact. Examples of thermoplastic resins that can be used include polyester, polypropylene, rayon, nylon, vinylon, aramid fiber, and biodegradable resins, and mixtures of these can also be used as appropriate.

The substrate used in the present invention may contain a thermoplastic resin as the main material, and may contain other materials as appropriate. Substrates containing a thermoplastic resin include those made of a thermoplastic resin, those mixed with other materials, and laminates having a thermoplastic resin layer. In a laminate, if the surface to be welded is made of a thermoplastic resin, other resins or layers other than resin may be provided in the other layers; for example, a laminate consisting of a paper layer and a resin layer can be used.

The substrate used in the present invention may be, for example, 60% by mass or more, 70% by mass or more, 80% by mass or more, 90% by mass or more, 95% by mass or more, or 98% by mass or more of a thermoplastic resin. The substrate used in the present invention may be made of a thermoplastic resin. Other materials that can be used include thermosetting resins, adhesives, weathering agents, stabilizers, plasticizers, colorants, pulp, natural materials, and various other materials used in forming sheets, fibers, membranes, films, nonwoven fabrics, synthetic paper, etc.

The substrate used in the present invention is preferably a nonwoven fabric. By using a nonwoven fabric, when incisions or cutouts are provided, the strength and shape of the cushioning material can be easily maintained even when the orientation and location of the cutouts can be freely designed in various directions and angles. Furthermore, the substrate used in the present invention preferably has a basis weight of 50 g/m ² or more. By using a nonwoven fabric with a high basis weight, shape stability when unfolded from the incisions is improved and the cushioning effect is also high. The basis weight is more preferably 60 g/m ² or more, or 70 g/m ² or more. Taking into account the processability of adhesion, incisions, and cutouts, the upper limit may be 150 g/m ² or less, 120 g/m ² or less, or 100 g/m ² or less. Polypropylene nonwoven fabric, which is suitable for processability, is particularly preferred.

[First roll 21, second roll 22]
The substrates used in the present invention are strip-shaped substrates, with the first substrate 11 being fed from a first roll 21 and the second substrate 12 being fed from a second roll 22. These are overlaid and laminated by a laminating roll 31. Before reaching the laminating roll 31, the substrates may be overlaid while appropriately controlling the edge position. The conveying speed of these substrates is set appropriately depending on the processing speed, etc.

[Laminated material 13]
The laminated material 13 is a substrate that is laminated to include a first substrate 11 and a second substrate 12. This lamination is performed by simply overlapping the first substrate 11 and the second substrate 12, making it easy to perform subsequent processing.

[Processing of laminated material 13]
Fig. 3 is a schematic diagram for explaining the manufacturing method of the present invention, which can be performed using the manufacturing apparatus 101, etc. Fig. 3 explains the processing performed on the laminated material 13, particularly, by the welding means 41 and the cutting means 51, etc. in the manufacturing apparatus 101. In Fig. 3, the laminated material 13, etc., is viewed from a planar direction, and the laminated material 13 is conveyed from left to right.

[Welding means 41]
1 and the like is a means for welding predetermined positions of the laminated material 13. Since the laminated material 13 is made by overlapping the base materials used in the present invention, it can be welded and bonded by heat treatment or ultrasonic treatment. For example, the welding means 41 can be a roll such as an ultrasonic roll, which has protrusions corresponding to the welding portions, and the protrusions weld the laminated material 13 where they come into contact.

Area A1 in Figure 3 illustrates the welding performed by the welding means 41. The welding means 41 provides a welding portion 710 in the laminate 13. This welding portion 710 is a welding portion that will become the welding portion 71 in the sheet-like cushioning material 701 shown in Figure 4. The welding portion 710 can be adjusted as appropriate to match the shape of the sheet-like cushioning material 701. When the opening 74 is used as the upper part, the sheet-like cushioning material 701 has a U-shaped bottom, narrowing in width toward the bottom and forming a receptacle with a closed bottom. The welding portion 710 is welded to correspond to this shape.

[Cutting processing means 51]
Area A2 in FIG. 3 is used to explain the cutting process performed by the cutting means 51. The cutting means 51 forms staggered cutouts 72 in the laminate 13 to match the welded portion 710. The cutting means 51 also forms cutouts 73 in the sheet-like cushioning material 701 (see FIG. 4). The cutouts 73 cut out a portion to be formed within the welded portion 710 (a portion along the center of the welded portion 710) and a cutout portion to be formed as an opening 74 (the lower end side in area A2 in FIG. 3). These cutouts 72 and cutouts 73 penetrate the first substrate 11 and second substrate 72 that constitute the laminate 13. The cutting means 51 may be a die-cut roll or other roll with protrusions corresponding to the cutouts 72 and cutouts 73, which are then used to process the portions where the protrusions contact the laminate 13.

Area A3 in Figure 3 is the scrap 14 of the laminated material 13 after it has passed through the cutting means 51. In the embodiment shown in Figures 1 and 3, the cutting means 51 punches out sheet-like cushioning material 701 from the laminated material 13. After processing the laminated material 13, the punched sheet-like cushioning material 701 is stored in the container 52 in a sheet-like form.

The scrap material 14 surrounding the portion that will become the sheet-like cushioning material is continuously wound up by the winder 61. In this embodiment, the scrap material 14 is the end portion of the laminated material 13. The center of the scrap material 14 is a space 141 punched out of the sheet-like cushioning material 701. In this embodiment, the scrap material 14 can be transported in a continuous, connected state, allowing it to be efficiently collected by the winder 61.

[Sheet-shaped cushioning material 701]
FIG. 4 is a schematic diagram of an embodiment of a sheet-like cushioning material of the present invention. FIG. 4 is a plan view of a sheet-like cushioning material 701 with the first substrate 11 side facing upward. The sheet-like cushioning material 701 has a laminated material 13 formed by overlapping a sheet-like first substrate 11 and a sheet-like second substrate 12 (back surface side). The sheet-like cushioning material 701 also has a welded portion 73 where the periphery of the laminated material 13 is welded. The sheet-like cushioning material 701 also has a staggered cutout portion 72 provided inside the plane of the welded portion 73. The sheet-like cushioning material 701 also has an opening 74 where the welded portion 73 is not provided.

The sheet-like cushioning material 701 can be unfolded and fruit or other items can be placed inside through the opening 74 to protect them. Because the opening 74 of the sheet-like cushioning material 701 is not welded, the first base material 11 and the second base material 12 are simply stacked on top of each other, and can be separated by pulling them apart. This allows the sheet-like cushioning material 701 to be unfolded into a bag shape.

In addition, because the cuts 72 are arranged in a staggered pattern, the more the sheet-like cushioning material 701 is unfolded into a bag shape, the wider these cuts 72 become, allowing for a larger opening. When unfolded, the cuts 72 unfold at an angle. The sloping edges between the cuts 72 create a shape that provides cushioning. Furthermore, because welded sections 73 are provided, the unfolded shape of the sheet-like cushioning material 701 remains constant. Furthermore, the welded sections 73 form a receiving section on the opposite side of the opening 74 (the right side in Figure 4) that forms the bottom of the closed shape. Therefore, stored items will not fall out or fall out from anywhere other than the opening 74.

The size of the sheet-like cushioning material 701 can be adjusted appropriately depending on the object to be stored. The size can be adjusted by changing the width of the base material used in the present invention or by setting the shape of the mold used for ultrasonic processing or heat processing to process the welded portion 71 (710) and the cut-out portion 73. The width of the opening 74 of the sheet-like cushioning material 701 (top and bottom in Figure 4) can be 3 cm to 20 cm, for example. The length of the sheet-like cushioning material 701 (left and right in Figure 4) can be 3 cm to 25 cm, for example. The lower limits of the width and length can be 5 cm or more, or 7 cm or more. The upper limits of the width and length can be 18 cm or less, 15 cm or less, or 12 cm or less. The width and length of the sheet-like cushioning material 701 can be approximately the same, or the width and length can be long or long. Furthermore, during storage, the sheet-like cushioning material 701 is a relatively thin sheet consisting of a first substrate and a second substrate stacked together. The thickness depends on the base material and processing process, but can be, for example, 10 mm or less, 5 mm or less, 3 mm or less, or 2 mm or less. The sheet-like cushioning material 701 is suitable for storing fruit, such as apples, pears, persimmons, and peaches, and the size is set to suit the items to be stored.

[Modification of manufacturing process]
FIG. 5 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 5 is a modified example of the schematic diagram shown in FIG. 3, and the configurations relating to areas A1 and A3 are common. In FIG. 5, the cutting process relating to area A2 in FIG. 3 is divided into areas A21 and A22. Area A21 is the area where the staggered cutouts 72 are first formed. Area A22 is the area where the cutouts 73 are subsequently formed and punched out. In this way, the process according to the present invention may be divided into multiple stages and performed separately, as appropriate.

[Manufacturing device 102]
6 is a schematic diagram of an embodiment of a manufacturing apparatus of the present invention. The manufacturing apparatus 102 is a partial modification of the manufacturing apparatus 101 of FIG. 1 and has a partially common configuration for processing the first substrate 11 and the second substrate 12. The manufacturing apparatus 102 has a cutting means 53 instead of the cutting means 51 of the manufacturing apparatus 101. The cutting means 53 is a device that processes incisions and cutouts in the laminated material 13.

The manufacturing device 102 is configured to wind up the sheet-like cushioning material as processed laminated material 15 without punching it out, while still connected to the portion that was turned into scrap material 14 in the manufacturing device 101. The manufacturing device 102 has a laminating roll 31, welding means 41, and cutting means 51. The laminating roll 31 forms the laminated material 13 by overlapping the first substrate 11 and the second substrate 12. The welding means 41 is a device for welding the laminated material 13 to form a welded portion.

[Manufacturing flow example]
FIG. 7 is a flow diagram of the manufacturing method of the present invention. This manufacturing flow can be performed using a manufacturing apparatus 102 or the like. In this manufacturing method, first, step S12 is a process of conveying the first substrate 11 and the second substrate 12. Next, step S22 is a process of partially welding the laminated material 13, which is made by overlapping the first substrate 11 and the second substrate 12, using welding means 41. Next, step S321 is a process of providing staggered slits (notches) to match the welded portions. Step S322 is a process of performing a cutout process to provide cutout portions to match the welded portions. This results in a processed laminated material 15 including a sheet-like cushioning material. Finally, step S42 is a process of winding the processed laminated material 15 onto a winder 61.

[Processing of laminated material 13]
Fig. 8 is a schematic diagram for explaining the manufacturing method of the present invention. Fig. 8 explains the processing performed on the laminated material 13 in the manufacturing apparatus 102, particularly by the welding means 41 and the cutting means 53. In Fig. 8, the laminated material 13 is viewed from a planar direction, and the laminated material 13 is transported from left to right. This processing is similar to that shown in Fig. 3.

Area A11 in Figure 8 explains the welding performed by the welding means 41. The welding means 41 provides a welding portion 13 on the laminate 13. This welding portion 710 is a welding portion that will become the welding portion 71 in the sheet-like cushioning material 702 shown in Figure 9. The welding portion 710 during processing can be adjusted as needed to match the shape of the sheet-like cushioning material 702. When the opening 74 is positioned facing left, the welding portion 71 of the sheet-like cushioning material 702 has a shape that forms a U-shaped bottom, creating a receptacle with a closed bottom. The welding portion 710 is welded to correspond to this shape.

[Cutting processing means 53]
Area A23 in FIG. 8 illustrates the cutting process performed by the cutting means 53. The cutting means 53 forms staggered cuts 72 in the laminate 13 in area A23 to match the welded portions 710. The cutting means 53 also forms cutouts 73 in the sheet-like cushioning material 702 (see FIG. 9 ) in area A24. The cutouts 73 are formed by intermittently cutting out portions to be formed within the welded portions 710. The cutouts 73 are formed near the center of the welded portions 710 in the TD direction, which is perpendicular to the machine direction (MD) of the laminate 13. The cutouts 72 penetrate the first substrate 11 and the second substrate 12 that constitute the laminate 13. The processed laminate 15, which has the welded portions 710, the cutouts 72, and the cutouts 73, includes the sheet-like cushioning material and is continuously wound up by the winder 61.

[Sheet-shaped cushioning material 702]
FIG. 9 is a schematic diagram of an embodiment of a sheet-like cushioning material of the present invention. The sheet-like cushioning material 702 in FIG. 9 has a configuration similar to that of the sheet-like cushioning material 701 in FIG. 4. The sheet-like cushioning material 702 is obtained from the processed laminated material 15 manufactured by the manufacturing example shown in FIGS. 6 to 8. The processed laminated material 15 has a cutout portion 73 formed therein. The sheet-like cushioning material 702 can be obtained by cutting along the cutout line of the cutout portion 73, similar to the sheet-like cushioning material 701.

The processed laminate 15 can be thought of as a continuous string of sheet-like cushioning materials 702, and in this state it can be transported and rolled up in a strip. The opening of this processed laminate 15 is located on the lower side in Figure 8. Therefore, while it is transported in a strip, objects can be continuously placed inside through the opening.

[Example of processing of laminated material 13]
FIG. 10 is a schematic diagram for explaining the manufacturing method of the present invention. FIG. 10 shows a processing example similar to the processing example of the laminated material 13 shown in FIG. 8 . In this processing example, in region A12, both ends of the laminated material 13 in the TD direction are welded, and the laminated material 13 is welded across the TD direction. In region A25, notches 72 are provided in a staggered pattern parallel to the conveying direction. In region A26, cutouts 73 are provided. Unlike the example shown in FIG. 8 , these cutouts 73 are provided at positions that do not overlap with the welded portions 710. The processed laminated material 151 is continuously transported in a strip shape.

[Sheet-like laminated material 703]
11 is a schematic diagram of an embodiment of the sheet-like cushioning material of the present invention. The sheet-like laminated material 703 is obtained by cutting the processed laminated material 151 of FIG. 10 at the cutout portion 73. The sheet-like laminated material 703 can be obtained by cutting in this manner.

In this way, the sheet-like cushioning material of the present invention can be stored in sheet form, stacked one on top of the other, or in roll form. Furthermore, when in use, it can be unfolded through the opening to protect fruit or other items.

Figure 12 is an image of a manufacturing example of a sheet-like cushioning material of the present invention. The left side of Figure 12 shows the sheet-like cushioning material during storage before unfolding. This sheet-like cushioning material was manufactured using two sheets of PP nonwoven fabric with a basis weight of 80 g/ ^m2 . Both ends, which form the long sides of the rectangle, and one side, which forms the short side, which forms the bottom, were welded using ultrasonic treatment. In addition, staggered cuts were made on the inside of the welded surface. Cutouts were made to match this shape, and the material was manufactured into sheets by punching.

The right side of Figure 12 shows this sheet-like cushioning material being used to contain and protect an apple. In this way, the sheet-like cushioning material of the present invention can be made into a thin sheet that does not take up much space during storage, and when in use, it can be unfolded and spread out through the opening to contain fruit or other items. In this case, using a nonwoven fabric with a large basis weight will provide even greater cushioning.

This invention can be used as a cushioning material to contain and protect fruit and other items, making it industrially useful.

REFERENCE SIGNS LIST 101, 102 Manufacturing apparatus 11 First substrate 12 Second substrate 13 Laminated material 14 Scrap material 15, 151 Processed laminated material 21 First roll 22 Second roll 31 Laminated roll 41 Welding means 51, 53 Cutting means 52 Container 61 Winder 701, 702, 703 Sheet-like cushioning material 71, 710 Welded portion 72 Cut portion 73 Cut portion 74 Opening

Claims (3)

a conveying step of continuously conveying a first substrate containing a roll-shaped thermoplastic resin and a second substrate containing a roll-shaped thermoplastic resin to form a laminated material in which the first substrate and the second substrate are superimposed;
a welding step of welding the laminated material to form a welded portion;
a cutting process step of forming staggered cuts in the laminated material in accordance with the welded portions, and processing the cutout portions of the sheet-like cushioning material,
The cutting process is a process of punching out a sheet-like cushioning material,
The manufacturing method includes a winding step of winding up the waste material around the sheet-like cushioning material. The manufacturing method according to claim 1 , wherein the first substrate and the second substrate are nonwoven fabrics having a basis weight of 50 g/m ² or more. a conveying means for continuously conveying a roll-shaped first substrate containing a thermoplastic resin and a roll-shaped second substrate containing a thermoplastic resin, and forming a laminated material by overlapping the first substrate and the second substrate;
a welding means for welding the laminated material to form a welded portion;
a cutting processing means for forming staggered cuts in the laminated material in accordance with the welded portions and processing the cutout portions of the sheet-like cushioning material,
the cutting means punches out the sheet-like cushioning material,
Furthermore, a winding machine that winds up the scrap material around the sheet-like cushioning material;
and a container for storing the punched sheet-like cushioning material in a stacked sheet form.