Method of manufacturing a toilet paper roll

Abstract

A method of manufacturing a toilet paper roll in which the layers of the toilet paper do not peel apart when the four layers of the toilet paper are torn, and in which the toilet paper roll maintains a good appearance. A sprayer (22a) sprays a liquid for bonding between the single layers of paper (110, 111), a sprayer (22b) sprays a liquid for bonding between the single layers of paper (111, 100), a sprayer (22c) sprays a liquid for bonding between the single layers of paper (100, 101), and a press roller (23) applies pressure to the single layers of paper (110, 111, 100, 101) so that the single layers of paper are superimposed.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a four-layer toilet paper roll formed by stacking four sheets of paper and then rolling them together. Background Technology

[0002] In the past, toilet paper rolls were generally manufactured and sold as single-layer rolls made by winding one sheet of paper, and as two-layer rolls made by stacking and winding two sheets of paper.

[0003] Furthermore, they also manufacture and sell toilet paper rolls made by layering and rolling three or more sheets of paper together to improve absorbency.

[0004] In addition, when there are three or more sheets of paper stacked as described above, the thickness of the stacked paper becomes quite thick, making it difficult to tear the part that has been pulled out of the paper roll.

[0005] Sometimes, pinholes are made at certain intervals on the paper roll obtained by stacking more than three sheets of paper, so that the stacked paper can be easily torn apart when pulled out of the paper roll.

[0006] For example, in manufacturing three-ply toilet paper rolls, sometimes glue is used to bond one of the front-side layers to at least one of the middle layers, and micro-embossing is formed on the two back-side layers, stacking them to make the layers difficult to peel off. Furthermore, in manufacturing four-ply toilet paper rolls, decorative embossing is formed on the two front-side layers, and micro-embossing is formed on the two back-side layers. Sometimes glue is used to bond one of the back-side layers of at least two front-side layers to one of the front-side layers of at least two back-side layers (Patent Document 1).

[0007] The aforementioned four-layer toilet paper roll is bonded together with glue, with the two middle layers being the core layers. Furthermore, the two outermost layers of the four layers form large decorative embossings, so that the micro-embossings formed on the glued middle layers strongly adhere to the decorative embossings and are stacked together in a way that makes it difficult for them to peel off.

[0008] Furthermore, the aforementioned four-layer toilet paper rolls sometimes have decorative embossing on one layer on the front side and micro-embossing on the three layers on the back side, using glue to bond the front layer to the second layer counting from the front side.

[0009] Prior art literature

[0010] Patent documents

[0011] Patent Document 1: Japanese Patent Application Publication No. 2018-23561 Summary of the Invention

[0012] The problem that the invention aims to solve

[0013] In four-layer toilet paper rolls manufactured by stacking multiple sheets of paper as described above, there are portions where the layers are formed by strong contact, for example, using embossing of different sizes, without the use of adhesive liquids such as water or paste. Therefore, when the roll is installed on a toilet paper holder and torn to the desired length, the individual sheets sometimes peel off from the torn end. If these peeled sheets are exposed from the toilet paper holder, the roll's appearance deteriorates.

[0014] This disclosure is made in view of the aforementioned problems, and provides a method for manufacturing a toilet paper roll that prevents the layers of paper from peeling off when the paper is pulled out of the four-layer toilet paper roll and maintains a good appearance.

[0015] Solution for solving the problem

[0016] The method for manufacturing toilet paper rolls disclosed herein is characterized by comprising: a first step of pulling out raw paper from a plurality of raw paper rolls; a second step of introducing the plurality of raw paper rolls into a stacking section, thereby stacking the plurality of raw paper rolls to form four-layer toilet paper; a third step of drying the four-layer toilet paper; and a fourth step of winding the four-layer toilet paper to manufacture a four-layer toilet paper roll, wherein the second step comprises: a fifth step of separating the plurality of raw paper rolls introduced into the stacking section into a first single-layer paper, a second single-layer paper, a third single-layer paper, and a fourth single-layer paper, such that the back side of the first single-layer paper faces the front side of the second single-layer paper, and the back side of the second single-layer paper faces the front side of the third single-layer paper. In the sixth step, adhesive liquid is sprayed onto the back of the first single-layer paper and the front of the second single-layer paper by the first sprayer; in the seventh step, adhesive liquid is sprayed onto the back of the second single-layer paper and the front of the third single-layer paper by the second sprayer; in the eighth step, adhesive liquid is sprayed onto the back of the third single-layer paper and the front of the fourth single-layer paper by the third sprayer; and in the ninth step, the first single-layer paper, the second single-layer paper, the third single-layer paper and the fourth single-layer paper are overlapped by the pressing roller, and pressure is applied to penetrate the adhesive liquid.

[0017] Furthermore, the feature is that, in the second step described above, the sixth step, the seventh step, and the eighth step described above are performed simultaneously.

[0018] Furthermore, the method is characterized in that, in the second step described above, the sixth step, the seventh step, and the eighth step are performed intermittently and repeatedly by alternately spraying the adhesive liquid by the first sprayer and the third sprayer and spraying the adhesive liquid by the second sprayer.

[0019] Furthermore, the method is characterized in that, in the second step described above, the sixth step, the seventh step, and the eighth step are performed intermittently and repeatedly by spraying the adhesive liquid from the first sprayer, the second sprayer, and the third sprayer at different durations.

[0020] Furthermore, the characteristic is that, in the seventh step described above, the amount of adhesive liquid sprayed from the second sprayer is less than the amount of adhesive liquid sprayed from the first sprayer and the amount of adhesive liquid sprayed from the third sprayer.

[0021] Furthermore, the characteristic is that, in the aforementioned seventh step, the amount of adhesive liquid sprayed from the aforementioned second sprayer is greater than the amount of adhesive liquid sprayed from the aforementioned first sprayer and the amount of adhesive liquid sprayed from the aforementioned third sprayer.

[0022] Invention Effects

[0023] According to this disclosure, when the paper is torn from a four-layer toilet paper roll, the layers can be prevented from peeling off, thus maintaining a good appearance. Attached Figure Description

[0024] Figure 1 This is an explanatory diagram showing a schematic configuration of a toilet paper roll manufacturing apparatus using a method for manufacturing toilet paper rolls according to an embodiment of the present disclosure.

[0025] Figure 2 It is shown Figure 1 An explanatory diagram illustrating the schematic structure of the stacking section in a toilet paper roll manufacturing apparatus. Detailed Implementation

[0026] The following describes one embodiment of the present invention.

[0027] (Implementation Method)

[0028] Figure 1 This is an explanatory diagram showing the schematic configuration of a toilet paper roll manufacturing apparatus 1 using a method for manufacturing toilet paper rolls according to an embodiment of the present disclosure.

[0029] The toilet paper roll manufacturing apparatus 1 is configured to manufacture a four-ply toilet paper roll 300, and includes, for example, a guide roller 2 that moves raw paper 10a and raw paper 11a pulled from raw paper roll 10 and raw paper roll 11 respectively toward a stacking section 20; and a stacking section 20 that uses the aforementioned raw paper 10a and raw paper 11a to form the four-ply toilet paper 200 as described later.

[0030] Furthermore, the toilet paper roll manufacturing apparatus 1 includes: a drying section 30 for drying four-ply toilet paper 200; and a winding section 40 for winding the dried four-ply toilet paper 200 to form a four-ply toilet paper roll 300.

[0031] In addition, the base paper 10a and base paper 11a shown here are two-layer base papers with two sheets of paper overlapping.

[0032] Figure 1 The illustrated toilet paper roll manufacturing apparatus 1 is configured to introduce two layers of raw paper 10a and 11a into the laminating section 20 to manufacture a four-layer toilet paper roll 300. The toilet paper roll manufacturing apparatus according to the present invention may also be configured to supply single-layer raw paper from four raw paper rolls to the laminating section 20.

[0033] Figure 1 The toilet paper roll manufacturing apparatus 1 is provided with a plurality of guide rollers 2, for example, in such a way that the paper 10a pulled from the paper roll 10 and the paper 11a pulled from the paper roll 11 are respectively introduced into the stacking section 20.

[0034] Figure 2 It is shown Figure 1 An explanatory diagram illustrating the schematic structure of the laminating section 20 of the toilet paper roll manufacturing apparatus 1.

[0035] The laminating section 20, for example, has a plurality of guide rollers 21 configured to separate two layers of base paper 10a supplied from the base paper roll 10 into single-layer paper 100 and single-layer paper 101 and move them toward the sprayer 22c respectively.

[0036] Furthermore, the multiple guide rollers 21 provided in the laminating section 20 are configured to separate the two layers of raw paper 11a supplied from the raw paper roll 11 into single-layer paper 110 and single-layer paper 111, and respectively move them to the vicinity of the sprayer 22a.

[0037] Furthermore, each guide roller 21 is configured to bring the conveyed single-layer paper 100 close to the sprayer 22c as described above, and also close to the sprayer 22b. Furthermore, each guide roller 21 is configured to bring the conveyed single-layer paper 111 close to the sprayer 22a as described above, and also close to the sprayer 22b.

[0038] In other words, the laminating section 20 has a plurality of guide rollers 21 so that if two layers of base paper 10a and 11a are introduced, base paper 10a is separated into single-layer paper 100 and single-layer paper 101, and base paper 11a is separated into single-layer paper 110 and single-layer paper 111. Furthermore, the laminating section 20 has a plurality of guide rollers 21 so that the single-layer paper 110, 111, 100, and 101 separated as described above are overlapped and clamped by the pressing roller 23.

[0039] The aforementioned pressing roller 23 is configured to form a four-layer toilet paper 200 by overlapping and applying appropriate pressure to the single-layer paper 110, 111, 100, and 101.

[0040] Furthermore, the laminating section 20 is equipped with a sprayer 22a for spraying adhesive liquid between single-layer paper 110 and single-layer paper 111 before the single-layer paper 110, 111, 100, and 101 are clamped by the pressing roller 23; a sprayer 22b for spraying adhesive liquid between single-layer paper 111 and single-layer paper 100; and a sprayer 22c for spraying adhesive liquid between single-layer paper 100 and single-layer paper 101. Water, an aqueous solution containing fragrance components, or a deodorizing component can be used as the adhesive liquid. Furthermore, regarding the adhesive liquid used by the sprayers 22a, 22b, and 22c, for example, it can be configured such that water is sprayed from one of the sprayers, and an aqueous solution containing fragrance components is sprayed from the other two, thereby controlling the concentration of the functional aqueous solution.

[0041] Next, the actions will be explained.

[0042] Figure 1 For example, the toilet paper roll manufacturing apparatus 1 pulls out long strips of two-layered raw paper 10a and 11a from two raw paper rolls 10 and 11 respectively, and transfers them to the stacking section 20 using multiple guide rollers 2.

[0043] The laminating section 20, as described later, allows the adhesive liquid to adhere to and be laminated onto the base paper 10a, 11a introduced by each guide roller 2, forming a long strip of four-layer toilet paper 200.

[0044] The four-layer toilet paper 200 formed by the lamination section 20 is introduced from the lamination section 20 to the drying section 30.

[0045] The drying section 30, for example, has multiple cylinders inside. The four-layer toilet paper 200 introduced into the drying section 30 is heated by passing through each of the cylinders to dry the four-layer toilet paper 200.

[0046] The four-ply toilet paper 200, dried by the drying section 30, is fed into the winding section 40.

[0047] The winding section 40 uses the winding press roller 42 and a plurality of winding rollers 43 to wind the four-ply toilet paper 200 that is introduced into the winding section 40 to produce a four-ply toilet paper roll 300.

[0048] Furthermore, the winding section 40 is equipped with a cutter 41, which cuts the four-ply toilet paper 200 that has been introduced into the winding section 40 after the four-ply toilet paper 200 of a specified length has been wound by the winding press roller 42 and the winding roller 43.

[0049] The winding section 40 winds four layers of toilet paper 200 supplied sequentially from the drying section 30. Then, as described above, the four layers of toilet paper 200 are cut using the cutter 41. This operation is repeated to manufacture a four-layer toilet paper roll 300.

[0050] Alternatively, the winding section 40 may be equipped with a cutter (not shown) that forms pinholes in the width direction of the four-ply toilet paper 200, forming pinholes in the four-ply toilet paper 200 at predetermined intervals, thereby manufacturing a four-ply toilet paper roll 300 with the pinholes.

[0051] Next, the operation of the laminating section 20 in which single-layer paper 110, 111, 100, and 101 are stacked to form four-layer toilet paper 200 will be explained.

[0052] When the laminating section 20 introduces the base paper 10a and base paper 11a, it causes them to pass through the guide rollers 21, separating the base paper 10a into single-layer paper 100 and single-layer paper 101. Furthermore, similarly to the base paper 10a, the base paper 11a is separated into single-layer paper 110 and single-layer paper 111.

[0053] After passing through the guide roller 21, the single-layer papers 110, 111, 100, and 101 are, for example, in a state where the back side of single-layer paper 110 faces the front side of single-layer paper 111. Furthermore, they are in a state where the front side of single-layer paper 111 faces the front side of single-layer paper 100, and furthermore, they are in a state where the back side of single-layer paper 100 faces the front side of single-layer paper 101.

[0054] As described above, the single-layer papers 110, 111, 100, and 101 facing each other are moved toward the pressing roller 23 by the guide roller 21 with appropriate gaps between the papers.

[0055] As described above, the laminating section 20 is equipped with sprayers 22a, 22b, and 22c that spray (adhere) adhesive liquid onto each side of the single-layer paper 110, 111, 100, and 101 conveyed by each guide roller 21. The sprayers 22a, 22b, and 22c are positioned between the position where the original paper 10a and 11a are separated into single-layer paper 110, 111, 100, and 101 by each guide roller 21 and the position where the pressing roller 23 overlaps the single-layer paper 110, 111, 100, and 101.

[0056] Sprayers 22a, 22b, and 22c are configured to spray the aforementioned adhesive liquid into a specified location space.

[0057] The sprayer 22a is configured, for example, to adhere the adhesive liquid to the back of the single-layer paper 110 and the front of the single-layer paper 111.

[0058] The sprayer 22b is configured, for example, to adhere the adhesive liquid to the back of the monolayer paper 111 and the front of the monolayer paper 100.

[0059] The sprayer 22c is configured, for example, to adhere the adhesive liquid to the back of the single-layer paper 100 and the front of the single-layer paper 101.

[0060] In addition, when the single-layer papers 110, 111, 100, and 101 that have passed through each guide roller 21 are clamped by the press roller 23, the spaces between these papers become narrower.

[0061] Figure 1 In order to reliably adhere the adhesive liquid to the front or back of each of the toilet paper rolls, the illustrated toilet paper roll manufacturing apparatus 1 has sprayers 22a, 22b, and 22c installed near the pressing roller 23 that narrows the gap between the rolls.

[0062] The structure of the toilet paper roll manufacturing apparatus 1, which implements the toilet paper roll manufacturing method of the present invention, is not affected by... Figure 1 The limitations on the installation positions of the sprayers 22a, 22b, and 22c shown.

[0063] For example, the lamination section 20 is sprayed with adhesive liquid simultaneously from sprayers 22a, 22b, and 22c onto the front or back of each of the aforementioned papers.

[0064] Alternatively, it can be configured such that, for example, the sprayer 22b is activated first to apply the adhesive liquid to the back of the single-layer paper 111 and the front of the single-layer paper 100, and then the sprayers 22a and 22c are activated to apply the adhesive liquid to the back of the single-layer paper 110 and the front of the single-layer paper 111, the back of the single-layer paper 100 and the front of the single-layer paper 101, respectively.

[0065] Alternatively, it can be configured such that sprayers 22a and 22c are activated first, so that the adhesive liquid is applied to the back of the single-layer paper 110 and the front of the single-layer paper 111, the back of the single-layer paper 100 and the front of the single-layer paper 101, respectively, and then sprayer 22b is activated so that the adhesive liquid is applied to the back of the single-layer paper 111 and the front of the single-layer paper 100.

[0066] As described above, single-layer paper 110 and single-layer paper 101 are sprayed with adhesive liquid on only one side, but single-layer paper 111 and single-layer paper 100 are sprayed with adhesive liquid on both sides.

[0067] Therefore, compared with single-layer paper 110 and 101, single-layer paper 111 and 100 are more prone to reduced strength due to the adhesive liquid adhering to them.

[0068] As described above, by making the timing (operation) of spraying the adhesive liquid from sprayer 22b onto the single-layer paper 111, 100 different from the timing (operation) of spraying the adhesive liquid from sprayers 22a, 22c, damage to the single-layer paper 111, 100 is prevented.

[0069] Specifically, the spraying actions of sprayers 22a, 22b, and 22c are performed intermittently and repeatedly. For example, the spraying timing of sprayers 22a and 22c is staggered from the spraying timing of sprayer 22b, that is, the spraying of sprayers 22a and 22c and the spraying of sprayer 22b are performed alternately.

[0070] Furthermore, in cases where spraying is performed intermittently as described above, sprayers 22a, 22b, and 22c can be sprayed separately for different durations.

[0071] For example, the spraying time of sprayer 22b can be shorter than that of sprayers 22a and 22c. Furthermore, if the single-layer paper 111 and 100 have sufficient strength even when soaked in adhesive liquid, the spraying time of sprayer 22b can also be longer than that of sprayers 22a and 22c.

[0072] Furthermore, as mentioned above, since the adhesive liquid adheres to both the front and back sides of the single-layer papers 111 and 100, the amount of adhesive liquid sprayed from the sprayer 22b can be less than the amount of adhesive liquid sprayed from the sprayers 22a and 22c respectively, and the amount of adhesive liquid adhering to the single-layer papers 110 and 101 can be adjusted to be appropriate.

[0073] In cases where the adhesive liquid has high permeability relative to the single-layer paper 110, 111, 100, 101, for example, the amount of adhesive liquid sprayed from sprayer 22b is set to the maximum, that is, a large amount of adhesive liquid adheres to the single-layer paper 111, 100 constituting the middle layer of the four-ply toilet paper 200. Alternatively, the amount of adhesive liquid sprayed from sprayers 22a, 22c can be less than the amount sprayed from sprayer 22b, that is, a small amount of adhesive liquid adheres to the single-layer paper 110, 101 constituting the outer layer of the four-ply toilet paper 200, and the adhesive liquid is permeated from the middle layer to the outer layer by the pressing of the pressing roller 23 (described later). In this way, damage to the single-layer paper 110, 101 that forms the outer layer of the four-ply toilet paper 200 (four-ply toilet paper roll 300) can be suppressed.

[0074] In addition, when the adhesive liquid has a high degree of permeability, an appropriate amount of adhesive liquid can be sprayed from the sprayer 22b, and when pressed by the pressing roller 23, the adhesive liquid can permeate all the single-layer paper 110, 111, 100, and 101 to form a four-layer toilet paper 200.

[0075] The back of single-layer paper 110 is brought into contact with the front of single-layer paper 111, the back of single-layer paper 111 is brought into contact with the front of single-layer paper 100, and the back of single-layer paper 100 is brought into contact with the front of single-layer paper 101. Single-layer papers 110, 111, 100, and 101, which are coated with adhesive liquid, are clamped by pressure roller 23.

[0076] The pressing roller 23 causes the adhesive liquid to penetrate between the fibers of the single-layer paper 110, 111, 100, and 101. Furthermore, it applies pressure to cause the back side fibers of the single-layer paper 110 to intertwine with the front side fibers of the single-layer paper 111, the back side fibers of the single-layer paper 111 to intertwine with the front side fibers of the single-layer paper 100, and the back side fibers of the single-layer paper 100 to intertwine with the front side fibers of the single-layer paper 101.

[0077] By applying the aforementioned pressure with the pressing roller 23, the single-layer paper 110, 111, 100, and 101 are bonded together to form a four-layer toilet paper 200.

[0078] As described above, the four-ply toilet paper 200 formed by the pressing roller 23 is dried by the drying section 30 and then wound by the winding section 40 to produce a four-ply toilet paper roll 300.

[0079] As described above, according to the embodiment, an adhesive liquid is applied between the single-layer paper 110, 111, 100, and 101, and the adhesive liquid is permeated by the pressing roller 23 to form a four-layer toilet paper roll 300 (four-layer toilet paper 200). Therefore, the adhesive liquid can be permeated in the thickness direction (the stacking direction of the single-layer paper 110, 111, 100, and 101) and along the front (back) side of the four-layer toilet paper 200. In the event that the paper pulled from the four-layer toilet paper roll 300 is torn at any length, the separation and peeling of the single-layer paper 110, 111, 100, and 101 can be suppressed.

[0080] Furthermore, the amount of adhesive liquid adhering to the single-layer paper 110, 111, 100, 101 can be adjusted, and the bonding strength between the single-layer paper 110, 111, 100, 101 can be set arbitrarily.

[0081] Explanation of reference numerals in the attached figures

[0082] 1 Toilet paper roll manufacturing apparatus

[0083] 2 guide rollers

[0084] 10 rolls of raw paper

[0085] 10a base paper

[0086] 11 rolls of raw paper

[0087] 11a base paper

[0088] 20-layer stack

[0089] 21 Guide rollers

[0090] 22a, 22b, 22c sprayers

[0091] 23 Pressing rollers

[0092] 30 Drying Section

[0093] 40 Winding section

[0094] 41 Cutter

[0095] 42 Winding Press Rollers

[0096] 43 winding rollers

[0097] 100 Single-layer paper

[0098] 101 Single-layer paper

[0099] 110 Single-layer paper

[0100] 111 Single-layer paper

[0101] 200 Four-ply toilet paper

[0102] 300 rolls of four-ply toilet paper

Claims

1. A method for manufacturing a toilet paper roll, characterized in that, The above-mentioned method for manufacturing toilet paper rolls includes: The first step involves pulling out raw paper from multiple rolls of raw paper. In the second step, multiple sheets of the above-mentioned base paper are introduced into the stacking section, so that the multiple sheets of base paper are stacked to form four layers of toilet paper; The third step is to dry the four layers of toilet paper; and The fourth step involves winding the four layers of toilet paper to create a four-ply toilet paper roll. The second process described above has the following characteristics: In the fifth step, the plurality of base papers introduced into the above-mentioned stacking section are separated into a first single-layer paper, a second single-layer paper, a third single-layer paper, and a fourth single-layer paper, with the back side of the first single-layer paper facing the front side of the second single-layer paper, the back side of the second single-layer paper facing the front side of the third single-layer paper, and the back side of the third single-layer paper facing the front side of the fourth single-layer paper. In the sixth step, the adhesive liquid is sprayed from the first sprayer onto the back of the first single-layer paper and the front of the second single-layer paper. In the 7th step, the adhesive liquid is sprayed from the 2nd sprayer onto the back of the 2nd single-layer paper and the front of the 3rd single-layer paper. In step 8, the adhesive liquid is sprayed from the third sprayer onto the back of the third single-layer paper and the front of the fourth single-layer paper; and In the 9th step, the first single-layer paper, the second single-layer paper, the third single-layer paper, and the fourth single-layer paper are overlapped by a pressing roller, and pressure is applied to impregnate the adhesive liquid.

2. The method for manufacturing a toilet paper roll as described in claim 1, characterized in that, In the second step described above, the sixth step, the seventh step, and the eighth step described above are performed simultaneously.

3. The method for manufacturing a toilet paper roll as described in claim 1, characterized in that, In the second step described above, the sixth step, the seventh step, and the eighth step are performed intermittently and repeatedly by alternately spraying the adhesive liquid with the first sprayer and the third sprayer and spraying the adhesive liquid with the second sprayer.

4. The method for manufacturing a toilet paper roll as described in claim 1, characterized in that, In the second step described above, the sixth, seventh, and eighth steps are performed intermittently and repeatedly by spraying the adhesive liquid from the first, second, and third sprayers for different durations.

5. The method for manufacturing a toilet paper roll as described in any one of claims 1 to 4, characterized in that, In the seventh step described above, the amount of adhesive liquid sprayed from the second sprayer is less than the amount of adhesive liquid sprayed from the first sprayer and the amount of adhesive liquid sprayed from the third sprayer.

6. The method for manufacturing a toilet paper roll as described in any one of claims 1 to 4, characterized in that, In the seventh step described above, the amount of adhesive liquid sprayed from the second sprayer is greater than the amount of adhesive liquid sprayed from the first sprayer and the amount of adhesive liquid sprayed from the third sprayer.

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