Manufacturing method of rolled sanitary paper

Abstract

To provide a manufacturing method of rolled sanitary paper which enables an easy check of a blade tip of a cutting blade.SOLUTION: The present invention relates to a manufacturing method of rolled sanitary paper 3 has a first check process of checking a disc type cutting blade 31 used to cut a paper log 5 of the rolled sanitary paper 3, and measuring a gap G between a tip of the cutting blade 31 and a flat plate 321 at least at two points when the cutting blade 31 is laid flat on the flat plate 321 in a check table 32 having the flat plate 321 at the top.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing rolls of sanitary paper, including a step of inspecting a cutting blade. [Background technology]

[0002] Conventionally, rolled sanitary paper (hereinafter simply referred to as "rolled sanitary paper"), which is sanitary paper such as toilet paper, kitchen paper, paper towels, and paper wipes (hereinafter simply referred to as "sanitary paper") wound into a roll, is obtained by cutting paper logs to the product width.However, the cutting blade that cuts the paper logs needs to ensure that the product width of the multiple rolled sanitary paper being cut is consistent, and in order to ensure that the cut edges are clean, the paper logs are inspected to see if they meet certain conditions, and only those that meet these conditions are used.

[0003] For example, Patent Document 1 describes a method for measuring the cutting thickness of a circular saw that cuts a workpiece using a laser device, and determining whether the thickness of the circular saw is within a predetermined range. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2021-053771 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in Patent Document 1, it is necessary to prepare a separate expensive device, and it is expected that it will take time and effort to master the use of the device.

[0006] An object of the present invention is to provide a method for manufacturing rolled sanitary paper that allows for easy inspection of the cutting edge of the cutting blade. [Means for solving the problem]

[0007] A first aspect of the method according to the present invention is a method for manufacturing rolled sanitary paper, characterized in that it includes a first inspection step for inspecting a disk-shaped cutting blade for cutting paper logs from the rolled sanitary paper, in which the cutting blade is placed flat on an inspection table having a flat plate on top, and the gap between the cutting edge of the cutting blade and the flat plate is measured at at least two points.

[0008] A second aspect of the method according to the present invention is the method described in the first aspect, further comprising a second inspection step of measuring the gap between the side surface of the disk-shaped cutting blade placed flat on the flat plate and the end surface of the ruler at at least two locations.

[0009] A third aspect of the method according to the present invention is described as the first aspect, characterized in that in the first inspection step, the gap between the cutting edge of the cutting blade and the flat plate is measured at four locations, from a first position to a fourth position, the first position and the second position being opposite each other in a first radial direction of the cutting blade, the third position and the fourth position being opposite each other in a second radial direction of the cutting blade, and the first radial direction and the second radial direction being approximately perpendicular to each other.

[0010] A fourth aspect of the method according to the present invention is described as the second aspect, characterized in that in the second inspection step, the gap between the side surface of the cutting blade and the end face of the ruler is measured at four locations, from the fifth position to the eighth position, the fifth position and the sixth position being opposite each other in the third radial direction of the cutting blade, the seventh position and the eighth position being opposite each other in the fourth radial direction of the cutting blade, and the third radial direction and the fourth radial direction being approximately perpendicular to each other.

[0011] A fifth aspect of the method according to the present invention is the first aspect described above, characterized in that in the first inspection step, the gap between the cutting edge of the cutting blade and the flat plate is measured when the front and back sides of the cutting blade are placed flat.

[0012] A sixth aspect of the method according to the present invention is the second aspect described above, characterized in that the second inspection step measures the gap between the side of the cutting blade and the end face of the ruler when the cutting blade is placed flat on both sides. [Effects of the Invention]

[0013] According to the present invention, the cutting blade edge can be easily inspected by placing the cutting blade flat on an inspection table and measuring the gap between the inspection table and the cutting edge of the cutting blade. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic perspective view of a production line in which a production method according to a first embodiment of the present invention is carried out. [Figure 2] 1A and 1B are diagrams for explaining a first inspection step according to a first embodiment of the present invention, where FIG. 1A is a plan view seen from above and FIG. 1B is a plan view seen from the side. [Figure 3] 10A and 10B are diagrams for explaining a first inspection step according to a modified example of the first embodiment of the present invention, where FIG. 10A is a plan view seen from above and FIG. 10B is a plan view seen from the side. [Figure 4] 4 is a flow chart of a first inspection step according to the first embodiment of the present invention. [Figure 5] 10A and 10B are diagrams for explaining a second inspection step according to a second embodiment of the present invention, where (a) is a plan view seen from above and (b) is a plan view seen from the side. [Figure 6] 10 is a flow chart of a second inspection process according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] An embodiment of the method for producing rolled sanitary paper according to the present invention will be described in detail with reference to Figures 1 to 6. However, the present invention is not limited to this embodiment.

[0016] In this specification and claims, "rolled sanitary paper" refers to sanitary paper rolled into a roll, as described above, and "sanitary paper" refers to toilet paper, kitchen paper, paper towels, paper wipes, etc.

[0017] First Embodiment <Production line> Fig. 1 is a schematic perspective view of a production line 1 in which a production method according to a first embodiment of the present invention is carried out, and Fig. 2 is a diagram for explaining a first inspection step according to this embodiment, with Fig. 2(a) being a plan view viewed from above and Fig. 2(b) being a plan view viewed from the side. The cutting blade 31 in the diagram is shown in a simplified form for ease of explanation.

[0018] As shown in FIG. 1, a production line 1 for rolled sanitary paper according to this embodiment produces rolled sanitary paper (toilet paper in this embodiment) 3, which is sanitary paper (toilet paper in this embodiment) wound into a roll.

[0019] The production line 1 is provided with a paper log generating unit 10 that forms roll-shaped paper logs 5 that are longer in the axial direction than the roll-shaped sanitary paper 3; an adjustment unit 20 that temporarily stores the paper logs 5 formed in the paper log generating unit 10 and adjusts the timing of the paper log 5's delivery; and a cutting unit (cutting device) 30 that cuts the paper logs 5 delivered from the adjustment unit 20 to predetermined dimensions to produce a plurality of roll-shaped sanitary paper 3. In this embodiment, the cutting unit 30 is provided with an inspection unit 300 that inspects the disk-shaped cutting blade (log saw) 31 that cuts the paper logs 5. The production line 1 also is provided with a packaging unit 40 that packages the roll-shaped sanitary paper 3 cut by the cutting unit 30 in predetermined numbers, and a boxing unit 50 that boxes the packages 9 of roll-shaped sanitary paper 3 packaged by the packaging unit 40.

[0020] Hereinafter, upstream and downstream are defined based on the order of processes performed by each section on the production line 1. On the production line 1, a paper log generating section 10, an adjusting section 20, a cutting section 30 (including an inspection section 300), a packaging section 40, and a boxing section 50 are arranged in this order from upstream to downstream.

[0021] The paper log producing unit 10 unwinds the base paper 11 (material) from a raw roll 12, which is a strip of base paper 11 that is wider than the rolled sanitary paper 3, and rewinds the base paper 11 with a winder 13 to form a paper log 5. The paper log 5 has an axial length equal to the axial length of the raw roll 12 and a diameter equal to the diameter of the product 3.

[0022] In the winder 13, the base paper 11 may be embossed or printed. The base paper roll 12 may be a primary base paper (jumbo roll) on which a single layer (one ply) of base paper 11 made of one sheet of paper material is wound, or a secondary base paper on which multi-layer (two or more plies) base paper 11 made of multiple sheets of paper material is wound.

[0023] The winder 13 cuts the base paper 11 every time it is wound around a cylindrical core 5c (long core tube) by a predetermined length, thereby continuously forming paper logs 5. The base paper 11 is wound from the inner periphery (core 5c side) of the paper log 5 toward the outer periphery (i.e., from the inside to the outside in the radial direction). Then, once a predetermined length of base paper 11 has been wound around the outer periphery of the core 5c, the base paper 11 is cut (divided) along a straight line intersecting the longitudinal direction of the base paper 11, thereby forming the paper log 5. Here, an example is shown in which the base paper 11 is cut along a straight line extending in its width direction (a direction perpendicular to the longitudinal direction).

[0024] As described above, of the base paper 11 that forms the continuous paper log 5, the downstream portion of the straight line becomes the winding end 5a (tail) of one paper log 5, and the upstream portion of the straight line (the portion separated from the winding end 5a) becomes the winding start end 5b of the next log 5.

[0025] As shown in FIG. 1, each paper log 5 has its winding end 5a glued (tail sealed) to the outer periphery in the gluing section 14, which is the final process in the paper log producing section 10, and then is sent to the adjusting section 20 downstream.

[0026] The adjusting unit 20 stores a plurality of paper logs 5 in the accumulator 21, and sequentially sends out the paper logs 5 to the downstream cutting unit 30. Here, an adjusting unit 20 that sends out two paper logs 5 at a time toward the cutting unit 30 is illustrated as an example.

[0027] The inspection unit 300 inspects the cutting blade 31 before the cutting process. A cutting blade 31 that is inspected and determined to be good by the inspection unit 300 is attached to the cutting device 30 (arrow A in FIG. 1). A cutting blade 31 that is inspected and determined to be bad by the inspection unit 300 is temporarily stored. Note that the cutting blade 31 that has been cutting the paper log 5 for a predetermined period of time may be removed from the cutting device 30 and moved to the inspection unit 300 (arrow B in FIG. 1) for further inspection. Details of the first and second inspection steps of the inspection unit 300 will be described later.

[0028] The cutting unit 30 cuts the paper log 5 sent out from the adjustment unit 20 at predetermined intervals in the axial direction using a cutting blade 31 that has been determined to be acceptable by the inspection unit 300. This causes each paper log 5 to be cut into multiple rolls of sanitary paper 3. In the present invention, for example, 20 rolls of sanitary paper 3 can be obtained by cutting one paper log 5.

[0029] The packaging unit 40 inserts, for example, eight rolls of sanitary paper 3 (four rolls x two rows) into a packing bag 19 and seals the opening 22 of the packing bag 19 to form a package 9.

[0030] The boxing section 50 packs a plurality of (for example, eight) packages 9 as one set into the cardboard box 23. Then, the packages 9 packed in the cardboard box 23 are shipped.

[0031] <Inspection Department> In the inspection section 300, as shown in Figures 1 and 2, a first inspection process is performed to inspect the disk-shaped cutting blade 31 for cutting the paper log 5 of the roll-type sanitary paper 3.The first inspection process is performed on an inspection table (inspection plate) 32 having a flat plate 321 on top, and measures the gap G between the cutting edge of the cutting blade 31 and the flat plate 321 at at least two locations (four locations in this embodiment) when the cutting blade 31 is placed flat on the flat plate 321.

[0032] With this configuration, the cutting blade 31 can be easily inspected by placing the cutting blade 31 flat on the inspection table 32 and measuring the gap G between the inspection table 32 and the cutting edge of the cutting blade 31. Furthermore, it is easy to inspect whether the cutting blade 31 is bent in a bowl shape or whether the cutting blade 31 is bent in a bow shape to the left or right. For example, a ruler 33 as shown in FIG. 2 is used as a measurement tool, but other known measurement tools (such as a scale) can also be used. In this embodiment, as shown in FIG. 2, the tip of the ruler 33 is placed against the cutting edge of the cutting blade 31 to measure the gap G between the cutting edge of the cutting blade 31 and the flat plate 321 of the inspection table 32.

[0033] In the manufacturing method according to this embodiment, as shown in FIG. 2, the inspection unit 300 measures the gap G between the cutting edge of the cutting blade 31 and the flat plate 321 at four locations, the first position D1 to the fourth position D4, where the first position D1 and the second position D2 are opposite each other in the first radial direction of the cutting blade 31, the third position D3 and the fourth position D4 are opposite each other in the second radial direction of the cutting blade 31, and the first radial direction and the second radial direction are approximately perpendicular to each other.

[0034] This configuration makes it possible to inspect the cutting edge of the cutting blade 31 with high precision.

[0035] In the manufacturing method according to this embodiment, the inspection unit 300 measures the gap G between the cutting edge of the cutting blade 31 and the flat plate when the front and back sides of the cutting blade 31 are placed flat.

[0036] This configuration makes it possible to inspect with high accuracy whether the cutting blade 31 is bent in a bowl shape or whether the cutting blade 31 is bent in a bow shape to the left or right.

[0037] In the present invention, as shown in the following FIG. 3, the inspection table 32' may be made larger than the cutting blade 31 to be inspected, and the tip of the ruler 33 may be placed on the upper surface of the flat plate 321' of the inspection table 32' to measure the gap G between the inspection table 32' and the cutting blade 31.

[0038] 3A and 3B are diagrams for explaining the first inspection step according to a modification of the first embodiment of the present invention, with Fig. 3A being a plan view seen from above and Fig. 3B being a plan view seen from the side. Of the elements constituting the production line 1 according to this modification, those having similar functions are assigned the same reference numerals as in the first embodiment of the present invention, and descriptions thereof will be omitted.

[0039] According to this modified example, similarly to the first embodiment of the present invention, it is possible to easily inspect the cutting edge of the cutting blade 31. Note that in the inspection table 32' according to this modified example, instead of contacting the tip of the ruler 33 with the flat plate 321' of the inspection table 32', the position of the ruler 33 may be adjusted so that the cutting edge of the cutting blade 31 is aligned with the edge of the inspection table 32', and the tip of the ruler 33 may be contacted with the cutting edge of the cutting blade 31 to measure the gap G between the cutting edge of the cutting blade 31 and the flat plate 321' of the inspection table 32', as shown in FIG.

[0040] FIG. 4 is a flow chart of the first inspection step according to the first embodiment of the present invention.

[0041] An operator inspecting the cutting blade 31 first places the cutting blade 31 on the upper plate 321 of the inspection table 32 (step S1), removes a cover (not shown) attached to the cutting blade 31, and measures the dimension G of the gap between the flat plate 321 of the inspection table 32 and the cutting edge of the cutting blade 31 at four diagonal points (first to fourth positions D1 to D4) (step S2). The operator then compares the dimension G at each of the four points with a predetermined dimension to determine whether it is within a predetermined tolerance (step S3). If the dimension G is within the predetermined tolerance at all positions in step S3, the operator attaches the cutting blade 31 to the cutting device 30 (step S4). If even one of the four points is not within the predetermined tolerance at step S3, the blade is determined to be defective and temporarily stored (step S5). Alternatively, if the dimension G is within the predetermined tolerance at all positions in step S3, the operator may insert a spatula-shaped object under the cutting blade 31, lift it up, insert a hand into the opening in the center of the cutting blade 31, and turn it over, repeating steps S1 to S3. The cover may be attached to the cutting blade 31 when carrying or turning over in steps S4 and S5.

[0042] The specified error range in step S3 varies depending on the thickness of the cutting blade 31. For example, if the thickness of the cutting blade 31 is approximately 4.76 mm, the specified error range may be approximately 2.38 mm ± 0.5 mm, and if the thickness of the cutting blade 31 is approximately 3.0 mm, the specified error range may be approximately 1.5 mm ± 0.5 mm.

[0043] Conventionally, cutting blades used to cut paper logs are required to ensure that the product width of the multiple rolls of sanitary paper being cut is consistent, and to ensure that the cut edges are clean, blades that meet certain conditions are inspected and only those that meet these conditions are used.

[0044] For example, Patent Document 1 describes a method for measuring the cutting thickness of a circular saw that cuts a workpiece using a laser device, and determining whether the thickness of the circular saw is within a predetermined range.

[0045] However, in Patent Document 1, it is necessary to prepare a separate expensive device, and it is expected that it will take time and effort to master the use of the device.

[0046] According to this embodiment, the cutting edge of the cutting blade 31 can be easily inspected by placing the cutting blade 31 flat on the inspection table 32 and measuring the gap G between the inspection table 32 and the cutting edge of the cutting blade 31.

[0047] Furthermore, according to this embodiment, it is possible to easily inspect whether the cutting blade 31 is bent in a bowl shape or whether the cutting blade 31 is bent in a bow shape to the left or right.

[0048] Second Embodiment In the inspection unit of the second embodiment of the present invention, in addition to the first inspection process in the first embodiment, there is a second inspection process in which a ruler is used to measure the gap between the side of the cutting blade 31 and determine distortion of the cutting blade 31.

[0049] 5A and 5B are diagrams for explaining the second inspection step according to the second embodiment of the present invention, with Fig. 5A being a plan view seen from above and Fig. 5B being a plan view seen from the side. Of the elements constituting the inspection unit 300 according to this embodiment, those having similar functions are assigned the same reference numerals as in the first embodiment, and descriptions thereof will be omitted.

[0050] In the inspection section 300 according to the second embodiment, as shown in FIG. 5, a second inspection process is performed in which the gap between the side of the cutting blade 31 placed flat on a flat plate 321 and the end face of the ruler 34 is measured at least at two locations (four locations in this embodiment).

[0051] This configuration allows the side surface of the cutting blade 31 to be easily inspected for distortion.

[0052] The ruler used to inspect the distortion in the present invention is partially or entirely straight, but a ruler 34 shaped like a combination of two trapezoids as shown in Fig. 5(b) is preferred from the viewpoint of being easy to hold and to align with the side of the cutting blade 31. The ruler 34 shown in Fig. 5(b) is made of metal (for example, stainless steel), has a pair of straight sections that diverge from a single point, and has an elongated shape like two joined trapezoids, with both ends of the ruler 34 being rounded. The straight sections are placed against the side of the object, the gap is measured, and the distortion is determined.

[0053] In the manufacturing method according to this embodiment, as shown in FIG. 5, the inspection unit 300 measures the gap between the side surface of the cutting blade 31 and the end face of the ruler 34 at four locations, from the fifth position D5 to the eighth position D8. The fifth position D5 and the sixth position D6 are opposite each other in the third radial direction of the cutting blade 31, and the seventh position D7 and the eighth position D8 are opposite each other in the fourth radial direction of the cutting blade 31, with the third radial direction and the fourth radial direction being approximately perpendicular to each other.

[0054] This configuration makes it possible to inspect the side surface of the cutting blade 31 for distortion with high precision.

[0055] More specifically, in the second inspection step according to this embodiment, one end of the ruler 34 is placed at a measurement point on the cutting blade 31 (the seventh position D7 in FIGS. 5(a) and 5(b)), and the ruler 34 is positioned along the radial direction of the circle of the cutting blade 31 (the fourth radial direction in FIGS. 5(a) and 5(b)). Similarly, for the fifth position D5, the sixth position D6, and the eighth position D8, the ruler 34 is placed at the corresponding measurement point and positioned along the third or fourth radial direction of the circle of the cutting blade 31. Note that, in the present invention, the fifth to eighth positions D5 to D8 may correspond to the first to fourth positions D1 to D4 in the first embodiment, and the third and fourth radial directions may correspond to the first and second radial directions in the first embodiment. In other words, the first and second inspection steps may be performed at the same position.

[0056] In the manufacturing method according to this embodiment, the inspection unit 300 measures the gap between the side surface of the cutting blade 31 and the end face of the ruler 34 when the cutting blade 31 is placed flat on both sides.

[0057] This configuration allows for more accurate inspection of the distortion of the side surface of the cutting blade 31.

[0058] FIG. 6 is a flow chart of a second inspection step according to the second embodiment of the present invention.

[0059] An operator inspecting the cutting blade 31 first places the cutting blade 31 on the flat plate 321 on the upper side of the inspection table 32 (step S6), removes the cover (not shown) attached to the cutting blade 31, and measures the gap between the end face of the ruler 34 and the side of the cutting blade 31 at four diagonal points (fifth to eighth positions D5 to D8) (step S7). The operator then compares the measurements at the four points with predetermined dimensions to determine whether they are within a predetermined tolerance (step S8). If the measurements at all positions are within the predetermined tolerance at step S8, the operator attaches the cutting blade 31 to the cutting device 30 (step S9). If even one of the four measurements is not within the predetermined tolerance at step S8, the blade is determined to be defective and temporarily stored (step S10). Alternatively, if the measurements at all positions are within the predetermined tolerance at step S8, the operator may insert a spatula-shaped object under the cutting blade 31, lift it up, insert a hand into the opening in the center of the cutting blade 31, and turn it over, repeating steps S6 to S8. The cover may be attached to the cutting blade 31 when carrying or turning over in steps S9 and S10.

[0060] The predetermined error range in step S8 is, for example, 0.5 mm or less.

[0061] The second inspection process may be performed before the first inspection process of the first embodiment, after the first inspection process, or in parallel with the first inspection process. For example, if the second inspection process is performed before the first inspection process of the first embodiment, steps S7 and S8 of the second inspection process may be performed after step S1 of the first inspection process of the first embodiment, and if the answer is YES in step S8, steps S2 and S3 of the first inspection process may be performed after step S8.

[0062] The present invention is not limited to the above-described embodiments or the modifications described throughout, and appropriate changes and modifications can be made without departing from the technical concept of the present invention. [Explanation of symbols]

[0063] 1. Sanitary paper roll production line 3. Sanitary paper rolls 5. Paper Log 5a End of winding 5b Starting end of winding 5c Core 10 Paper Log Generation Unit 11 Base paper (materials) 12 Raw roll 13 Winder 14 Gluing section 20 Adjustment part 21 Accumulator 30 Cutting section 31 Cutting Blade 300 Inspection Department 32, 32' Examination table 321, 321' flat plate 33 Ruler 34 Straight scale D1~D8 1st to 8th positions G Gap 40 Packaging Department 50 Packing Department

Claims

1. A method for producing rolled sanitary paper, comprising the steps of: A manufacturing method characterized by including a first inspection step of inspecting a disk-shaped cutting blade for cutting paper logs of the roll-shaped sanitary paper, the first inspection step including measuring the gap between the cutting edge of the cutting blade and the flat plate at at least two points when the cutting blade is placed flat on the flat plate on an inspection table having a flat plate on top.

2. 2. The manufacturing method according to claim 1, further comprising a second inspection step of measuring a gap between a side surface of the disk-shaped cutting blade placed flat on the flat plate and a straight end surface of the disk-shaped cutting blade at at least two points.

3. In the first inspection step, a gap between the cutting edge of the cutting blade and the flat plate is measured at four positions including a first position to a fourth position; The manufacturing method described in claim 1, characterized in that the first position and the second position are opposite each other in a first radial direction of the cutting blade, the third position and the fourth position are opposite each other in a second radial direction of the cutting blade, and the first radial direction and the second radial direction are approximately perpendicular to each other.

4. In the second inspection step, the gap between the side surface of the cutting blade and the end surface of the straight edge is measured at four positions, ie, a fifth position to an eighth position; The manufacturing method described in claim 2, characterized in that the fifth position and the sixth position are opposite each other in a third radial direction of the cutting blade, the seventh position and the eighth position are opposite each other in a fourth radial direction of the cutting blade, and the third radial direction and the fourth radial direction are approximately perpendicular to each other.

5. 2. The manufacturing method according to claim 1, wherein the first inspection step includes measuring a gap between the cutting edge of the cutting blade and the flat plate when the front and back sides of the cutting blade are placed flat.

6. 3. The manufacturing method according to claim 2, wherein the second inspection step includes measuring a gap between a side surface of the cutting blade and a straight end surface of the cutting blade when the cutting blade is placed flat on both sides.

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