Manufacturing method and tool for rolled sanitary paper

Abstract

To accurately measure and to simply inspect an outer dimension in an axial direction of rolled sanitary paper.SOLUTION: A method for manufacturing rolled sanitary paper 3 has an inspection step which inspects with a tool 35 whether or not an outer dimension in an axial direction X of a rolled sanitary paper 3 is included within a prescribed range. The tool 35 includes: a table 350 having a flat foundation surface F0 above; a first flat plate 351 having in a lower part a first flat surface F1 opposite to and parallel to the foundation surface F0; a second flat plate 352 which is arranged side by side with the first flat plate 351 and has in a lower part a second flat surface F2 opposite to and parallel to the foundation surface F0; a first connection member 361 which connects the table 350 and the first flat plate 351 so that a first gap G1 is formed between the foundation surface F0 and the first flat surface F1; and a second connection member 362 connecting the table 350 and the second flat plate 352 so that a second gap G2 larger than the first gap G1 is formed between the foundation surface F0 and the second flat surface F2.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a roll-shaped sanitary paper having a step of inspecting the dimensions of the roll-shaped sanitary paper and a jig for performing the inspection.

Background Art

[0002] Conventionally, roll-shaped sanitary papers (hereinafter also simply referred to as "roll-shaped sanitary papers") obtained by cutting a paper log, such as toilet paper, kitchen paper, paper towels, and paper wipes (hereinafter also simply referred to as "sanitary papers"), need to be inspected to determine whether the outer dimensions in the axial direction of the roll-shaped sanitary paper are cut to the product width.

[0003] For example, Patent Document 1 describes imaging a roll-shaped sanitary paper being conveyed with a camera, determining a defect in the outer dimensions of the subject, and dropping the one determined to be defective.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in Patent Document 1, it is necessary to separately prepare an expensive device, and it is expected that it will take time and effort to use the device proficiently.

[0006] An object of the present invention is to provide a method for manufacturing a roll-shaped sanitary paper and a jig that can accurately measure and easily inspect the outer dimensions in the axial direction of the roll-shaped sanitary paper.

Means for Solving the Problems

[0007] A first aspect of the method according to the present invention is a method for manufacturing a roll-shaped sanitary paper, which includes an inspection step of inspecting, by means of a jig, whether the outer dimensions in the axial direction of the roll-shaped sanitary paper are within a predetermined range. The jig includes a table having a flat base surface on the upper part, a first flat plate having a first plane facing and parallel to the base surface on the lower part, a second flat plate juxtaposed with the first flat plate and having a second plane facing and parallel to the base surface on the lower part, a first connecting member connecting the table and the first flat plate so that a first gap is formed between the base surface and the first plane, and a second connecting member connecting the table and the second flat plate so that a second gap larger than the first gap is formed between the base surface and the second plane.

[0008] A second aspect of the method according to the present invention includes a cutting step of cutting each of a plurality of paper logs of the roll-shaped sanitary paper during conveyance while rotating a cutting blade. The inspection step is to inspect whether the roll-shaped sanitary paper passes through the second gap and does not pass through the first gap of the jig in a posture where the axial direction of the cut roll-shaped sanitary paper is orthogonal to the base surface, as described in the first aspect.

[0009] A first form of the jig according to the present invention is a jig for inspecting whether the outer dimensions in the axial direction of a roll-shaped sanitary paper are within a predetermined range. The jig includes a table having a flat base surface on the upper part, a first flat plate having a first plane facing and parallel to the base surface on the lower part, a second flat plate juxtaposed with the first flat plate and having a second plane facing and parallel to the base surface on the lower part, a first connecting member connecting the table and the first flat plate so that a first gap is formed between the base surface and the first plane, and a second connecting member connecting the table and the second flat plate so that a second gap larger than the first gap is formed between the base surface and the second plane. [Effect of the Invention]

[0010] According to the present invention, regarding the outer dimensions of the roll-shaped toilet paper in the axial direction, by confirming that the roll-shaped toilet paper does not pass through the first gap of the jig and passes through the second gap, it becomes possible to accurately measure and easily inspect the outer dimensions of the roll-shaped toilet paper in the axial direction.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0012] Embodiments of a production method and a jig for manufacturing roll-shaped toilet paper according to the present invention will be described in detail with reference to FIGS. 1 to 3. However, the present invention is not limited to the aspects of this embodiment.

[0013] In addition, in this specification and the claims, "roll-shaped toilet paper" is, as described above, toilet paper wound in a roll shape, and "toilet paper" is referred to as referring to toilet paper, kitchen paper, paper towels, paper wipes, etc.

[0014] Also, in this specification and the claims, "up" refers to the direction perpendicular to the base surface of the jig table and toward the first flat plate (or the second flat plate) from the base surface, and "down" refers to the opposite direction. However, these terms are for convenience only and do not define the absolute position in the direction of gravity.

[0015] <Production Line> FIG. 1 is a schematic perspective view of a manufacturing line (manufacturing apparatus) 1 in which a manufacturing method according to an embodiment of the present invention is performed, FIG. 2 is a schematic view showing the entire jig 35 according to the present embodiment, FIG. 2(a) is a perspective view, and FIG. 2(b) is a plan view seen from the front.

[0016] As shown in FIG. 1, a manufacturing line 1 for manufacturing roll-shaped toilet paper according to the present embodiment manufactures a roll-shaped toilet paper (toilet roll) 3 in which toilet paper (toilet paper in the present embodiment) is wound in a roll shape.

[0017] The manufacturing line 1 is provided with a paper log generation unit 10 that forms a roll-shaped paper log 5 that is longer in the axial direction than the roll-shaped toilet paper 3, an adjustment unit 20 that temporarily stores the paper log 5 formed by the paper log generation unit 10 and adjusts the delivery timing of the paper log 5, and a cut unit (cutting device) 30 that generates a plurality of roll-shaped toilet papers 3 by cutting the paper log 5 sent out from the adjustment unit 20. In the present embodiment, an inspection unit (inspection device, jig) 35 is provided for inspecting whether the outer dimensions in the axial direction X of the roll-shaped toilet paper 3 after cutting are within a predetermined range. Further, the manufacturing line 1 is provided with a packaging unit 40 that packages the roll-shaped toilet papers 3 separated by the cut unit 30 in predetermined numbers, and a boxing unit 50 that boxes the packages 9 of the roll-shaped toilet papers 3 packaged by the packaging unit 40.

[0018] Hereinafter, upstream and downstream are defined based on the order of the processes of each part implemented in the manufacturing line 1. In the manufacturing line 1, the paper log generation unit 10, the adjustment unit 20, the cut unit 30, the packaging unit 40, and the boxing unit 50 are arranged in this order from upstream to downstream. In the present embodiment, the inspection unit 35 is provided after the process of the cut unit 30.

[0019] The paper log generation unit 10 feeds out the base paper 11 (material), which is a strip wider than the roll-shaped sanitary paper 3, from the base roll 12 around which the base paper 11 is wound, and forms the paper log 5 by rewinding the base paper 11 with the winder 13. The paper log 5 is in the shape of a roll with an axial length equal to the axial length of the base roll 12 and a diameter equal to the diameter of the product 3.

[0020] In the winder 13, embossing or printing may be performed on the base paper 11. Further, the base roll 12 may be a primary base roll (jumbo roll) around which a single-layer (1 ply) base paper 11 made of a single paper material is wound, or a secondary base roll around which a multi-layer (2 plies or more) base paper 11 formed by laminating a plurality of paper materials is wound.

[0021] The winder 13 cuts the base paper 11 every time a predetermined length of the base paper 11 is wound around the cylindrical core 5c (long core tube) to continuously form the paper log 5. The base paper 11 is wound from the inner peripheral side (core 5c side) to the outer peripheral side of the paper log 5 (that is, from the inner side to the outer side in the radial direction). Then, when a predetermined length of the base paper 11 is wound around the outer periphery of the core 5c, the paper log 5 is formed by cutting (dividing) the base paper 11 along a straight line intersecting the longitudinal direction of the base paper 11. 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).

[0022] Among the base paper 11 that continuously forms the paper log 5 as described above, the portion on the downstream side of the straight line becomes the winding end 5a (tail) in one paper log 5, and the portion on the upstream side of the straight line (the portion separated from the winding end 5a) becomes the starting end of the next log 5.

[0023] As shown in FIG. 1, each paper log 5 is sent to the downstream adjustment unit 20 after the winding end 5a is pasted (tail sealed) on the outer peripheral surface in the pasting unit 14, which is the final process of the paper log generation unit 10.

[0024] The adjusting unit 20 stores a plurality of paper logs 5 in the accumulator 21 and sequentially feeds out the paper logs 5 to the downstream cutting unit 30. Here, an example of the adjusting unit 20 that feeds out two paper logs 5 at a time toward the cutting unit 30 is illustrated.

[0025] The cutting unit 30 cuts the paper logs 5 fed out from the adjusting unit 20 at a predetermined interval in the axial direction while rotating the cutting blade 31. As a result, each paper log 5 is cut into a plurality of roll-shaped sanitary papers 3. In the present invention, for example, one paper log 5 is cut to obtain 25 (or 20) roll-shaped sanitary papers 3. In the present invention, the number of cuts is not limited. For example, in the case of a towel product, it can be cut into 10 pieces.

[0026] In the inspection unit 35, as described above, it is inspected whether the outer dimensions in the axial direction X of the roll-shaped sanitary paper 3 after cutting are within a predetermined range. Details of the process in the inspection unit 35 will be described later.

[0027] The packaging unit 40 inserts, for example, eight (four × two-stage) roll-shaped sanitary papers 3 as a set into the packaging bag 19, seals the opening 22 of the packaging bag 19, and forms the package 9.

[0028] The boxing unit 50 packs eight sets of a plurality of (for example, eight) packages 9 into a cardboard box 23. Then, the packages 9 packed in the cardboard box 23 are shipped.

[0029] <Inspection Unit> In the present embodiment, as shown in FIGS. 1, 2(a), and 2(b), a jig 35 is used to inspect whether the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X are within a predetermined range. The jig 35 includes a base 350 having a flat base surface F0 at the upper part, a first flat plate 351 having a first plane F1 parallel to and facing the base surface F0 at the lower part, a second flat plate 352 juxtaposed with the first flat plate 351 and having a second plane F2 parallel to and facing the base surface F0 at the lower part, a first connecting member 361 connecting the base 350 and the first flat plate 351 such that a first gap G1 is formed between the base surface F0 and the first plane F1, and a second connecting member 362 connecting the base 350 and the second flat plate 352 such that a second gap G2 larger than the first gap G1 is formed between the base surface F0 and the second plane F2.

[0030] With this configuration, regarding the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X, by confirming that the roll-shaped toilet paper 3 does not pass through the first gap G1 of the jig 35 and passes through the second gap G2, it becomes possible to accurately measure and simply inspect the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X.

[0031] In this embodiment, as shown in FIG. 2(b), the first connecting member 361 includes an L-shaped member 37 having an L-shape formed by a surface portion 371 fixedly connected to the first flat plate 351 (e.g., by a pair of fastening members such as bolts and nuts) and a surface portion 372 that is bent at a right angle to the surface portion 371 and is provided with a pair of vertically long holes into which the threaded legs of the bolts are inserted and can move up and down. Further, it includes a connecting surface portion 38 that is fixedly connected to the base 350 and is fixed to the L-shaped member 37 via a pair of holes provided in the L-shaped member 37 and a pair of fastening members 39 of bolts and nuts passed through the pair of vertically long holes. The first flat plate 351 and the L-shaped member 37 are slidable in the pair of vertically long holes by loosening the tightening of the nuts, and can move up and down with respect to the base 350. The configuration of the second connecting member 362 is the same as that of the first connecting member 361. For those having the same functions, the same reference numerals as those of the first connecting member 361 are given and their descriptions are omitted. That is, the difference between the first connecting member 361 and the second connecting member 362 is the gap between the base surface F0 of the base 350 and the plane fixedly connected to the surface portion 371 of the L-shaped member 37.

[0032] The first flat plate 351 and the second flat plate 352 are made of a transparent resin (e.g., acrylic resin) such that the state of the roll-shaped toilet paper 3 can be easily confirmed in, for example, inspection. The base 350 is made of metal (e.g., stainless steel) in order to make it difficult to move during inspection. Also, the L-shaped member 37 and the connecting surface portion 38 are made of metal (e.g., stainless steel) so as to withstand the fixing of bolts and nuts. In the present invention, this is not the limit, and various materials can be adopted for the members constituting the jig 35 as long as the effects of the present invention can be achieved.

[0033] FIG. 3 is a flow of an inspection process according to an embodiment of the present invention.

[0034] In the inspection process according to this embodiment, in a posture where the axial direction X of the cut roll-shaped toilet paper 3 is orthogonal to the base surface F0, it is inspected whether the roll-shaped toilet paper 3 passes through the second gap G2 without passing through the first gap G1 of the jig 35.

[0035] An operator who inspects the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X first, for example, before taking out the roll-shaped toilet paper 3 from the conveying unit 34 (e.g., a conveyor) where the cut roll-shaped toilet paper 3 is flowing, inspects and cleans the conveying unit 34, and also checks whether the jig 35 is correctly set, and prepares for the start of the inspection (step S1). Then, the operator takes out the flowing roll-shaped toilet paper 3 and tries to pass it through the first gap G1 of the jig 35 so that the axial direction X of the roll-shaped toilet paper 3 is orthogonal to the base surface F0 of the jig 35 (step S2). If the roll-shaped toilet paper 3 does not pass through the first gap G1, the process proceeds to the next step S3. When preparing for the start of the inspection in step S1, for each operation of the cutting device 30, in order to prevent dimensional defects, it may be checked whether the jig 35 is correctly set using a test piece, and it may be confirmed that there is no gap between the base surface F0, the first plane F1, and the second plane F2. Also, when preparing for the start of the inspection in step S1, before the inspection, air may be blown onto the roll-shaped toilet paper 3 to be inspected to blow off paper powder and dust on the surface.

[0036] Subsequently, the roll-shaped toilet paper 3 that did not pass through the first gap G1 in step S2 is tried to be passed through the second gap G2 of the jig 35 in the same procedure as in step S2 (step S3). If the roll-shaped toilet paper 3 passes through the second gap G2, it is considered that there is no abnormality in the outer dimensions (cut width) in the axial direction X of the roll-shaped toilet paper 3, and the cutting process is continued (step S4). In step S2, if the roll-shaped toilet paper 3 passes through the first gap G1, or in step S3, if the roll-shaped toilet paper 3 does not pass through the second gap G2, it is considered that there is an abnormality in the outer dimensions (cut width) in the axial direction X of the roll-shaped toilet paper 3, and the cutting process is stopped (step S5).

[0037] In this embodiment, for the inspection objects in the above steps S1 to S5, for the roll-shaped toilet paper 3 with 20 (or 25) cut paper logs 5 arranged side by side, the first and the last ones other than the trims (corresponding to both ends of the cut paper log 5) are taken out one by one and inspected respectively. In this embodiment, since the paper log 5 is a line running in two columns, there are a total of 4, but in the present invention, the paper log 5 may run in 4 columns, and in this case, the number of inspection objects is, for example, 8 in total. Further, the present invention is not limited to this, and in addition to (or instead of) the first and the last ones, the ones on the center side may be used for inspection, and the number of inspections may also be plural instead of one by one. In this embodiment, compared with the ones on the center side, the 3 to 4 rolls immediately after the front trim and the 3 to 4 rolls immediately before the rear trim tend to have more length differences or diagonal cuts, so the ones on the end side are inspected. The reason for "tend to have more length differences or diagonal cuts" is that near the trim, it is difficult for the spring presser to be stable. More specifically, when cutting around the center of the paper log 5, there are supports of the log brakes (leaf springs) before and after, and the cut is made while pressing with the log clamp, but when the front and rear sides near the trim are cut, there is no support of the log brakes. The inspection according to this embodiment is performed every 30 minutes, but in the present invention, the inspection interval is not limited to this, such as being performed every 15 minutes, and at a predetermined time, the inspection interval may be narrowed or, conversely, widened.

[0038] In this embodiment, in step S5, when there is an abnormality in the outer dimension (cut width) in the axial direction X of the roll-shaped toilet paper 3, the cutting device 30 is stopped and the rotation of the cutting blade 31 is stopped.

[0039] In the present invention, the procedures of step S2 and step S3 may be reversed. That is, first, it may be inspected whether it passes through the second gap G2, and if it passes through the second gap G2, it may be inspected whether it passes through the first gap G1. Further, in this embodiment, the left side of the jig 35 has the first gap G1 and the right side has the second gap G2, but in the present invention, it may be reversed left and right, and the right side of the jig 35 may have the first gap G1 and the left side may have the second gap G2.

[0040] Regarding the predetermined range of the outer dimensions of the roll-shaped sanitary paper 3 in the axial direction X, in the present embodiment, the roll-shaped sanitary paper 3 is a toilet roll, the first gap G1 is 112 mm, and the second gap G2 is 116 mm. These dimensions comply with JIS P 4501. In the present invention, not limited to this, when the roll-shaped sanitary paper 3 is a paper towel, the first gap G1 may be 226 mm and the second gap G2 may be 230 mm. Also, the dimensions of the first gap G1 and the second gap G2 and the difference between the second gap G2 and the first gap G1 are not limited to this and can be adjusted as appropriate. For example, in the case of a toilet roll with a length (cut width) in the axial direction X of 109 mm, when the difference between the second gap G2 and the first gap G1 is 6 mm, the first gap G1 can be 106 mm and the second gap G2 can be 112 mm, or when the difference between the second gap G2 and the first gap G1 is 4 mm, the first gap G1 can be 107 mm and the second gap G2 can be 111 mm, or when the difference between the second gap G2 and the first gap G1 is 2 mm, the first gap G1 can be 108 mm and the second gap G2 can be 110 mm, etc. As long as the effects of the present invention are achieved, various numerical values can be adopted.

[0041] Conventionally, roll-shaped sanitary paper is obtained by cutting a paper log, but regarding the outer dimensions of the roll-shaped sanitary paper in the axial direction, it is necessary to inspect whether the roll-shaped sanitary paper is cut at the product width.

[0042] Therefore, for example, Patent Document 1 describes imaging the roll-shaped sanitary paper during conveyance with a camera, discriminating a defect in the outer dimensions of the subject, and dropping the one discriminated as a defect.

[0043] However, in Patent Document 1, it is necessary to separately prepare an expensive device, and it is expected that it will take time and effort to use the device skillfully.

[0044] According to this embodiment, regarding the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X, by confirming that the roll-shaped toilet paper 3 does not pass through the first gap G1 of the jig 35 and passes through the second gap G2, it becomes possible to accurately measure and easily inspect the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X.

[0045] Also, according to this embodiment, regarding the outer dimensions of the roll-shaped toilet paper 3 in the axial direction X, since it can be determined only by whether the roll-shaped toilet paper 3 passes through the gap of the jig 35, it is possible to inspect more quickly than measuring by applying a ruler.

[0046] <Others> The present invention is not limited to the above-described embodiments and the modified examples described throughout, and appropriate changes and modifications can be made without departing from the technical idea of the present invention.

[0047] For example, in the above embodiment, the inspection by the jig 35 is performed immediately after the cutting process. However, in the present invention, the inspection by the jig 35 may be performed immediately before the packaging process of the packaging unit 40, or may be appropriately performed in each of the above-described processes.

Explanation of Signs

[0048] 1 Manufacturing line of roll-shaped toilet paper 3 Roll-shaped toilet paper 5 Paper log 5a End of winding 5c Core 10 Paper log generation unit 11 Base paper (material) 12 Mother roll 13 Winders 14 Gluing section 20 Adjusting section 21 Accumulator 30 Cutting section (cutting device) 31 Cutting blade 35 Inspection section (inspection device, jig) 350 Stand F0 Base surface 351 First flat plate F1 First plane 352 Second flat plate F2 Second plane 361 First connecting member 362 Second connecting member G1 First gap G2 Second gap 40 Packaging part 50 Boxing part

Claims

1. A method for manufacturing a roll-shaped sanitary paper, comprising: an inspection step of inspecting, by means of a jig, whether an outer dimension in the axial direction of the roll-shaped sanitary paper is within a predetermined range; wherein the jig comprises: a base having a flat base surface at the top; a first flat plate having a first plane parallel to and facing the base surface at the bottom; a second flat plate juxtaposed with the first flat plate and having a second plane parallel to and facing the base surface at the bottom; a first connecting member connecting the base and the first flat plate such that a first gap is formed between the base surface and the first plane; a second connecting member connecting the base and the second flat plate such that a second gap larger than the first gap is formed between the base surface and the second plane. The manufacturing method is characterized by comprising the above.

2. The method according to claim 1, further comprising a cutting step of cutting a plurality of paper logs of the roll-shaped sanitary paper during conveyance while rotating a cutting blade, wherein the inspection step inspects whether the roll-shaped sanitary paper passes through the second gap but not through the first gap of the jig in a posture where the axial direction of the cut roll-shaped sanitary paper is orthogonal to the base surface.

3. A jig for inspecting whether an outer dimension in the axial direction of a roll-shaped sanitary paper is within a predetermined range, comprising: a base having a flat base surface at the top; a first flat plate having a first plane parallel to and facing the base surface at the bottom; a second flat plate juxtaposed with the first flat plate and having a second plane parallel to and facing the base surface at the bottom; a first connecting member connecting the base and the first flat plate such that a first gap is formed between the base surface and the first plane; a second connecting member connecting the base and the second flat plate such that a second gap larger than the first gap is formed between the base surface and the second plane. The jig is characterized by comprising the above.

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