Method for sorting sanitary paper bundle and method for manufacturing sanitary paper bundle product

Abstract

To properly distribute sanitary paper bundles to a plurality of conveyance paths.SOLUTION: A method for sorting sanitary paper bundles B uses a sorting device 3 including a main conveyor 11, a sorting part 20 for sorting the sanitary paper bundles B conveyed by the main conveyor 11, and a plurality of main individual conveyors 13 (a) to (c) provided in parallel. The sorting method includes a conveyance step of conveying a plurality of sanitary paper bundles B at intervals by the main conveyor 11, a feeding step of feeding a part of the plurality of sanitary paper bundles B being conveyed from the conveyance path by the main conveyor 11 or the conveyance path continuing from the main conveyor 11 to another conveyance path, and a delivery step of delivering the sanitary paper bundle B delivered from the main conveyor 11 to the sorting section 20 from the sorting section 20 to any of the plurality of main individual conveyors 13 (a) to 13 (c) by shifting the sorting section 20.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for allocating the transport path of a stack of sanitary paper such as tissue paper during transport, and also to a method for producing a sanitary paper product in which the stack of sanitary paper is wrapped in a flexible film or the like. [Background technology]

[0002] BACKGROUND ART Conventionally, products in which sanitary paper such as tissue paper is packaged in a resin film (so-called soft pack products) have been known (Patent Document 1).

[0003] Furthermore, tissue paper is generally produced using a method in which a continuous sheet fed from multiple rolls is folded and stacked in a multi-stand interfolder (also called a multi-stand interfolder), and then cut into individual sizes using a cutter to obtain sanitary paper bundles (Patent Document 2).This method allows sanitary paper bundles to be obtained continuously and at high speed.

[0004] Furthermore, a packaging machine for automatically packaging a bundle of multiple articles into a packaging bag made of resin film or the like is also known (Patent Document 3). This type of packaging machine is configured to open the opening of the packaging bag, and then push the multiple articles into the packaging bag through the opening while maintaining the packaging bag in the opened state. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent Publication No. 2021-133981 [Patent Document 2] Japanese Patent Application Laid-Open No. 2012-011170 [Patent Document 3] Japanese Patent Application Laid-Open No. 2014-125228 Summary of the Invention [Problem to be solved by the invention]

[0006] When manufacturing soft pack products in which sanitary paper bundles, such as tissue paper, are packaged in a resin film, a manufacturing process can be considered in which a multi-reel machine is used to continuously produce sanitary paper bundles at high speed, and then a packaging machine such as that described in Patent Document 3 is used to push the sanitary paper bundles into a packaging bag. However, as mentioned above, a packaging machine for resin film requires the process of unfolding the packaging bag and then pushing the sanitary paper bundle into the packaging bag while maintaining that state, which makes it difficult to quickly store the sanitary paper bundle into the packaging bag. In particular, because both the sanitary paper bundle and the packaging bag are soft, the sanitary paper bundle needs to be pushed into the packaging bag at a relatively slow speed to properly store the sanitary paper bundle inside the packaging bag. Thus, while a multi-reel machine can continuously produce sanitary paper bundles at high speed, a packaging machine for film cannot adequately keep up with the production speed of this multi-reel machine, which presents a manufacturing challenge for soft pack products.

[0007] In order to address the above-mentioned problems, the present inventors have been considering a method for manufacturing soft pack products, in which sanitary paper bundles obtained by a multi-packaging machine are sorted and transported along multiple transport paths, and a packaging machine is provided for each transport path, so that the sanitary paper bundles are packaged sequentially by the multiple packaging machines. Therefore, a main object of the present invention is to provide a technology that can appropriately sort sanitary paper bundles along multiple transport paths. [Means for solving the problem]

[0008] A first aspect of the present invention relates to a method for sorting sanitary paper stacks. The sorting method of the present invention uses an apparatus including a main conveyor, a sorting unit, and multiple main individual conveyors. The sorting unit has the function of sorting sanitary paper stacks transported by the main conveyor. The sorting unit is basically located downstream of the main conveyor. The multiple main individual conveyors are arranged in parallel with each other. Each main conveyor is basically located downstream of the sorting unit. The multiple main individual conveyors may be arranged in a planar direction (left and right) or vertical direction (up and down). Here, in the sorting method of the present invention, the main conveyor transports multiple sanitary paper stacks at intervals (conveying step). Furthermore, in the sorting method of the present invention, some of the multiple sanitary paper stacks being transported can be sent from the transport path of the main conveyor to another transport path (sending step). The transport path of the main conveyor or a transport path continuing from the main conveyor is also called the "main path," and a transport path other than the main path is also called the "sub-path." Sanitary paper stacks not subject to the feeding process continue to travel along the main path, while sanitary paper stacks subject to the feeding process branch off from the main path and travel along a sub-path. In the sorting method according to the present invention, the sorting unit is shifted, and the sanitary paper stack transferred from the main conveyor to the sorting unit is transferred from the sorting unit to one of multiple main individual conveyors (transfer process). The shifting of the sorting unit may be in a planar direction (left and right shifting) or in a vertical direction (up and down shifting). The shifting operation of the sorting unit is not particularly limited. For example, one conveyor constituting the sorting unit may shift with its upstream side as a fulcrum to sort the sanitary paper stack, or multiple conveyors constituting the sorting unit may shift with its downstream side as a fulcrum to receive the sanitary paper stack into the sorting unit. The sorting unit may also shift a guide on a wide conveyor to sort the sanitary paper stack.

[0009] As in the above configuration, in addition to the transport path (main path) for sanitary paper stacks that are sorted from the main conveyor to multiple main individual conveyors via a sorting unit, by providing a transport path (sub-path) separate from the main path along which sanitary paper stacks are sent from the main conveyor, it is possible to appropriately sort sanitary paper stacks to multiple transport paths. Therefore, for example, by arranging a packaging machine for each transport path, the sanitary paper stacks can be packaged sequentially by multiple packaging machines.

[0010] In the sorting method according to the present invention, in the sending step, a wide-gap section where the spacing between sanitary paper bundles is increased is formed at a location on the main conveyor that sends the sanitary paper bundle to another transport path (sub-path). In this case, if the sorting section is configured so that the upstream and / or downstream ends can be shifted, the shifting of the sorting section is preferably performed when the wide-gap section reaches the upstream or downstream end of the sorting section. If the sorting section were to be shifted while the spacing between the sanitary paper bundles remains narrow, the transitioning end (upstream and / or downstream end) of the sorting section would need to be moved at high speed, and moving the transitioning end at high speed could cause the sanitary paper bundle to shift or collapse. In this regard, by forming a wide-gap section where the spacing between sanitary paper bundles is increased in the sending step and shifting the sorting section at this wide-gap section, the shifting of the sorting section does not need to be performed at high speed, and shifting or collapsing of the sanitary paper bundle due to the shifting of the sorting section can be prevented.

[0011] In the sorting method according to the present invention, the sending step may include using a pusher to push at least a portion of the sanitary paper stack traveling along the main conveyor's transport path or a transport path continuing from the main conveyor onto another transport path. In particular, the pusher preferably pushes the sanitary paper stack traveling along the transport path continuing from the main conveyor at an angle relative to the transport path and sends it onto another transport path. Furthermore, in the sending step, a sensor preferably detects both or either the gap between the sanitary paper to be pushed by the pusher and the preceding sanitary paper, and the gap between the sanitary paper to be pushed by the pusher and the succeeding sanitary paper, and controls the pusher based on the sensor's detection information. In this way, by detecting the gap between the sanitary paper sheets with a sensor and controlling the pusher based on the detection information, the pusher can accurately send specific sanitary paper sheets onto another transport path.

[0012] In the sorting method according to the present invention, it is preferable that the device for carrying out this sorting method further includes at least one sub-conveyor. This sub-conveyor is a conveyor forming the other transport path (sub-path) described above, and may be arranged so as to extend obliquely relative to the main conveyor at a position where it branches off from the main conveyor. In this way, a sub-conveyor branching off obliquely from the main conveyor may be provided, and this sub-conveyor may form a sub-path separate from the main path. This allows for efficient distribution of sanitary paper stacks to the main conveyor and the sub-conveyor.

[0013] In the sorting method according to the present invention, examples of the sorting section (sorting equipment) include a sorting conveyor arranged between the main conveyor and a plurality of main individual conveyors, or a blade arranged on the main conveyor.

[0014] Furthermore, in the feeding step, multiple sanitary paper stacks can be continuously fed to another transport path (sub-path).

[0015] Furthermore, if the number of sanitary paper bundles continuously sent to other transport paths in the sending-out process is a, and the number of destinations for the sanitary paper bundles (the number of main paths and sub-paths actually in operation) is b, then the number c of sanitary paper bundles transported by the main conveyor after the sending-out process is preferably c = (b - 1) x a. Note that the number c is preferably greater than or equal to a and less than or equal to (b - 1) x a. It is particularly preferable that the number c is (b - 1) x a. Note that (b - 1) x a applies when the capacities of the downstream processes are the same; if the capacities are different, the number of bundles to be distributed can be set according to each capacity.

[0016] The device may further include a secondary individual conveyor provided downstream of the secondary conveyor. In this case, the sorting method according to the present invention preferably includes a second delivery step of delivering the sanitary paper stacks diverted from the main conveyor to the secondary conveyor from the secondary conveyor to the secondary individual conveyor.

[0017] The auxiliary individual conveyor may be provided in parallel with the main individual conveyor.

[0018] Furthermore, when the angle of the sub-conveyor relative to the main conveyor is θ1 and the angle of the extrusion direction of the sanitary paper stack by the extrusion device relative to the traveling direction of the main conveyor is θ2, it is preferable that angle θ1 > angle θ2.

[0019] A second aspect of the present invention relates to a method for manufacturing a sanitary paper bundle product. The sanitary paper bundle product here refers to a product in which one or more sanitary paper bundles are packaged. The packaging for the sanitary paper bundles is preferably a packaging bag made of resin film or the like, rather than a carton. The manufacturing method for a sanitary paper bundle product according to the present invention includes the steps of sorting the sanitary paper bundles using the sorting method according to the first aspect described above, and packaging the sanitary paper bundles sorted by this sorting method.

[0020] According to the present invention, sanitary paper stacks can be appropriately distributed to a plurality of transport paths. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 shows a schematic diagram of a method for producing a sanitary paper bundle product. [Figure 2] FIG. 2 is a plan view schematically illustrating a first embodiment of a sorting device for sanitary paper stacks. [Figure 3] FIG. 3 is a side view showing an example of the configuration of the sorting conveyor. [Figure 4] FIG. 4 shows an example of an extrusion device. [Figure 5] FIG. 5 is a plan view that schematically illustrates one embodiment of a method for sorting a sanitary paper stack. [Figure 6] FIG. 6 is a side view showing an example of the configuration of the extrusion device. [Figure 7] FIG. 7 is a side view showing an example of the configuration of an extrusion device. [Figure 8] FIG. 8 is a side view showing an example of the configuration of the extrusion device. [Figure 9] FIG. 9 is a flow diagram showing an example of a method for producing a sanitary paper bundle product. [Figure 10] FIG. 10 is a plan view showing an example of a deceleration step in a method for producing sanitary paper bundle products. [Figure 11] FIG. 11 is a plan view showing an example of a gap adjusting step in the manufacturing method of sanitary paper bundle products. [Figure 12] FIG. 12 shows an example of the operation of a certain path in the spacing adjustment process. [Figure 13] FIG. 13 is a plan view schematically illustrating a second embodiment of a sorting device for sanitary paper stacks. [Figure 14] FIG. 14 is a side view schematically illustrating a third embodiment of a sorting device for sanitary paper stacks. [Figure 15] FIG. 15 is a plan view that schematically shows a path switching device for returning the sanitary paper stack from the sub-path to the main path. DETAILED DESCRIPTION OF THE INVENTION

[0022] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below, but also includes appropriate modifications of the embodiments below within the scope obvious to those skilled in the art.

[0023] FIG. 1 shows a process for manufacturing a sanitary paper bundle product, showing the steps from when a sanitary paper bundle B obtained using a multi-sheet machine 1 is packaged in a packaging machine 4. As shown in FIG. 1, the multi-sheet machine 1 folds and stacks sanitary paper P (base paper) unwound from multiple rolls to form a continuous stack of sanitary paper P. The multi-sheet machine 1 is provided with a number of rolls corresponding to the number of stacked sheets of sanitary paper. For example, to obtain a product consisting of 200 sets of tissues (400 sheets in total), each consisting of two tissues, the multi-sheet machine 1 is equipped with 200 sets of rolls (400 rolls in total), each consisting of two tissues. A known multi-sheet machine 1 (multi-stand interfolder) may be used. The stack of sanitary paper P formed by the multi-sheet machine 1 is then transported downstream and cut at predetermined intervals by a cutter 2, resulting in individual sanitary paper bundles B. A known rotary cutter may be used as the cutter 2. In this way, sanitary paper bundles B can be produced continuously and at high speed. Sanitary paper stack B is made up of sanitary paper sheets folded approximately in half, with half of two other sheets of sanitary paper inserted between each sheet of sanitary paper, so that when one sheet of sanitary paper is lifted up, the sanitary paper underneath it is also lifted up, forming a pop-up type stack.

[0024] The multiple sanitary paper stacks B are then transported downstream in a single file by a conveyor or other device. There is a speed difference between the speed of the sanitary paper stacks B within the cutter 2 and the speed of the sanitary paper stacks B transported by the conveyor immediately afterwards, with the speed of the sanitary paper stacks B transported by the conveyor immediately afterwards being set faster. This increases the spacing between the sanitary paper stacks B. However, the speed difference is not necessarily required on the conveyor following the cutter; the spacing between the sanitary paper stacks B can be adjusted between the cutter and the sorter 3. The spacing between the sanitary paper stacks B during sorting is preferably 5% to 30% of the product length, and more preferably 10 to 25%. If it is less than 5%, there is a risk of the products coming into contact with the products in front and behind them during sorting, causing them to change direction or collapse. If it is more than 30%, the transport speed will be too fast, resulting in a large facility size for the deceleration process. The sorter 3 is located downstream of the cutter 2. The sorting device 3 will be described in detail later, but this sorting device 3 has the function of sorting multiple sanitary paper stacks B that have been transported in a line along one transport path into multiple transport paths.

[0025] It is advisable to install a known discharge device on the transport path between the cutter 2 and the sorting device 3 that detects defects in the sanitary paper stack B and discharges any sanitary paper stack B that is deemed defective. Such a discharge device is arranged for the purpose of discharging sanitary paper stack B that is not suitable for product production during initial operation, or discharging sanitary paper stack B that is not suitable for product production during a sudden stop due to a problem in a downstream process. It is also possible to use the main path as the discharge destination. In this case, the products to be discharged can be transported to the discharge section at the end of the main path without being sorted by the extrusion device. In the example shown in Figure 1, multiple sanitary paper stacks B are sorted into four transport paths. The number of transport paths for the sanitary paper stacks B is not limited to four, and may be two, three, or five or more.

[0026] Furthermore, a packaging machine 4 is provided downstream of each conveying path. It is preferable to use a packaging machine 4 that has the function of packaging one or more sanitary paper bundles B in flexible packaging bags made of resin film or the like. The packaging bags are preferably made of resin, such as polyethylene, polypropylene, polyvinyl chloride, polyester, or polyvinyl acetate. However, the packaging bags may also be paper bags. Known packaging machines, such as those disclosed in Patent Document 3, can be used as such packaging machines. In this way, sanitary paper bundle products (so-called soft pack products) can be produced in which one or more sanitary paper bundles B are packaged in packaging bags.

[0027] FIG. 2 shows a first embodiment of the sorting device 3. As shown in FIG. 2, the sorting device 3 includes a conveyor device 10 for transporting the sanitary paper stack B, a sorting conveyor 20 (sorting section) for sorting the sanitary paper stack B, and a push-out device 30 for sending the sanitary paper stack B from the main path to the sub-path. In the example shown in FIG. 2, the sorting conveyor 20 is depicted as supporting the sanitary paper stack B only from its bottom side to make the position of the sanitary paper stack B easier to understand. In this way, the sorting conveyor 20 may be configured to have a conveyor device only on the bottom side of the sanitary paper stack B, but as will be described later, it is preferable that the sorting conveyor 20 be configured to have upper and lower conveyor devices for sandwiching the sanitary paper stack B from both its bottom and top sides.

[0028] The conveyor device 10 includes a main conveyor 11, a sub-conveyor 12, a plurality of main individual conveyors 13(a) to (c), and a sub-individual conveyor 14. Each of the conveyors 11 to 14 may be a general conveyor having a structure in which an endless belt is stretched around pulleys including a drive pulley and a driven pulley.

[0029] In this embodiment, the main conveyor 11 transports the sanitary paper stacks B in a single file and hands them over to the sorting conveyor 20, which will be described later. The sorting conveyor 20 switches the transport path of the sanitary paper stacks B. The sorting conveyor 20 switches the transport path and hands over the sanitary paper stacks B to one of the main individual conveyors 13(a) to (c) located downstream of it. The multiple main individual conveyors 13(a) to (c) are located in parallel downstream of the sorting conveyor 20. In other words, the main individual conveyors 13(a) to (c) that receive the sanitary paper stacks B from the sorting conveyor 20 are alternatively selected. In this embodiment, the main individual conveyor 13(a) In the conveying passages 11 to (c), a first main individual conveyor 13(a), a second main individual conveyor 13(b), and a third main individual conveyor 13(c) are arranged, but the number of main individual conveyors 13 is not limited to three and can be two or four or more. In this specification, the transport path for the sanitary paper stack B formed by the main conveyor 11, the sorting conveyor 20, and the multiple main individual conveyors 13(a) to (c) is referred to as the "main path."

[0030] On the other hand, in this embodiment, the sub-conveyor 12 is arranged to branch off from the middle of the main conveyor 11. This sub-conveyor 12 is configured to extend obliquely with respect to the conveying direction of the main conveyor 11. The sanitary paper stack B conveyed on the main conveyor 11 is pushed out by a push-out device 30 (described later) and sent onto the conveying surface of the sub-conveyor 12. In this way, the sanitary paper stack B conveyed on the main conveyor 11 is selectively sent to the sub-conveyor 12 by the push-out device 30. In addition, a sub-individual conveyor 14 is arranged downstream of the sub-conveyor 12. Therefore, the sanitary paper stack B conveyed by the sub-conveyor 12 is delivered to this sub-individual conveyor 14. As shown in FIG. 2, in this embodiment, the multiple main individual conveyors 13(a)-(c) and the sub-individual conveyor 14 are arranged in parallel. Specifically, the conveying directions of the main individual conveyors 13(a)-(c) and the sub-individual conveyor 14 are approximately parallel. In this specification, the transport path for the sanitary paper stack B formed by the sub-conveyor 12 and the sub-individual conveyor 14 is referred to as the "sub-path." As shown in Figure 2, this sub-path branches off from the main path.

[0031] As described above, the sorting conveyor 20 is disposed between the main conveyor 11 and the plurality of main individual conveyors 13(a)-(c). A portion of the sanitary paper stacks B conveyed by the main conveyor 11 is introduced into the sorting conveyor 20, guided by the sorting conveyor 20, and then transferred to one of the individual conveyors 13(a)-(c). As shown in FIG. 2, the sorting conveyor 20 has a predetermined pivot point 23. Therefore, the outlet end side of the sorting conveyor 20 (i.e., the end side that hands over the sanitary paper stacks B to the next conveyor) rotates horizontally relative to the pivot point 23, i.e., along the conveying surface of the main conveyor 11. Specifically, the pivot point 23 of the sorting conveyor 20 is provided on the introduction end side (i.e., the end side that receives the sanitary paper stacks B). For this reason, the position of the introduction end of the sorting conveyor 20 is substantially fixed immediately after the main conveyor 11, but the outlet end of the sorting conveyor 20 moves significantly toward the main individual conveyors 13(a)-(c). Such rotation of the sorting conveyor 20 about the rotation fulcrum 23 can be achieved by a known actuator such as a motor or piston. Furthermore, the rotation of the sorting conveyor 20 is controlled by a control device (not shown) such as a computer.

[0032] The sorting conveyor 20 also includes a sensor 24 near the outlet end or within the guide path. This sensor 24 is located to identify gaps between sanitary paper stacks B being led from the sorting conveyor 20 to the main individual conveyors 13(a) to (c). Specifically, the sensor 24 detects the presence or absence of sanitary paper stacks B near the leading edge of the sorting conveyor 20 or within the guide path, thereby identifying when a gap between sanitary paper stacks B is approaching the leading edge of the sorting conveyor 20. A control device (not shown) controls the sorting conveyor 20 based on the detection information from the sensor 24, and rotates the sorting conveyor 20 when a gap between sanitary paper stacks B appears near the leading edge of the sorting conveyor 20, thereby switching the transport path for the sanitary paper stacks B. The sensor 24 can also measure the length of the gaps between sanitary paper stacks B. It is possible to control the system so that if the gap between sanitary paper stacks B is equal to or greater than a certain length, the transport path for the sanitary paper stack B is switched at that gap, and if the gap is less than the certain length, the transport path for the sanitary paper stack B is not switched at that gap. The sensor 24 is not particularly limited as long as it can detect the presence or absence of a sanitary paper stack B, and any known sensor such as an optical sensor (photoelectric sensor), ultrasonic sensor, or pressure sensor may be used. The transport path can also be switched by setting a timer after the sensor 24 detects a gap between sanitary paper stacks B (to switch after a certain time has elapsed since detection), or by adjusting the position of the sensor 24.

[0033] FIG. 3 shows a specific example of the sorting conveyor 20. In the example shown in FIG. 3, the sorting conveyor 20 includes a lower conveyor 21 and an upper conveyor 22. The upper and lower conveyors 21 and 22 are each configured as belt conveyors. The upper and lower conveyors 21 and 22 sandwich the sanitary paper stack B between belts 21a and 22a, and transport the sanitary paper stack B downstream as the belts 21a and 22a move. More specifically, the upper and lower conveyors 21 and 22 include endless belts 21a and 22a, drive pulleys 21b and 22b, and head pulleys 21c and 22c, respectively. The belts 21a and 22a are stretched across these pulleys. The drive pulleys 21b and 22b are self-rotating pulleys that drive the belts 21a and 22a in a fixed direction, and are located closest to the introduction end of the sorting conveyor 20. Furthermore, head pulleys 21c, 22c are pulleys that rotate in accordance with the rotation of belts 21a, 22a, and are arranged closest to the output end of sorting conveyor 20. As a result, belt 21a of lower conveyor 21 contacts the underside of sanitary paper stack B, and belt 22a of upper conveyor 22 contacts the upper side of sanitary paper stack B, with sanitary paper stack B being sandwiched between these upper and lower conveyors 21, 22 and transported downstream.

[0034] FIG. 4 shows an example of a push-out device 30. The push-out device 30 has a contact piece 31 that comes into contact with the side of the sanitary paper stack B. The push-out device 30 controls the operation of the contact piece 31 so that it diagonally crosses the main path formed by the main conveyor 11. In this way, the push-out device 30 presses the contact piece 31 against the side of the sanitary paper stack B, causing the sanitary paper stack B to slide on the main conveyor 11. This causes the sanitary paper stack B to deviate from the main path. As shown in FIG. 2, a sub-conveyor 12 (omitted in FIG. 4) is provided at the end of the push-out direction of the push-out device 30, and the sanitary paper stack B pushed out by the push-out device 30 is introduced into this sub-conveyor 12.

[0035] More specifically, in the example shown in FIG. 4 , the pusher 30 is disposed above the main path of the main conveyor 11. In the pusher 30, an endless belt 34 is stretched between a drive pulley 32 and a driven pulley 33, and rotating the drive pulley 32 in a fixed direction causes the belt 34 to move in a fixed direction. The belt 34 is also equipped with a contact piece 31 for contacting the side of the sanitary paper stack B. Specifically, in the pusher 30, the lower surface of the belt 34 stretched between the drive pulley 32 and the driven pulley 33 is the forward surface that faces the sanitary paper stack B, and the upper surface of the belt 34 is the backward surface that moves away from the sanitary paper stack B. Therefore, when the belt 34 is rotated in a fixed direction, the contact piece 31 repeatedly moves toward the sanitary paper stack B on the lower surface of the belt 34 and then moves away from the sanitary paper stack B on the upper surface of the belt 34. As a result, when the sanitary paper stack B, which needs to have its transport path switched, arrives below the extrusion device 30, the belt 34 is rotated to bring the contact piece 31 close to the sanitary paper stack B, and the contact piece 31 is brought into contact with the side of the sanitary paper stack B and pushed out obliquely, allowing the sanitary paper stack B to slide.

[0036] It is preferable to use a timing belt for the belt 34, as this makes it easier to control the movement and position of the contact piece 31. For the same reason, it is also possible to use a chain instead of the belt 34. The movement speed of the contact piece 31 when pushing out the product (the rotation speed of the belt 34) can be equal to 1 / cosθ relative to the transport speed of the sanitary paper stack B, or it can be slightly faster. By then rotating the belt 34 in the same direction, the contact piece 31 passes above the belt 34 and returns to a position where it can push out the sanitary paper stack B again. In this way, the contact piece 31 always moves in a fixed direction (it does not move back and forth), so the sorting operation of the multiple sanitary paper stacks B being transported by the main conveyor 11 can be performed at high speed.

[0037] Returning to FIG. 2, the angle of the sub-conveyor 12 relative to the main conveyor 11 is indicated by θ1, and the angle of the extrusion direction of the sanitary paper stack B by the extrusion device 30 relative to the direction of travel of the main conveyor 11 is indicated by θ2. In this case, it is preferable that angle θ1 ≥ angle θ2, and it is particularly preferable that angle θ1 > angle θ2. If angle θ2 exceeds angle θ1, the extrusion angle θ2 of the sanitary paper stack B becomes too steep, which could cause the sanitary paper stack B to collapse when extruded, or prevent the sanitary paper stack B from being properly transferred from the main conveyor 11 to the sub-conveyor 12. On the other hand, if the extrusion angle θ2 of the sanitary paper stack B is less than the inclination angle θ1 of the sub-conveyor 12, the sanitary paper stack B can be gently extruded in the direction of travel, preventing the sanitary paper stack B from collapsing and allowing the sanitary paper stack B to be properly transferred from the main conveyor 11 to the sub-conveyor 12. Specifically, the push-out angle θ2 of the sanitary paper stack B is preferably 50 to 100% of the inclination angle θ1 of the sub-conveyor 12, and particularly preferably 70 to 95%.

[0038] As shown in FIG. 2, the pusher 30 is disposed so that the direction of travel of the contact piece 31 is inclined relative to the direction of travel of the main conveyor 11. The push-out angle θ2 of the sanitary paper stack B, more specifically, the approach angle θ2 of the contact piece 31 (the angle between the direction of travel of the contact piece 31 and the direction of travel of the main conveyor 11) is preferably 15 to 35 degrees. If the approach angle θ2 of the contact piece 31 exceeds 35 degrees, the speed at which the contact piece 31 slides the sanitary paper stack B laterally becomes too fast when it comes into contact with the side of the sanitary paper stack B, which may result in the sanitary paper stack B collapsing or the top paper being turned up. On the other hand, if the approach angle θ2 of the contact piece 31 is less than 15 degrees, the distance the contact piece 31 must push the sanitary paper stack B to discharge it from the main conveyor 11 to the sub-conveyor 12 becomes too long, resulting in an increase in the overall length of the sorter 3. For this reason, the approach angle θ2 of the contact piece 31 is preferably set to 15 to 35 degrees, and more preferably to 20 to 30 degrees.

[0039] In FIG. 2, the inclination angle of the contact piece 31 itself is indicated by θ3. The inclination angle θ3 of the contact piece 31 (particularly the surface that contacts the sanitary paper stack B) is the angle at which the contact piece 31 is inclined relative to the direction of travel of the main conveyor 11 when the contact piece 31 is in contact with the side of the sanitary paper stack B. The inclination angle θ3 of the contact piece 31 can be 0 degrees, but is preferably set to 5 to 35 degrees, and particularly preferably 10 to 25 degrees or 20 to 25 degrees. That is, the contact piece 31 is preferably inclined gently downward toward the front so that its leading edge 21a (the end on the downstream side in the conveying direction) contacts the side of the sanitary paper stack B before its trailing edge 21b (the end on the upstream side in the conveying direction). If the inclination angle θ3 of the contact piece 31 exceeds 25 degrees, the contact piece 31 will make point contact with the sanitary paper stack B at a sharp angle, which may cause problems such as the sanitary paper stack B collapsing. On the other hand, if the inclination angle θ3 of the contact piece 31 is less than 5 degrees, the contact piece 31 will be in nearly surface contact with the sanitary paper stack B, which will increase the impact when the contact piece 31 comes into contact with the sanitary paper stack B, and in this case too, may lead to problems such as the sanitary paper stack B crumbling. Because the sanitary paper stack B is soft and easily crumbled, it is preferable to adjust the inclination angle θ3 of the contact piece 31 to an appropriate range of 5 to 25 degrees so that the contact piece 31 comes into contact with the sanitary paper stack B at a gentle angle.

[0040] Next, a method for sorting sanitary paper stacks B will be described with reference to Fig. 5. First, as shown in Fig. 5(a), multiple sanitary paper stacks B are introduced into the main conveyor 11. The main conveyor 11 continuously transports multiple sanitary paper stacks B at intervals. In the state shown in Fig. 5(a), the operation of the push-out device 30 is stopped, so the sanitary paper stacks B being transported by the main conveyor 11 pass directly below the push-out device 30 and are introduced into the sorting conveyor 20 located downstream.

[0041] Next, as shown in Figure 5(b), after a predetermined number of sanitary paper stacks B have passed through the push-out device 30, the push-out device 30 begins operation and continuously pushes out the predetermined number of sanitary paper stacks B, sending these sanitary paper stacks B from the main conveyor 11 to the sub-conveyor 12. For convenience, in Figure 5, the group of sanitary paper stacks B passed from the main conveyor 11 to the sorting conveyor 20 is referred to as a first group G1, and the group of sanitary paper stacks B sent from the main conveyor 11 to the sub-conveyor 12 is referred to as a second group G2. In the example shown in Figure 5, the number of sanitary paper stacks B included in this first group G1 is the number of main individual conveyors 13(a) to 13(c) multiplied by the number of sanitary paper stacks B passed to the second group G2. In the example shown in Figure 5, the number of sanitary paper stacks B included in the second group G2 is set to 2. Therefore, the number of sanitary paper stacks B included in the first group G1 is 3 x 2 = 6. When the sanitary paper stacks B are evenly distributed among the main individual conveyors 13(a) to 13(c), a total of 6 sanitary paper stacks B will be transported to the sub-conveyor 12. By adjusting the number of sanitary paper sheets B contained in the first group G1 and the second group G2 in this way, it is preferable that the number of sanitary paper sheets B sent to each of the main individual conveyors 13(a) to 13(c) is ultimately the same as the number of sanitary paper sheets B sent to the sub-conveyor 12, but of course these numbers may be different. For example, the number of sanitary paper sheets B sent to the sub-conveyor 12 may be less or more than the number of sanitary paper sheets B contained in each of the main individual conveyors 13(a) to 13(c).

[0042] 5, the group of sanitary paper stacks B following the second group G2 is referred to as the first group G1'. Like the first group G1, this first group G1' is transferred from the main conveyor 11 to the sorting conveyor 20, but because it contains sanitary paper stacks B that are different from the first group G1, it is referred to as the first group G1' for convenience. As shown in FIG. 5(b), of the multiple sanitary paper stacks B transported on the main conveyor 11, after the first group G1 passes through the extrusion device 30, the second group G2 is sent to the sub-conveyor 12 by the extrusion device 30. This forms a wide gap S between the sanitary paper stacks B between the first group G1 and another first group G1' following the second group G2. The first group G1 and the other first group G1' are transferred from the main conveyor 11 to the sorting conveyor 20 while maintaining this wide gap S.

[0043] Next, as shown in FIG. 5(c), the initial first group G1 passes through the sorting conveyor 20 and is transferred to one of the main individual conveyors 13(a) to (c) located downstream thereof. In the example shown in FIG. 5(c), the first group G1 is transferred to the second main individual conveyor 13(b), which is located in the middle of the parallel-arranged main individual conveyors 13(a) to (c). The second group G2 is transported by the sub-conveyor 12 toward the sub-individual conveyor 14. Another first group G1' is introduced from the main individual conveyor 13 to the sorting conveyor 20 while maintaining the wide interval S between it and the first group G1 in front of it.

[0044] Next, as shown in Figure 5(d), after all of the sanitary paper stacks B contained in the initial first group G1 have been transferred from the sorting conveyor 20 to the second main individual conveyor 13(b), the sorting conveyor 20 rotates (transitions) during the period until the subsequent another first group G1' reaches the outlet end of the sorting conveyor 20. That is, since a wide gap portion S is formed between the first group G1 and the subsequent another first group G1 as described above, the sorting conveyor 20 rotates during the period when this wide gap portion S passes the outlet end side of the sorting conveyor 20. In the example shown in Figure 5(d), the rotation of the sorting conveyor 20 switches the destination of the sanitary paper stacks B from the second main individual conveyor 13(b) to the first main individual conveyor 13(a). For this reason, as mentioned above, the first first group G1 is transferred from the sorting conveyor 20 to the second main individual conveyor 13(b), but the subsequent another first group G1' is transferred from the sorting conveyor 20 to the first main individual conveyor 13(a).

[0045] In this way, by rotating the sorting conveyor 20 at the location where the wide gap section S is formed to switch the transport path of the sanitary paper stacks B, sufficient spacing between the sanitary paper stacks B is maintained during the rotation, so there is no need to rotate the sorting conveyor 20 at high speed. Therefore, the rotation speed of the sorting conveyor 20 can be set to a low speed to prevent the sanitary paper stacks B placed on the sorting conveyor 20 from becoming distorted or crumpled. As a result, it is possible to effectively prevent the sanitary paper stacks B from becoming displaced or crumpled due to the rotation of the sorting conveyor 20.

[0046] Although not shown, after two first groups G1 are sent to the first main individual conveyor 13(a), the sorting conveyor 20 is rotated to switch the transport path of the sanitary paper stack B to the second main individual conveyor 13(b), and after one first group G1 is sent to this second main individual conveyor 13(b), the sorting conveyor 20 is rotated to switch the transport path of the sanitary paper stack B to the third main individual conveyor 13(c).Similarly, after two first groups G1 are sent to the third main individual conveyor 13(c), the sorting conveyor 20 is rotated to switch the transport path of the sanitary paper stack B to the second main individual conveyor 13(b), and after one first group G1 is sent to this second main individual conveyor 13(b), the sorting conveyor 20 is rotated to switch the transport path of the sanitary paper stack B to the first main individual conveyor 13(a). By operating the sorting conveyor 20 in this pattern, the number of sanitary paper stacks B sent to each of the main individual conveyors 13(a) to (c) can be made uniform. In this way, when switching from the conveying paths on both sides (for example, the first main individual conveyor 13(a) or the third main individual conveyor 13(c)) to the central conveying path (the second main individual conveyor 13(b)), it is preferable to send out a predetermined number (for example, 4 or 6) of sanitary paper stacks B onto the side sanitary paper stacks twice (for example, 8 or 12 stacks) before switching to the central conveying path. This results in an equal amount of sanitary paper stacks B being sent out from both side conveying paths and the central conveying path.

[0047] In the example shown in FIG. 5, the number "a" of sanitary paper stacks B continuously sent to the sub-path by the extrusion device 30 is two. The number "b" of destinations for the sanitary paper stacks (the number of main and sub-paths actually in operation) is four. The number "c" of sanitary paper stacks B transported along the main path after the extrusion device 30 sends the sanitary paper stacks B to the sub-path is six. In this way, the number c is preferably set to c = (b - 1) x a. However, if the number of sanitary paper stacks at each destination becomes unbalanced (for example, if there are too many or too few in one location), in the case of the sub-path, this can be adjusted by temporarily changing the number (b - 1) x a. In the case of other paths, this can be adjusted by temporarily changing the destination of the sorting unit.

[0048] The wide gap portion S between the first group G1 and the subsequent another first group G1' can be identified based on detection information from a sensor 24 provided on the guide path of the sorting conveyor 20. Specifically, the control device (not shown) can identify that the wide gap portion S has arrived in front of the sensor 24 when a predetermined time has passed since the sensor 24 was no longer able to detect the sanitary paper stack B. Therefore, the control device can take into account the distance from the sensor 24 to the outlet end of the sorting conveyor 20 and control the sorting conveyor 200 to start the transport path switching operation at the timing when the wide gap portion S has reached the outlet end of the sorting conveyor 20.

[0049] As shown in FIG. 5(d), the sanitary paper stacks B included in the second group G2 being transported by the sub-individual conveyors 14 are transferred from one sub-individual conveyor 14 to another sub-individual conveyor 14.

[0050] By repeating the above steps, the multiple sanitary paper stacks B traveling on the main conveyor 11 can be sorted into a first group G1 of sanitary paper stacks B traveling along the main path formed by the main conveyor 11, the sorting conveyor 20, and the main individual conveyors 13(a)-(c), and a second group G2 of sanitary paper stacks B traveling along the sub-path formed by the main conveyor 11, the sub-individual conveyor 14, and the sub-individual conveyor 14. As described above, the timing for switching the transport path by the sorting conveyor 20 is preferably the timing after two first groups G1 have been sent to the first main individual conveyor 13(a), the timing after one first group G1 has been sent to the second main individual conveyor 13(b), and the timing after two first groups G1 have been sent to the third main individual conveyor 13(c). In this case, the interval at which the sanitary paper stacks B that will become the second group G2 are sent to the sub-individual conveyor 14 can be set to correspond to the interval at which the transport path is switched by the sorting conveyor 20. Specifically, the sanitary paper stacks B can be sent from the main conveyor 11 to the sub-individual conveyor 14 in the following pattern: first group G1, first group G1 (bound for the first main individual conveyor 13(a)), second group G2, first group G1 (bound for the second main individual conveyor 13(b)), second group G2, first group G1, first group G1 (bound for the third main individual conveyor 13(b)), second group G2, etc. However, the pattern is not limited to this, and it is also possible to adopt a pattern in which the first group G1 and the second group G2 alternate, such as first group G1, second group G2, first group G1, second group G2, etc.

[0051] 6 to 8 are schematic side views of the extrusion device 30, illustrating the relationship between the extrusion device 30 and the sanitary paper stack B, as well as improved and modified examples of the extrusion device 30. FIG. 6(a) shows the extrusion device 30 having one contact piece 31. As described above, the extrusion device 30 is configured so that by rotating the chain (or belt) 34 in a fixed direction, the contact piece 31 attached to the chain 34 also rotates, allowing the sanitary paper stack B to be repeatedly extruded. In this embodiment, the sanitary paper stack B is extruded continuously without any gaps. Note that the speed of the forward and return movements of the contact piece 31 do not need to be the same, and it is preferable that the return movement be faster than the forward movement.

[0052] In the example of Figure 6(b), the number of sanitary paper stacks pushed out by one pushing operation (pushing step) by the contact piece 31 is set to "2." In other words, two contact pieces 31(a) and (b) are arranged side by side in the pushing device 30, and two sanitary paper stacks B are pushed out almost simultaneously by the pushing operation of these two contact pieces 31(a) and 31(b). In this way, it is also possible to arrange multiple contact pieces 31 side by side in the pushing device 30 and push out multiple sanitary paper stacks B almost simultaneously. Note that even in this case, the sanitary paper stacks B are pushed out continuously without any gaps between them.

[0053] In the example of Figure 6(c), the number of sanitary paper stacks pushed out by one pushing operation (pushing step) by the contact piece 31 is set to "4." In other words, the push-out device 30 has four contact pieces 31(a), (b), (c), and (d) arranged side by side, and four sanitary paper stacks B are pushed out almost simultaneously by the pushing operation of these four contact pieces 31(a), (b), (c), and (d).

[0054] In the example of Figure 7, two pushers 30(a) and (b) are arranged side by side and used as a single pusher. In other words, it is assumed that the two pushers 30(a) and (b) are used as a single pusher to distribute paper to a single sub-conveyor 12. Each of the two pushers 30(a) and (b) is equipped with a contact piece 31(a) and (b), a drive pulley 32(a) and (b), a driven pulley 33(a) and (b), and a chain 34(a) and (b). Therefore, the two pushers 30(a) and (b) can independently control the rotation speed of the chain 34(a) and (b) and the timing at which the contact pieces 31(a) and (b) contact the sanitary paper stack B.

[0055] Figure 8 shows a modified example of the contact piece 31 attached to the push-out device 30. As shown in Figure 8, the contact surface of the contact piece 31 that comes into contact with the side of one stack of sanitary paper B may be divided into multiple small pieces. In this case, as the contact piece 31 turns back at the rear end or front end of the push-out device 30 and passes over the curved surface of the drive pulley 32 or driven pulley 33, the small pieces that make up the contact piece 31 move away from each other. This allows the contact piece 31 to move smoothly over this curved surface, preventing malfunctions and the like in the push-out device 30.

[0056] Next, Fig. 9 shows a flow diagram from sorting the sanitary paper stack B into multiple conveying paths to packaging the sanitary paper stack B on each conveying path to obtain a sanitary paper stack product. As shown in Fig. 9, the method for manufacturing a sanitary paper stack product preferably includes, in this order, a sorting step (S1), a deceleration step (S2), a spacing adjustment step (S3), and a packaging step (S4).

[0057] The sorting step (S1) is a step of sorting a plurality of sanitary paper stacks B that are continuously transported along one path into a plurality of transport paths. Details of the sorting step are as described above.

[0058] The deceleration process (S2) is a process of slowing down the conveying speed of the sanitary paper stack B along each conveying path after the sorting process. As described above, the multiplexer 1 (see FIG. 1) produces the sanitary paper stack B at high speed, and the sorting device 3 sorts the sanitary paper stack B to each conveying path while maintaining the conveying speed. At this time, the packaging machine 4 provided for each conveying path may not be able to handle the conveying speed after the sorting process. Therefore, it is preferable to slow down the conveying speed of the sanitary paper stack B to a speed that the packaging machine 4 can handle after the sorting process. Extracting products from the main path at regular intervals results in wider product intervals, making it necessary to slow down the speed to adjust the product intervals. Figure 10 shows an example of this deceleration process. In the example shown in Figure 10, multiple deceleration conveyors 15(a)-(c) are arranged downstream of the main individual conveyors 13(a)-(c) and the sub-individual conveyors 14 along each conveying path, gradually slowing down the conveying speed of the sanitary paper stack B. If the conveying speed of the sanitary paper stack B is suddenly reduced, the spacing between the sanitary paper stacks B may become too narrow, causing the sanitary paper stacks B to collide with each other or lose their shape. Therefore, it is preferable to gradually reduce the conveying speed of the sanitary paper stack B. In the example shown in FIG. 10, each conveying path includes a first deceleration conveyor 15(a) that receives the sanitary paper stack B from one of the main individual conveyors 13(a) to (c) or the sub-individual conveyor 14, a second deceleration conveyor 15(b) that has a slower conveying speed than the first deceleration conveyor 15(a), and a third deceleration conveyor 15(c) that has an even slower conveying speed than the second deceleration conveyor 15(b). This allows the conveying speed of the sanitary paper stack B to be gradually reduced to a speed that can be handled by the packaging machine 4. Note that the deceleration conveyors 15(a) to (c) can also be pitch-adjusting conveyors with freely rotating rolls placed on the surface of the conveyor.

[0059] As another example of the deceleration step (S2), a non-driven area such as a metal plate may be provided after the main individual conveyors 13(a)-(c) and the sub-individual conveyor 14, and the sanitary paper stack B may be fed into this non-driven area and temporarily stopped in the non-driven force area. The sanitary paper stack B is transferred onto the non-driven area by the momentum of transport by the main individual conveyors 13(a)-(c) and the sub-individual conveyor 14, and is stopped by frictional resistance in the non-driven area. After a certain number of sanitary paper stacks B have accumulated in the non-driven area, a pusher (conveyor bar, etc.) is used to send the sanitary paper stack B from the non-driven area to another conveyor downstream. This allows the sanitary paper stack B to be rapidly decelerated in a shorter space.

[0060] The spacing adjustment process (S3) is a process of adjusting the spacing between the sanitary paper stacks B on each conveying path after the deceleration process. Since there may be variations in the spacing between the sanitary paper stacks B distributed to each conveying path, it is advisable to adjust the spacing between the sanitary paper stacks B to be more or less uniform before introducing the sanitary paper stacks B into the packaging machine 4. Note that if the conveying speed of the entire facility is slow, the deceleration process (S2) is not necessarily required, and the spacing adjustment process (S3) alone will suffice.

[0061] 11 and 12 show an example of this interval adjustment process. In the example shown in FIG. 11, a waiting zone 16(a), a receiving zone 16(b), and an adjustment zone 16(c) are provided in this order on each conveying path downstream of the aforementioned deceleration conveyors 15(a) to (c). Each zone is formed by one or more conveyors. In the example shown in FIG. 11, the waiting zone 16(a) and the receiving zone 16(b) each consist of one conveyor, and the adjustment zone 16(c) consists of three conveyors. The conveyors constituting each zone can be individually controlled to move (convey the sanitary paper stack B downstream) or stop (hold the sanitary paper stack B on the conveyor). Note that this example assumes that each group of sanitary paper stacks B consecutively sorted to the same path in the sorting process (S1) contains four sanitary paper stacks B. In this way, the number of conveyors constituting the adjustment zone 16(c) needs to be one less than the number of sanitary paper stacks B belonging to one group, but there is no problem with a greater number.

[0062] Figure 12 shows an example of the operation of a waiting zone 16(a), a receiving zone 16(b), and an adjustment zone 16(c), which form a single path. Along this path, the operations shown in Figures 12(a), (b), (c), and (d) are repeated in this order. Also, in Figure 12, a leading group containing four sanitary paper stacks B is indicated by the symbol G1, a trailing group (also containing four sanitary paper stacks B) conveyed a predetermined distance from the leading group G1 is indicated by the symbol G1', and a further trailing group (also containing four sanitary paper stacks B) is indicated by the symbol G1''.

[0063] First, as shown in Figure 12(a), the previous group G1 passes through the waiting zone 16(a) and receiving zone 16(b) and enters the adjustment zone 16(c). This adjustment zone 16(c) supplies the sanitary paper stacks B one by one to the packaging machine in accordance with the processing capacity (packaging speed) of the packaging machine. Specifically, the adjustment zone 16(c) is composed of three conveyors and the receiving zone 16(b) is composed of one conveyor, so the total number of conveyors in these zones corresponds to the number of sanitary paper stacks B included in the previous group G1. The advance and stop of the four conveyors that make up these zones are controlled to temporarily hold the sanitary paper stacks B one by one, and then send them downstream one by one in accordance with the processing capacity of the packaging machine, allowing the sanitary paper stacks B to be supplied one by one to the packaging machine.

[0064] Meanwhile, as shown in Figure 12(a), the conveyor in waiting zone 16(a) is stopped, and the four sanitary paper stacks B included in the subsequent group G1' are held on this conveyor. The conveyor in waiting zone 16(a) keeps the sanitary paper stacks B waiting on that conveyor until all of the sanitary paper stacks B included in the previous group G1 have passed through receiving zone 16(b). In the state shown in Figure 12(a), the last sanitary paper stack B included in the previous group G1 is still in receiving zone 16(b), so the subsequent group G1' is kept waiting in waiting zone 16(a).

[0065] 12(b), when all of the sanitary paper stacks B in the previous group G1 have passed through the receiving zone 16(b), the next group G1' that has been waiting in the waiting zone 16(a) is sent from the waiting zone 16(a) to the receiving zone 16(b). Note that even at this time, the supply of sanitary paper stacks B to the packaging machine continues in the adjustment zone 16(c).

[0066] Next, as shown in FIG. 12(c), the receiving zone 16(b) holds the subsequent group G1' on the conveyor constituting this receiving zone 16(b) until all of the sanitary paper stacks B contained in this subsequent group G1' have been received. In other words, the sanitary paper stacks B are not sent from the receiving zone 16(b) to the adjustment zone 16(c) until all of the sanitary paper stacks B of the subsequent group G1' have been transferred from the waiting zone 16(a) to the receiving zone 16(b). In this way, all of the sanitary paper stacks B contained in the subsequent group G1' temporarily wait on the conveyor constituting the receiving zone 16(b). Note that even at this time, the adjustment zone 16(c) continues to supply the sanitary paper stacks B to the packaging machine. Some of the conveyors constituting the adjustment zone 16(c) may not hold the sanitary paper stacks B, but this does not cause any problems.

[0067] Next, as shown in FIG. 12(d), after the sanitary paper stacks B of the latter group G1' have been gathered in the receiving zone 16(b), the sanitary paper stacks B begin to be sent from the receiving zone 16(b) to the adjustment zone 16(c). The group G1' sent to the adjustment zone 16(c) is then supplied to the packaging machine following the previous group G1. At this time, no sanitary paper stacks B remain in the waiting zone 16(a), so the sanitary paper stacks B of the further later group G1" are supplied to this waiting zone 16(a) and made to wait on the conveyor that makes up this waiting zone 16(a). The further later group G1" waiting in the waiting zone 16(a) waits until the receiving zone 16(b) is empty, as shown in FIGS. 12(a) and 12(b), and at this point, sending to the receiving zone 16(b) begins.

[0068] 12(a) to 12(d) is repeated. This allows the sanitary paper stacks B to be supplied to the packaging machine one by one in accordance with the processing capacity of the packaging machine. Furthermore, since the sanitary paper stacks B are continuously supplied to the packaging machine basically at uniform time intervals, the packaging machine can be used efficiently.

[0069] In the packaging step (S4), after adjusting the spacing, the sanitary paper bundles B are packaged using packaging machines 4 arranged along each conveying path to obtain sanitary paper bundle products. The packaging machines 4 may package each sanitary paper bundle B in a packaging bag, or may collect multiple sanitary paper bundles B and package them together in a packaging bag. In the example shown in Figure 11, groups are formed for each predetermined number of sanitary paper bundles B (for example, four). In this case, the multiple sanitary paper bundles B belonging to each group may be collected and packaged.

[0070] Fig. 13 shows a second embodiment of the sorting device 3. In the second embodiment shown in Fig. 13, the same components as those in the first embodiment shown in Fig. 2 are denoted by the same reference numerals. Hereinafter, for embodiments different from the first embodiment, the description of the same components as those in the first embodiment will be omitted, and the description will focus on the components different from those in the first embodiment.

[0071] As shown in Figure 13, the second embodiment employs a wide conveyor 17 instead of the sub-conveyor 12 used in the first embodiment. The wide conveyor 17 is disposed between the main conveyor 11 and the sorting conveyor 20. As a result, a portion of the sanitary paper stack B transported by the main conveyor 11 is handed over to the wide conveyor 17, moves on the wide conveyor 17, is handed over from the wide conveyor 17 to the sorting conveyor 20, and is ultimately introduced into one of the main individual conveyors 13(a) to (c). In this way, the main path described above is formed by the main conveyor 11, the wide conveyor 17, the sorting conveyor 20, and the main individual conveyors 13(a) to (c).

[0072] The wide conveyor 17 is also located between the main conveyor 11 and the auxiliary individual conveyor 14. In other words, the wide conveyor 17 is wide enough to be located upstream of both the sorting conveyor 20 and the auxiliary conveyor 12. A portion of the sanitary paper stack B transported by the main conveyor 11 is handed over to the wide conveyor 17 and moves on the wide conveyor 17. While the sanitary paper stack B is moving on the wide conveyor 17, it is pushed out by the push-out device 30 in a direction diagonal to the main path, and its transport path is switched to the auxiliary path toward the auxiliary conveyor 12. In this way, the main conveyor 11, the wide conveyor 17, and the auxiliary individual conveyor 14 form the aforementioned auxiliary path. Note that if there is a possibility that the auxiliary individual conveyor 14 will interfere with the main individual conveyors 13(a) to (c), the auxiliary individual conveyor 14 may be disposed obliquely to the main individual conveyors 13(a) to (d), as shown in FIG. 13.

[0073] The second embodiment employs a wide conveyor 17 instead of the sub-conveyor 12 of the first embodiment, but other components and operations are the same as those of the first embodiment. Therefore, the second embodiment can distribute the sanitary paper stack B to one of the multiple main individual conveyors 13(a) to (c) and the sub-individual conveyor 14, following the same operation as the first embodiment shown in Figure 5.

[0074] Figure 14 shows a third embodiment of the sorting device 3. As shown in Figure 14, the third embodiment differs from the first embodiment in that a sorting conveyor 20 sorts sanitary paper stacks B vertically, and multiple main individual conveyors 13 are also installed vertically in line with this. The other configurations of the third embodiment are basically the same as those of the first embodiment.

[0075] FIG. 14 shows a side view of the main conveyor 11, the sorting conveyor 20, and the multiple main individual conveyors 13(a) and (b). As shown in FIG. 14(a), the sorting conveyor 20 includes a lower transport conveyor 25 and an upper transport conveyor 26 arranged parallel to each other above and below. These lower transport conveyor 25 and upper transport conveyor 26 each rotate to transport the sanitary paper stack B placed on their upper surfaces downstream (to the left in the figure). The multiple main individual conveyors 13(a) and (b) also include a first main individual conveyor 13(a) located on the lower side and a second main individual conveyor 13(b) located on the upper side. These first and second main individual conveyors 13(a) and (b) are arranged parallel to each other above and below.

[0076] As shown in Figure 14(a), the sanitary paper stack B transported from the main individual conveyor 13 is handed over to the lower transport conveyor 25 of the sorting conveyor 20, and is then transported by this lower transport conveyor 25 and sent out to the first main individual conveyor 13(a).

[0077] As shown in FIG. 14(b), the sorting conveyor 20 is configured to be able to rotate (transfer) in the vertical direction. Specifically, in the example shown in FIG. 14(b), the lower transport conveyor 25 and the upper transport conveyor 26 constituting the sorting conveyor 20 each rotate up and down on the upstream side with respect to a pivot point 23 on the downstream side of each conveyor. For example, as shown in FIG. 14(b), the upstream sides of the lower transport conveyor 25 and the upper transport conveyor 26 can be rotated downward while maintaining their parallel state. As a result, as shown in FIG. 14(d), the sanitary paper stack B conveyed from the main individual conveyor 13 is delivered to the upper transport conveyor 26 rather than the lower transport conveyor 25. The upper transport conveyor 26 conveys the sanitary paper stack B received from the main individual conveyor 13 downstream and sends it to the second main individual conveyor 13(b). Although not shown in the figure, the transport path of the sanitary paper stack B can be returned to the original state shown in Figures 14(a) and (b) by rotating the lower transport conveyor 25 and the upper transport conveyor 26 upward.

[0078] Furthermore, the rotation of the lower transport conveyor 25 and the upper transport conveyor 26 can be controlled based on detection information from the sensor 24. In this embodiment, the sensor 24 may be located, for example, downstream of the main individual conveyor 13. When this sensor 24 detects that the spacing between the sanitary paper stacks B has exceeded a predetermined distance, the lower transport conveyor 25 and the upper transport conveyor 26 can be rotated up and down to switch the transport path for the sanitary paper stacks B.

[0079] FIG. 15 is a plan view showing an example of a path switching device 40 for returning a sanitary paper stack B transported along a sub-path to the main path. This path switching device 40 can be combined with, for example, the first and second embodiments described above. As shown in FIG. 15, the path switching device 40 is basically disposed downstream of the multiple main individual conveyors 13(a)-(c) and the sub-individual conveyor 14. The path switching device 40 is configured to return the sanitary paper stack B transported by the sub-individual conveyor 14 to the same path as the sanitary paper stack B transported by the main individual conveyors 13(a)-(c). For example, if a problem occurs in a packaging machine or conveyor downstream of the sub-path and the device is stopped, it is effective to return the sanitary paper stack B sent out onto the sub-path to one of the main paths.

[0080] Specifically, the path switching device 40 comprises a wide conveyor 41 and multiple movable guides 42(a)-(c). The wide conveyor 41 is located downstream of all of the multiple main individual conveyors 13(a)-(c) and sub-individual conveyor 14, and has a width sufficient to receive the sanitary paper stacks B transported by these conveyors. The multiple movable guides 42(a)-(c) are arranged on this wide conveyor 41. Each of the movable guides 42(a)-(c) has a rotation fulcrum at its upstream end, and the downstream side can rotate around this rotation fulcrum.

[0081] As shown in Figure 15, suppose the first movable guide 42(a) is rotated diagonally relative to the conveying direction of the wide conveyor 41. In this case, the sanitary paper stack B conveyed by the auxiliary individual conveyor 14 proceeds along this first movable guide 42(a) on the wide conveyor 41 and can be moved to the conveying path (main path 3) downstream of the third main individual conveyor 13(c). Note that when the first movable guide 42(a) is not rotated, the sanitary paper stack B conveyed by the auxiliary individual conveyor 14 continues on the conveying path (auxiliary path) downstream of the auxiliary individual conveyor 14.

[0082] 15, suppose the second movable guide 42(b) is rotated obliquely relative to the conveying direction of the wide conveyor 41. In this case, the sanitary paper stack B traveling on the conveying path (main path 3) downstream of the third main individual conveyor 13(c) can be moved along the second movable guide 42(b) to the conveying path (main path 2) downstream of the second main individual conveyor 13(b). Note that when the second movable guide 42(b) is not rotated, the sanitary paper stack B traveling on main path 3 continues to move on this main path 3.

[0083] 15, the third movable guide 42(c) is rotated obliquely relative to the conveying direction of the wide conveyor 41. In this case, the sanitary paper stack B traveling on the conveying path (main path 2) downstream of the second main individual conveyor 13(b) can be moved along the third movable guide 42(c) to the conveying path (main path 1) downstream of the first main individual conveyor 13(a). Note that when the third movable guide 42(c) is not rotated, the sanitary paper stack B traveling on main path 2 continues to move on this main path 2. Furthermore, if there is no need to move the sanitary paper stack B to main path 1, the third movable guide 42(c) may be omitted.

[0084] In this way, by using multiple movable guides 42(a) to (c), the sanitary paper stack B being transported along the sub-path can be moved to one of the main paths 1 to 3. This makes it possible to return the sanitary paper stack B sent to the sub-path to one of the main paths and continue the packaging process, even if a problem occurs in a process downstream of the sub-path.

[0085] In the above description of the present invention, the embodiments of the present invention have been described with reference to the drawings in order to express the contents of the present invention. However, the present invention is not limited to the above embodiments, and includes modifications and improvements that are obvious to those skilled in the art based on the matters described in the present specification. [Explanation of symbols]

[0086] 1...Multiple machine 2...Cutting machine 3… Sorting device 4… Packing machine 10...Conveyor device 11...Main conveyor 12... Sub-conveyor 13... Main individual conveyor 14... Sub-individual conveyor 15... Deceleration conveyor 16(a) Waiting Zone 16(b) Receiving Zone 16(c)...Adjustment zone 17...Wide conveyor 20...Sorting conveyor (sorting section) 21...Lower conveyor 22...Upper conveyor 23...Pivot point 24...Sensor 25...Lower conveyor 26...Upper conveyor 30...Extrusion device 31...contact piece 32...drive pulley 33...Driven pulley 34...Belt (or chain) 40...Path switching device 41...Wide conveyor 42... Movable guide P... Sanitary paper B…Sanitary paper bundle S…Wide interval section

Claims

1. A method for sorting a sanitary paper stack, comprising: The apparatus includes a main conveyor, a sorting unit that sorts the sanitary paper stacks transported by the main conveyor, and a plurality of main individual conveyors arranged in parallel, a conveying step of conveying a plurality of sanitary paper bundles at intervals by the main conveyor; a sending step for sending some of the plurality of sanitary paper bundles being conveyed from the conveyance path of the main conveyor or a conveyance path continuing from the main conveyor to another conveyance path; a transfer step of transferring the sanitary paper stack, which has been transferred from the main conveyor to the sorting section, from the sorting section to one of the plurality of main individual conveyors by moving the sorting section. Sorting method.

2. In the feeding step, a wide interval portion where the interval between the sanitary paper stacks is widened is formed at a location where the sanitary paper stack is fed to the other transport path, The distribution section may have a transitional upstream end and / or a transitional downstream end, The transition of the distribution section is performed at the timing when the wide-interval section reaches the upstream end or the downstream end. The method of allocating according to claim 1.

3. the sending step includes pushing, by a pusher, at least a portion of the sanitary paper stack traveling along a transport path of the main conveyor or a transport path continuing from the main conveyor onto the other transport path; A sensor detects both or either of the gap between the sanitary paper to be extruded by the extrusion device and the preceding sanitary paper, and the gap between the sanitary paper to be extruded by the extrusion device and the succeeding sanitary paper, and the extrusion device is controlled based on the detection information from the sensor. The method of allocating according to claim 1.

4. the device further includes at least one sub-conveyor forming the other transport path; The sub-conveyor extends obliquely to the main conveyor at a position where it branches off from the main conveyor. The method of allocating according to any one of claims 1 to 3.

5. a step of sorting the sanitary paper stack by the sorting method according to claim 1; a step of packaging the sanitary paper stacks sorted by the sorting method, A method for manufacturing sanitary paper bundle products.

Images