CA1257566A - Method of producing roll of compressed roll paper and apparatus therefor - Google Patents
Method of producing roll of compressed roll paper and apparatus thereforInfo
- Publication number
- CA1257566A CA1257566A CA000575993A CA575993A CA1257566A CA 1257566 A CA1257566 A CA 1257566A CA 000575993 A CA000575993 A CA 000575993A CA 575993 A CA575993 A CA 575993A CA 1257566 A CA1257566 A CA 1257566A
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- roll
- roll paper
- paper
- compressed
- chamber
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Abstract
ABSTRACT
A method and apparatus for producing a compressed roll of roll paper wherein a compressing pressure is applied to a cylindrical roll of roll paper with crepe having an axis and a diametrical thickness.
A roll pressure plate reciprocates in a compressive direction to compress the roll paper. The roll paper is in a chamber and a lid is opposed to the pressure plate forming a wall portion of the chamber.
The compressing pressure is in one direction to deform the roll into a flat shape having a second thickness in the direction. The compressing pressure is continuously applied to the flat shape until said second thickness is reduced to between one-half and one-fifth of the diametrical distance of the cylindrical roll of roll paper before compression, while simultaneously restricting expansion of the roll in the direction lateral to the one direction of compressing pressure. These directions are substantially perpendicular to the axis of the roll. A further plate faces in a direction perpendicular to the compressive direction for limiting the expansion of the roll paper in the perpendicular direction. A roll positioning member is connected to the limiting plate through a spring device so as to protrude into the roll compressing chamber or retract therefrom.
A method and apparatus for producing a compressed roll of roll paper wherein a compressing pressure is applied to a cylindrical roll of roll paper with crepe having an axis and a diametrical thickness.
A roll pressure plate reciprocates in a compressive direction to compress the roll paper. The roll paper is in a chamber and a lid is opposed to the pressure plate forming a wall portion of the chamber.
The compressing pressure is in one direction to deform the roll into a flat shape having a second thickness in the direction. The compressing pressure is continuously applied to the flat shape until said second thickness is reduced to between one-half and one-fifth of the diametrical distance of the cylindrical roll of roll paper before compression, while simultaneously restricting expansion of the roll in the direction lateral to the one direction of compressing pressure. These directions are substantially perpendicular to the axis of the roll. A further plate faces in a direction perpendicular to the compressive direction for limiting the expansion of the roll paper in the perpendicular direction. A roll positioning member is connected to the limiting plate through a spring device so as to protrude into the roll compressing chamber or retract therefrom.
Description
~5~ Page 1 Sl'ECIFICA'rION
1. TITLE OF TIIE INVENTION
METHOD OF PRODUCING ROLL OF COMPRESSED ROLL PAPER
AND APPARATUS T~IEREFOR
1. TITLE OF TIIE INVENTION
METHOD OF PRODUCING ROLL OF COMPRESSED ROLL PAPER
AND APPARATUS T~IEREFOR
2. DET~ILED DESCRIPTION OF TIIE INVENTION
This invention relates to compressed toilet roll paper nn(l towel roll paper, -i.e. compressed roll paper, and more particularly to a method of and an apparatus for producing a roll oE roll paper reduced in volume.
In general, a roll of roll paper is formed into a cylindrical shape by winding toilet paper or towel paper on a hollow cylindrical core, so that a roll of roll paper can be continuously taken out of a holder in use.
Ilowever, the cylindrical outer shape and the hollow cylindrical core lead to increased voids in the loading, storage and the like of rolls of roll paper, thus result-ing in bulkiness. Due to this bulkiness, with the rolls of the conventional roll paper, freight charges, warehouse charges and the like are rather high, which is not neglectable in view of a sales cost of a roll of roll paper. Moreover, in the case of export, the freight charges and warehouse charges are increased to a huge amount, the reduction of which has been a great question in view of a reduced unit cost of a roll of roll paper.
To obviate the drawback caused by the cylindrical shape of roll paper as described above, there have been proposed measures for deforming a roll of roll paper into ~257~.~6~ Page 2 a flaL sllal)c lo dccrcil~q( cosLs re(luire(l for packing, transporting and storing of rolls of roll paper.
However, none of such measures has been put into practice.
The reason is that, as for roll paper, even if it is deformed into crooked shape during transportation for example, its value as an article of trade is deemed to be lowered. When a roll of roll paper is compression deformed into a flaL shape, the roll of roll paper is bulged out in one direction and crapes formed thereon are flattened, and folding wrinkles are left to lower elastic-ity of the roll of roll paper. Although the flattened roll of roll paper is restored to be a round shape for use, the crooked shape of the roll of roll paper cannot be easily obviated and left as it is. Even if a roll of roll payer is pressed and compression deformed illtO a flat shape, the roll of roll paper is easily inflated again due to its inherent elasticity when the pressing force is removed. Thus, it is not easy to maintain the shape of the roll of roll paper at the time of being compression deformed due to the pressing, and consequently, the effect of reducing the volunle due to the compression deformation is not so much expected.
The inventors of the present invention have repeated studies on the compression deformation of the roll of compressed roll paper due to the pressing and the characteristics of restoration to its initial shape, and reached the following methods and apparatuses.
~5~,~6~,i Namely, the present invention resides in that a roll of compressed roll paper characterized in that said roll of roll paper is at least liquid-nonpermeably wrapped with a film or films and has a flat shape in its side surface, a method of compression deforming a roll of roll-shaped roll paper to produce a flat-shaped roll of compressed roll paper, characterized in that pressing of said roll of roll paper in directions of compression is continued while the bulging-out sides of the roll of roll paper are pressed, a method of pressure deforming a rol] of roll-shaped roll paper to produce a roll of compressed roll paper, characterized in that, while the bulging-out sides of said roll paper are pressed, pressing of said roll of roll paper ln direct:ions of compress:Lon is continued to form a roll of flat-shaped compres.sed roll paper at an inter-mediate stage, said :Elat-shaped roll of compressed roll paper at the intermediate stage is wrapped with a heat-sllrinlcable po:Lymer film or films and heated, an apparatus for producing a roll of compressed roll paper having a flat shape in its side surface, character-ized by a roll receiving device for a roll of roll paper, a roll cutting device for a roll of roll paper and a pressure forming device for roll paper or a roll of roll paper, an apparatus for producing a rol.l of compressed roll paper having a flat shape in its side surface, character-ized by:
~ 2~6f~ Page a roll paper pressure containing portion comprising a roll paper support p:Late and a pair of side plates provided at opposite ends of said support plate and opposed to each other;
a push rod bear:ing member opposed to said roll paper support plate of said roll paper pressure containing portion and provided at end portions of said side plates;
a push rod movably supported by a bearing of said bearing member and provided at an end thereof with a pressure plate; and a roll paper positioning member provided at least at one of said side plates in a manner to be linearly movable into and out of said roll paper pressure containing portion, and an apparatus for producing a roll of compressed roll paper, characterized by:
a fixed shaft;
a cam affixed to said fixed shaft;
a push rod provided at one end thereof with a roller being in contact with said cam and at the other end there-of with a push plate;
a rotatable drum-shaped roll paper support member concentric with said fixed shaft, provided outside said cam and having a side wall extending outwardly at one end thereof;
a pair of side push plates affixed to side walls of said drum-shaped roll paper support member and forming a roll paper support space;
~57. 3~ Page 5 a push rod bearing for movably supporting said push rocl provided a~ :inller C'lld porLions of said side push plates;
a lid member with a lever, openably provided at outer end portions of said side plates and having a roller;
a frame concentric with said drum-shaped roll paper support member, positioned outwardly of said support member and being in contact with the roller of said lid member;
a push rod support rail provicded at least at a portion not covered by said frame; and a lid member opening rail engaged with said lever.
In the present invention, compressed roll paper means compressed roll of toilet paper and paper towel, which need not necessarily be one roll of roll paper, but, may be one including the length of a plurality of rolls of roll paper with single perforated lines or the like provided at every bordèrs so as to be cut. The shape of compressed roll paper is a shape of being flatter than a circle in its side surface, including not only an elliptical shape but also a rectangular shape, and moreover, various shapes covering a variety between the rectangular shape and the elliptical shape.
~ 7.~,6~
According to the present invention, a roll of compressed roll paper is formed and produced under pressure, an(l, it is preferable to apply pressure to the roll of roll paper simultaneously with film sealing in order to suppress the flattening of crapes to the utmost during production. In consequence, pressure may be applied in the vertical direction for example.
However, the application of pressure not only in the vertical direction but also the lateral direction makes it possible to form the roll of roll paper having a suitable shape in its side surface. Needless to say, it is preferable that the application of pressure in the bulging-out directions in addition to the lateral direction. Thus, the suppression of bulge-out through the application of pressure not only in the vertical direction but also in the bulging-out directions makes it possible to reali~e the compression of the outer diameter of 27mm on the shorter diameter's side of the roll of roll paper of a single roll type having a winding length of 55m.
With the above arrangement, for example, a roll of flatly compressed roll paper of a single roll type having a winding length of 55m can be industrially manufactured to have an outer diameter on the shorter diameter's side of 50mm or less, particularly 45mm or less, and an outer dialneter on the longer diameter's side of 124mm or more.
~2S7.~6~3 ~ lowever, if the outer diameter on the shorter diameter's side of a roll of roll paper is compressed to an extreme flatness, :i.e. lOmm by one step for example, then a perforated line or the like positioned at a bulging-out portion may be broken off or corners bulge out to an extreme extent where folding wrinkles become ununiform, whereby the restoration to a circular shape for use cannot be effected, and further, breakage may easily occur at end portions, i.e. selvedges. Hence, in such cases as described above, it is desirable that the compression is confined to an outer diameter of about 30 - 20mm on the shorter diameter's side at the side surface of roll paper for example, the compressed article is wrapped with a heat~shrinkable polymer film, and further, shrunk to predetermined dimensions by the operation of shrinkage by the heated film.
With the above arrangement, the compression may be achieved witll no perforated line brolcen off even when such perforated line is positioned at the bulging-out portion of roll paper and no selvedges broken in use.
Since the pressure formed roll of roll paper has a restoring force after the formation to some extent as described above, it is preferable to wrap roll paper with a plastics film or the like simultaneously with the formation in order to maintain the shape of roll paper at the time of formation.
To wrap the roll of compressed roll paper thus flatly formed, any of wrap materials including a paper container, ~ 2~ 6~ Pag e 8 a plastics container, a can and the like may be used in addition to plastics film wrapping. Particularly, the plastics film wrapping is easily mechani~ed, whereby film seal, particular:Ly individual film seal is easily performed, and moreover, air-tight or liquid-nonpermeable seal is practicable, so that the articles can be prevented from deteriorating in quality due to rain, moisture and the like during transportation and storage, thereby proving very sanitary. Further, in the case where both the flat formation under pressure and the film wrapping are simultalleously performed, if the sealing under pressure is effected in vacuo, then the compression can be achieved to a volume half that of the conventional roll-shaped roll paper, and moreover, the restoring force is preferably large as compared with the small volume thereof. It is preferable to use a heat-shrinkable polymer film as the plastics film because the pressure formation can be carried out simultaneously with the wrapping.
According to the present invention, the compression formation of a roll of roll-shaped roll paper under pressure is carried out by pushing the roll of roll paper by means of a push rod. In this case, the pushing stroke by the push rod is such that, for example, when there is a case where an outer diameter of the roll of compressed roll paper is 50mm on the shorter diameter's side in compressing the roll of roll paper of a single roll type having a winding length of 55m, the pushing stroke is ~ 257 .~6~j P age 9 83mm. In this case, the outer diameter of the roll of roll paper of single roll type having a winding length of 55m can be compressed to 27mm on the shorter diameter's side.
Ilowever, this compression of roll paper is performed such that the pressing process by means of the push rod is not pushed at once, but gradually pushed. Moreover, in the case of a roll of roll paper of a single roll type having a winding length of 55m for example, the pressing of the push rod i8 not stopped at a position where an outer diameter reaches 20 to 30mm, e.g. 27mm on the shorter diameter's side. On the contrary, the roll of roll paper must be maintained under the pressing force for a predetermined period of time, e.g. 15sec or more, pref-erably, 20sec or more. Such pressing force as described above may be gradually released, or the compressed roll paper may be held as it is under the final pressure for a predetermined period of time. With the above arrange-ment, even when the pressing force is removed, the outer diameter of the roll of compressed roll paper remains at about 50mm on the shorter diameter's side, so that flat rolls of roll paper is stably produced. In consequence, subsequent works can be easily carried out.
Furthermore, the inventors of the present inven~ion have found that, in producing the roll of compressed roll paper by the above-described method, a roll of roll paper of a single roll type having a winding length of 55m is produced with its crapes not being protected, and, when ., .
~ z~ ~ Page 10 the outer diameter on ttle shorter diameter's side is lOmm upon the compression deformation, if roll paper is re-stored, then the outer diameter on the shorter diameter's side becomes 26mm, however, this roll of roll paper, havi.ng folding lines, and cannot easily return to a circular shape. Further, when the outer diameter on the shorter diameter's side is 16mm upon the compression deformation, the outer diameter on the shorter diameter's side is 27mm after the restoration, which is substantially similar to the above case, it is necessary for securing the characteristics of restoration of the compressed roll paper that the outer diameter on the shorter diameter's side becomes 45 - 50mm or more upon the restration after the compression ~ n apparatus for producing the compressed roll paper according to the present invention is of such an arrange-ment that a roller is provided at one end of a push rod, and this roller is brought into engagement with a guide cam for pressing, whereby a path for the roller is guided by the guide cam for pressing, so that a moving stroke of a push plate of the push rod during the pressing process can be adjusted in accordance with a schedule.
The guide cam for pressing may be provided upwardly or downwardly of a pressing container, whereby a circula-tion path of either a horizontal type or a verticai type is formed. However, the guide cam for pressing may be affixed to a fixed shaft, being centered about the shaft, and a plurality of pressing devices each having a push rod ~ 2~
may be radially, rotatably provided around the guide cam in the vertical type. The cam is affixed to the fixed shaft as described above, whereby the construction of the cam is simplified, so that an area for installation can be reduced. No matter which type may be adopted, the shape of the guide cam for pressing is determined in accordance with the pressing force of roll paper, i.e. the moving stroke of the push plate.
The pressing container includes side walls, a roll paper support plate and an openable door capable of receiving or discharging roll paper, to thereby form a roll paper receiving chamber. The door, for example, may be replaced with a be(ll)late for supporting roll paper or a lid plate, both of which are made openable. It is preferable to provide a roll paper positioning member on the roll paper receiving chamber oE the pressing contain-er, so that a roll of roll paper rnay be positioned at a predetermined position in pressing the roll.
A mere fixation of the pressing container by use of a fixedly supporting device makes it possible to perEorm the pressing of a roll of roll paper. However, a roller is provided outwardly of the bedplate and this roller is brought into engagement with a guide plate such as a frame plate, so that a load acting on the fixedly supporting device can be reduced.
Particularly, when the apparatus for the production according to the present invention is formed into a rotary type, it is preferable that a push rod support rail to be ~5~.~6~ Page 12 brought into engagement with the roller of the push rod be provided around the cam for pressing for example.
Further, it is preferable that a lid member open-close rail engageable with a lever provided on the bedplate, lid member or a cover be provided.
~2~7 ~ Page 13 Fig. 1 is a side view of an embodiment of a roll of flat toilet paper produced according to the invention of the present application;
Fig. 2 is a flow sheet showing an embodiment of the method of and the apparatus for producing a roll of flatly compressed roll paper according to the invention of the present application;
Fig. 3 is schematic diagram showing the pressure formation process in another embodiment of the method of and the apparatus for producing a roll of compressed roll paper according to the invention of the present application;
Fig. 4 is a schematic diagram showing part of the film seal process of in another embodiment of the method of and the apparatus for producing a roll of compressed roll paper according to the invention of the present application;
Fig. S is a sectional side view showing an embodiment of the apparatus for producing a roll of compressed roll paper according to the invention of the present applica-tion; and Fig. 6 is a partially sectional, enlarged view showing the roll paper feeding portion shown in Fig. 5.
~257.~16~ Page 14 Detailed description will hereunder be given of the present invention with reference to the drawings.
However, the present invention need not necessarily be limited to this description.
Referring to Fig. 1, designated at 1 is a core, 3 a hollow portion of the core, and 4 a plastics film wrapping. In this ~rawing, the hollow portion 3 of the care is fairly exaggeratedly drawn, whereby an inner space is shown as being fairly large. However, in the case of a tubular paper core, opposing inner wall surfaces of the hollow portion of the core are almost in contact with each other, whereby the inner space is very small even if it exists. However, depending upon the material forming the core ancd conclitiorls oE formation-seal process, the hollow portions of the roll of flatly compressed roll paper according to the invention of the present application may vary widely from a state where the inner space being left as shown in the drawing to a state where the inner wall surfaces of the core are almost in contact with each other, whereby, almost no inner space is left.
A roll 9 of roll-shaped toilet roll paper thus produced is conveyed by a conveyor belt 8 from a roll receiving process 5 to a cutter, e.g. a cutting process 6 having an automatic circular cutter where the roll 9 is cut to a suitable length. In the cutting process 6 having the cutter, the roll 9 of roll-shaped roll paper may be cut to a suitable length or provided thereon with perforated lines to be cut. In Fig. 2, there are shown ~ 1.2~7r-~only rolls 10 of roll-shaped roll paper, which have been cut to a length of use, however, those rolls may otherwise be rolls of roll-shaped roll paper each provided thereon with perforated lines that may be suitable cut to a length of use.
A roll of roll-shaped roll paper cut during the cutti.ng process, :in ~he pr:ior art, is film-packed as is, then, packed in a case or the like and shipped, however, according to the invention of the present application, the roll is conveyed to a pressure-seal process 7, where the roll is formed into a flat shape and sealed with film.
The roll 10 of roll-shaped paper roll, which has been cut during the cutting process 6, is conveyed to a formation-seal process 7 by the conveyor belt 8. While, in the formation-seal process 7, plastics films 14 and 15 for wrapping are delivered Erom delivery film rollers 12 and 13, passed through guide rolls 16, 17 and guide plates 18, 19 and conveyed to a formation-seal portion 22. The cut roll 10 of roll-shaped roll paper together with a lower film 15 are conveyed to the formation-seal portion ; 22. Furthermore, an upper film is passed through an upper guide plate and covered around an upper portion of the cut roll lO of roll-shaped roll paper to cover the same in the formation-seal portion 22 or in the front of the formation-seal portion 22.
: In the formation-seal portion 22, there are provided presses 20 and 21 for pressure formation each having means for sealing film. Limit frames, not shown, are opposed ~ ~5~.r~6~ Page 16 to each other in a directioll traversing a path of the formation-seal portion 22. The cut roll 10 of roll-shaped roll paper is conveyed to a space formed between the opposing limit frames, pressed, in such conditions where it is covered by the upper and lower films, by the presses 20 and 21 from above and below, and sealed with films simultaneously with the formation.
The limit frames may be fixedly provided. However, it is preferable to provide the limit frames in such a manner that the interval of opposition is suitably adjustable. The provision of the limit frames at a suitable interval makes it possible to adjust the pressing in the lateral direction and form the rolls into various types of flatness.
The roll of compressed roll paper thus sealed simultaneously with the formation is moved from the formation-seal portion 22, transferred from a belt conveyor 23 to a chute 24, then, packed in corrugated case or the like, and then shipped.
Fig. 2 shows a case of an example where a cut roll of roll paper is sealed with film simultaneously with the pressure formation thereof. However, a plurality of rolls may be wrappingly sealed with film into a single pack simultaneously with the pressure formation, and a long roll of roll paper may be sealed in the same manner as above. Needless to say, the formation process and the seal process may be effected separately of each other.
In this case, one or a plurality of rolls of flatly ~. ' ,:
~ 257 ~~ 7 Page 17 compresse(l roll pal)er, which have undergone the pressure formation only, are covered with film and sealed.
The provision of a hollow core with elasticity, which is even slight, makes it possible to easily return from the flat shape to the cylindrical shape. As a material of the hollow core described above, it suffices to use one which can be easily restored from the flat shape, particularly a thin flat shape to the circle, i.e. the cylindrical shape. The material of the hollow core may be formed of a rubber or plastics rubber, which are easily returned to the cylindrical shape by unpacking for example, and further, may be formed of one which is easily deformably flexible, i.e. a material having slight elasticity, such as a tubular paper core. When the conventional roll paper using the tubular paper core is pressure formed into a Llat shape for example, wrinkles are formed at flexed side portions of the tubular paper core. However, when a slight force is applied to the flexed side portions to expand the center portions for use, the tubular paper core can be readily formed into a cylindrical shape, i.e. a roll shape, thus raising no problem.
A roll 25 of roll-shaped roll paper, which has been given perforated lines and cut to a suitable length during the cutting process, not shown, in Fig. 3, is covered at its upper and lower portions with plastics films delivered from a plastics film delivery roller 26 (a lower roller not shown), conveyed by hold-down rollers 29, 32 and ~257. ~ Page 18 carrying rollers 30, 35, 37 and 39, and formed into a flat shape under pressure of pressure rollers 34, 36 and 38.
For example, during the forming process shown in Fig.
This invention relates to compressed toilet roll paper nn(l towel roll paper, -i.e. compressed roll paper, and more particularly to a method of and an apparatus for producing a roll oE roll paper reduced in volume.
In general, a roll of roll paper is formed into a cylindrical shape by winding toilet paper or towel paper on a hollow cylindrical core, so that a roll of roll paper can be continuously taken out of a holder in use.
Ilowever, the cylindrical outer shape and the hollow cylindrical core lead to increased voids in the loading, storage and the like of rolls of roll paper, thus result-ing in bulkiness. Due to this bulkiness, with the rolls of the conventional roll paper, freight charges, warehouse charges and the like are rather high, which is not neglectable in view of a sales cost of a roll of roll paper. Moreover, in the case of export, the freight charges and warehouse charges are increased to a huge amount, the reduction of which has been a great question in view of a reduced unit cost of a roll of roll paper.
To obviate the drawback caused by the cylindrical shape of roll paper as described above, there have been proposed measures for deforming a roll of roll paper into ~257~.~6~ Page 2 a flaL sllal)c lo dccrcil~q( cosLs re(luire(l for packing, transporting and storing of rolls of roll paper.
However, none of such measures has been put into practice.
The reason is that, as for roll paper, even if it is deformed into crooked shape during transportation for example, its value as an article of trade is deemed to be lowered. When a roll of roll paper is compression deformed into a flaL shape, the roll of roll paper is bulged out in one direction and crapes formed thereon are flattened, and folding wrinkles are left to lower elastic-ity of the roll of roll paper. Although the flattened roll of roll paper is restored to be a round shape for use, the crooked shape of the roll of roll paper cannot be easily obviated and left as it is. Even if a roll of roll payer is pressed and compression deformed illtO a flat shape, the roll of roll paper is easily inflated again due to its inherent elasticity when the pressing force is removed. Thus, it is not easy to maintain the shape of the roll of roll paper at the time of being compression deformed due to the pressing, and consequently, the effect of reducing the volunle due to the compression deformation is not so much expected.
The inventors of the present invention have repeated studies on the compression deformation of the roll of compressed roll paper due to the pressing and the characteristics of restoration to its initial shape, and reached the following methods and apparatuses.
~5~,~6~,i Namely, the present invention resides in that a roll of compressed roll paper characterized in that said roll of roll paper is at least liquid-nonpermeably wrapped with a film or films and has a flat shape in its side surface, a method of compression deforming a roll of roll-shaped roll paper to produce a flat-shaped roll of compressed roll paper, characterized in that pressing of said roll of roll paper in directions of compression is continued while the bulging-out sides of the roll of roll paper are pressed, a method of pressure deforming a rol] of roll-shaped roll paper to produce a roll of compressed roll paper, characterized in that, while the bulging-out sides of said roll paper are pressed, pressing of said roll of roll paper ln direct:ions of compress:Lon is continued to form a roll of flat-shaped compres.sed roll paper at an inter-mediate stage, said :Elat-shaped roll of compressed roll paper at the intermediate stage is wrapped with a heat-sllrinlcable po:Lymer film or films and heated, an apparatus for producing a roll of compressed roll paper having a flat shape in its side surface, character-ized by a roll receiving device for a roll of roll paper, a roll cutting device for a roll of roll paper and a pressure forming device for roll paper or a roll of roll paper, an apparatus for producing a rol.l of compressed roll paper having a flat shape in its side surface, character-ized by:
~ 2~6f~ Page a roll paper pressure containing portion comprising a roll paper support p:Late and a pair of side plates provided at opposite ends of said support plate and opposed to each other;
a push rod bear:ing member opposed to said roll paper support plate of said roll paper pressure containing portion and provided at end portions of said side plates;
a push rod movably supported by a bearing of said bearing member and provided at an end thereof with a pressure plate; and a roll paper positioning member provided at least at one of said side plates in a manner to be linearly movable into and out of said roll paper pressure containing portion, and an apparatus for producing a roll of compressed roll paper, characterized by:
a fixed shaft;
a cam affixed to said fixed shaft;
a push rod provided at one end thereof with a roller being in contact with said cam and at the other end there-of with a push plate;
a rotatable drum-shaped roll paper support member concentric with said fixed shaft, provided outside said cam and having a side wall extending outwardly at one end thereof;
a pair of side push plates affixed to side walls of said drum-shaped roll paper support member and forming a roll paper support space;
~57. 3~ Page 5 a push rod bearing for movably supporting said push rocl provided a~ :inller C'lld porLions of said side push plates;
a lid member with a lever, openably provided at outer end portions of said side plates and having a roller;
a frame concentric with said drum-shaped roll paper support member, positioned outwardly of said support member and being in contact with the roller of said lid member;
a push rod support rail provicded at least at a portion not covered by said frame; and a lid member opening rail engaged with said lever.
In the present invention, compressed roll paper means compressed roll of toilet paper and paper towel, which need not necessarily be one roll of roll paper, but, may be one including the length of a plurality of rolls of roll paper with single perforated lines or the like provided at every bordèrs so as to be cut. The shape of compressed roll paper is a shape of being flatter than a circle in its side surface, including not only an elliptical shape but also a rectangular shape, and moreover, various shapes covering a variety between the rectangular shape and the elliptical shape.
~ 7.~,6~
According to the present invention, a roll of compressed roll paper is formed and produced under pressure, an(l, it is preferable to apply pressure to the roll of roll paper simultaneously with film sealing in order to suppress the flattening of crapes to the utmost during production. In consequence, pressure may be applied in the vertical direction for example.
However, the application of pressure not only in the vertical direction but also the lateral direction makes it possible to form the roll of roll paper having a suitable shape in its side surface. Needless to say, it is preferable that the application of pressure in the bulging-out directions in addition to the lateral direction. Thus, the suppression of bulge-out through the application of pressure not only in the vertical direction but also in the bulging-out directions makes it possible to reali~e the compression of the outer diameter of 27mm on the shorter diameter's side of the roll of roll paper of a single roll type having a winding length of 55m.
With the above arrangement, for example, a roll of flatly compressed roll paper of a single roll type having a winding length of 55m can be industrially manufactured to have an outer diameter on the shorter diameter's side of 50mm or less, particularly 45mm or less, and an outer dialneter on the longer diameter's side of 124mm or more.
~2S7.~6~3 ~ lowever, if the outer diameter on the shorter diameter's side of a roll of roll paper is compressed to an extreme flatness, :i.e. lOmm by one step for example, then a perforated line or the like positioned at a bulging-out portion may be broken off or corners bulge out to an extreme extent where folding wrinkles become ununiform, whereby the restoration to a circular shape for use cannot be effected, and further, breakage may easily occur at end portions, i.e. selvedges. Hence, in such cases as described above, it is desirable that the compression is confined to an outer diameter of about 30 - 20mm on the shorter diameter's side at the side surface of roll paper for example, the compressed article is wrapped with a heat~shrinkable polymer film, and further, shrunk to predetermined dimensions by the operation of shrinkage by the heated film.
With the above arrangement, the compression may be achieved witll no perforated line brolcen off even when such perforated line is positioned at the bulging-out portion of roll paper and no selvedges broken in use.
Since the pressure formed roll of roll paper has a restoring force after the formation to some extent as described above, it is preferable to wrap roll paper with a plastics film or the like simultaneously with the formation in order to maintain the shape of roll paper at the time of formation.
To wrap the roll of compressed roll paper thus flatly formed, any of wrap materials including a paper container, ~ 2~ 6~ Pag e 8 a plastics container, a can and the like may be used in addition to plastics film wrapping. Particularly, the plastics film wrapping is easily mechani~ed, whereby film seal, particular:Ly individual film seal is easily performed, and moreover, air-tight or liquid-nonpermeable seal is practicable, so that the articles can be prevented from deteriorating in quality due to rain, moisture and the like during transportation and storage, thereby proving very sanitary. Further, in the case where both the flat formation under pressure and the film wrapping are simultalleously performed, if the sealing under pressure is effected in vacuo, then the compression can be achieved to a volume half that of the conventional roll-shaped roll paper, and moreover, the restoring force is preferably large as compared with the small volume thereof. It is preferable to use a heat-shrinkable polymer film as the plastics film because the pressure formation can be carried out simultaneously with the wrapping.
According to the present invention, the compression formation of a roll of roll-shaped roll paper under pressure is carried out by pushing the roll of roll paper by means of a push rod. In this case, the pushing stroke by the push rod is such that, for example, when there is a case where an outer diameter of the roll of compressed roll paper is 50mm on the shorter diameter's side in compressing the roll of roll paper of a single roll type having a winding length of 55m, the pushing stroke is ~ 257 .~6~j P age 9 83mm. In this case, the outer diameter of the roll of roll paper of single roll type having a winding length of 55m can be compressed to 27mm on the shorter diameter's side.
Ilowever, this compression of roll paper is performed such that the pressing process by means of the push rod is not pushed at once, but gradually pushed. Moreover, in the case of a roll of roll paper of a single roll type having a winding length of 55m for example, the pressing of the push rod i8 not stopped at a position where an outer diameter reaches 20 to 30mm, e.g. 27mm on the shorter diameter's side. On the contrary, the roll of roll paper must be maintained under the pressing force for a predetermined period of time, e.g. 15sec or more, pref-erably, 20sec or more. Such pressing force as described above may be gradually released, or the compressed roll paper may be held as it is under the final pressure for a predetermined period of time. With the above arrange-ment, even when the pressing force is removed, the outer diameter of the roll of compressed roll paper remains at about 50mm on the shorter diameter's side, so that flat rolls of roll paper is stably produced. In consequence, subsequent works can be easily carried out.
Furthermore, the inventors of the present inven~ion have found that, in producing the roll of compressed roll paper by the above-described method, a roll of roll paper of a single roll type having a winding length of 55m is produced with its crapes not being protected, and, when ., .
~ z~ ~ Page 10 the outer diameter on ttle shorter diameter's side is lOmm upon the compression deformation, if roll paper is re-stored, then the outer diameter on the shorter diameter's side becomes 26mm, however, this roll of roll paper, havi.ng folding lines, and cannot easily return to a circular shape. Further, when the outer diameter on the shorter diameter's side is 16mm upon the compression deformation, the outer diameter on the shorter diameter's side is 27mm after the restoration, which is substantially similar to the above case, it is necessary for securing the characteristics of restoration of the compressed roll paper that the outer diameter on the shorter diameter's side becomes 45 - 50mm or more upon the restration after the compression ~ n apparatus for producing the compressed roll paper according to the present invention is of such an arrange-ment that a roller is provided at one end of a push rod, and this roller is brought into engagement with a guide cam for pressing, whereby a path for the roller is guided by the guide cam for pressing, so that a moving stroke of a push plate of the push rod during the pressing process can be adjusted in accordance with a schedule.
The guide cam for pressing may be provided upwardly or downwardly of a pressing container, whereby a circula-tion path of either a horizontal type or a verticai type is formed. However, the guide cam for pressing may be affixed to a fixed shaft, being centered about the shaft, and a plurality of pressing devices each having a push rod ~ 2~
may be radially, rotatably provided around the guide cam in the vertical type. The cam is affixed to the fixed shaft as described above, whereby the construction of the cam is simplified, so that an area for installation can be reduced. No matter which type may be adopted, the shape of the guide cam for pressing is determined in accordance with the pressing force of roll paper, i.e. the moving stroke of the push plate.
The pressing container includes side walls, a roll paper support plate and an openable door capable of receiving or discharging roll paper, to thereby form a roll paper receiving chamber. The door, for example, may be replaced with a be(ll)late for supporting roll paper or a lid plate, both of which are made openable. It is preferable to provide a roll paper positioning member on the roll paper receiving chamber oE the pressing contain-er, so that a roll of roll paper rnay be positioned at a predetermined position in pressing the roll.
A mere fixation of the pressing container by use of a fixedly supporting device makes it possible to perEorm the pressing of a roll of roll paper. However, a roller is provided outwardly of the bedplate and this roller is brought into engagement with a guide plate such as a frame plate, so that a load acting on the fixedly supporting device can be reduced.
Particularly, when the apparatus for the production according to the present invention is formed into a rotary type, it is preferable that a push rod support rail to be ~5~.~6~ Page 12 brought into engagement with the roller of the push rod be provided around the cam for pressing for example.
Further, it is preferable that a lid member open-close rail engageable with a lever provided on the bedplate, lid member or a cover be provided.
~2~7 ~ Page 13 Fig. 1 is a side view of an embodiment of a roll of flat toilet paper produced according to the invention of the present application;
Fig. 2 is a flow sheet showing an embodiment of the method of and the apparatus for producing a roll of flatly compressed roll paper according to the invention of the present application;
Fig. 3 is schematic diagram showing the pressure formation process in another embodiment of the method of and the apparatus for producing a roll of compressed roll paper according to the invention of the present application;
Fig. 4 is a schematic diagram showing part of the film seal process of in another embodiment of the method of and the apparatus for producing a roll of compressed roll paper according to the invention of the present application;
Fig. S is a sectional side view showing an embodiment of the apparatus for producing a roll of compressed roll paper according to the invention of the present applica-tion; and Fig. 6 is a partially sectional, enlarged view showing the roll paper feeding portion shown in Fig. 5.
~257.~16~ Page 14 Detailed description will hereunder be given of the present invention with reference to the drawings.
However, the present invention need not necessarily be limited to this description.
Referring to Fig. 1, designated at 1 is a core, 3 a hollow portion of the core, and 4 a plastics film wrapping. In this ~rawing, the hollow portion 3 of the care is fairly exaggeratedly drawn, whereby an inner space is shown as being fairly large. However, in the case of a tubular paper core, opposing inner wall surfaces of the hollow portion of the core are almost in contact with each other, whereby the inner space is very small even if it exists. However, depending upon the material forming the core ancd conclitiorls oE formation-seal process, the hollow portions of the roll of flatly compressed roll paper according to the invention of the present application may vary widely from a state where the inner space being left as shown in the drawing to a state where the inner wall surfaces of the core are almost in contact with each other, whereby, almost no inner space is left.
A roll 9 of roll-shaped toilet roll paper thus produced is conveyed by a conveyor belt 8 from a roll receiving process 5 to a cutter, e.g. a cutting process 6 having an automatic circular cutter where the roll 9 is cut to a suitable length. In the cutting process 6 having the cutter, the roll 9 of roll-shaped roll paper may be cut to a suitable length or provided thereon with perforated lines to be cut. In Fig. 2, there are shown ~ 1.2~7r-~only rolls 10 of roll-shaped roll paper, which have been cut to a length of use, however, those rolls may otherwise be rolls of roll-shaped roll paper each provided thereon with perforated lines that may be suitable cut to a length of use.
A roll of roll-shaped roll paper cut during the cutti.ng process, :in ~he pr:ior art, is film-packed as is, then, packed in a case or the like and shipped, however, according to the invention of the present application, the roll is conveyed to a pressure-seal process 7, where the roll is formed into a flat shape and sealed with film.
The roll 10 of roll-shaped paper roll, which has been cut during the cutting process 6, is conveyed to a formation-seal process 7 by the conveyor belt 8. While, in the formation-seal process 7, plastics films 14 and 15 for wrapping are delivered Erom delivery film rollers 12 and 13, passed through guide rolls 16, 17 and guide plates 18, 19 and conveyed to a formation-seal portion 22. The cut roll 10 of roll-shaped roll paper together with a lower film 15 are conveyed to the formation-seal portion ; 22. Furthermore, an upper film is passed through an upper guide plate and covered around an upper portion of the cut roll lO of roll-shaped roll paper to cover the same in the formation-seal portion 22 or in the front of the formation-seal portion 22.
: In the formation-seal portion 22, there are provided presses 20 and 21 for pressure formation each having means for sealing film. Limit frames, not shown, are opposed ~ ~5~.r~6~ Page 16 to each other in a directioll traversing a path of the formation-seal portion 22. The cut roll 10 of roll-shaped roll paper is conveyed to a space formed between the opposing limit frames, pressed, in such conditions where it is covered by the upper and lower films, by the presses 20 and 21 from above and below, and sealed with films simultaneously with the formation.
The limit frames may be fixedly provided. However, it is preferable to provide the limit frames in such a manner that the interval of opposition is suitably adjustable. The provision of the limit frames at a suitable interval makes it possible to adjust the pressing in the lateral direction and form the rolls into various types of flatness.
The roll of compressed roll paper thus sealed simultaneously with the formation is moved from the formation-seal portion 22, transferred from a belt conveyor 23 to a chute 24, then, packed in corrugated case or the like, and then shipped.
Fig. 2 shows a case of an example where a cut roll of roll paper is sealed with film simultaneously with the pressure formation thereof. However, a plurality of rolls may be wrappingly sealed with film into a single pack simultaneously with the pressure formation, and a long roll of roll paper may be sealed in the same manner as above. Needless to say, the formation process and the seal process may be effected separately of each other.
In this case, one or a plurality of rolls of flatly ~. ' ,:
~ 257 ~~ 7 Page 17 compresse(l roll pal)er, which have undergone the pressure formation only, are covered with film and sealed.
The provision of a hollow core with elasticity, which is even slight, makes it possible to easily return from the flat shape to the cylindrical shape. As a material of the hollow core described above, it suffices to use one which can be easily restored from the flat shape, particularly a thin flat shape to the circle, i.e. the cylindrical shape. The material of the hollow core may be formed of a rubber or plastics rubber, which are easily returned to the cylindrical shape by unpacking for example, and further, may be formed of one which is easily deformably flexible, i.e. a material having slight elasticity, such as a tubular paper core. When the conventional roll paper using the tubular paper core is pressure formed into a Llat shape for example, wrinkles are formed at flexed side portions of the tubular paper core. However, when a slight force is applied to the flexed side portions to expand the center portions for use, the tubular paper core can be readily formed into a cylindrical shape, i.e. a roll shape, thus raising no problem.
A roll 25 of roll-shaped roll paper, which has been given perforated lines and cut to a suitable length during the cutting process, not shown, in Fig. 3, is covered at its upper and lower portions with plastics films delivered from a plastics film delivery roller 26 (a lower roller not shown), conveyed by hold-down rollers 29, 32 and ~257. ~ Page 18 carrying rollers 30, 35, 37 and 39, and formed into a flat shape under pressure of pressure rollers 34, 36 and 38.
For example, during the forming process shown in Fig.
3, a roll 31 of compressed roll paper, which has been deformed, is sealed by jointing an upper and a lower films in front and at the back thereof, and conveyed by carrying rollers after a surplus portion of the sealed film has been cut away.
The feed speeds of a conveyor belt 47, a hold-down roller 48 and a carrying roller 49 are made higher than the feed speeds of hold-down rollers 41 and 42, whereby an interval between the rolls of compressed roll paper is increased and the films become stretched therebetween.
Then, the upper and the lower films are clamped between heating seal devices 44 and 45, to thereby seal the upper and the lower films and cut the same off.
During the above sealing, vacuum sealing may be effected by a vacuum device suitably provided.
~ roll 46 of compressed roll paper sealed therearound by the films is conveyed by a belt conveyor 47 to be case-packed.
In pressure forming the roll 25 of toilet roll paper by use of pressure forming rollers 34, 36 and 38, the formed shape of the roll may be suitably adjusted by limit plates provided at opposite sides of the roll 25 of roll-shaped roll paper.
The roll 31 of toilet roll paper thus flatly formed is conveyed by a carrying roller to a subsequent process.
~2~;7,~ i Page 19 Fig. 3 shows the rolls of roll-shaped roll paper, which have been given perforated lines and have a length corresponding to three rolls. However, needless to say, one roll of roll-shaped toilet roll paper as well as a long one such as a ro:ll of roll-shaped roll paper may be formed into a flat shape in its side surface.
Figs. 2 through 4 illustrate the processes in which a roll of roll-shaped paper is cut, thereafter, formed and sealed to produce intended flat rolls of compressed roll paper. However, needless to say, cut and seal may be effected after the formation. As the pressure formation device in this case, the one shown in Fig. 3 for example is preferable because the device may be continuously operated.
A roll paper pressing container 50 is continuously, rotatably movable from a roll paper pressing position 51 to a roll paper pressing position 62. Each of the press-ing containers 50 comprises side plate 63 and 64, a lid member 65, an upper roller 66, a push plate 67, a push rod 68, a push rod bearing 69 and a lower roller 70. The side plate 63 is affixed at opposite ends thereof to a drum side plate 71. Thus, a pair of side plates 63 and 64 partition in the front and at the back of a pressing container for roll paper, to thereby form the pressing container. One 63 of the pair of side plates is provided thereon with a member for positioning a roll of roll paper, e.g. a positioning block 72. This member determines a position of a roll of roll paper, ~ 2~7.~j Page 20 which has been supplied into the pressing container, prior to the compression. A fulcrum 73 for opening or closing the lid member is provided at one end of the side plate 63 provided in the rear, and said lid member 65 is rotatably secured to this fulcrum. A lever 74 for closing the lid member is provided on the lid member 65 on the side of the fulcrum 73 for opening or closing the lid member, to function of closing the lid member, which has opened. In the -interior of the pressing container 50 defined by the push plate 67, side plates 63, 64 and drum side plate 71, the push plate 67 moves within a predetermined stroke, to thereby compress the roll of roll paper in the pressing container 50. This moving stroke is effected by the operation of the push rod 68 loosely couplingly supported by the rod bearing 69. The pushing operation of this push rod 68 is performed by the contact-ing engagement between the lower roller 70 and a guide cam 75 for pressing. The guide cam 75 for pressing is affixed to a fixed shaft 76, whereby the pressing container 50 is rotatable with the drum side plates 71. The upper roller 66 of the pressing container 50 moves in contact with the inner surface of a frame 77 concentric with the fixed shaEt 76. A take-out position 57 is positioned at a posi-tion past the tail end of the frame 77. A push rod support rail 78 is formed along the outer periphery of the guide cam 75 for pressing between this take-out position 57 to a pressing start position 62 where the starting end of the frame 77 is disposed. At the take-out position 57, ~ z57.r6~ Page Zl the pressing container 50 is supported by the support rail 78, however, the lid member 65 is automatically opened downwardly because nothing supports the weight thereof, and a take-out tool 80 for a roll 79 of compressed roll paper and a conveyor 81 for carrying out the roll of compressed roll paper are disposed directly beneath the pressing container 50. A feed plate 82 and a roll paper feed tool 83 are provided obliquely upwardly of a roll paper feeding position 60. This roll paper feed tool 83 is operated by a cylinder 84. A drum support roller 86 is provided in contact with a drum 85 supported by ~he drum support roller 86.
The drum support roller 86 is rotatably driven by a driving source, not shown, to thereby turn the drum 85.
A lid member open-close rail 87 is provided in contact with the end of the lever 74 from a position past the take-out position 57 for the roll of compressed roll paper to a position past the roll paper feeding position 60.
The apparatus for producing a roll of compressed roll paper according to the present invention is of such arrangement as described above, whereby the roll of roll paper is supplied into the pressing container 50 at the roll paper feeding position from the feed plate 82 and the roll paper feed tool 83. The pressing container moves upwardly as the drum rotates (rotating in a forward direc-tion from 51 to 62 in the drawing) due to the rotation of the drum support roller 86. The end of the lever 74 moves along the open-close rail 87 and the lid member 65 is ~Z57,~6~ Page 22 closed at a position where the open-close rail 87 is bent in the direction of lifting the end of the lever 74, The roll 79 of roll paper in the pressing container is positioned by the positioning block 72, whereby the pressing container 50 moves within a pressing area in the frame 77 including 51, 52, 53, 54, 55, 56 and 57. As a rotatable drum 85 rotates, the lower roller 70 of the push rod 68 moves along the surface of the guide cam 75 for pressing, whereby the push rod 68 slowly pushes into the pressing container 50 at a speed of 4.3mm/sec on a average, to thereby push the roll 79 of roll paper. The shape of the guide cam 75 for pressing is determined in accordance with the magnitude bf a pushing load and the speed of insertion of the push rod 58. The movement of the push rod 68 is stopped at a position where the push plate 67 is 25mm apart from the l:id member 65, and the push rod 68 is held thereat for 17.5sec. On the other hand, the upper roller leaves the frame 77 after a lapse of 17.5 sec. The lid member 65 opens by its gravity, and the roll 79 of compressed roll paper is pushed out by the push rod 68. The roll of compressed roll paper is taken out by the take-out tool 80 and carried out by the conveyor 81 for carrying out.
The rotatable drum 85 is continuously turned by the rotation of the drum support rollers 86 for driving.
The roll 79 of compressed roll paper thus conveyed is covered by the heat-shrinkable plastics films each having a thickness of about 0.02mm and compressingly ' , ~57,r~
sealed at a sealing temperature of 200C for example.
In a case capable oL colltaining therein 120 rolls of the standard roll paper of a single roll type having an outer diameter of about 50mm on the shorter diameter's side, an outer diameter of about 124mm on the longer diameter's side and a paper width of 114mm, there may be contained 208 rolls of compressed roll paper thus sealed.
Hence, if the rolls of compressed roll paper are held in the apparatus shown in the above embodiment for 20 sec or more, Lhell, the rolls of the standard roll paper are deformed to have an outer diameter of about 45mm on the shorter diameter's side and an outer dimeter of about 124mm on the longer diameter's side, and, in the above case of capable of containing therein 120 rolls, there may be contained 212 rolls, so that the number of the deformed rolls thus compressed which are contained in the same case is increased by 76.7% as compared with the rolls of the standard roll paper. Even if a ready made case is used as described above, track load charges for example during transportation, warehouse storage charges and the like are saved by about 40%. A roll of roll-shaped toilet roll paper of a single roll type having a winding length of 65m has a diameter of 10.5cm and a length of 11.7cm. In con-trast thereto, the roll of toilet roll paper according to the invention of the present application has a width of 12cm, a length of 11.7cm and a thickness of 4cm, whereby the volume is reduced to one half and the configuration is not bulky, whereby the load per unit volume can be ~57~6~
Page Z4 increased, thus proving outstandingly advantageous from the viewpoint of transportation and the like of toilet rol:l paper. And cylindrical towel paper, for example, having a winding length of 18m has a dizmeter of about 12cm and a length about 24cm is compressed to have a width of about 16cm, a length of about 24cm and a thickness of about 4.5cm according to the present invention.
However, if the rolls of compressed toilet roll paper are contained in a case specially fitted thereto, then the space in the case is more effectively used, so that the number of rolls contained in the case is increased by 100%, so that the expenses for transportation can be reduced to one half.
Moreover, the roll of compressed roll paper obtained according to the present invention can maintain the flat shape even when the pressing force is released, so that the volume reduction as described above can be contemplated. Hence, if a heat-shrinkable polymer film is used, then the compression can be easily effected, the wrapping by use of a plastics film or the like can be easily performed and the handling of articles thereafter can be easily made. The roll of compressed roll paper as being the products according to the present invention, in the case of a single roll type having a winding length of 55m, can be strongly compressed to a thickness of 27mm with crapes being protected for example. However, roll is returned to a thickness of about 50mm due to a restoring force of crapes, emboss formation or the like.
~257- J~ Page 25 Hence, for use, the center portions are pressed to be inflated to easily restore to a circle, whereby no trouble is caused in use.
~ oreover, the roll of compressed roll paper according to the present invention can be maintained in a flat state for a long period of time, so that the further handling may be easily made. The wrapping by use of plastics films or the like may be automatically carried out at any time as well as during the production process. Particularly, the rolls, which have been liquid-nonpermeably wrapped by a plastic film or plastics films or have been air-tightly wrapped by a plastic film or plastic films, can be prevented from deteriorating in quality due to rain, moisture and the like during transportation and storage, thereby proving very sanitary.
As has been described hereinabove, the influence brought about by the present invention is significant.
~L2~7 ~r,~
Designated at 1 is a core, 2 a roll of toilet roll paper, 3 a hollow portion of the core, 4 a plastics film, 5 a roll receiving process for roll-shaped toilet roll paper, 6 a cutting process, and 7 a formation-seal process. Denoted at 9 is a roll of roll-shaped toilet roll paper, and 10 a roll of roll-shaped toilet roll paper obtained by cutting the roll 9. Indicated at 12 and 13 are plastics film rollers, and 19 and 20 form a 75 a guide cam for pressing, 76 a fixed shaft, 77 a frame, 78 a support rail, 79 a roll of roll paper, 80 a take-out tcol, 81 a conveyor for carrying out, ~2 a roll paper feed plate, 8~ a rotary drum, 85 a drum support conveyor, 86 a driving roller, 87 an open-close rail, and 88 a stopper.
This application is a division of application Serial Number 455rO51 filed May 24, 1984.
The feed speeds of a conveyor belt 47, a hold-down roller 48 and a carrying roller 49 are made higher than the feed speeds of hold-down rollers 41 and 42, whereby an interval between the rolls of compressed roll paper is increased and the films become stretched therebetween.
Then, the upper and the lower films are clamped between heating seal devices 44 and 45, to thereby seal the upper and the lower films and cut the same off.
During the above sealing, vacuum sealing may be effected by a vacuum device suitably provided.
~ roll 46 of compressed roll paper sealed therearound by the films is conveyed by a belt conveyor 47 to be case-packed.
In pressure forming the roll 25 of toilet roll paper by use of pressure forming rollers 34, 36 and 38, the formed shape of the roll may be suitably adjusted by limit plates provided at opposite sides of the roll 25 of roll-shaped roll paper.
The roll 31 of toilet roll paper thus flatly formed is conveyed by a carrying roller to a subsequent process.
~2~;7,~ i Page 19 Fig. 3 shows the rolls of roll-shaped roll paper, which have been given perforated lines and have a length corresponding to three rolls. However, needless to say, one roll of roll-shaped toilet roll paper as well as a long one such as a ro:ll of roll-shaped roll paper may be formed into a flat shape in its side surface.
Figs. 2 through 4 illustrate the processes in which a roll of roll-shaped paper is cut, thereafter, formed and sealed to produce intended flat rolls of compressed roll paper. However, needless to say, cut and seal may be effected after the formation. As the pressure formation device in this case, the one shown in Fig. 3 for example is preferable because the device may be continuously operated.
A roll paper pressing container 50 is continuously, rotatably movable from a roll paper pressing position 51 to a roll paper pressing position 62. Each of the press-ing containers 50 comprises side plate 63 and 64, a lid member 65, an upper roller 66, a push plate 67, a push rod 68, a push rod bearing 69 and a lower roller 70. The side plate 63 is affixed at opposite ends thereof to a drum side plate 71. Thus, a pair of side plates 63 and 64 partition in the front and at the back of a pressing container for roll paper, to thereby form the pressing container. One 63 of the pair of side plates is provided thereon with a member for positioning a roll of roll paper, e.g. a positioning block 72. This member determines a position of a roll of roll paper, ~ 2~7.~j Page 20 which has been supplied into the pressing container, prior to the compression. A fulcrum 73 for opening or closing the lid member is provided at one end of the side plate 63 provided in the rear, and said lid member 65 is rotatably secured to this fulcrum. A lever 74 for closing the lid member is provided on the lid member 65 on the side of the fulcrum 73 for opening or closing the lid member, to function of closing the lid member, which has opened. In the -interior of the pressing container 50 defined by the push plate 67, side plates 63, 64 and drum side plate 71, the push plate 67 moves within a predetermined stroke, to thereby compress the roll of roll paper in the pressing container 50. This moving stroke is effected by the operation of the push rod 68 loosely couplingly supported by the rod bearing 69. The pushing operation of this push rod 68 is performed by the contact-ing engagement between the lower roller 70 and a guide cam 75 for pressing. The guide cam 75 for pressing is affixed to a fixed shaft 76, whereby the pressing container 50 is rotatable with the drum side plates 71. The upper roller 66 of the pressing container 50 moves in contact with the inner surface of a frame 77 concentric with the fixed shaEt 76. A take-out position 57 is positioned at a posi-tion past the tail end of the frame 77. A push rod support rail 78 is formed along the outer periphery of the guide cam 75 for pressing between this take-out position 57 to a pressing start position 62 where the starting end of the frame 77 is disposed. At the take-out position 57, ~ z57.r6~ Page Zl the pressing container 50 is supported by the support rail 78, however, the lid member 65 is automatically opened downwardly because nothing supports the weight thereof, and a take-out tool 80 for a roll 79 of compressed roll paper and a conveyor 81 for carrying out the roll of compressed roll paper are disposed directly beneath the pressing container 50. A feed plate 82 and a roll paper feed tool 83 are provided obliquely upwardly of a roll paper feeding position 60. This roll paper feed tool 83 is operated by a cylinder 84. A drum support roller 86 is provided in contact with a drum 85 supported by ~he drum support roller 86.
The drum support roller 86 is rotatably driven by a driving source, not shown, to thereby turn the drum 85.
A lid member open-close rail 87 is provided in contact with the end of the lever 74 from a position past the take-out position 57 for the roll of compressed roll paper to a position past the roll paper feeding position 60.
The apparatus for producing a roll of compressed roll paper according to the present invention is of such arrangement as described above, whereby the roll of roll paper is supplied into the pressing container 50 at the roll paper feeding position from the feed plate 82 and the roll paper feed tool 83. The pressing container moves upwardly as the drum rotates (rotating in a forward direc-tion from 51 to 62 in the drawing) due to the rotation of the drum support roller 86. The end of the lever 74 moves along the open-close rail 87 and the lid member 65 is ~Z57,~6~ Page 22 closed at a position where the open-close rail 87 is bent in the direction of lifting the end of the lever 74, The roll 79 of roll paper in the pressing container is positioned by the positioning block 72, whereby the pressing container 50 moves within a pressing area in the frame 77 including 51, 52, 53, 54, 55, 56 and 57. As a rotatable drum 85 rotates, the lower roller 70 of the push rod 68 moves along the surface of the guide cam 75 for pressing, whereby the push rod 68 slowly pushes into the pressing container 50 at a speed of 4.3mm/sec on a average, to thereby push the roll 79 of roll paper. The shape of the guide cam 75 for pressing is determined in accordance with the magnitude bf a pushing load and the speed of insertion of the push rod 58. The movement of the push rod 68 is stopped at a position where the push plate 67 is 25mm apart from the l:id member 65, and the push rod 68 is held thereat for 17.5sec. On the other hand, the upper roller leaves the frame 77 after a lapse of 17.5 sec. The lid member 65 opens by its gravity, and the roll 79 of compressed roll paper is pushed out by the push rod 68. The roll of compressed roll paper is taken out by the take-out tool 80 and carried out by the conveyor 81 for carrying out.
The rotatable drum 85 is continuously turned by the rotation of the drum support rollers 86 for driving.
The roll 79 of compressed roll paper thus conveyed is covered by the heat-shrinkable plastics films each having a thickness of about 0.02mm and compressingly ' , ~57,r~
sealed at a sealing temperature of 200C for example.
In a case capable oL colltaining therein 120 rolls of the standard roll paper of a single roll type having an outer diameter of about 50mm on the shorter diameter's side, an outer diameter of about 124mm on the longer diameter's side and a paper width of 114mm, there may be contained 208 rolls of compressed roll paper thus sealed.
Hence, if the rolls of compressed roll paper are held in the apparatus shown in the above embodiment for 20 sec or more, Lhell, the rolls of the standard roll paper are deformed to have an outer diameter of about 45mm on the shorter diameter's side and an outer dimeter of about 124mm on the longer diameter's side, and, in the above case of capable of containing therein 120 rolls, there may be contained 212 rolls, so that the number of the deformed rolls thus compressed which are contained in the same case is increased by 76.7% as compared with the rolls of the standard roll paper. Even if a ready made case is used as described above, track load charges for example during transportation, warehouse storage charges and the like are saved by about 40%. A roll of roll-shaped toilet roll paper of a single roll type having a winding length of 65m has a diameter of 10.5cm and a length of 11.7cm. In con-trast thereto, the roll of toilet roll paper according to the invention of the present application has a width of 12cm, a length of 11.7cm and a thickness of 4cm, whereby the volume is reduced to one half and the configuration is not bulky, whereby the load per unit volume can be ~57~6~
Page Z4 increased, thus proving outstandingly advantageous from the viewpoint of transportation and the like of toilet rol:l paper. And cylindrical towel paper, for example, having a winding length of 18m has a dizmeter of about 12cm and a length about 24cm is compressed to have a width of about 16cm, a length of about 24cm and a thickness of about 4.5cm according to the present invention.
However, if the rolls of compressed toilet roll paper are contained in a case specially fitted thereto, then the space in the case is more effectively used, so that the number of rolls contained in the case is increased by 100%, so that the expenses for transportation can be reduced to one half.
Moreover, the roll of compressed roll paper obtained according to the present invention can maintain the flat shape even when the pressing force is released, so that the volume reduction as described above can be contemplated. Hence, if a heat-shrinkable polymer film is used, then the compression can be easily effected, the wrapping by use of a plastics film or the like can be easily performed and the handling of articles thereafter can be easily made. The roll of compressed roll paper as being the products according to the present invention, in the case of a single roll type having a winding length of 55m, can be strongly compressed to a thickness of 27mm with crapes being protected for example. However, roll is returned to a thickness of about 50mm due to a restoring force of crapes, emboss formation or the like.
~257- J~ Page 25 Hence, for use, the center portions are pressed to be inflated to easily restore to a circle, whereby no trouble is caused in use.
~ oreover, the roll of compressed roll paper according to the present invention can be maintained in a flat state for a long period of time, so that the further handling may be easily made. The wrapping by use of plastics films or the like may be automatically carried out at any time as well as during the production process. Particularly, the rolls, which have been liquid-nonpermeably wrapped by a plastic film or plastics films or have been air-tightly wrapped by a plastic film or plastic films, can be prevented from deteriorating in quality due to rain, moisture and the like during transportation and storage, thereby proving very sanitary.
As has been described hereinabove, the influence brought about by the present invention is significant.
~L2~7 ~r,~
Designated at 1 is a core, 2 a roll of toilet roll paper, 3 a hollow portion of the core, 4 a plastics film, 5 a roll receiving process for roll-shaped toilet roll paper, 6 a cutting process, and 7 a formation-seal process. Denoted at 9 is a roll of roll-shaped toilet roll paper, and 10 a roll of roll-shaped toilet roll paper obtained by cutting the roll 9. Indicated at 12 and 13 are plastics film rollers, and 19 and 20 form a 75 a guide cam for pressing, 76 a fixed shaft, 77 a frame, 78 a support rail, 79 a roll of roll paper, 80 a take-out tcol, 81 a conveyor for carrying out, ~2 a roll paper feed plate, 8~ a rotary drum, 85 a drum support conveyor, 86 a driving roller, 87 an open-close rail, and 88 a stopper.
This application is a division of application Serial Number 455rO51 filed May 24, 1984.
Claims (12)
1. Apparatus for compressing rolls of roll papers in a roll compressing chamber to form compressed roll papers each having a flat shape, wherein said roll compressing chamber comprises:
a roll pressure plate reciprocatingly movably connected to the compressing apparatus in a compressive direction so that the roll of the roll paper can be compressed;
a lid opposed to said pressure plate, forming a wall portion of the chamber and secured to the chamber through a hinge device, so that the roll paper can be inserted into the compressing chamber or removed therefrom;
a plate facing a direction perpendicular to said compressive direction, for limiting the expansion of the roll paper in the said perpendicular direction; and a roll positioning member constituting at least a portion of said roll paper expansion limiting plate and secured to said roll paper expansion limiting plate through a spring device so as to protrude into the roll compressing chamber or retract therefrom; the compressing apparatus having a stroke capable of compressing the roll of roll paper into a flattened shape having a thickness of about 1/2 to 1/5 of the thickness of the roll before the roll is so compressed.
a roll pressure plate reciprocatingly movably connected to the compressing apparatus in a compressive direction so that the roll of the roll paper can be compressed;
a lid opposed to said pressure plate, forming a wall portion of the chamber and secured to the chamber through a hinge device, so that the roll paper can be inserted into the compressing chamber or removed therefrom;
a plate facing a direction perpendicular to said compressive direction, for limiting the expansion of the roll paper in the said perpendicular direction; and a roll positioning member constituting at least a portion of said roll paper expansion limiting plate and secured to said roll paper expansion limiting plate through a spring device so as to protrude into the roll compressing chamber or retract therefrom; the compressing apparatus having a stroke capable of compressing the roll of roll paper into a flattened shape having a thickness of about 1/2 to 1/5 of the thickness of the roll before the roll is so compressed.
2. Apparatus for compressive deforming of a roll of paper, comprising a chamber for receiving the roll of paper, the chamber comprising a lid which is openable to allow entry of the roll into the chamber, a piston constituted by a pressure plate movable to press the roll against the lid, side plates positioned to control lateral expansion of the roll, and a member which is spring-biased to protrude into the chamber to engage, and determine the position of, a roll before the roll is compressed.
3. Apparatus according to claim 1 or claim 2 wherein the chamber is mounted on a rotary carrier and wherein there are provided means for enabling the lid to open to release a roll from a chamber at one position and to close the chamber at another position of the rotary carrier and cam means cooperating with a cam follower coupled to the piston for effecting pressure on the roll while the lid closes the chamber.
4. Apparatus according to claim 3, wherein a multiplicity of chambers is arranged around the periphery of the carrier.
5. Apparatus according to claim 4 in which rail means extending around the carrier are adapted to engage a roller mounted on the lid, the said means being arranged so that the roller disengages from the rail means at the first said position and allows the lid to fall open under the influence of gravity.
6. Apparatus according to claim 5 in which the cam means comprises a fixed cam engaged by a respetive roller constituting a cam follower for each piston, guide means being provided for maintaining the rollers in contact with the cam while the respective chambers are rotated from the position wherein the chambers are opened to a position wherein the chambers are reclosed by the aforementioned rail means extending around the carrier.
7. Apparatus according to any foregoing claim and including means for wrapping the compressed roll in liquid impermeable film.
8. A method of producing a compressed roll of roll paper with preserved crepe deformed into a flat shape comprising the steps of:
applying a compressing pressure to a cylindrical roll of roll paper with crepe having an axis and a diametrical thickness, the compressing pressure being in one direction to deform said roll into a flat shape having a second thickness in said direction; and continuing application of said compressing pressure to said flat shape until said second thickness is reduced to between one-half and one-fifth of said diametrical distance of said cylindrical roll of roll paper before compression, while simultaneously restricting expansion of said roll in a direction lateral to said one direction of compressing pressure, said directions being substantially perpendicular to said axis of said roll.
applying a compressing pressure to a cylindrical roll of roll paper with crepe having an axis and a diametrical thickness, the compressing pressure being in one direction to deform said roll into a flat shape having a second thickness in said direction; and continuing application of said compressing pressure to said flat shape until said second thickness is reduced to between one-half and one-fifth of said diametrical distance of said cylindrical roll of roll paper before compression, while simultaneously restricting expansion of said roll in a direction lateral to said one direction of compressing pressure, said directions being substantially perpendicular to said axis of said roll.
9. A method according to claim 8 in which the roll is compressed by a piston against the head of a cylinder of which two opposite side walls restrict the said lateral expansion.
10. A method according to claim 9 in which rolls are fed in succession to cylinders which are spaced around a rotary frame and each roll is compressed as aforesaid by the piston of the respective cylinder, the compressing movement of each piston being controlled by a cam, around which the frame rotates, and a cam follower connected to the piston.
11. A method according to claim 10 in which the or each cylinder head is maintained closed during compression of a roll by a member extending partly around the rotary member and hinges open automatically uner gravity after compression has been completed.
12. A method according to foregoing claims 8-11, in which the or each compression-deformed roll is tightly wrapped in a liquid-impermeable film.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000575993A CA1257566A (en) | 1983-05-24 | 1988-08-29 | Method of producing roll of compressed roll paper and apparatus therefor |
Applications Claiming Priority (8)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP58-91231 | 1983-05-24 | ||
| JP58091231A JPS59218127A (en) | 1983-05-24 | 1983-05-24 | Toilet toll paper and method and apparatus for producing same |
| JP58-158721 | 1983-08-30 | ||
| JP58158721A JPS6052447A (en) | 1983-08-30 | 1983-08-30 | Roll paper towel and manufacture |
| JP59-62293 | 1984-03-30 | ||
| JP59062293A JPS60204554A (en) | 1984-03-30 | 1984-03-30 | Method and apparatus for manufacturing compressed roll paper |
| CA000455051A CA1254539A (en) | 1983-05-24 | 1984-05-24 | Compressed roll paper |
| CA000575993A CA1257566A (en) | 1983-05-24 | 1988-08-29 | Method of producing roll of compressed roll paper and apparatus therefor |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000455051A Division CA1254539A (en) | 1983-05-24 | 1984-05-24 | Compressed roll paper |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1257566A true CA1257566A (en) | 1989-07-18 |
Family
ID=27426389
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000575993A Expired CA1257566A (en) | 1983-05-24 | 1988-08-29 | Method of producing roll of compressed roll paper and apparatus therefor |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1257566A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116534624A (en) * | 2023-05-05 | 2023-08-04 | 东莞市恒耀超音波设备有限公司 | Compression manufacturing equipment for compression bath towel |
-
1988
- 1988-08-29 CA CA000575993A patent/CA1257566A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116534624A (en) * | 2023-05-05 | 2023-08-04 | 东莞市恒耀超音波设备有限公司 | Compression manufacturing equipment for compression bath towel |
| CN116534624B (en) * | 2023-05-05 | 2023-10-13 | 东莞市恒耀超音波设备有限公司 | Compression manufacturing equipment for compression bath towel |
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