GB2143197A

GB2143197A - A compressed paper roll package and method of producing same

Info

Publication number: GB2143197A
Application number: GB08413317A
Authority: GB
Inventors: Kouzou Watanabe; Yasuhiko Saito
Original assignee: Individual
Current assignee: Individual
Priority date: 1983-05-24
Filing date: 1984-05-24
Publication date: 1985-02-06
Also published as: KR910000378B1; IT8448255A0; GB2173765A; GB8611815D0; GB2173765B; IT1177749B; CA1254539A; GB2143197B; DE3418951C2; FR2546478B1; GB8413317D0; DE3418951A1; CA1257566C; KR850000225A; KR900000821B1; FR2546478A1

Abstract

To avoid deterioration due to moisture and to reduce transportation and storage costs, a roll of paper 2 on a core 3, eg toilet paper, is compressed and wrapped in at least one liquid impermeable, preferably heat-shrinkable, film 4. Compressing by means of a reciprocal plunger, or by a series of roller pairs spaced along a feed path having a reducing gap between the rollers of each pair towards the downstream pair, or by a rotary cam operated turret press, are illustrated. <IMAGE>

Description

SPECIFICATION Method of producing roll of compressed roll paper and apparatus therefor This invention relates to compressed toilet roll paper and towel roll paper, i.e. compressed roll paper, and more particularly to a method of and an apparatus for producing a roll of 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.

However, 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 resulting in bulkiness.

Due to this bulkiness, with the rolls of the conventional roll paper, freight charges, warehouse charges and the like are rather high, and are not negligible in relation to the sale price of a role 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 a flat shape to decrease costs required for packing, transporting and storing of rolls of roll paper.

However, none of such measures has been put into practice.

The reason is that if roll paper 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 flat shape, the roll of roll paper bulges out in one direction, crinkles formed thereon are flattended, and folding wrinkles are left to lower elasticity of the roll of roll paper. Although the flattened roll of roll paper may be restored to 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 paper is pressed and compression deformed inot 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 if it is compression deformed and consequently the effect of reducing the volume due to the compression deformation is not so much as might be expected.

The inventors of the present invention have made 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.

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 in 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 flatshaped 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 mehtod of pressure deforming a roll 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 in directions of compression is continued to form a roll of flat-shaped compressed roll paper at an intermediate stage, said flatshaped roll of compressed roll paper at the intermediate stage is wrapped with a heatshrinkable polymer film or flims and heated, an apparatus for producing a roll of compressed roll paper having a flat shape in its side surface, characerized 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 roll of compressed roll paper having a flat shape in its side surface, characterized by:: a roll paper pressure containing portion comprising a roll paper support plate and a pair of side plates provided at opposite ends of said support plate and opposed to each other; a push rod bearing 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 therof 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 thereof with a push plate; a rotable drum-shaped roll paper support member concentric with said fixed shaft, provided outside said can 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; a push rod bearing for movably supporting said push rod provided at inner end portions 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 provided 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 inluding the length of a plurality of rolls of roll paper with single perforated lines or the like provided at every border so as to be severable. The shape of compressed roll paper may be flatter than a circle at its side surface, and the shape may be either elliptical or substantially rectangular or intermediate rectangular and elliptical.

As for the shape of side surface of the roll of compressed roll paper according to the present invention in particular, various shapes between elliptical and rectangular may be adopted; however, it is preferable from the viewpoint of use and forming to adopt a substantially rectangular shape having rounded corners so that no folding wrinkles are present at the corners. Furthermore, the core need not necessarily have elasticity.

However, the provision of a hollow core with even slight elasticity makes it possible to easily return from a flat shape to the cylindrical shape. As for the material of the hollow core described above, it suffices to use one which can be easily restored from a flat shape, particularly a thin flat shape, to a circular, i.e., cylindrical shape. The material of the hollow core niay be formed of a rubber or plastics rubber, which is easily returned to a cylindrical shape by unpacking, for example, and further, may be one which is easily deformably flexible, i.e. a material having slight elasticity, such as a tubular paper core. When a roll of the conventional roll paper using the tubular core is pressure formed into a flat 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. The provision of the core is preferable because paper or a thin paper board can easily return from a flat shape to the cylindrical shape, thus proving highly economical.

The dimensions and shape of the side surface of the roll of compressed roll paper obtained according to the present invention vary to some extent depending upon what the pressure conditions are, what the magnitude of crape is and whether a double roll type or a single roll type is adopted. Out of various types of roll-shaped roll paper, a roll of toilet roll paper of a single roll type having a winding length of 55m, an outer diameter of 100mm and a core diameter of 38mm may be considered as an example. When the rolls of toilet roll paper of this type are compressed, rolls having various shapes in their side surfaces within a range of dimensions of an outer diameter on the shorter diameter's side of 67mm or less and an outer diameter on the longer diameter's side of 11 7mm or more are obtainable. In this case, the core becomes 59mm or more on the longer diamter's side.Anong all of these, particularly, it is preferable to adopt ones having outer diameters on the shorter diameter's side of about 50mm or less, on the longer diameter's side of about 1 24mm or more, cores on the longer diameter's side of about 60mm or more and on the shorter diameter's side of about 50mm or less from the viewpoint of volume reduction, easiness in the restoration and the like.

To state the characteristics of restoration of the roll of compressed roll paper, in order to reley on the elasticity of crinkles or the like for example, the crinkles must be protected in compression deforming a roll of roll paper.

However, if a roll of roll paper is merely compression deformed, then the roll bulges out in directions perpendicular to the directions of compression, crinkles are flattened out, whereby elasticity and softness of the roll of roll paper are lost.

In consequence, according to the present invention, a roll of compressed roll paper is formed and produced under pressure, and, it is preferable to apply pressure to the roll of roll paper simultaneously with film sealing in order to suppress the flattening of crinkles 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 pressure be applied 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 realize 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 diameter on the longer diameter's side of 1 24mm or more.

However, if the outer diameter on the shorter diameter's side of a roll of roll paper is compressed to an extreme flatness, i.e. 1 Omm 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 non-uniform, whereby restoration of the roll 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 daimeter of about 30-20mm on the shorter side 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 with no perforated line broken off even when such peforated line is positioned at the bulging out portion of roll paper and no selvedges broken in use.

Since the pressure formed roll or 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, a plastics container, a can and the like may be used in addition to plastics film wrapping. Particularly, the plastics film wrapping is easily mechanized, whereby a film seal, particularly an individual film seal is easily performed, and moreover, an air-tight or liquid-nonpermeable seal is practicable, so that the articles can be prevented from deteriorating in quality due to rain, moisture and 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 simultaneously 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 pressure formation can thereby be performed simultaneously with wrapping. The compression formation of a roll of roll-shaped roll paper under pressure is preferably 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 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.

However, this compression of roll paper is peformed such that the pressing process by means of the push rod is not immediate but gradual. Moreover, in the case of a roll of roll paper of a single roll type having a length of 55m for example, the pressing of the push rod is 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 should be maintained under the pressing force for a predetermined period of time, e.g. 1 Ssec or more, preferably, 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 arrangement, 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 work can be easily carried out.

Furthermore, the inventors of the present invention have found that, in producing the roll of compressed roll paper by the abovedescribed method, a roll of roll paper of a single roll type having a length of 55m is produced with its crinkles not being protected, and, when the outer diameter on the shorter diamter's side is 1 Omm upon the compression deformation, if roll paper is restored, then the outer diameter on the shorter diameter's side becomes 26 mum, however, this roll of paper has folding lines and cannot easily return to a circular shape.Further, when the outer diamter on the shorter diameter's side is 16mm upon the compresion deformation, the outer diameter on the shorter 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 restoration after the compression.

An apparatus for producing the compressed roll paper according to the present invention is of such an arrangement 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 circulation path of either a horizontal type or a vertical 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 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 bedplate 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 of the pressing container, so that a roll or roll paper may 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 perform 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, with 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 brought into engagment 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.

Figure 1 is a side view of an embodiment of a roll of flat toilet paper according to the invention of the present application; Figure 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; Figure 3 is schematic diagram showing the pressure formation process in another embodiment of the method of and the apparatus for providing a roll of compressed roll paper according to the invention of the present application; Figure 4 is a schematic diagram showing part of the film 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;; Figure 5 is a sectional side view showing an embodiment of the apparatus for producing a roll of compressed roll paper acording to the invention of the present application; and Figure 6 is a partially sectional, enlarged view showing the roll paper feeding portion shown in Fig. 5.

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 drawing, the hollow portion 3 of the core 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 and conditions of 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 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 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 cutting process, in the prior art, is filmpacked as it is, then, packed in a case or the like and shipped, however, according to the present invention, 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 1 5 for wrapping are delivered from delivery film rollers 12 and 13, passed through guide rolls 16, 1 7 and guide plates 18, 1 9 and conveyed to a formation-seal portion 22. The cut roll 10 of roll-shaped roll paper together with a lower film 1 5 are conveyed to the formation-seal portion 22. Furthermore, an upper film is passed through an upper guide plate and disposed around an upper portion of the cut roll 10 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 to each other in a direction 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 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 compressed roll paper, 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, can 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 flat 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 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 holddown 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.

A 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.

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 roll 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, there after, 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 pressing 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, 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 contacting 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 shaft 76. A take-out position 57 is positioned at a position 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 takeout position 57 to a pressing start position 62 where the starting end of the frame 77 is disposed.At the take-out position 57, 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 contaner 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 the 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 direction from 51 to 62 in the drawing) due to the rotation of the drum support roller 86. The ene of the lever 74 moves along the open-close rail 87 and the lid member 65 is 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 of a pushing load and the speed of insertion of the push rod 68.

The movement of the push rod 68 is stopped at a position where the push plate 67 is 25mm apart from the lid member 65, and the push rod 68 is held thereat for 1 7.5sec. 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 sealed at a sealing temperature of 200"C for example.

In a case capable of containing therein 1 20 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 20sec or more, then, the rolls of the standard roll paper are deformed to have an outer diamter of about 45mm on the shorter diamter's side and on the outer diameter of about 124mm on the loner diameter's side, and, in the above case, capable of containing therein 1 20 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 length of 65m has a diameter of 10.5cm and a length of 11.7cm.

In contrast thereto, the roll of toilet roll paper according to the invention of the present applications 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 increased, thus proving outstandingly advantageous from the viewpoint of transportation and the like of toilet roll paper. Cylindrical towel paper, for example, having a winding length of 18m, a diameter of about 12cm and a length of about 24cm may be comprised 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 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. Hence, for use, the center portions are pressed to be inflated to easily restore to a circle, whereby no trouble is caused in use.

Moreover, 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 airtightly 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.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side view showing an embodiment of a roll of flat toilet roll paper according to the invention of the present application: Figure 2 is a flow sheet having an embodiment of the method of and the apparatus for producing rolls of flat toilet roll paper according to the invention of the present appplication; Figure 3 is a schematic diagram showing the pressure formation process of another embodiment of the method of and the apparatus for producing rolls of toilet roll paper according to the invention of the present application; Figure 4 is a schematic diagram showing part of the film seal process in another embodiment of the method of and the apparatus for producing according to the invention of the present application;; Figure 5 is a sectional side view showing an embodiment of the apparatus for producing rolls of compressed roll paper according to the present invention; and Figure 6 is a partially enlarged sectional view showing the roll paper feeding portion shown in Fig. 5.

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 rollshaped 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 1 9 and 1 2 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 tool, 81 a conveyor for carrying out, 82 a roll paper feed plate, 84 a rotary drum, 85 a drum support conveyor, 86 a driving roller, 87 an open-close rail, and 88 a stopper.

Claims

1. 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.

2. A method of compression deforming a roll of roll-shaped roll paper to produce a flatshaped roll of compressed roll paper, characterized in that pressing of said roll of roll paper in the direction of compression is continued while bulging-out sides of said roll of roll paper are pressed.

3. A method of pressure deforming a roll of roll-shaped roll paper to produce a roll of compresed roll paper, characterized in that, while bulging-out sides of said roll of roll paper are pressed, pressing of said roll of roll paper in directions of compression is continued to form a flat-shaped roll of compressed roll paper at an intermediate stage, said flat-shaped roll of compressed roll paper at the intermediate stage is wrapped with a heat-shrinkable polymer film and heated.

4. An apparatus for producing a roll of compressed roll paper having a flat shape in its side surface, characterized by a roll receiving device for roll paper, a roll cutting device for a coll of roll paper and a pressure forming device for a roll of roll paper.

5. An apparatus for producing a roll of compressed roll paper having a flat shape in its side surface, characterized by: a roll paper pressure holding portion comprising a roll paper support plate and a pair of side plates provided at opposite ends of said support plate and opposed to each other; a push rod bearing 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 and 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.

6. 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 thereof 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; a push rod bearing for movably supporting said push rod provided at inner end portions 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 provided at least at a portion not covered by said frame; and a lid member open-close rail engaged with said lever.

7. A roll of compressed roll paper as set forth claim 1 , characterized in that said roll of roll paper is air-tightly wrapped with a plastic film or plastic films.

8. A method of producing a roll of compressed roll paper having a flat shape in its side surface as set forth in claim 2 , characterized in that at least liquid-nonpermeable film or films sealing is effected simultaneously with pressure formation of said roll of roll paper.