Patent ID: 12202689

DESCRIPTION OF EMBODIMENTS

In a method for producing coreless roll paper according to the present disclosure, a shaft is extracted with a cover member left in roll paper, and then the cover member is removed from the roll paper. Hence, it is possible to reliably protect a center hole in the roll paper with the cover member when the shaft is extracted. Accordingly, because the winding-start end of the paper is not pulled out, it is possible to stably produce coreless roll paper.

The method for producing coreless roll paper according to the present disclosure includes: a transport step in which transport means draws paper from a material roll and transports the paper; a winding step in which the transported paper is wound on a shaft and is formed in a roll shape; an extracting step in which the shaft is extracted from the roll paper, which is paper formed in a roll shape, to form a center hole at the center of the roll paper; and an application step in which adhesive supply means is inserted into the center hole to apply an adhesive to an inner wall portion of the center hole. The shaft includes a body part having gear-like grooves in an outer circumferential side surface thereof, and a cover member is put on and fixed to the body part. In the winding step, paper is wound on the cover member. In the extracting step, the shaft is extracted with the cover member left in the roll paper. Then, the cover member is removed from the roll paper. Hence, by protecting the center hole in the roll paper with the cover member, it is possible to extract the shaft from the roll paper without causing deformation. Furthermore, because it is possible to directly apply the adhesive to the inner wall portion of the center hole, which is formed by extracting the shaft, only the minimum area necessary for preventing deformation of the roll paper can be adhered and solidified.

In the method for producing coreless roll paper according to the present disclosure, the cover member is made of a flexible, non-adhesive film or a sheet. Hence, it is possible to easily put the cover member on the outer circumferential side surface of the shaft. Furthermore, because it is non-adhesive, the friction caused when the shaft is extracted from the roll paper can be reduced. Moreover, when the cover member is removed from the roll paper, the cover member can be easily removed. Accordingly, compared with a case where the cover member is not a flexible, non-adhesive film or sheet, it is possible to more reliably prevent the winding-start end of the paper from being pulled out.

In the method for producing coreless roll paper according to the present disclosure, the cover member is tubular. Hence, it is possible to easily fix the cover member to the outer circumferential side surface of the shaft.

Embodiments of the present disclosure will be described below.

First Embodiment

FIG.1is an explanatory diagram showing a schematic structure of a production apparatus1for performing a method for producing coreless roll paper according to a first embodiment of the present disclosure, and shows the arrangement configuration of the respective components of the apparatus when the production apparatus1is viewed from a side.FIG.2is an enlarged view showing a shaft20, serving as a winding shaft in the production apparatus1, and the vicinity thereof, as viewed from a side.

As shown inFIG.1, in the production apparatus1, a material roll10is disposed at a predetermined position, and the production apparatus1includes feed rollers2and3, serving as transport means, arranged so as to be in contact with the outer circumference of the material roll10. The feed rollers2and3draw paper11from the material roll10and transport the paper toward the shaft20(in the transport direction shown by arrow X inFIG.1). The paper11drawn from the material roll10is transported also by a guide and rollers (not shown), besides the feed rollers2and3.

The production apparatus1also includes an adhesive supplier7serving as adhesive supply means, and a cutter8, at a position above the transported paper11and between the material roll10and the shaft20. The adhesive supplier7and the cutter8are disposed at a position immediately before the position where the paper11transported by the feed rollers2and3is wound on the shaft20(i.e., near the shaft20).

The production apparatus1also includes winding auxiliary rollers4and5and a pressure roller6in the vicinity of the shaft20. The winding auxiliary rollers4and5and the pressure roller6are arranged so as to allow the transported paper11to be wound on the shaft20.

The pressure roller6is arranged above the shaft20and presses, from above, the paper11wound on the shaft20. Hence, the paper11is wound under a predetermined tension, while being pressed by the pressure roller6. The pressure roller6is supported by support means9or the like so as to be movable in the top-bottom direction. Thus, the pressing force thereof is adjusted according to the outside diameter of a roll paper12, which is the paper11wound on the shaft20and is formed in a roll shape (FIG.2shows the position relationship among the winding auxiliary rollers4and5, the pressure roller6, and the roll paper12).

The adhesive supplier7is disposed above the transported paper11(seeFIG.1). The adhesive supplier7applies an adhesive40to the surface of the transported paper11, by jetting or dropping, as droplets, the adhesive40from above. The adhesive40hardens and solidifies the laminated paper11when dried.

Furthermore, the amount of the adhesive40to be applied by the adhesive supplier7and the area thereof are controlled by control means or the like (not shown). More than one adhesive supplier7may be arranged in a straight line between the ends of the paper11in the width direction. AlthoughFIG.1shows, for the purpose of explaining the adhesive supplier7, a state in which the adhesive40is being applied, in actuality, the adhesive40is applied only to the winding-start end (not shown) of the paper11.

Similarly to the adhesive supplier7, the cutter8is disposed above the paper11(seeFIG.1). The cutter8cuts the paper11that is drawn toward the shaft20. More specifically, when the outside diameter of the roll paper12has reached a desired value, the cutter8is driven to cut the paper11. The driving of the cutter8is controlled by control means or the like (not shown).

Although a configuration in which the material roll10is disposed at a predetermined position, and the paper11is fed from the material roll10and is wound on the shaft20is shown in this embodiment, a configuration is also possible in which a paper making machine including a wire part, a press part, a dryer part, and the like is provided instead of the material roll10, the feed rollers2and3, and the like, and the paper11produced by this paper making machine is transported to the shaft20and the like by the transport means.

FIG.3is a perspective view showing an end of the shaft20in the production apparatus1.FIG.4is an enlarged view showing the end of the shaft20. InFIG.3, the illustration of the winding auxiliary rollers4and5, the pressure roller6, and the like, shown inFIG.1, is omitted.

The shaft20is a cylindrical shaft member, and the paper11is wound on the outer circumferential side surface of a body part22at the center. In the shaft20, the outside diameter of ends21of the shaft20is smaller than the outside diameter of the body part22(seeFIG.3), and the ends21are rotatably and removably engaged with engaging portions (not shown) of the production apparatus1.

Furthermore, as shown inFIG.4, the shaft20has grooves23formed by cutting straight grooves, extending from one end to the other end of the body part22, in the outer circumferential side surface of the body part22. More specifically, a plurality of grooves23is successively formed in the circumference of the body part22. Due to the successive grooves23, the outer circumferential side surface of the body part22has a gear-like structure. In other words, the outer circumferential side surface of the body part22has a plurality of ridges23aand channels23barranged alternately in the circumference.

Furthermore, a sleeve30, serving as a cover member, is fixed to the shaft20so as to cover the grooves23in the circumference of the body part22(seeFIG.2). The sleeve30is formed of a flexible, non-adhesive film or sheet and is formed in a cylindrical shape. The sleeve30is fixed in a state in which the shaft20passes therethrough and the sleeve30is put on the body part22. The sleeve30is formed such that the inside diameter thereof is slightly larger than the outside diameter of the body part22and thus can be fixed simply by putting it on the body part22.

The sleeve30is put on the shaft20so as to be stretched from a ridge23ato an adjoining ridge23aof the grooves23. Hence, portions of the sleeve30opposed to the channels23bare fixed so as to be slightly bent toward the axis center of the shaft20(seeFIG.2).

Various films or sheets may be used for the sleeve30. For example, a film or a sheet that is made of a synthetic resin, such as polyethylene, polypropylene, polyvinyl chloride, or polystyrene, may be used, and the thickness thereof is, for example, from 10 μm to 1 mm. It is desirable that the sleeve30be made of a film or a sheet that is made of polyethylene or polypropylene, from the standpoint that it has flexibility, non-adhesiveness, and the property in which it is not easily adhered by a typical adhesive.

Although a configuration in which the cover member is the cylindrical sleeve30that can be fixed to the body part22simply by putting it thereon has been described in this embodiment, a configuration is also possible in which, for example, the cover member is formed of a rectangular film or sheet, and the film or sheet is wrapped around the body part22and is fixed with fastening means (not shown), such as adhesive tape or the like.

Next, the operation of the production apparatus1will be described.

FIGS.5,6,7, and8are explanatory diagrams showing transitions of the roll paper12produced with the production apparatus1.FIG.5shows a state in which the paper11is wound to form the roll paper12, andFIG.6shows a state in which the outside diameter of the roll paper12has reached a desired value. Furthermore,FIG.7shows the roll paper12after the shaft20has been extracted, andFIG.8shows the roll paper12after the sleeve30has been removed from a center hole13.

(Transport Step)

In the production apparatus1, the feed rollers2and3, as shown inFIG.1, are rotationally driven to rotate the material roll10, which is in contact with the feed rollers2and3at the outer circumference thereof. As a result, the paper11is drawn from the material roll10and is transported at a predetermined speed. The paper11drawn from the material roll10is transported toward the shaft20(in the transport direction, shown by arrow X inFIG.1) at the above-described predetermined speed by a guide and rollers.

(Application Step)

Subsequently, the adhesive supplier7applies the adhesive40to the winding-start end of the transported paper11. Herein, the winding-start end is a portion corresponding to a plurality of layers of the paper11to be initially wound on the shaft20and is a portion having a length corresponding to, for example, five to twenty turns around the shaft20after the end of the paper11starts to be wound on the shaft20. Hence, in the production apparatus1, the application of the adhesive40is started when the end of the paper11is transported below the adhesive supplier7, and the application of the adhesive40is stopped when the paper11is wound five to twenty turns around the shaft20.

(Winding Step)

Subsequently, after the adhesive40is applied, the paper11reaching the shaft20is nipped between the shaft20and the winding auxiliary roller4and then between the shaft20and the winding auxiliary roller5and, consequently, is wound on the circumference of the shaft20. In other words, the paper11passes on the upper-end side of the winding auxiliary rollers4and5and is wound on the shaft20such that the side to which the adhesive40has been applied is located on the inner side of the roll.

Furthermore, in the winding step, the sleeve30has been fixed so as to be put on the circumference of the shaft20, more specifically, the grooves23in the body part22(seeFIGS.5and6). Hence, the paper11is not directly wound on the shaft20, but is wound on the shaft20with the sleeve30therebetween (seeFIG.5).

The paper11wound on the shaft20and formed in a roll shape is laminated on the sleeve30while being pressed by the pressure roller6. By being pressed by the pressure roller6, the paper11is wound without creases and in the form of a perfect circle around the shaft20, serving as the axis.

Although a configuration in which the side to which the adhesive40is applied is located on the inner side of the roll has been described in this embodiment, a configuration is also possible in which the end of the paper11is folded back when the paper11starts to be wound, so that the side to which the adhesive40is applied is not in contact with the surface of the sleeve30.

Then, when the outside diameter of the paper11wound on the shaft20and formed in a roll shape, that is, the roll paper12, has reached a predetermined value (seeFIG.6), feeding of the paper11from the material roll10is stopped, and the paper11is cut with the cutter8. It is possible to configure such that application means or the like (not shown) applies an adhesive or moisture to the cut end of the paper11(the terminal end of the paper11wound on the shaft20), so that the terminal end is fixed to the outer circumferential surface of the roll paper12.

(Extracting Step)

Subsequently, the shaft20is removed from the engaging portions of the production apparatus1, and the roll paper12is transferred to a support base (not shown). Then, the shaft20is extracted from the roll paper12fixed to the support base. Herein, when the shaft20is extracted from the roll paper12, only the shaft20is extracted such that the sleeve30is left in the roll paper12. By doing so, the center hole13, which remains after the shaft20is extracted, is formed in the center of the roll paper12, and the sleeve30is left in the inner wall portion of the center hole13(seeFIG.7). The center hole13is formed as a through-hole extending along the axis of the roll paper12, and a texture pattern corresponding to the grooves23is formed on the inner wall portion (seeFIGS.7and8).

Next, the sleeve30is removed from the inner wall portion of the center hole13(seeFIG.8). For example, the sleeve30may be perforated in advance, so that the sleeve30can be torn in two by pulling the longitudinal ends of the sleeve30in opposite directions. With this configuration, by pulling the ends of the sleeve30from the ends of the center hole13, the sleeve30is torn at the perforated line and can be easily removed.

In this embodiment, although a configuration in which the sleeve30is removed from the center hole13after the shaft20is extracted has been described, for example, a configuration is also possible in which the body part22of the shaft20has a variable outside diameter, the outside diameter of the body part22is reduced after the paper11is wound, and the sleeve30is removed at the same time when the shaft20is extracted.

Furthermore, in this embodiment, although a configuration in which the paper11is wound on the single shaft20has been described, for example, a configuration is also possible in which a plurality of shafts20is provided, and the paper11is successively wound thereon. In that case, although a configuration in which the paper11is cut with the cutter8when the roll paper12has reached a predetermined outside diameter has been described in this embodiment, for example, a configuration in which a next shaft20is supplied from above the paper11, at a position between the adhesive supplier7and the cutter8, before the paper11is cut is desirable.

More specifically, when the paper11is cut, one end is wound on the roll paper12, and the other end is wound on the next shaft20. Hence, the adhesive supplier7preliminarily applies the adhesive40to the ends and the vicinity thereof, and the next shaft20is supplied so as to be lightly pressed against this portion. By doing so, it is possible to cut the paper11in a state in which the portion serving as the end of the paper11is temporarily adhered to the sleeve30of the next shaft20. When the cutter8performs cutting, for example, an air jetting device (not shown) may be provided below the cutter8to jet air from below to prevent the temporarily adhered paper from peeling off.

After the paper11is cut, the next shaft20to which the end of the paper11is temporarily adhered is moved to the position above the winding auxiliary rollers4and5in accordance with the restart of the transportation of the paper11. Thereafter, the paper11is wound as in the normal winding step. By performing the extracting step on the roll paper12located on the winding auxiliary rollers4and5simultaneously with the movement of the next shaft20, the next shaft20can be successively supplied to the position above the winding auxiliary rollers4and5in accordance with the transfer of the roll paper12to the support base. This way, it is possible to successively wind the paper11on the shaft20.

The method for producing coreless roll paper according to this embodiment is configured as above. With this production method, when the shaft20is extracted from the roll paper12, it is possible to extract the shaft20from the roll paper12while reliably protecting the center hole13in the roll paper12with the sleeve30. Accordingly, even though the paper11is loosely wound on the shaft20, it is possible to prevent the winding-start end of the paper11from being pulled out when the shaft20is extracted, and thus, it is possible to stably produce the coreless roll paper12.

Second Embodiment

Next, a method for producing coreless roll paper according to a second embodiment of the present disclosure will be described.

FIG.9is an explanatory diagram showing a schematic structure of a production apparatus50for performing a method for producing coreless roll paper according to the second embodiment of the present disclosure.FIG.10is an explanatory diagram showing adhesive suppliers60of the production apparatus50. The configurations that are the same as those of the production apparatus1will be denoted by the same reference signs, and detailed descriptions thereof will be omitted. The configurations different from those in the production apparatus1will be mainly described.

As shown inFIG.9, in the production apparatus50, the material roll10is disposed at a predetermined position, and the production apparatus50includes the feed rollers2and3arranged so as to be in contact with the outer circumference of the material roll10, the winding auxiliary rollers4and5and the pressure roller6arranged near the shaft20, and the cutter8arranged near the shaft20. This configuration is the same as that of the production apparatus1.

As shown inFIG.10, the production apparatus50includes a pair of adhesive suppliers60opposed to each other, instead of the adhesive supplier7of the production apparatus1. The adhesive suppliers60are a pair of tubular members with sealed ends and are inserted into the center hole13remaining after the shaft20is extracted from the roll paper12and then the sleeve30is removed.

More specifically, the movement of insertion ends60aand60bof the adhesive suppliers60is controlled by control means and the like (not shown), and the insertion ends60aand60bare inserted from the ends of the center hole13(seeFIG.10). Furthermore, the insertion ends60aand60bhave a plurality of jetting holes (not shown) in the circumferences thereof, through which the adhesive40is jetted by delivery means, such as a pump or the like (not shown). The amount and area of the adhesive40jetted from the jetting holes in the insertion ends60aand60bare controlled by the delivery means.

Next, the operation of the production apparatus50will be described.

The operation in the application step, which is different from that in the production method according to the first embodiment, will be mainly described. Furthermore, in the method for producing coreless roll paper according to the second embodiment, because the application step is performed after the extracting step, the paper11is wound on the shaft20without the adhesive40.

(Application Step)

In the roll paper12after the shaft20is extracted in the extracting step and then the sleeve30is removed, the insertion ends60aand60bof the adhesive suppliers60are inserted from the ends of the center hole13. Then, the insertion ends60aand60binserted into the center hole13jets the adhesive40onto the inner wall portion of the center hole13through the jetting holes (seeFIG.10). With this configuration, it is possible to apply an appropriate amount of the adhesive40only to the minimum area of the inner wall portion of the center hole13that needs to be adhered and solidified.

The method for producing coreless roll paper according to this embodiment is configured as above. With this production method, even though the roll paper12is wound without the adhesive40, it is possible to extract the shaft20from the roll paper12without causing deformation by protecting the center hole13with the sleeve30. Moreover, because it is possible to directly jet the adhesive40to the inner wall portion of the center hole13remaining after the shaft20is extracted and the sleeve30is removed, only the minimum area necessary for preventing deformation of the roll paper12can be adhered and solidified. Accordingly, because the portion solidified with the adhesive40is small, the coreless roll paper12can be easily used up to the end.

Although a configuration in which the paper11is wound without the adhesive40has been described in this embodiment, a configuration is also possible in which, in order to prevent the paper11from being unwound when it is wound on the shaft20, the paper11is wound on the shaft20in a temporarily adhered state by jetting water onto the winding-start end of the paper11.

Although the embodiments of the present disclosure have been described in detail above, the present disclosure is not limited to the above-described embodiments, and various design changes may be made as long as such changes do not depart from the claims.

REFERENCE SIGNS LIST

1production apparatus2,3feed roller4,5winding auxiliary roller6pressure roller7adhesive supplier8cutter9support means10material roll11paper12roll paper13center hole20shaft21end22body part23groove23aridge23bchannel30sleeve (cover member)40adhesive50production apparatus60adhesive supplier60a,60binsertion endX transport direction