U.S. patent application number 10/778359 was filed with the patent office on 2004-08-19 for toilet paper roll and method of manufacturing the paper roll.
This patent application is currently assigned to Kasuga Seishikogyo Co., Ltd.. Invention is credited to Kubota, Ryuzou, Watanabe, Sukesada.
Application Number | 20040159730 10/778359 |
Document ID | / |
Family ID | 27554727 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040159730 |
Kind Code |
A1 |
Kubota, Ryuzou ; et
al. |
August 19, 2004 |
Toilet paper roll and method of manufacturing the paper roll
Abstract
A toilet paper roll capable of remarkably reducing unwinding
noise when used as a toilet paper roll, improving a refuse
treatment measure by easily crushing and disposing off a thick core
of the paper roll, reducing the production cost of the paper roll,
flowing the thick core into a toilet and, when used, allowed to be
recovered generally to a circular section form for practical use
while the storage and transportation costs of the paper roll are
reduced, comprising the thick core(1) made of thin paper of approx.
4 cm in outside diameter and toilet paper(2) generally softly wound
on the thick core(1) from the first to the last, wherein the thick
core(1) is formed flat as required, and the toilet paper(2) is also
formed in a flat elliptic shape so as to follow up the flat thick
core(1).
Inventors: |
Kubota, Ryuzou; (Fuji-shi,
JP) ; Watanabe, Sukesada; (Fuji-shi, JP) |
Correspondence
Address: |
MCGINN & GIBB, PLLC
8321 OLD COURTHOUSE ROAD
SUITE 200
VIENNA
VA
22182-3817
US
|
Assignee: |
Kasuga Seishikogyo Co.,
Ltd.
Fuji-shi
JP
|
Family ID: |
27554727 |
Appl. No.: |
10/778359 |
Filed: |
February 17, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10778359 |
Feb 17, 2004 |
|
|
|
10203792 |
Dec 2, 2002 |
|
|
|
Current U.S.
Class: |
242/160.1 |
Current CPC
Class: |
B65H 18/28 20130101;
A47K 10/16 20130101 |
Class at
Publication: |
242/160.1 |
International
Class: |
B65H 018/28 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 15, 2000 |
JP |
37300/2000 |
Feb 15, 2000 |
JP |
37301/2000 |
Feb 15, 2000 |
JP |
37302/2000 |
Feb 15, 2000 |
JP |
37303/2000 |
Dec 27, 2000 |
JP |
399230/2000 |
Dec 27, 2000 |
JP |
399231/2000 |
Claims
1. A toilet paper roll characterized in comprising: a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm; and toilet paper which is wound substantially
loosely from beginning to end around this thick tubular core.
2. A toilet paper roll characterized in comprising: a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm; and toilet paper which is wound around this
thick tubular core tightly in the initial several turns and
thereafter wound substantially loosely to the end, thereby being
wound substantially loosely as a whole.
3. A toilet paper roll characterized in comprising: a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm; and toilet paper which is wound around this
thick tubular core tightly for several turns at a part excluding
the initial part and thereafter wound substantially loosely,
thereby being wound substantially loosely as a whole.
4. The toilet paper roll according to claim 1, 2 or 3,
characterized in that said thick tubular core is manufactured from
percolation paper.
5. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound substantially
loosely from beginning to end around this thick tubular core, and
characterized in that said thick tubular core is formed into a flat
shape and said toilet paper is also formed into a flat elliptical
shape in compliance with said flat thick tubular core.
6. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound around this
thick tubular core tightly in the initial several turns and
thereafter wound substantially loosely to the end, thereby being
wound substantially loosely as a whole, and characterized in that
said thick tubular core is formed into a flat shape and said toilet
paper is also formed into a flat elliptical shape in compliance
with said flat thick tubular core.
7. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound around this
thick tubular core tightly for several turns at a part excluding
the initial part and thereafter wound substantially loosely,
thereby being wound substantially loosely as a whole, and
characterized in that said thick tubular core is formed into a flat
shape and said toilet paper is also formed into a flat elliptical
shape in compliance with said flat thick tubular core.
8. The toilet paper roll according to claim 5, 6 or 7,
characterized in being formed such that during the formation of
said toilet paper into a flat elliptical shape, there is no
compression yield point at which, when a compressive load of a
prescribed value is applied to a semi-manufactured toilet paper
roll, the amount of displacement increases even without applying
further pressure, and such that the amount of displacement only
increases under pressure that increases gradually in the range of
half or less the compressive load of said prescribed value.
9. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound substantially
loosely around this thick tubular core from beginning to end, and
characterized in that said thick tubular, core is formed into a
substantially flat shape having fig-like expanded portions on both
sides, and said toilet paper is also formed into a flat elliptical
shape in compliance with said substantially flat thick tubular
core.
10. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound around this
thick tubular core tightly in the initial several turns and
thereafter wound substantially loosely to the end, thereby being
wound substantially loosely as a whole, and characterized in that
said thick tubular core is formed into a substantially flat shape
having fig-like expanded portions on both sides, and said toilet
paper is also formed into a flat elliptical shape in compliance
with said substantially flat thick tubular core.
11. A toilet paper roll characterized in comprising a thick tubular
core which is manufactured from thin paper and has a diameter of
approximately 4 cm and toilet paper which is wound around this
thick tubular core tightly for several turns at a part excluding
the initial part and thereafter wound substantially loosely,
thereby being wound substantially loosely as a whole, and
characterized in that said thick tubular core is formed into a
substantially flat shape having fig-like expanded portions on both
sides, and said toilet paper is also formed into a flat elliptical
shape in compliance with said substantially flat thick tubular
core.
12. The toilet paper roll according to claim 9, 10 or 11,
characterized in being formed such that during the formation of
said toilet paper into a flat elliptical shape, there is no
compression yield point at which, when a compressive load of a
prescribed value is applied to a semi-manufactured toilet paper
roll, the amount of displacement increases even without applying
further pressure, and such that the amount of displacement only
increases under pressure that increases gradually in the range of
half or less the compressive load of said prescribed value.
13. A manufacturing method for a toilet paper roll, characterized
in comprising the steps of: manufacturing a semi-manufactured
toilet paper roll comprising a thick tubular core which is made of
thin paper and which has a diameter of approximately 4 cm, and
toilet paper which is wound substantially loosely as a whole around
this thick tubular core; fixing and supporting this
semi-manufactured toilet paper roll in a substantially outer
diametrical position with facing pressing support plates; and
pressing the semi-manufactured toilet paper roll inward at a
substantially central position in the two substantially orthogonal
directions to the direction of spacing between the two pressing
support plates using pressing portions on the ends of hydraulic
cylinders, whereby the thick tubular core is formed into a
substantially flat shape as a whole while forming fig-like expanded
portions on the two end positions of the substantially flat thick
tubular core, and the toilet paper is also formed into a flat
elliptical shape in compliance with said substantially flat thick
tubular core.
14. A manufacturing method for a toilet paper roll, characterized
in comprising the steps of: manufacturing a semi-manufactured
toilet paper roll comprising a thick tubular core which is made of
thin paper and which has a diameter of approximately 4 cm, and
toilet paper which is wound substantially loosely as a whole around
this thick tubular core; and stretching said thick tubular core by
inserting two hole-widening round bars therein for forming said
thick tubular core into a flat elliptical shape while pressing said
thick tubular core inward from both sides using hydraulic cylinders
in directions which are orthogonal to the spacing between said two
hole-widening round bars while, whereby the thick tubular core is
formed into a substantially flat shape as a whole while forming
fig-like expanded portions on the two end positions of the
substantially flat thick tubular core, and the toilet paper is also
formed into a flat elliptical shape in compliance with said
substantially flat thick tubular core.
Description
TECHNICAL FIELD
[0001] The present invention relates to a toilet paper roll having
a thick tubular core which is mountable on a thick shaft portion of
a typical household toilet paper roll holder, and a method of
manufacturing the paper roll.
BACKGROUND ART
[0002] In a typical conventional toilet paper roll, the toilet
paper and a paper tube (core) are provided separately, the core
being a tubular body formed from a thick paper material made of
cardboard with a diameter of approximately 3.8 cm up to
approximately 4.5 cm. In recent years, on the other hand, a
so-called core-less toilet paper roll, comprising the toilet paper
and a core formed from one part of the toilet paper in the central
part of the roll into which the toilet paper is wound, has been
researched, developed, and has arrived on the market.
[0003] Two types of this core-less toilet paper roll exist: a type
in which the inner diameter of the hole in the center of the roll
is particularly small, and a type in which the inner diameter of
the hole is large so as to be mountable on a thick shaft portion of
a typical household toilet paper roll holder. The type in which the
inner diameter of the hole is small is used when the diameter of
the shaft portion of the holder also has a small diameter, and is
therefore unfavorable since it cannot be used with the thick shaft
portion of a toilet paper roll holder used in a typical
household.
[0004] Regardless of whether the inner diameter of the central hole
of the roll is large or small, almost all of these core-less toilet
paper rolls of both kinds are wound substantially tightly from the
beginning to the end [of the roll], and there has never existed a
roll which is wound loosely. This is because it is believed that in
order to form the core from one part of the toilet paper in the
center of the wound roll, winding the paper tightly from first to
last is a necessary requirement (see Japanese Utility Model
Publication H6-47356). Consequently, general markets and users have
requested the development of a loosely-wound, loose type core-less
toilet paper roll.
[0005] In response to these requests and so on, a loose type
core-less toilet paper roll has been developed in which the entire
roll is wound substantially loosely, and the initial turns in the
central part of the roll are adhered with an adhesive to form a
tubular core portion. Although not specified as loose type, an
adhered tubular core portion is disclosed in Japanese Patent
Application Laid-Open H7-2395. Although such tubular core portions
are formed by adhering the point at which the toilet paper is
initially loosely wound using an adhesive, there exists no such
core-less toilet paper roll that is produced systematically. The
outer appearance of the shape of the hole of these tubular core
portions is such that the initially wound section generally appears
highly irregular, as if the shape of the inner diameter of the hole
has been damaged, and it has not been easy to bring familiarity to
such products on the market. It is technically difficult to
systematically mold the central portions of the roll at the
initially wound section of such loose type core-less toilet paper
rolls. Another disadvantage is that the machine for manufacturing
these loose type core-less toilet paper rolls is of a special
specification, meaning that such toilet paper rolls are
comparatively extremely expensive to produce.
[0006] Furthermore, a trend has arisen in recent years in which
women and the like have taken a great dislike to the rattle-like
unwinding noise that is generated during toilet paper roll use.
Consequently, there have been requests for the development of a
toilet paper roll in which no unwinding noise, or an extremely soft
unwinding noise, is produced during use.
[0007] Also, processing of marketed paper toilet paper rolls, and
particularly of the paper tube which forms the core in the central
portion of the roll following use thereof, is considered a problem.
More specifically, since the core is made of a thick cardboard
paper material, the core is not easy for women and children to
crush, and thus disadvantages arise such as the core being rather
bulky to dispose of as refuse. Furthermore, the paper tube cores of
these toilet paper rolls are thrown into the lavatories of public
toilets and the like, causing many cases of toilet blockages, and
it is also to take measures against paper tube cores that the
present applicant has developed a core-less type toilet paper roll.
A product has also been developed in which the paper tube core can
be flushed down the toilet, but this product is expensive and not
suited to general use.
[0008] A toilet paper roll in the form of a flat ellipse has also
been developed as a product (Japanese Utility Model Application
Laid-Open H7-25894), but since the paper tube core is formed from a
thick cardboard paper material, a great deal of force is required
to work the product into a flat form, and thus a special device has
to be used (Japanese Patent Publications H5-21814 and H6-84220).
The product is therefore disadvantaged in that the manufacturing
cost per unit is high. Moreover, as is illustrated in FIG. 43, the
paper tube core formed from thick cardboard paper material does not
become circular during use, and thus even when mounted on the thick
shaft part of a typical household toilet [paper roll] holder,
inconveniences arise such as the generation of excessively loud
noise.
DISCLOSURE OF THE INVENTION
[0009] In order to solve the aforementioned problems, the present
invention comprises a toilet paper roll which is constituted by a
thick tubular core manufactured from thin paper and having a
diameter of approximately 4 cm and toilet paper 2 which is wound
substantially loosely around this thick tubular core from beginning
to end. By mounting this on the thick shaft portion of a typical
household toilet paper roll holder, unwinding noise can be reduced
considerably, refuse processing of the thick tubular core can be
performed favorably, the thick tubular core can be manufactured at
a reasonable cost, whereby the manufacturing costs of the toilet
paper roll can also be reduced, and manufacturing costs can be
improved in comparison with a toilet paper roll that is wound
entirely loosely up to the core.
[0010] The present invention also comprises a toilet paper roll
constituted by a thick tubular core manufactured from thin paper
and having a diameter of approximately 4 cm and toilet paper which
is wound around this thick tubular core tightly in the initial
several turns and thereafter wound substantially loosely to the
end, thereby being wound substantially loosely as a whole. Although
the toilet paper is wound around the thick tubular core tightly in
the initial several turns and thereafter wound substantially
loosely to the end, as a whole the toilet paper is wound
substantially loosely, and therefore has the same constitution and
exhibits the same effects as the aforementioned toilet paper roll,
which is wound substantially loosely from beginning to end. The
present invention further comprises a toilet paper roll constituted
by a thick tubular core which is manufactured from thin paper and
has a diameter of approximately 4 cm, and toilet paper which is
wound around this thick tubular core tightly for several turns at a
part excluding the initial part and thereafter wound substantially
loosely, thereby being wound substantially loosely as a whole. Here
also, being wound around the thick tubular core tightly for several
turns at a part excluding the initial part and thereafter wound
substantially loosely, and thereby being wound substantially
loosely as a whole, this toilet paper roll has the same
constitution and exhibits the same effects as the aforementioned
toilet paper roll, which is wound substantially loosely from
beginning to end.
[0011] In the aforementioned three constitutions of the present
invention, the thick tubular core is constituted by percolation
paper. As a result, the thick tubular core differs from a
conventional cardboard paper tube core in that its strength is a
great deal weaker, and in that percolation paper has a
water-soluble property such that toilet blockages can be avoided
even when the thick tubular core which remains on the thick shaft
portion of a typical household toilet paper roll holder after use
of the toilet paper roll is flushed down the toilet (see FIG. 9).
Thus, the toilet paper roll is extremely convenient in that after
each use thereof, the thick tubular core is not disposed of as
general refuse.
[0012] The present invention is also comprised of a toilet paper
roll which is constituted by a thick tubular core manufactured from
thin paper and having a diameter of approximately 4 cm and toilet
paper which is wound substantially loosely around this thick
tubular core from beginning to end, wherein this thick tubular core
is formed into a flat shape and the toilet paper is also formed
into a flat elliptical shape in compliance with the flat thick
tubular core. Thus, even though the thick tubular core is flat, the
thick tubular core is made of thin paper, and so when the toilet
paper roll is mounted onto the thick shaft portion of a toilet
paper roll holder, it can be returned to a substantially perfect
circle which is adequate for use due to the synergistic action
between the loose toilet paper and the fact that almost no pressure
is applied even when the thick tubular core is flattened. Further,
since the toilet paper roll has a flat elliptical form, advantages
are obtained over a conventional perfectly circular toilet paper
roll in that space can be greatly economized such that storage and
transportation costs can be reduced.
[0013] The present invention is further comprised by a toilet paper
roll which is constituted by a thick tubular core which is
manufactured from thin paper and has a diameter of approximately 4
cm and toilet paper which is wound around this thick tubular core
tightly in the initial several turns and thereafter wound
substantially loosely to the end, thereby being wound substantially
loosely as a whole, wherein the thick tubular core is formed into a
flat shape and the toilet paper is also formed into a flat
elliptical shape in compliance with the flat thick tubular core, or
which is constituted by a thick tubular core which is manufactured
from thin paper and has a diameter of approximately 4 cm and toilet
paper which is wound around this thick tubular core tightly for
several turns at a part excluding the initial part and thereafter
wound substantially loosely, thereby being wound substantially
loosely as a whole, wherein the thick tubular core is formed into a
flat shape and the toilet paper is also formed into a flat
elliptical shape in compliance with the flat thick tubular
core.
[0014] The present invention is further comprised by a toilet paper
roll constituted by a thick tubular core which is manufactured from
thin paper and has a diameter of approximately 4 cm and toilet
paper which is wound substantially loosely around this thick
tubular core from beginning to end, wherein the thick tubular core
is formed into a substantially flat shape having fig-like expanded
portions on both sides, and the toilet paper is also formed into a
flat elliptical shape in compliance with the substantially flat
thick tubular core. Thus, even though the thick tubular core is
flat, the thick tubular core is made of thin paper, and so when the
toilet paper roll is mounted onto the thick shaft portion of a
toilet paper roll holder, it can be returned to a substantially
perfect circle which is adequate for use due to the synergistic
action between the loose toilet paper and the fact that almost no
pressure is applied even when the thick tubular core is flattened
and has fig-like expanded portions on both sides, and due to the
absence of kinks because of the existence of the expanded parts.
Further, since the toilet paper roll has a flat elliptical form,
advantages are obtained over a conventional perfectly circular
toilet paper roll in that space can be greatly economized such that
storage and transportation costs can be reduced.
[0015] The present invention is further comprised by a toilet paper
roll of the aforementioned constitution which is formed such that
during the formation of the toilet paper into a flat elliptical
shape, there exists no compression yield point at which, when a
compressive load of a prescribed value is applied to a
semi-manufactured toilet paper roll, the amount of displacement
increases even without applying increased pressure beyond the
prescribed value, and such that the amount of displacement only
increases with the gradual application of pressure of half or less
than half of the compressive load of the prescribed value. Thus,
the semi-manufactured toilet paper roll can be systematically
formed into a flat elliptical shape with the application of slight
pressure of half or less than half of the compressive load of the
prescribed value. In particular, since the compression yield point
K, at which the amount of displacement increases even without the
application of further pressure, does not exist upon reaching the
compressive load of the prescribed value, no large machine for
forming the toilet paper roll into a flat elliptical shape is
necessary, and since little force is required to return the toilet
paper roll to its original circular shape, packaging of the flat
elliptical toilet paper rolls can be easily achieved using a simple
device or the like. Conversely, when there is a cardboard paper
tube core such as in marketed items a and b in FIGS. 36 and 44, the
compressive yield point K, having a prescribed value which is a
large compressive load, exists, and therefore a large force is
required to compress the core. As a result, when the toilet paper
roll is placed in a bag or the like, great repulsive force is
necessary to return the toilet paper roll from an elliptical form
to a circular form, and a large sealing device must be employed.
These conventional inconveniences have been eliminated by the
present invention.
[0016] The present invention further comprises a toilet paper roll
manufacturing method which comprises the steps of: manufacturing a
semi-manufactured toilet paper roll comprising a thick tubular core
which is made of thin paper and which has a diameter of
approximately 4 cm, and toilet paper which is wound substantially
loosely as a whole around this thick tubular core; fixing and
supporting this semi-manufactured toilet paper roll in a
substantially outer diametrical position with facing pressing
support plates; pressing the semi-manufactured toilet paper roll
inward at a substantially central position from the two
substantially orthogonal directions to the direction of spacing
between the two pressing support plates using pressing portions on
the ends of hydraulic cylinders; forming the entire thick tubular
core into a substantially flat shape while forming fig-like
expanded portions on the two end positions of the substantially
flat thick tubular core; and also forming the toilet paper into a
flat elliptical shape in compliance with the substantially flat
thick tubular core. The advantage here is that since the
semi-manufactured toilet paper roll is supported, the toilet paper
roll is prevented from becoming flat, and in this state, due to the
synergistic action between the facts that the toilet paper roll is
only pressed inward at the center thereof, the thick tubular core
is manufactured from thin paper, and the toilet paper is wound
substantially loosely as a whole, the fig-like expanded portions
can be formed with ease.
[0017] The present invention further comprises a toilet paper roll
manufacturing method which comprises the steps of: manufacturing a
semi-manufactured toilet paper roll comprising a thick tubular core
which is made of thin paper and which has a diameter of
approximately 4 cm, and toilet paper which is wound substantially
loosely as a whole around this thick tubular core; stretching the
thick tubular core by inserting two hole-widening round bars
therein; pressing the thick tubular core inward from both sides
using hydraulic cylinders in directions which are orthogonal to the
spacing between the two hole-widening round bars while forming the
thick tubular core into a flat elliptical shape; and forming the
entire thick tubular core into a substantially flat shape by
forming fig-like expanded portions on both sides of the thick
tubular core while also forming the toilet paper into a flat
elliptical shape in compliance with the substantially flat thick
tubular core. The advantage here is that due to the synergistic
action among the two hole-widening round bars, the thin paper thick
tubular core, and the toilet paper which is wound substantially
loosely as a whole, the fig-like expanded portions can be molded
comparatively easily. A further advantage is that this toilet paper
roll can be formed into a substantially circular form with no kinks
in the thick tubular core thereof upon mounting onto the thick
shaft portion of a toilet paper roll holder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a perspective view of a toilet paper roll of a
first embodiment of the present invention;
[0019] FIG. 1B is a partially enlarged perspective view of FIG.
1A;
[0020] FIG. 1C is a side view of FIG. 1A and a rendering of the
flat elliptical form during storage and the like [of the toilet
paper roll];
[0021] FIG. 2A is a side view of the first embodiment of the
present invention;
[0022] FIG. 2B is a partially enlarged view of FIG. 2A;
[0023] FIG. 2C is a partial schematic view of FIG. 2A;
[0024] FIG. 3A is a side view of a second embodiment of the present
invention;
[0025] FIG. 3B is a partially enlarged view of FIG. 3A;
[0026] FIG. 3C is a partial schematic view of FIG. 3A;
[0027] FIG. 4A is a side view of a third embodiment of the present
invention;
[0028] FIG. 4B is a partially enlarged view of FIG. 4A;
[0029] FIG. 4C is a partial schematic view of FIG. 4A;
[0030] FIG. 5A is a view showing the state of unwinding of the
present invention;
[0031] FIG. 5B is an enlarged cross-sectional view of the S portion
of FIG. 5A, and a view showing a state in which a sound source is
eliminated or reduced;
[0032] FIGS. 6A and 6B are views showing the state of the central
portion of the toilet paper roll during an unwinding process of the
present invention;
[0033] FIGS. 7A and 7B are views showing the state of the central
portion of the toilet paper roll during the unwinding process of a
conventional product;
[0034] FIG. 8A is a view showing a normal process to crush a thick
tubular core of the present invention;
[0035] FIG. 8B is a view showing another state in which the thick
tubular core of the present invention is crushed;
[0036] FIG. 8C is a view showing a further state in which the thick
tubular core of the present invention is crushed;
[0037] FIGS. 9A through 9E are views showing states of flushing the
thick tubular core of the present invention down a toilet;
[0038] FIG. 10A is a perspective view of a semi-manufactured toilet
paper roll of a fourth embodiment of the present invention;
[0039] FIG. 10B is a partially enlarged perspective view of FIG.
10A;
[0040] FIG. 10C is a perspective view of the toilet paper roll of
the fourth embodiment of the present invention as a finished
product, and a rendering of the semi-manufactured product
thereof;
[0041] FIG. 11A is a side view of the semi-manufactured toilet
paper roll of the fourth embodiment of the present invention, and a
rendering of the finished product thereof;
[0042] FIG. 11B is a partially enlarged view of FIG. 11A;
[0043] FIG. 11C is a partial schematic view of FIG. 11A;
[0044] FIG. 12A is a side view of a semi-manufactured toilet paper
roll of a fifth embodiment of the present invention, and a
rendering of a finished-product thereof;
[0045] FIG. 12B is a partially enlarged view of FIG. 12A;
[0046] FIG. 12C is a partial schematic view of FIG. 12A;
[0047] FIG. 13A is a side view of a semi-manufactured toilet paper
roll of a sixth embodiment of the present invention, and a
rendering of a finished product thereof;
[0048] FIG. 13B is a partially enlarged view of FIG. 13A;
[0049] FIG. 13C is a partial schematic view of FIG. 13A;
[0050] FIGS. 14A through 14D are views of a process to mount the
toilet paper rolls of the fourth through sixth embodiments of the
present invention on a thick shaft of a toilet paper roll holder by
returning the toilet paper roll to its original circular shape;
[0051] FIG. 15A is a perspective view of a semi-manufactured toilet
paper roll of a seventh embodiment of the present invention;
[0052] FIG. 15B is a partially enlarged perspective view of FIG.
15A;
[0053] FIG. 15C is a perspective view of the toilet paper roll of
the seventh embodiment of the present invention as a finished
product, and a rendering of the semi-manufactured product
thereof;
[0054] FIG. 16A is a side view of the semi-manufactured toilet
paper roll of the seventh embodiment of the present invention, and
a rendering of the finished product thereof;
[0055] FIG. 16B is a partially enlarged view of FIG. 16A;
[0056] FIG. 16C is a partial schematic view of FIG. 16A;
[0057] FIG. 17A is a side view of a semi-manufactured toilet paper
roll of an eighth embodiment of the present invention, and a
rendering of a finished product thereof;
[0058] FIG. 17B is a partially enlarged view of FIG. 17A;
[0059] FIG. 17C is a partial schematic view of FIG. 17A;
[0060] FIG. 18A is a side view of a semi-manufactured toilet paper
roll of a ninth embodiment of the present invention, and a
rendering of a finished product thereof;
[0061] FIG. 18B is a partially enlarged view of FIG. 18A;
[0062] FIG. 18C is a partial schematic view of FIG. 18A;
[0063] FIGS. 19A through 19D are views of a process to mount the
toilet paper rolls of the seventh through ninth embodiments of the
present invention on a thick shaft of a toilet paper roll holder by
returning the toilet paper roll to its original circular shape;
[0064] FIG. 20A is a simplified plan view showing the final stage
of the manufacturing process for the toilet paper roll of the
seventh to ninth embodiments in a third manufacturing method of the
present invention;
[0065] FIG. 20B is a plan view showing the main components of FIG.
20A;
[0066] FIGS. 21A through 21F are views showing the process for
working the toilet paper roll of the seventh to ninth embodiments
into a flat ellipse in the third manufacturing method of the
present invention;
[0067] FIGS. 22A through 22E are views showing the process for
working the toilet paper roll of the seventh to ninth embodiments
into a flat ellipse in the third manufacturing method of the
present invention;
[0068] FIG. 23 is a perspective view of the main components used in
manufacturing the toilet paper roll of the seventh to ninth
embodiments in the third manufacturing method of the present
invention;
[0069] FIG. 24A is a front view of the main components used in
manufacturing the toilet paper roll of the seventh to ninth
embodiments in a fourth manufacturing method of the present
invention;
[0070] FIG. 24B is a view showing the manufacturing method of FIG.
24A;
[0071] FIG. 25A is a table of the rate of change under load
categorized by winding type;
[0072] FIG. 25B is a simplified view of a measurement method for
measuring the rate of change under load;
[0073] FIG. 25C is a graph comparing the rates of change under load
categorized by winding type;
[0074] FIG. 26 is a table of the measurement data for the rate of
change under load of the product implemented in the present
invention;
[0075] FIG. 27 is a table of the measurement data for the rate of
change under load of a slightly loose toilet paper roll;
[0076] FIG. 28 is a table of the measurement data for the rate of
change under load of another slightly loose toilet paper roll;
[0077] FIG. 29 is a table of the measurement data for the rate of
change under load of a toilet paper roll of regular tightness;
[0078] FIG. 30 is a table of the measurement data for the rate of
change under load of a slightly tight toilet paper roll;
[0079] FIG. 31 is a table of the measurement data for the rate of
change under load of a tight toilet paper roll;
[0080] FIG. 32 is a table comparing measurements for toilet paper
roll unwinding noise;
[0081] FIG. 33 is a graph comparing measurements for toilet paper
roll unwinding noise;
[0082] FIG. 34 is a table comparing familiar noises and noise
levels;
[0083] FIG. 35 is a line diagram of the compressive load
displacements of paper tubes of toilet paper rolls, comparing the
product implemented in the present invention and a conventional
product;
[0084] FIG. 36 is a line diagram of the compressive load
displacements during the manufacture of flat elliptical toilet
paper rolls, comparing the product implemented in the present
invention and a conventional product;
[0085] FIG. 37 is a view showing a compressive load displacement
experiment performed during manufacture of the toilet paper roll of
the present invention;
[0086] FIG. 38A is a view showing a single unit of the product of
the present invention in a wrapped state;
[0087] FIG. 38B is a view showing the products of the present
invention wrapped in parallel;
[0088] FIG. 39 is a view showing a compressive load displacement
experiment performed during manufacture of the toilet paper roll of
the present invention;
[0089] FIG. 40A is a view showing a single unit of the product of
the present invention in a wrapped state;
[0090] FIG. 40B is a view showing the products of the present
invention wrapped in parallel;
[0091] FIG. 41A is a perspective view of a toilet paper roll carton
holding six of the toilet paper rolls of the present invention in a
wrapped state;
[0092] FIG. 41B is a lateral cross section of FIG. 41A;
[0093] FIG. 41C is a lateral cross section of a different
embodiment to that in FIG. 41B;
[0094] FIG. 42A is a perspective view of a toilet paper roll carton
holding six conventional toilet paper rolls in a wrapped state;
[0095] FIG. 42B is a lateral cross section of FIG. 42A;
[0096] FIGS. 43A through 43D are views showing [a process in which]
a conventional flat toilet paper roll is returned to its original
state;
[0097] FIG. 44A shows a state in which a compressive load
displacement experiment is about to begin during the manufacture of
a conventional toilet paper roll;
[0098] FIG. 44B shows the locations of the compression points of
yield during the experiment of FIG. 44A; and
[0099] FIG. 44C shows the final stage of the experiment of FIG.
44A.
BEST MODE FOR CARRYING OUT THE INVENTION
[0100] The present invention will be described below with reference
to the drawings.
[0101] In a first embodiment, as is illustrated in FIGS. 1 and 2, a
toilet paper roll is constituted by a thick tubular core 1 which is
made of thin paper and has a diameter of approximately 4 cm, and
toilet paper 2 which is wound around the thick tubular core 1
substantially loosely from beginning to end. The thickness of the
thick tubular core 1 in FIGS. 1A, 1C and 2A is thicker than the
thickness of the toilet paper 2, but the thick tubular core 1 is
manufactured from thin paper and consequently is expressed in the
drawings only by a line. This applies similarly to the second
through ninth embodiments hereinbelow. FIG. 1B in particular shows
that the paper thickness of the thick tubular core 1 is thicker
than the paper thickness of the toilet paper 2. The aforementioned
toilet paper roll indicates a finished product in which the toilet
paper 2 is formed into a roll. The aforementioned toilet paper 2
indicates paper of appropriate length and includes paper in either
a rolled or unrolled form. As is illustrated in FIG. 1A, the toilet
paper roll as a finished product may be sold in a state in which a
circular cross section is maintained, or, due to the looseness of
the entire product, may be sold in a flat elliptical form, as is
illustrated by the dot/dash line in FIG. 1C. FIG. 2C is a schematic
view of one part of FIG. 2A, and illustrates the entire height
H.sub.0of the wound toilet paper 2 (subject to no load) when wound
substantially loosely. In other words, gaps occur between the
layers of wound toilet paper 2.
[0102] The thick tubular core 1 is manufactured from thin paper and
has an inner diameter of approximately 4 cm (specifically a
diameter of approximately 3.8 cm to approximately 4.5 cm), and is
manufactured by overlapping a plurality of thin paper sheets,
generally of approximately 30 (g/m.sup.2) (weight in grams per 1
m.sup.2 of paper) through 100 (g/m.sup.2), twisting these sheets
into a spiral form, and joining the sheets using an adhesive. In so
doing, the weight of the regular paper alone cannot be measured,
and therefore the weight of the thick tubular core 1 with an inner
diameter of approximately 4 cm is measured in widths of one toilet
paper roll (approximately 11 cm). According to this measurement,
the weight of the thick tubular core 1, including the weight of
glue and the like, was between approximately 1 (g/roll) and 3
(g/roll). The material for the thin paper of the thick tubular core
1 includes both water-soluble percolation paper and non-percolation
paper that is unlikely to dissolve in water, or water-soluble
percolation paper only. Thus, when no limitations are placed on the
material for the thick tubular core 1, percolation paper and
non-percolation paper are referred to. The aforementioned toilet
paper 2 is percolation paper generally weighing from approximately
16 (g/m.sup.2) to approximately 23 (g/m.sup.2). In the
aforementioned inner diameter of approximately 4 cm, diameters from
approximately 3 cm up to 5 cm are included. The material for the
thick tubular core 1 typically differs from the material for the
toilet paper 2. Here, the thick tubular core 1 is manufactured from
thin paper. Although paper of approximately 70 (g/m.sup.2) to 100
(g/m.sup.2) does not generally lie within the concept of thin
paper, in this specification particularly, the thick tubular core 1
uses woodfree paper with a general weight of approximately 30
(g/m.sup.2) to 100 (g/m.sup.2), as opposed to the cardboard used as
the material for marketed paper tube cores, which generally weighs
from approximately 200 (g/m.sup.2) to approximately 220
(g/m.sup.2), and is therefore referred to as being manufactured
from thin paper. The toilet paper roll of a second embodiment, as
illustrated in FIG. 3, is one in which toilet paper 2 is initially
wound tightly around a thick tubular core 1 made of thin paper and
with a diameter of around 4 cm, and thereafter wound loosely to the
end, thus being substantially loosely wound as a whole.
"Substantially loosely wound as a whole" is equivalent to the
previously mentioned "wound substantially loosely from beginning to
end", and cases to be mentioned hereinbelow are similar. FIG. 3C is
a partial schematic diagram of FIG. 3A, and illustrates a tightly
wound region H.sub.2 and a substantially loosely wound region
H.sub.3 within the entire height H.sub.0of the wound toilet paper 2
(when subject to no load). Hence, H.sub.2+H.sub.3=H.sub.0.
[0103] The toilet paper roll in a third embodiment is comprised by
toilet paper 2, one part of which, excluding the initial part, is
wound tightly around a thick tubular core 1 made of thick paper and
with a diameter of around 4 cm, and the remainder thereof is wound
substantially loosely, thus being wound substantially loosely as a
whole. Specifically, as is illustrated in FIG. 4, this is a case in
which the final few turns are wound tightly but the turns in all
the other positions are wound substantially loosely. This type of
winding is also indicated by "wound substantially loosely as a
whole". Further, although not shown in the drawing, several turns
may be wound tightly in an intermediate position in the toilet
paper roll and the turns in all of the other positions wound
substantially loosely. This also qualifies as "being wound
substantially loosely as a whole". FIG. 4C is a partial schematic
diagram of FIG. 4A in which a tightly wound region H.sub.4 and a
substantially loosely wound region H.sub.5 are illustrated within
the entire height H.sub.0 of the wound toilet paper 2 (when subject
to no load). Hence, H.sub.4+H.sub.5=H.sub.0.
[0104] Further, in a fourth embodiment, as is illustrated in FIGS.
10 and 11, the toilet paper roll is constituted by a thick tubular
core 1 manufactured from thin paper and having a diameter of
approximately 4 cm, and toilet paper 2 which is wound substantially
loosely around the thick tubular core 1 from beginning to end. As
is shown in FIG. 10C, the thick tubular core 1 is formed into a
flat shape, and the toilet paper 2 is also formed in a flat
elliptical shape in compliance with the flat thick tubular core 1.
The toilet paper roll as a finished product is illustrated in FIG.
10C. FIG. 10A shows a semi-manufactured product directly after the
toilet paper 2 has been wound around the thick tubular core 1.
Further, in the fourth through ninth embodiments of this
specification, referring simply to the thick tubular core 1
indicates both the circular form (see FIG. 10A) and the flat form
(seethe unbroken line in FIG. 10C). Moreover, referring simply to
the toilet paper 2 indicates paper of appropriate length and
includes paper in either a rolled or unrolled form.
[0105] In a fifth embodiment, as is illustrated in FIG. 12, the
toilet paper roll is formed such that toilet paper 2 is initially
wound tightly around a thick tubular core 1 made of thin paper and
with a diameter of around 4 cm, and thereafter wound substantially
loosely so as to be wound substantially loosely as a whole. The
thick tubular core 1 is formed into a flat shape, and the toilet
paper 2 is also formed into a flat elliptical shape in compliance
with the elliptical thick tubular core 1. FIG. 12C is a partial
schematic diagram of FIG. 12A. In FIG. 12, the entire height
H.sub.0 (when subject to no load), the region H.sub.2 and the
region H.sub.3 are similar to those in FIG. 3. The unbroken line in
FIG. 12A indicates a semi-manufactured toilet paper roll, and the
dot/dash line therein indicates the toilet paper roll as a finished
product.
[0106] The toilet paper roll in a sixth embodiment, as illustrated
in FIG. 13, is formed such that one part of the toilet paper 2,
excluding the initial part, is wound tightly around a thick tubular
core 1 made of thin paper and with a diameter of around 4 cm, and
the remainder thereof is wound substantially loosely around the
thick tubular core 1, thus being wound substantially loosely as a
whole. The thick tubular core 1 is formed into a flat shape, and
the toilet paper 2 is also formed into a flat elliptical shape in
compliance with the flat thick tubular core 1. Specifically, as
shown in FIG. 13, the final few turns may be wound tightly, with
the turns in all of the other positions wound substantially
loosely. In FIG. 13, the entire height H.sub.0 (when subject to no
load), the region H.sub.4 and the region H.sub.5 are similar to
those of FIG. 4. In FIG. 13A also, the unbroken line indicates a
semi-manufactured toilet paper roll, and the dot/dash line therein
indicates the toilet paper roll as a finished product.
[0107] In order to manufacture the toilet paper roll of the fourth
to sixth embodiments, the two following types of manufacturing
method are employed. In a first manufacturing method, the thick
tubular core 1 is initially inserted into a roller shaft in perfect
circle form. In this state, the toilet paper 2 is wound
substantially loosely around the thick tubular core 1 from
beginning to end, upon completion of which a semi-manufactured
toilet paper roll aggregate body (i.e. between 10 and 20
semi-manufactured toilet paper rolls joined together with a
circular cross section) is produced. Next, the roller shaft is
removed from the semi-manufactured toilet paper roll aggregate
body. In the following process, the top and bottom (see unbroken
line in FIG. 1A) or both sides of the cross section of the
semi-manufactured toilet paper roll are pushed inward to form the
cross section of the thick tubular core 1 into a flat shape, and
also to form the toilet paper 2 into a flat elliptical shape in
compliance with the flat thick tubular core 1 (see dot/dash line in
FIG. 11A).
[0108] In a second manufacturing method, pressure is applied to the
entire cross section of the toilet paper roll of the fourth through
sixth embodiments so as to form the roll into a flat elliptical
shape. However, this may be achieved with only slight pressure, and
therefore there are cases in which this process is performed on a
semi-manufactured toilet paper roll and cases in which the toilet
paper roll as a finished product is formed into a flat elliptical
shape by pushing in both sides with guides on both sides which are
used in the wrapping process.
[0109] The toilet paper roll in a seventh embodiment, as is
illustrated in FIGS. 15 and 16, is constituted by a thick tubular
core 1 which is manufactured from thin paper and has a diameter of
approximately 4 cm, and toilet paper 2 which is wound substantially
loosely around the thick tubular core 1 from beginning to end. As
is shown in FIG. 15C, the thick tubular core 1 is formed into a
substantially flat shape having expanded portions 1a, 1a on both
sides thereof in the form of a sycamore seed, and the toilet paper
2 is also formed into a flat elliptical shape in compliance with
the flat thick tubular core 1. The toilet paper roll as a finished
product is shown in FIG. 15C. FIG. 15A shows the semi-manufactured
product directly after the toilet paper 2 has been wound onto the
thick tubular core 1. The gaps that are produced between the layers
of wound toilet paper 2 are as in the first embodiment.
[0110] The toilet paper roll in an eighth embodiment, as is
illustrated in FIG. 17, is formed such that toilet paper 2 is
initially wound tightly around a thick tubular core 1 made of thin
paper and with a diameter of around 4 cm, and thereafter wound
substantially loosely so as to be wound substantially loosely as a
whole. The thick tubular core 1 is formed into a substantially flat
shape having expanded portions 1a, 1a on both sides thereof in the
form of a sycamore seed, and the toilet paper 2 is also formed into
a flat elliptical shape in compliance with the flat thick tubular
core 1. FIG. 17C is a partial schematic diagram of FIG. 17A, and
the entire height H.sub.0 (when subject to no load), the region
H.sub.2 and the region H.sub.3 in FIG. 17 are similar to those in
FIG. 3. The unbroken line in FIG. 17A indicates a semi-manufactured
toilet paper roll, whereas the dot/dash line therein indicates the
toilet paper roll as a finished product.
[0111] The toilet paper roll in a ninth embodiment, as is
illustrated in FIG. 18, is formed such that one part [of the toilet
paper 2], excluding the initial part, is wound tightly around a
thick tubular core 1 made of thin paper and with a diameter of
around 4 cm, and the remainder thereof is wound substantially
loosely around the thick tubular core 1, thus being wound
substantially loosely as a whole. The thick tubular core 1 is
formed into a substantially flat shape having expanded portions 1a,
1a on both sides thereof in the form of a sycamore seed, and the
toilet paper 2 is also formed into a flat elliptical shape in
compliance with the flat thick tubular core 1. More specifically,
as shown in FIG. 18, the final few turns are wound tightly, and the
turns in all of the other positions are wound substantially
loosely. The entire height H.sub.0 (when subject to no load), the
region H.sub.4 and the region H.sub.5 in FIG. 18 are similar to
those in FIG. 4. The unbroken line in FIG. 13A also indicates a
semi-manufactured toilet paper roll, whereas the dot/dash line
indicates the toilet paper roll as a finished product.
[0112] In order to manufacture the toilet paper roll of the seventh
to ninth embodiments, the following two types of manufacturing
method are employed. A third manufacturing method uses a flattening
device M shown in FIG. 20. This flattening device M is for
positioning the semi-manufactured toilet paper rolls after the
semi-manufactured toilet paper roll aggregate body has been cut
into individual toilet paper rolls by a cutter N. To explain this
manufacturing method specifically, as shown in FIGS. 21 through 23,
the circular semi-manufactured toilet paper rolls are transported
onto the flattening device M, and in this position a conveyor 25
stops (see FIG. 21A). Simultaneously, two hole-widening round bars
30, 30 which are clamped by front side position clamp portions 31,
31, are inserted into the thick tubular core 1 of the
semi-manufactured toilet paper roll (see FIG. 21B). Next, the
hole-widening round bars 30, 30 are clamped at the rear end side
thereof by rear side position clamp portions 31, 31 (see FIGS. 21C
and 21D). In this state, the upper hole-widening round bar 30 is
raised (see FIGS. 21E and 21F) such that the shape of the hole in
the thick tubular core 1 is altered to a vertical flat ellipse (see
FIG. 22A). In this state, the semi-manufactured toilet paper roll
is pressed inward from the left and right by pressing portions 33,
33 on the ends of rods 32a, 32a of hydraulic cylinders 32, 32
(predominantly pneumatic cylinders) (see FIGS. 22B and 23), thereby
forming fig-like expanded portions 1a, 1a on both sides (in FIG. 22
on the top and bottom) of the thick tubular core 1. Hence, the
entire thick tubular core 1 is formed into a substantially flat
shape, and the toilet paper 2 also takes on a flat elliptical shape
in compliance with the flat thick tubular core 1, thus completing
the molding [process].
[0113] The front side position clamp portions 31, 31 are then
removed, and at the same time the toilet paper roll finished
product is transported on the now moving conveyor 25 to the
wrapping machine C side (see FIG. 22C). Next, the two hole-widening
round bars 30, 30 which are clamped by the rear side position clamp
portions 31, 31 make a reverse turn such that the rear side
position clamp portions 31, 31 become front side position clamp
portions 31, 31 (see FIG. 22D). The upper hole-widening round bar
30 is lowered to return to its original position (see FIG. 22E),
whereby, returning to FIG. 21A, the next semi-manufactured toilet
paper roll undergoes flattening. During transportation of the
toilet paper roll finished product, the shape of the flattened
toilet paper roll is maintained by a curved guide 26 and a straight
guide. 27 (see FIG. 20B). At the front and rear of the flattening
machine M, the toilet paper roll is transported along a conveyor 23
and supported by straight guides 24, 24 on both sides.
[0114] In order to manufacture the toilet paper roll of the seventh
to ninth embodiments using a fourth manufacturing method, a
flattening device X in FIG. 24 is used instead of the flattening
device M. Specifically, the flattening device X is provided with
upper and lower pressing support plates 40, 40 and left and
right-side hydraulic cylinders 41, 41 (predominantly pneumatic
cylinders) (see FIG. 24A). In this operation, [the
semi-manufactured toilet paper roll] is pressed inward by pressing
portions 42, 42 on the ends of rods 41a, 41a of the hydraulic
cylinders 41, 41, simultaneously being supported by the upper and
lower pressing support plates 40, 40 (see FIG. 24B). Thereby,
sycamore seed-type expanded portions 1a, 1a are formed in the upper
and lower positions of the flattened thick tubular core 1, and
hence the entire thick tubular core 1 is formed into a
substantially flat shape, and the toilet paper 2 also takes on a
flat elliptical shape in compliance with the flat thick tubular
core 1, thus completing the molding [process].
[0115] The above product of the present invention is used when
mounted on a thick shaft portion 10 of a toilet paper roll holder.
The aforementioned "wound substantially loosely from beginning to
end" and "wound substantially loosely as a whole" indicate that the
amount of air gaps between the layers of toilet paper 2 has been
increased. As a result of this increase in the amount of air gaps,
when toilet paper which is mounted on the thick shaft portion 10 of
the toilet paper roll holder is pulled, the toilet paper roll
rotates such that the thick tubular core 1 and the thick shaft
portion 10 of the toilet paper roll holder contact each other
irregularly, whereby the toilet paper roll generates an unwinding
noise. Nevertheless, the toilet paper 2 which is "wound
substantially loosely from beginning to end" or "wound
substantially loosely as a whole" exists around the thick tubular
core 1, and thus, by means of the air gaps between the layers of
toilet paper, this noise is eliminated or reduced without reaching
the outside (see the S portion in FIG. 5A and FIG. 5B).
Furthermore, since the thick tubular core 1 is made of thin paper
and the toilet paper 2 that is "wound substantially loosely from
beginning to end" or "wound substantially loosely as a whole"
exists on the thick tubular core 1, one location on the thick
tubular core 1 of the toilet paper roll becomes flattened when the
toilet paper 2 is unrolled (pulled) (see FIG. 5A). Further, at this
point in time, the thick tubular core 1 and the thick shaft portion
10 are in close contact at a shaft side point P.sub.C2 and a tube
side point P.sub.O2, whereas no contact is made at a shaft side
point P.sub.C1 and a tube side point P.sub.O1, as is illustrated in
FIG. 6A. In the next moment, contact continues to be made at the
shaft side point P.sub.C2 and tube side point P.sub.O2, while
contact is also made at the shaft side point P.sub.C1 and tube side
point P.sub.O1. Thus, during rotation, contact is made as a
surface. In this manner, surface contact is made due to the
looseness [of the toilet paper roll], whereby either no noise or an
extremely soft sound is produced. On the other hand, as is
illustrated in FIG. 7, in a cardboard tube core a of a conventional
toilet paper roll, at one moment there are points which contact the
thick shaft portion 10, and a shaft side point P.sub.c and a tube
side point P.sub.O which do not make contact. At the next moment,
however, the shaft side point P.sub.C and tube side point P.sub.O
contact each other but the points that were previously in contact
separate from each other. Thus, during rotation, contact is made at
points, and in this state of point contact a large unwinding noise
is generated in the toilet paper roll. The product of the present
invention solves such a disadvantage by the surface contact action
shown in FIG. 6.
[0116] As described above, the product of the present invention is
able to drastically reduce unwinding noise in a toilet paper roll
because the increase in the amount of air gaps between the layers
of the toilet paper 2 and the surface contact of the loose surfaces
act synergistically.
[0117] Further, as shown in FIG. 9, the percolation paper that is
the material of the thick tubular core 1 has a water-soluble
property, and thus softens when holding water, thereby altering the
form of the thick tubular core 1. Hence, a toilet can be prevented
from blocking even when the thick tubular core 1 which remains on
the thick shaft portion 10 of a typical household toilet paper roll
holder following use of a toilet paper roll is flushed down the
toilet.
[0118] Also, as is illustrated in FIG. 14A, the thick tubular core
1 of the product of the present invention is formed into a flat
shape, and the toilet paper 2 is formed into a flat elliptical
shape in compliance with the flat thick tubular core. Nevertheless,
when mounted on the thick shaft portion 10 of a toilet paper roll
holder, the toilet paper roll can be returned to a substantially
perfect circle form. As is illustrated in FIGS. 14A through 14D,
since the thick tubular core 1 is made of thin paper and the toilet
paper is "wound substantially loosely from beginning to end" or
"wound substantially loosely as a whole", the toilet paper roll can
be returned to a substantially perfect circle form due to the
synergistic action between the loose toilet paper 2 and the fact
that almost no pressure [need be] applied even when the thick
tubular core 1 is flattened since the thick tubular core 1 is made
of thin paper. Furthermore, even though the thick tubular core 1 is
formed into a substantially flat shape having fig-like expanded
portions 1a, 1a on both sides, and the toilet paper 2 is formed
into a flat elliptical shape in compliance with the flat thick
tubular core 1, the expanded portions 1a, 1a on both sides create
no kinks whatsoever in the thick tubular core 1 upon mounting onto
the thick shaft portion 10 of the toilet paper roll holder, and
thus, the thick tubular core 1 can be returned to a substantially
perfect circular form.
[0119] FIG. 41A shows six of the toilet paper rolls of the present
invention sealed in one carton. FIG. 41B shows the state of
insertion of the toilet paper rolls in a lateral cross section of
the carton. FIG. 41C shows a cross section of the toilet paper roll
carton in a case in which the thick tubular core 1 is formed into a
substantially flat shape having fig-like expanded portions 1a, 1a
on both sides. If the conventional type toilet paper roll cartons
of FIGS. 42A and B are compared with the toilet paper roll carton
of the present invention in FIG. 41, it can be seen as a result of
experiment that the surface area of the lateral cross section of
the product of the present invention is approximately 30% to 40%
smaller than that of the conventional product.
Experiment 1
[0120] In this specification, "wound substantially loosely"
indicates that when a 13 kg load measuring weight 21 is applied to
a toilet paper roll, the rate of change under load thereof is
approximately 36% or greater. This is according to the following
experiment.
Rate of change under load=(H.sub.0-H.sub.1)/H.sub.0.times.100
[0121] H.sub.0: height when subject to no load
[0122] H.sub.1: height when a 13 kg load measuring weight 21 is
applied
[0123] In the experiment, as is shown in FIG. 25B, a measuring
shaft 20 was inserted into the thick tubular core 1 of the toilet
paper roll manufactured according to the present invention, the
paper tube core of a marketed toilet paper roll, or a toilet paper
roll core, the height of the uppermost position on the periphery of
the thick tubular core 1 etc. was set to 0, this was set as the
reference height position, and the height therefrom to the
uppermost end position on the periphery of the toilet paper 2 of
the toilet paper roll with no load thereupon, or in other words the
height of the toilet paper roll when subject to no load, was set as
H.sub.0. A 13 kg measuring weight 21 was placed upon the toilet
paper roll subject to no load, and at that time, the gaps between
the layers of toilet paper 2 became narrower due to the measuring
weight 21, thereby reducing the height. The height to the uppermost
end position on the periphery of the toilet paper 2 at this time,
or in other words the height upon application of a 13 kg load, was
set as H.sub.1.
[0124] In the experiment, the following were used for rate of
change under load measurement data: the product of the present
invention (see FIG. 26); loosely wound with core A (see FIG. 27)
and loosely wound with core B (see FIG. 28), which were chosen
appropriately with texture as a reference and are wound slightly
loosely at their center; normally wound with core (see FIG. 29) in
which the surface turns are wound at a normal level of tightness;
tightly wound with core (see FIG. 30) which is wound slightly
tightly; and tightly wound no core (see FIG. 31) which is wound
tightly. The H.sub.0 and H.sub.1 of this plurality of samples were
measured. The resulting measurement data are shown in FIGS. 26
through 31, and the maximum rate of change under load, average rate
of change, and minimum rate of change are gathered and shown in
FIG. 25A. When made into a comparison graph, such as FIG. 25C, the
following can be observed.
[0125] That is, "tightly wound" indicates a rate of change under
load of 0% to approximately 9%; "slightly tightly wound" indicates
a rate of change under load of approximately 9% to approximately
21%; "wound to a normal level of tightness" indicates a rate of
change under load of approximately 21% to approximately 36%;
"slightly loosely wound" indicates a rate of change under load of
approximately 36% to approximately 49%; and "loosely wound"
indicates a rate of change under load of approximately 49% or
greater. Thus, since "substantially loosely wound" includes
"loosely wound" and "slightly loosely wound", the previously
mentioned "substantially loosely wound" indicates that under a load
of 13 kg, the rate of change under load is approximately 36% or
greater. This value may vary by approximately 10% depending on the
temperature, humidity, air pressure and so on in the placement
condition of the toilet paper roll.
[0126] Further, the (H.sub.0-H.sub.1) of the previous equation also
expresses the amount of air gaps between the layers of the toilet
paper 2 in the toilet paper roll, and therefore the rate of change
under load according to this equation can be said to be
substantially equal to the air gap ratio. Accordingly, an air gap
ratio of approximately 36% or greater can be said to be "wound
substantially loosely". It is important to note here that the
surface load is 13 kg. With an 18 kg measuring weight 21, the value
of (H.sub.0-H.sub.1) increases such that the rate of change under
load increases for all of the categories of winding method.
Thereby, a rate of change under load of approximately 40% or
greater indicates "wound substantially loosely". With a 7 kg
measuring weight 21, for example, the value of (H.sub.0-H.sub.1)
decreases such that the rate of change under load decreases for all
of the categories of winding method. Thereby, a rate of change
under load of approximately 30% or more indicates "wound
substantially loosely".
Experiment 2
[0127] In an experiment shown in FIG. 32 to measure the unwinding
noise of the toilet paper roll of the present invention, the toilet
paper roll of the present invention was compared with a
conventional toilet paper roll with a typical cardboard paper tube
core, whereby it was learned that the toilet paper roll of the
present invention becomes progressively quieter. To described the
experiment specifically, the thick tubular core 1 relating to the
present invention is made from thin paper, has an inner diameter of
approximately 3.8 cm, and weighs approximately 1.6 g per length of
toilet paper roll (approximately 11 cm). The thick tubular core 1
is formed from two thin paper sheets of approximately 50
(g/m.sup.2) which are appropriately twisted into spiral form and
overlapped. Water-soluble percolation paper is used as the material
for the thin paper of the thick tubular core 1. As the conventional
product, a so-called normally wound with core toilet paper roll was
used, wound at a normal level of tightness onto a cardboard paper
tube core with an inner diameter of approximately 3.8 cm. Both the
toilet paper roll of the present invention, manufactured with
toilet paper 2 which is "loosely wound" and the conventional
normally wound with core toilet paper roll were set with outer
diameters of approximately 110 mm. The toilet paper rolls were
mounted onto the thick shaft portion 10 of a typical household one
touch-type toilet paper roll holder, the lid of the toilet paper
roll holder was removed so as to eliminate contact noise between
the lid and the toilet paper, and the unwinding noise generated
when pulling the toilet paper was measured. Measurement was
performed with a sound sensor disposed at approximately 50 cm, 1 m,
and 1.5 m from the location of the toilet paper roll holder. Even
if the unwinding rate of the toilet paper is constant, the toilet
paper roll is unwound from the outer periphery side, and therefore
the rate is slow at the peripheral portion which has a large outer
diameter, and the rate increases as the diameter grows smaller
toward the central portion. Consequently, measurement was performed
at three locations, the peripheral portion, an intermediate
portion, and the central portion (at the thick tubular core
side).
[0128] As is shown in the table in FIG. 32, the unwinding noise
grew quieter by between 12 dB (decibels) and 17 dB in all of the
peripheral portion, intermediate portion, and central portion (at
the thick tubular core side) positions. In a toilet or the like, it
is normal for another person to be removed by at least 1 m, and
hence, taking an average of the two samples, [the noise level of]
the conventional normally wound with core-type was 65 dB, and the
product of the present invention was 53 dB. Although the difference
is only 12 dB, decibels express sound levels as logarithms, and
hence a difference of 10 dB corresponds to a sound level that is 10
times higher. In other words, the progressive differences are as
follows: a difference of 12 dB corresponds to a sound level that is
approximately 16 times higher; 13 dB corresponds to approximately
20 times higher; 14 dB corresponds to approximately 25 times
higher; 15 dB corresponds to approximately 3 2 times higher; 16dB
corresponds to approximately 40 times higher; and 17 dB corresponds
to approximately 50 times higher. Expressing the table in FIG. 32
as a graph results in FIG. 33, wherein the differences in unwinding
noise between the conventional product and the product of the
present invention become obvious. By referencing a comparative
table of familiar noises and noise levels, as in FIG. 34, it can be
seen that approximately 65 dB is in an intermediate position
between a regular conversation and the sound of a noisy office or a
telephone, whereas the approximately 53 dB of the product of the
present invention is a sound close to a quiet office. Therefore,
simply considering the level of noise, the difference is extremely
striking. Thus, when the product of the present invention is used,
the unwinding sound of the toilet paper roll becomes extremely
small, and hence the toilet paper roll can be used freely, even by
women, without anxiety.
Experiment 3
[0129] FIG. 35 is a line diagram of the compressive load
displacements of paper tubes of toilet paper rolls (paper tube
cores, the thick tubular core 1 of the present invention and so
on). The thick tubular core 1 of the present invention has an inner
diameter of approximately 3.8 cm, and thick tubular cores 1 with
weights per one length of toilet paper roll (approximately 11 cm)
of 1.0 (g/roll), 1.6 (g/roll), 2.0 (g/roll), 2.4 (g/roll) and 3.0
(g/roll) were used. Conventional cardboard paper tube cores of 5.9
(g/roll) and 6.4 (g/roll) were also used. Water-soluble percolation
paper was used as the material for the thin paper of the thick
tubular core 1. The aforementioned 1.0 (g/roll), 1.6 (g/roll), 2.0
(g/roll), 2.4 (g/roll) and 3.0 (g/roll) thick tubular cores 1 are
formed by two sheets of thin paper with respective weights of
approximately 30 (g/m.sup.2), approximately 50 (g/m.sup.2),
approximately 65 (g/m.sup.2), approximately 80 (g/m.sup.2), and
approximately 100 (g/m.sup.2), twisted appropriately into spiral
form and overlapped. Further, the conventional cardboard paper tube
cores of 5.9 (g/roll) and 6.4 (g/roll) are formed by two sheets of
thick paper respectively weighing approximately 200 (g/m.sup.2) and
approximately 220 (g/m.sup.2), twisted appropriately into spiral
form and overlapped. In this experiment, a load was applied to the
thick tubular core 1 and the paper tube core, having an inner
diameter of approximately 3.8 cm, so as to cause height variations
from 0 to 15 mm, and thus a line diagram of the compressive load
displacements of the paper tubes of toilet paper rolls was
determined.
[0130] As is shown in FIG. 35, the results thereof indicate that
the 2.0 (g/roll) thick tubular core 1 of the present invention can
be pressed inward with up to one twentieth of the force (N)
required for the 6.4 (g/roll) conventional cardboard paper tube
core. Thus, as noted previously, the thick tubular core 1 can be
crushed easily and with far less force than that required by a
conventional cardboard paper tube core (see FIG. 8). It can also be
understood from FIG. 35 that woodfree paper of up to approximately
3 (g/roll) is appropriate for the thin paper used to manufacture
the thick tubular core 1 of the present invention. Further, the
weight of the thick tubular core 1 varies by approximately 10% to
20% according to the amount of glue, and therefore woodfree paper
of up to approximately 4 (g/roll) may also be included in the thin
paper used to manufacture the thick tubular core 1 of the present
invention.
Experiment 4
[0131] FIG. 36 is a line diagram of toilet paper roll compressive
load displacements upon the manufacture of the toilet paper rolls
of the fourth through ninth embodiments of the present invention in
particular. The thick tubular core 1 of the present invention has
an inner diameter of approximately 3.8 cm, and a weight per one
length (approximately 11 cm) of toilet paper roll of 1.6 (g/roll).
The toilet paper roll used is wound loosely and has an outer
diameter of approximately 11 cm. A toilet paper roll with a
cardboard paper tube core weighing 6.4 (g/roll), which is normally
wound with a core and has an outer diameter of approximately 11 cm,
is used as marketed product a, and a toilet paper roll with a
cardboard paper tube core weighing 5.9 (g/roll), which is loosely
wound with a core and has an outer diameter of approximately 11 cm,
is used as marketed product b.
[0132] In the experiment, a compressive load was applied and the
resulting displacement was measured. In this specification, there
is a factor of error of approximately 2%, and 1 kgf is set as 10N
(Newton). Hence, as is illustrated in FIG. 36, when a compressive
load is gradually applied to the circular marketed product a,
applying approximately 5N causes displacement of approximately 8
mm, and applying approximately 10N causes displacement of
approximately 14 mm. Further, when the maximum compressive load of
approximately 10.5N is applied, displacement of approximately 15 mm
occurs (see FIG. 44B). Thereafter, the amount of displacement
increases even when a compressive load which is no more than the
maximum compressive load is applied. At the point when
approximately 9.5N causes an approximately 50 mm displacement, the
paper tube core becomes flattened and the toilet paper is formed
into a flat elliptical shape (see FIG. 44C). Further, in circular
marketed product b, application of approximately 6N causes
displacement of 20 mm, and approximately 10.2N causes displacement
of 30 mm. When the maximum compressive load of 10.5N is applied,
displacement of 32 mm occurs (see FIG. 44B), after which the amount
of displacement increases even when a compressive load which is no
more than the maximum compressive load is applied. At the point
when approximately 9.9N causes an approximately 60 mm displacement,
the paper tube core becomes flattened and the toilet paper is
formed into a flat elliptical shape (see FIG. 44C). Note that in a
tensile test, the point at which the amount of displacement
increases without increasing the tensile load is defined in JIS
terminology as the "yield point". In the present invention, it is a
compressive displacement experiment that is performed, but since
the amount of displacement increases from the point of maximum
compressive load without adding to the compressive load, this
maximum compressive load point is referred to as the "compression
yield point" in this specification. In this compressive
displacement experiment, the height of the marketed product a and
marketed product b prior to shape alteration is set as Y.sub.0, and
the height thereof following compression into a flat elliptical
shape is set as Y.sub.2 (see FIG. 44).
[0133] In the present invention, as is shown in FIG. 36, the
circular semi-manufactured toilet paper roll is displaced by 18 mm
when approximately 1N is applied, and by 30 mm when 2N are applied.
When the maximum compressive load of approximately 4N is applied,
the toilet paper roll changes shape by approximately 42 mm of
displacement, and at this point the thick tubular core 1 becomes
flattened and the toilet paper 2 is formed into a flat elliptical
shape. In this compressive displacement experiment, when the height
of the circular toilet paper roll of the present invention prior to
displacement is set as Y.sub.0, the height thereof following
compression into a flat elliptical shape becomes Y.sub.1, and no
compression occurs beyond the aforementioned height Y.sub.2. Hence,
height Y.sub.1>height Y.sub.2 (see FIGS. 37, 39 and 44).
Further, there is no compression yield point in the product of the
present invention. In the marketed products a and b, the amount of
displacement is large as a whole when moving from the state in FIG.
44B to that in FIG. 44C. In other words, during the
pressure-flattening operation of the paper tube core in the
compression process, a large amount of force is required at the
point where the paper tube core takes a rhomboid elliptical shape
due to the hardness of the cardboard paper tube core, and up to
that point the upper and lower layers of toilet paper 2 are pressed
together and compressed (see FIG. 44B). The maximum value at this
point is a prescribed value, and the point of this prescribed value
is referred to as compression yield point K (see FIG. 36). From the
point of this compression yield point K, the amount of displacement
increases even without increasing the pressure of the compressive
load on the semi-manufactured toilet paper roll above the
prescribed value (in the graph in FIG. 36, approximately 10N and
1.05 kgf). At this time, the paper tube core is flattened and the
degree of flatness of the toilet paper increases further to form a
flat elliptical shape.
[0134] As is illustrated in FIGS. 38 and 40, since only a small
amount of pressure (compressive load) need be applied to flatten
the thin paper thick tubular core 1 and form the loosely wound
toilet paper 2 into a flat elliptical shape, the repulsive force f,
f needed in order to return the toilet paper roll to its original
circular form is also small, and packaging by sealing the product
into a bag 50 can be performed easily. In the present invention, in
the operation to form the toilet paper 2 into a flat elliptical
shape, the applied pressure is merely up to 4N, and thus the toilet
paper roll responds sufficiently well to the application of
pressure in the packaging process. Manufacture can also be easily
accomplished at approximately 5N.
[0135] According to the present invention as described above, the
unwinding noise of a toilet paper roll can be reduced considerably.
More specifically, even if the toilet paper roll of the present
invention is mounted onto the thick shaft portion of a typical
household toilet paper roll holder or the like such that the thick
shaft portion and the thick tubular core contact one another while
rotating to produce contact noise, squeaks or the like, this noise
is eliminated or reduced without being transmitted to the outside
due to the fact that the thick tubular core is made of thin paper
and therefore rotates in compliance with the toilet paper roll
holder so as to make surface contact therewith, and due to the fact
that toilet paper that is "wound substantially loosely" exists
around the thick tubular core and air gaps exist between the layers
of the toilet paper. This fact was clearly proven in the experiment
in FIG. 32 and 33. In this experiment, a reduction in unwinding
noise of between approximately 12 dB and approximately 17 dB was
achieved. In actuality, however, almost no noise could be heard. As
a result, a silent-type toilet paper roll can be provided having
the great advantage that unwinding noise such as rattling noise
generated when using the toilet paper in a toilet can be
eliminated, whereby women in particular can use the toilet paper
without anxiety.
[0136] Furthermore, in the present invention, the thick tubular
core is manufactured from thin paper, and therefore has far less
strength than a conventional cardboard paper tube core. As a
result, even women and children can easily crush the thick tubular
core which remains on the thick shaft portion of a typical
household toilet paper roll holder after use of the toilet paper
roll (see FIG. 8). This has the advantages of enabling a reduction
in household refuse and allowing the thick tubular core to be
disposed of as general refuse. Moreover, since the thick tubular
core is manufactured from thin paper, this paper is thinner than
that of a conventional cardboard paper tube core, and the amount of
paper used is lower. Thus, the unit price of the core itself can be
reduced. As a result, the entire toilet paper roll can be produced
at a comparatively reasonable price. Further, soft type core-less
toilet paper rolls exist in one part of the market, but the glued
sections of the core have a damaged appearance, making it difficult
for such products to penetrate general markets. Alternatively, the
machines for manufacturing these soft type core-less toilet paper
rolls are special machines of a particular specification, meaning
that such toilet paper roll is comparatively extremely expensive to
produce. In the present invention, however, the outer appearance of
the paper tube core is substantially identical in form to that of a
typical paper tube core, and the production costs thereof can be
progressively improved. Hence, in addition to the elimination of
noise and favorability in respect of refuse disposal as described
above, the price of a single unit of the product can be
reduced.
[0137] Moreover, according to the present invention, since the
thick tubular core is made of percolation paper and therefore has a
water-soluble property, toilet blockages can be avoided even when
the thick tubular core is flushed down the toilet after use. The
toilet paper roll of the present invention also has a flat
elliptical shape, and therefore, in comparison with a conventional
toilet paper roll in perfect circle form, has the advantages of
greatly reducing space such that storage costs, transport costs and
so on can be reduced.
Industrial Applicability
[0138] The present invention may be used as a toilet paper roll in
which unwinding noise is greatly reduced even upon mounting onto
the thick shaft portion of a typical household toilet paper roll
holder, in which the thick tubular core of the toilet paper roll
can be easily crushed and disposed of and is therefore favorable as
regards refuse processing, in which the thick tubular core can also
be manufactured reasonably such that the manufacturing cost of the
toilet paper roll can also be reduced in price, in which the thick
tubular core can also be flushed into the toilet, in which
moreover, since the toilet paper roll is manufactured into a flat
elliptical form, storage costs, transport costs and the like can be
reduced, and in which during use, the cross section becomes
substantially circular such that the toilet paper roll is
sufficiently usable.
* * * * *