Adhesive-Film Cardboard Core for Damage-Free Tissue Log Extraction
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Solution Overview
Problem
Existing methods for forming coreless paper rolls face issues with core extraction, leading to damage and deformation of innermost paper spirals, and the use of deformable plastic cores is costly and bulkier, while traditional cardboard cores are inefficient and require disposal.
Innovation Solution
A corewinder that forms a core using cardboard strips with an adhesive film to facilitate easy extraction, where the adhesive film reduces friction and allows for smooth detachment of the core from the paper plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cardboard cores are used, then the core structure provides support during winding, but the core extraction causes damage and deformation to innermost paper spirals
Solution Approach 1:
The core is segmented into two functional parts: an inner extractable core made of soft, easily removable material (paper, fabric, or plastic) and an outer structural core made of rigid cardboard that remains in the log. The inner core can be easily extracted without damaging the paper, while the outer core maintains structural integrity during winding and storage.
Solution Approach 2:
An intermediary inner core acts as a mediator between the winding process and the final log structure. This inner core provides temporary support during winding, facilitates easy extraction without paper damage, and can be removed through the center of the log without affecting the outer paper structure.
2Ease of operation
If deformable plastic cores are used to enable easy extraction, then core extraction becomes easier, but the logs become bulkier and costs increase
Solution Approach 1:
The inner core is made from inexpensive, disposable materials such as paper strips, fabric, or thin plastic that can be easily discarded after serving its temporary purpose during winding. This eliminates the need for expensive, reusable plastic cores while maintaining easy extractability.
Solution Approach 2:
The inner core uses flexible, thin materials like paper strips or fabric that can be easily compressed and removed. These thin-film materials provide sufficient structural support during winding without adding significant bulk to the log, unlike rigid plastic cores.
3Ease of operation
If deformable plastic cores are used for easy extraction, then extraction is facilitated, but the core material cost increases and disposal is required when damaged
Solution Approach 1:
The inner core is made from inexpensive, disposable materials such as paper strips, fabric, or thin plastic that can be easily discarded after serving its temporary purpose during winding. This eliminates the need for expensive, reusable plastic cores while maintaining easy extractability.
Solution Approach 2:
The material parameters of the inner core are optimized to use low-cost materials with sufficient mechanical properties for temporary support during winding. The material is selected to be inexpensive, easily removable, and environmentally friendly, changing from expensive reusable plastic to cheap disposable materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adhesive film-covered cardboard core enables easy and efficient extraction without damaging the paper, maintaining compact log bulk and reducing costs compared to plastic cores.
Implementation Method 1
the adhesive film reduces friction and allows for smooth detachment of the core from the paper plies
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A corewinder (100) to form a core (200) for tissue paper logs (300) from cardboard strips (201, 202) is described, the corewinder (100) comprises an unwinding station (10) adapted to unwind two or more reels (11, 12) of a cardboard strip (201, 202); a forming station (20), placed downstream of the unwinding station (10) and adapted to spirally wind at least an upper strip (201) and a lower strip (202) being unwound from the reels (11, 12) one on the other, joining them to form a tube (203); a cutting station (30) placed downstream of the forming station (20) and configured to cut the tube (203) being formed to obtain a core (200); the corewinder (100) also comprises a dispenser assembly (40) for an adhesive film (41), configured to unwind an adhesive film (41) connectable to said upper strip (201) to obtain a core (200) at least partially covered by said adhesive film. A process to make a core (200) at least partially covered by such an adhesive film (41) and a tissue paper log (300) comprising such a core (200) are also described.