Grooved Composite Transfer Roll Core for Delamination Resistance

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Solution Overview

Problem

Traditional transfer roll cores made from laminated paper are prone to delamination and failure under manufacturing stresses, leading to safety hazards and high costs due to frequent replacement and disposal issues.

Innovation Solution

A durable transfer roll core with an elongate body featuring grooves and ridges, made from materials like plastic or metal, which provides enhanced tensile strength and impact resistance, allowing for longer use and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional laminated paper cores are used, then manufacturing cost is reduced and ease of manufacture is improved, but reliability deteriorates due to delamination and fracture under stress

Engineering Contradiction:

Improvecore durabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by combining plastic (polymer matrix) with metal reinforcement elements (wire mesh, spirals, or cages) to create a transfer roll core that achieves superior strength, durability, and resistance to delamination while maintaining manufacturability through established composite fabrication processes

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the fundamental material parameters from traditional paper-based laminates to plastic-metal composites, transforming the core's mechanical properties including tensile strength, impact resistance, and dimensional stability to eliminate delamination failures while remaining manufacturable

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If traditional paper cores are used, then initial cost is lower, but loss of substance increases due to disposal costs and limited recyclability

Engineering Contradiction:

Improvedisposal costVSAvoidrecyclability

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent enables recovery and recycling of the plastic-metal composite core materials after their service life, allowing metal components to be reclaimed and plastic to be recycled or repurposed, thereby eliminating disposal costs and reducing material loss compared to single-use paper cores

Inventive Principle:

Principle #34Discarding and recovering

3Stability of the object's composition

If traditional paper cores are used, then weight is reduced, but stability deteriorates making the transfer roll dangerously unstable for operators

Engineering Contradiction:

Improvetransfer roll stabilityVSAvoidcore weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent uses plastic-metal composite construction where the plastic provides lightweight properties and the metal reinforcement (wire mesh, spirals, or cages) provides structural stability and strength, achieving an optimal balance between weight and stability that prevents transfer roll instability while remaining safer than traditional paper cores

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250250141A1Durable transfer roll core and method of making and using the same

Publication Date: 2025.08.07 PROCTER & GAMBLE CO

AI summary

A durable transfer roll core may comprise an elongate body comprising a groove, the elongate body having an elongate body longitudinal axis. First and second ridges may be on each side of the groove and may be asymmetrical relative to the groove longitudinal axis.