Compressed hollow coreless re-formable roll products
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Solution Overview
Problem
Conventional absorbent paper products, such as tissue rolls, have a large central void and cylindrical shape that increases transportation volume, leading to higher costs and aesthetic issues when compressed to reduce volume, as they often fail to recover their original shape satisfactorily.
Innovation Solution
The development of compressed hollow coreless rolls with a substantially collapsed central axial cavity that can be re-formed into a cylindrical shape for dispensing, using a tubular dispensing core that is smaller than the original cavity, allowing for significant volume reduction without compromising product quality or consumer acceptance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If rolls are compressed to eliminate the hollow center space, then transportation volume is reduced, but the rolls do not recover their cylindrical shape sufficiently to satisfy consumers' aesthetic demands
Solution Approach 1:
The invention removes the traditional hollow cylindrical core from the tissue roll, creating a solid coreless structure. This extraction of the core eliminates the primary source of volume inefficiency while maintaining the roll's ability to be compressed and subsequently reformed into a satisfactory cylindrical shape for consumer use.
Solution Approach 2:
The invention changes the structural parameter of the roll from hollow-cored to solid coreless, and utilizes controlled compression to temporarily alter the density and shape parameters during transportation. The coreless structure allows the roll to be compressed to a fraction of its original volume while maintaining the ability to recover its functional form through simple reformation.
2Strength
If a large paperboard core is used in conventional rolls, then structural integrity is maintained, but cost, weight and volume increase
Solution Approach 1:
The invention extracts and eliminates the paperboard core component entirely, replacing it with a solid tissue structure. This removal eliminates the additional weight, volume, and cost associated with the core while the tissue itself provides sufficient structural integrity for the roll to function normally during dispensing and use.
Solution Approach 2:
The tissue material itself serves multiple functions: it provides the absorbent functionality, forms the structural body of the roll, and replaces the need for a separate core component. The solid coreless structure performs both the wrapping and supporting functions that were previously divided between the tissue and the paperboard core.
3Volume of moving object
If conventional compression methods are applied to cored rolls, then volume reduction is achieved, but re-shaping to cylindrical form becomes difficult due to creases in the paperboard core
Solution Approach 1:
By removing the paperboard core, the invention eliminates the source of compression-induced creases and deformation. The solid coreless tissue structure compresses uniformly without the rigid core that would otherwise create permanent creases and make re-shaping difficult, allowing easy reformation into a cylindrical shape after compression.
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
This solution achieves volume reductions of up to 40% compared to conventional cored products, enhances re-formability, and eliminates the need for specific roll diameter requirements, making the production and transportation of absorbent paper products more cost-effective and efficient.
Implementation Method 1
compressing the hollow coreless roll such that the axial cavity is substantially collapsed
Implementation Method 2
the resilient nature of absorbent paper products. However, efforts to eliminate the excess volume contributed by the hollow center void have been less successful in consumer markets, as rolls that have been compressed sufficiently to eliminate the hollow center space apparently do not recover their overall cylindrical shape sufficiently to satisfy consumers' aesthetic demands
Data Source
Figure 1A~2B
Figure 3A~4
Figure 5~6
AI summary
A compressed hollow coreless roll of absorbent paper sheet produced by way of providing a roll of absorbent paper sheet by winding the sheet about a forming core member having a diameter in the range of 30 mm to 50 mm; removing the forming core member such that there is provided a hollow coreless roll of absorbent paper sheet with an axial cavity having a diameter in the range of 30 mm to 50 mm and compressing the hollow coreless roll such that the axial cavity is substantially collapsed. The compressed hollow coreless rolls are readily re-formed into cylindrical shape. Space saving packages of the rolls are overwrapped with tubular polymer film to provide a flexible reconfigurable package of a series of individually encased rolls. Volume reductions of about 10 to about 20%, about 14% to about 20%, 30%, 40% and more as compared with conventional products are realized.