Coreless roll of absorbent sheet and method for manufacturing the same
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Solution Overview
Problem
Coreless rolls of absorbent sheet products face challenges with collapsing during manufacturing, storage, and transport, leading to difficulties in maintaining a stable axial hollow passageway and increased risk of clogging sewage systems, while existing solutions lack sufficient flexibility and elasticity, and often result in irreversible deformation and decreased product quality.
Innovation Solution
A coreless roll design featuring a continuous web of absorbent material with a coating composition comprising a nonionic cellulose ether applied to the second end, which provides excellent stiffness, resistance to collapsing, and flexibility, allowing the roll to maintain a well-defined axial hollow passageway and prevent sewage clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If coreless rolls are made without a temporary core, then storage and transport space is reduced and manual handling is simplified, but the roll collapses and the axial hollow passageway becomes unstable
Solution Approach 1:
The patent applies a coating composition containing cellulose ether to the second end of the continuous web. This chemical modification changes the physical parameters of the paper material, providing stiffness and structural support that prevents roll collapse while maintaining the coreless design for space-efficient storage and transport.
Solution Approach 2:
The invention creates a composite structure by applying a cellulose ether coating to the absorbent sheet material. This composite combines the absorbent properties of the paper web with the structural reinforcement of the cellulose ether coating, achieving both collapse resistance and coreless design benefits.
2Adaptability or versatility
If the roll is made flexible to allow compression for storage, then storage and transport costs are reduced, but the roll becomes prone to irreversible deformation and quality degradation
Solution Approach 1:
The cellulose ether coating modifies the mechanical parameters of the paper web, creating an optimal balance between flexibility and structural integrity. This allows the roll to be compressed for storage while maintaining sufficient stiffness to prevent irreversible deformation and quality degradation during handling and use.
3Stability of the object's composition
If a temporary core is used during manufacturing, then the axial hollow passageway is maintained during winding, but the core requires additional storage space and manual handling
Solution Approach 1:
The patent extracts the temporary core from the manufacturing process entirely, achieving a true coreless design. The cellulose ether coating on the second end provides sufficient structural support to maintain the axial hollow passageway during winding without requiring any core material, thereby eliminating storage and handling requirements for cores.
Solution Approach 2:
The absorbent sheet material itself, through the cellulose ether coating, provides the structural support function that would otherwise require a separate core component. The coated second end self-reinforces to maintain the hollow passageway during the winding process, making the core unnecessary.
4Stability of the object's composition
If the first inner turns are tightly wound to define the axial hollow passageway, then the passageway is clearly defined, but the roll becomes stiff and resistant to compression
Solution Approach 1:
The cellulose ether coating changes the local mechanical parameters of the paper at the second end, providing targeted stiffness where needed for passageway definition while allowing the rest of the roll to remain compressible. This localized parameter modification resolves the contradiction between structural definition and overall flexibility.
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 coreless roll exhibits improved stiffness and resistance to collapsing, maintaining a stable axial hollow passageway and preventing sewage clogging, while allowing for full-length use and reduced storage and transport costs, enhancing product quality and usability.
Implementation Method 1
the absorbent sheet product constituting the first inner turns of the roll (i.e. the turns forming the axial hollow passageway at winding start) cannot be stably maintained
Implementation Method 2
the roll can be returned from its compressed (oval) form to the uncompressed (cylindrical) form by applying pressure along the longer diameter
Implementation Method 3
the continuous web of absorbent material being wound such as to define an axial hollow passageway
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
The present invention relates to a coreless roll of an absorbent sheet product such as napkins, toilet paper, towels etc. made of a spirally wound continuous web of absorbent material having a first end and a second end, wherein a coating composition comprising a nonionic cellulose ether is coated onto the second end. The coreless roll of the present invention has excellent stiffness and resistance to collapsing, as well as sufficient flexibility and elasticity. Moreover, the coreless roll of the present invention has excellent disintegrability in water and can be used up over its whole length. The present invention also relates to a process for the manufacture of the coreless roll.