Coreless Paper Roll Adhesive Zoning for Easy Sheet Separation
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Solution Overview
Problem
Conventional coreless paper rolls face issues where the stiffened core portion makes it difficult to separate sheets from the roll, leading to wastage as the roll is almost used up, resulting in a portion being discarded.
Innovation Solution
A method involving a wide tissue web unrolled from a parent roll, with a first adhesive applied to both ends and positions where cutting occurs, and a second adhesive with lower bonding strength applied between, allowing for easy sheet separation and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is uniformly applied to stiffen the core portion, then the roll shape is maintained and sheets are prevented from tearing, but sheets cannot be easily separated from the stiffened portion leading to waste
Solution Approach 1:
The patent applies different adhesive properties to different regions of the tissue web. The first adhesive with higher bonding strength is applied at both ends and cutting positions to maintain roll shape and prevent deformation, while the second adhesive with lower bonding strength is applied to intermediate portions to enable easy sheet separation. This local differentiation resolves the contradiction between maintaining structural integrity and enabling operational ease.
Solution Approach 2:
The adhesive application is segmented into distinct zones along the tissue web width. By dividing the adhesive application into end regions (first adhesive) and intermediate regions (second adhesive), the patent creates functionally distinct zones that simultaneously provide structural support and facilitate sheet separation, resolving the contradiction between strength and separability.
2Stability of the object's composition
If adhesive is applied to stiffen the core portion, then the roll maintains its shape under external force, but the stiffened portion must be discarded when the roll is almost used up
Solution Approach 1:
By applying the first adhesive only at specific locations (both ends and cutting positions) rather than uniformly across the entire width, the patent maintains roll shape stability where needed while leaving intermediate portions with lower adhesive content that can be easily separated and used, thereby eliminating tissue material waste.
Solution Approach 2:
The patent enables recovery of previously discarded tissue material by making the intermediate portions separable. The lower bonding strength adhesive in intermediate regions allows sheets to be easily pulled from the roll even after use, converting what would have been discarded material into usable tissue sheets.
3Ease of manufacture
If uniform adhesive application is used, then manufacturing is simple, but the roll cannot be used completely without leaving unused portions
Solution Approach 1:
The patent maintains manufacturing simplicity by using a systematic adhesive application process with two distinct adhesive types applied in specific patterns. This local differentiation enables complete roll usability by allowing intermediate portions to be easily separated, thereby improving productivity without significantly complicating the manufacturing process.
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
Enables the complete use of the paper roll without leaving unused portions, allowing easy unrolling to the end without sheet tearing.
Implementation Method 1
a first adhesive, which has a bonding strength capable of solidifying the wide tissue web wound on the winding mandrel and capable of separating a sheet of tissue from the solidified wide tissue web
Implementation Method 2
a second adhesive having a lower bonding strength than the first adhesive is deposited on portions between the positions where the first adhesive is deposited
Data Source
AI summary
A coreless paper roll manufacturing method includes: unrolling a wide tissue web from a parent roll; spraying adhesive on the wide tissue web; winding the wide tissue web on a winding mandrel to form a log roll; and cutting the log roll to form a plurality of paper rolls. The spraying includes depositing a first adhesive, having a bonding strength capable of solidifying the wide tissue web wound on the winding mandrel and separating a sheet of tissue from the solidified wide tissue web, on parts of the wide tissue web from which the wide tissue web starts to be wound, the parts including both ends of the wide tissue web in the width direction and positions at which the log roll is cut, and depositing a second adhesive having a lower bonding strength than the first adhesive on parts between the parts where the first adhesive is deposited.