Coreless Paper Roll With Adhesive-Stiffened Inner Section
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Solution Overview
Problem
Traditional paper rolls with rigid cardboard cores generate excessive waste and increase manufacturing and shipping costs, while coreless alternatives often collapse under weight, making them inconvenient to use.
Innovation Solution
A paper roll design featuring a spirally wound inner section bonded with an adhesive that provides rigidity, degrades in water, and includes optional fragrance and disinfectant agents, eliminating the need for a cardboard core by using a low-friction tube for winding and curing the adhesive to create a structurally sound core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid cardboard core is used to maintain roll integrity, then the roll structure is stable and easy to use, but waste generation increases and manufacturing costs rise
Solution Approach 1:
The invention extracts the core function (providing structural support) from the traditional cardboard tube and transfers it to the bonded inner layers of the paper roll itself. The inner layers are adhesive-bonded to form a rigid structure that eliminates the need for a separate cardboard core, thereby removing the source of waste while maintaining structural integrity.
Solution Approach 2:
The invention merges the core support function with the paper layers themselves. By adhesive-bonding the inner layers to each other, the paper roll creates its own internal rigid structure, combining the functions of the core and the paper into a single integrated system that eliminates unnecessary materials.
2Stability of the object's composition
If a rigid cardboard core is used to maintain roll integrity, then the roll structure is stable, but manufacturing and shipping costs increase
Solution Approach 1:
The invention extracts the core support function from the separate cardboard tube and transfers it to the bonded inner layers of the paper roll. This eliminates the need to manufacture, handle, and ship separate cardboard cores, reducing manufacturing complexity and costs while maintaining structural stability.
Solution Approach 2:
The invention merges the core support function with the paper layers themselves. By adhesive-bonding the inner layers to each other, the paper roll creates its own internal rigid structure, combining multiple functions into one process and eliminating the need for separate core manufacturing and assembly steps.
3Loss of substance
If the inner layers are adhered together to create a coreless roll, then waste is reduced, but the roll collapses under weight making it inconvenient to use
Solution Approach 1:
The invention applies adhesive to the inner layers during the manufacturing process, before the roll is put into service. This preliminary bonding action creates the rigid internal structure needed for structural integrity, allowing the roll to support its own weight and maintain stability during use without requiring a separate cardboard core.
Solution Approach 2:
The invention changes the physical-chemical parameters of the inner layers by applying adhesive that bonds the layers together. This parameter change (from unbonded to bonded layers) transforms the mechanical properties of the roll, creating sufficient rigidity and structural integrity to prevent collapse under weight while eliminating the cardboard core.
4Stability of the object's composition
If an adhesive is used to bond inner layers for structural support, then roll integrity is maintained without a cardboard core, but the adhesive must degrade in water for environmentally friendly disposal
Solution Approach 1:
The invention selects an adhesive with specific parameter characteristics: it must provide strong bonding and rigidity when dry, but degrade when exposed to water. This parameter change capability allows the adhesive to fulfill the structural support function during use, then break down for environmentally friendly disposal, resolving the contradiction between stability and degradability.
Solution Approach 2:
The invention applies adhesive with specific local properties to the inner layers. The adhesive is chosen to have dual characteristics: high bonding strength for structural integrity during use, and water solubility or biodegradability for easy disposal. This local quality differentiation allows the same material to serve opposing functions at different times.
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 solution reduces waste and manufacturing costs while maintaining roll integrity and convenience, allowing for easy disposal and sanitization, with the adhesive degrading in water to match the paper's properties for flushing.
Implementation Method 1
The inner layers of the roll are bonded together by an adhesive to form a rigid inner section
Implementation Method 2
the adhesive is configured to degrade when in contact with water
Implementation Method 3
winding a plurality of sheets about a low-friction tube to form a roll
Implementation Method 4
circulating air through the tubular platen such that negative pressure is generated at the apertures, thereby securing the plurality of sheets to the tubular platen
Implementation Method 5
The temperature of the air circulated through the tubular platen is configured to decrease curing time of the applied adhesive
Implementation Method 6
generating positive pressure at the plurality of recesses to remove the roll from the tubular platen
Data Source
AI summary
A paper roll and method of manufacturing. The paper roll includes a plurality of sheets spirally wound forming a roll. The roll includes a first end and a second end, wherein the first end forms an inner section. The inner section defines an axial passageway that extends from a first side of the roll to a second side of the roll. An adhesive that can stiffen the inner section joins the plurality of sheets of the first end. The method for manufacturing the paper roll includes winding the plurality of sheets about a low-friction tube to form a roll, applying an adhesive to the plurality of sheets at a first end of the roll forming an inner section having an axial passageway, curing the adhesive configured to stiffen the inner section, and removing the low-friction tube from the roll.