Coreless Roll Additive Application for Clean High-Speed Winding
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Solution Overview
Problem
Existing coreless roll production methods face challenges in applying additives at high web speeds while minimizing contamination and ensuring efficient engagement and disengagement, particularly for coreless bathroom tissue and kitchen towel products.
Innovation Solution
An additive applicator system is integrated into the rewinder line, utilizing an anilox roller and applicator roller configuration, which intermittently applies additives to the web or mandrel at high speeds, minimizing contamination and optimizing additive application through oscillating subplates and actuators, with optional secondary applicators for enhanced absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additive is applied continuously to the web or mandrel, then additive coverage is improved, but contamination increases and engagement/disengagement efficiency deteriorates
Solution Approach 1:
The additive applicator uses oscillating subplates with anilox rollers that intermittently engage and disengage from the mandrel in a periodic manner. This allows additive to be applied only during the engagement phase, providing sufficient coverage while minimizing contamination during the disengagement phase, thus resolving the contradiction between additive coverage and contamination.
2Productivity
If additive applicator engages and disengages at high frequency, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The applicator system employs dynamic oscillating subplates that can rapidly engage and disengage from the mandrel through controlled mechanical oscillation. This dynamic mechanism allows high-frequency engagement/disengagement cycles while maintaining precise additive application during each engagement, thereby improving productivity without sacrificing manufacturing precision.
3Ease of operation
If oscillating subplates are used for additive application, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The oscillating subplate mechanism combines multiple functions into a single integrated unit: it holds the anilox roller, provides the oscillating motion for engagement/disengagement, and controls the additive application timing. This merging of functions simplifies the overall control system while maintaining the necessary complexity for precise periodic action, thereby improving ease of operation without excessive device complexity.
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 system enables high-frequency engagement and disengagement of additive application, maintaining product quality and minimizing contamination, facilitating efficient production of coreless rolls with stable central holes.
Implementation Method 1
anilox roller and applicator roller configuration, which intermittently applies additives to the web or mandrel
Implementation Method 2
oscillating subplates and actuators, with optional secondary applicators for enhanced absorption
Data Source
AI summary
A coreless log of convolutely wound web material is formed by directing the web around an applicator roller that is in contact with a first surface of the web. An additive is transferred from a supply roller to the applicator roller over a first distance of the web and stopped over a second distance of the web. The web is directed around at least one further roller that is in contact with the second surface of the web that is opposite the first surface. The web is then wound around an elongated mandrel. The first distance of the web comprises a first set of windings nearest the center of the log, and the second distance of the web comprises a second set of windings wound around and extending radially outward from the first set of windings. The mandrel may then be removed to form the coreless log.