Coreless Roll Insertion Core for Deformed Center Holes
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Solution Overview
Problem
Coreless paper rolls, such as bathroom tissue and paper towels, often have deformed center holes due to compression during packaging, making it difficult to insert a spindle without tearing the innermost layers, leading to uneven dispensing and waste.
Innovation Solution
A reusable core replacement tool with an open-ended tubular construction and inwardly inclined or spheroidal end sections for easy insertion into the deformed center hole, along with a detachable attachment device to secure the core apparatus, allowing for smooth dispensing without damaging the paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coreless paper rolls are compressed tightly during packaging, then shipping efficiency is improved, but the center hole becomes deformed and difficult to insert a spindle into
Solution Approach 1:
A core insertion tool serves as an intermediary device between the deformed center hole and the spindle. The tool has a tapered or spheroidal end section that fits into the compressed center hole, and the spindle is then inserted through this tool, allowing the spindle to pass through without directly contacting the deformed paper layers.
Solution Approach 2:
The core insertion tool is inserted into the deformed center hole before the spindle is inserted. This preliminary action prepares the path for the spindle by using the tool's smooth tapered or spheroidal surface to guide and protect the paper layers during the insertion process.
2Ease of operation
If a standard spindle is passed into the deformed center hole, then the roll can be mounted for dispensing, but the innermost layers of paper are torn and damaged
Solution Approach 1:
The core insertion tool acts as a protective intermediary between the spindle and the paper layers. The smooth surface of the tool prevents the sharp edges of the spindle from directly contacting and tearing the innermost paper layers during insertion.
Solution Approach 2:
The tapered or spheroidal shape of the insertion tool provides a gradual transition zone that cushions the paper layers during compression and insertion, preventing sudden stress concentrations that would cause tearing.
3Ease of operation
If the deformed center hole is manually manipulated to open it, then insertion becomes easier, but significant time and effort are required
Solution Approach 1:
The core insertion tool serves as a mechanical intermediary that requires minimal manual manipulation. Instead of manually opening the deformed center hole, the user simply inserts the pre-shaped tool which already has the appropriate geometry to fit into and guide the spindle through the compressed hole.
Data Source
AI summary
A tool for mounting a coreless roll of flexible sheet material on a replacement core apparatus including a replacement core and an insertion aid having a polygonal outer end and a base having a profile that matches the profile of outer surface of the replacement core, the replacement core in an embodiment having an enlarged lip member on at least one end, whereby the insertion aid is dimensioned such that it fits over the enlarged lip member enabling the replacement core to be inserted into a central aperture of a coreless roll with the end having the enlarged lip member passing through the center aperture, and in another embodiment the insertion aid having a crenulated tapered section that transitions the outer surface from a polygonal shape to a circular shape to match the cross section of the at least one lip member or outer surface of the replacement core.