Coreless Roll Temporary Support Device for Shipment Stability
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Solution Overview
Problem
Coreless paper products are prone to deformation during shipment and storage due to the absence of a supporting tube, making them difficult to insert into dispensers and leading to reduced capacity and increased crushing risks.
Innovation Solution
A method involving the use of a temporary support device inserted into the center aperture of coreless rolls, which is expanded to approximate the dimensions of the aperture, and a support structure with a diameter similar to traditional cored rolls for winding and cutting to form coreless rolls, allowing for stability during storage and shipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coreless rolls are manufactured without a supporting tube to increase capacity and minimize crushing, then the center aperture capacity increases, but the rolls become prone to deformation during shipment and storage
Solution Approach 1:
A temporary support device is inserted into the center aperture of the coreless roll before shipment or storage. This preliminary action provides the necessary structural support to prevent deformation during transit, while allowing the roll to maintain its coreless design for increased capacity. The support device is temporarily placed and can be removed before dispensing.
Solution Approach 2:
The temporary support device acts as an intermediary element between the coreless roll structure and the external environment during shipment. It mediates the mechanical stresses and forces applied during transit, preventing the roll from deforming while maintaining the benefits of a coreless design. The support device is inserted into the center aperture and provides the necessary structural reinforcement.
2Quantity of substance
If the center aperture diameter is reduced to minimize crushing occurrence, then the roll capacity increases, but the roll becomes difficult to insert onto dispensing spindles
Solution Approach 1:
A support device is preliminarily inserted into the center aperture to maintain its shape and dimensions. This preliminary support ensures that the aperture remains sufficiently large and structurally intact for easy insertion onto dispensing spindles, while the roll maintains its high-capacity coreless design. The support device prevents aperture collapse that would otherwise occur with reduced diameter.
3Stability of the object's composition
If traditional cored roll structure is used to provide stability during shipment, then the roll stability improves, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The permanent core structure is extracted from the design, replacing it with a temporary support device that is inserted only when needed for shipment or storage. This extraction simplifies the manufacturing process by eliminating the need for core integration during roll formation, while still providing stability when required. The support device is a separate, removable component rather than an integrated part of the roll structure.
Solution Approach 2:
Instead of using a permanent core structure that complicates manufacturing, a simple, inexpensive temporary support device is used. This support device serves its purpose during shipment and storage, then can be discarded or removed before dispensing. The temporary nature of this support element reduces manufacturing complexity while providing necessary stability during critical periods.
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 method effectively reduces deformation and crushing of coreless rolls during storage and shipment, enabling easier dispensing and maintaining product integrity, while also allowing for the use of existing equipment and processes similar to cored roll production.
Implementation Method 1
expanding the temporary support device to approximate dimensions of the center aperture
Data Source
AI summary
A method of converting a plurality of coreless roll products includes providing a first support structure and winding a paper product around the first support structure. The method also includes cutting through the paper product and the first support structure to form a plurality of cut portions of the paper product each wound around a cut portion of the first support structure. The method further includes removing the cut portion of the first support structure from each of the cut portions of the paper product to form a plurality of coreless roll products each comprising a center aperture. A method of preparing a coreless roll product for storage or shipment includes providing a coreless roll product comprising a center aperture and inserting a temporary support device into the center aperture of the coreless roll product. The method also includes expanding the temporary support device to approximate dimensions of the center aperture, wherein the temporary support device is configured to reduce deformation of the center aperture during storage or shipment.