Coreless Tissue Roll Design for Stability Without Core Waste
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Solution Overview
Problem
Coreless rolls of tissue paper products, such as household towel, lack stability and customer satisfaction due to reduced thickness and strength compared to rolls with cores, while also generating waste from discarded cores.
Innovation Solution
A coreless roll is designed with a spirally wound continuous web of tissue paper product, featuring two or three plies that are embossed and nested to enhance caliper and tensile strength, eliminating the need for a core and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a core is used in tissue paper rolls, then stability and structural strength are improved, but waste is generated from discarded cores
Solution Approach 1:
The invention extracts and eliminates the core component from the roll structure, transitioning from a core-based design to a coreless design where the tissue paper itself forms the structural foundation of the roll
Solution Approach 2:
The invention changes the structural parameters of the tissue paper by implementing specific embossing patterns and ply configurations that alter the physical properties of the paper to provide the stability previously achieved only through cores
2Loss of substance
If coreless rolls are manufactured, then waste from cores is reduced, but stability and customer satisfaction deteriorate
Solution Approach 1:
The invention applies nesting by configuring multiple plies of tissue paper in a nested arrangement where inner plies are positioned within outer plies, creating a compact and stable coreless roll structure that maintains structural integrity without requiring a separate core
Solution Approach 2:
The invention creates a composite structure by combining multiple plies of tissue paper with different embossing patterns and properties to form a unified coreless roll that achieves the mechanical stability previously provided by cores
3Strength
If plies are embossed and nested, then caliper and tensile strength are enhanced, but manufacturing complexity increases
Solution Approach 1:
The invention applies preliminary action by pre-embossing the tissue paper plies before they are wound into rolls, ensuring that the embossing patterns and nested configurations are established in advance to achieve the desired caliper and tensile strength properties
Solution Approach 2:
The invention segments the tissue paper structure into multiple distinct plies with specific embossing patterns, allowing each ply to contribute different functional properties to the overall roll structure while maintaining manufacturability through standardized processing
Data Source
AI summary
Disclosed is a coreless roll of a tissue paper product having a first end and a second end, and a web of tissue paper product being wound such as to define a central inner hole with the first end located on the outer side and the second end located at the inner hole, the product including a bonded first ply and a second ply, a grammage of the product being 35 to 55 g/m2, and having a Geometric Mean Tensile strength of at least 200 N/m, the first ply and the second ply being made of Conventional Wet Press (CWP) paper and embossed to be nested, the coreless roll having an outer diameter of 95 to 150 mm, an inner hole diameter of 20 to 50 mm, and a density of the coreless roll of 70 to 90 kg/m3, a caliper ratio of the roll of 40% to 70%.