Coreless Rolls of a Tissue Paper Product and Methods of Manufacturing Coreless Rolls
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Solution Overview
Problem
Coreless rolls of tissue paper products, such as toilet paper, lack stability compared to core-based rolls, leading to reduced customer satisfaction and increased waste due to the need for cardboard cores, which end up as waste.
Innovation Solution
A coreless roll design featuring a spirally wound continuous web of tissue paper with embossed plies, where at least one ply is embossed and bonded using adhesive, creating glued areas with embossments, and non-glued areas, achieving a radial compression strength of 20 N or more by maintaining a specific distribution and density of embossments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cardboard core is used in tissue paper rolls, then structural stability and ease of operation are improved, but waste generation increases due to the core being discarded
Solution Approach 1:
The invention extracts and removes the cardboard core from the roll structure, creating a coreless design. The tissue paper is wound in a spiral configuration without requiring a central support element, thereby eliminating the waste generation associated with traditional cores while maintaining functional integrity through the spiral geometry and adhesive bonding of plies
Solution Approach 2:
The tissue paper roll is segmented into multiple plies that are bonded together through adhesive application. This segmentation allows the plies to be arranged in a spiral configuration that provides structural stability without a core, with each ply contributing to the overall mechanical strength and dimensional stability of the coreless structure
2Strength
If adhesive is applied to bond plies in glued embossed areas, then radial compression strength is improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the embossing and adhesive application processes into a single integrated operation. The adhesive is applied directly to the embossed surface of the tissue plies, combining two manufacturing steps into one that reduces process complexity while achieving both the desired mechanical strength and the structural integrity provided by the embossed pattern
Solution Approach 2:
Adhesive is applied selectively to specific glued embossed areas rather than uniformly across the entire ply surface. This localized application targets regions where maximum bonding strength is needed, optimizing radial compression strength while minimizing adhesive consumption and simplifying the manufacturing process by avoiding complex coating operations
3Strength
If embossments are closely spaced in glued embossed areas, then radial compression strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The embossing pattern is pre-designed and pre-positioned on the tissue ply before adhesive application and bonding. The embossment locations, spacing, and geometry are established in advance during the embossing process, allowing subsequent adhesive application to follow a predetermined pattern that ensures optimal radial compression strength without requiring high-precision real-time positioning during assembly
Solution Approach 2:
The invention optimizes embossment parameters such as spacing, depth, and geometry to achieve the desired radial compression strength. By carefully selecting and adjusting these parameters during design, the system achieves high strength with closely spaced embossments while keeping manufacturing precision requirements within practical limits through standardized embossing patterns
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 design enhances radial compression strength, stability, and customer satisfaction while reducing waste by maintaining a high percentage of glued embossed areas with closely spaced embossments, ensuring robustness and environmental sustainability.
Implementation Method 1
Several plies may be combined together by a combining operation of a chemical nature (e.g., by adhesive bonding)
Implementation Method 2
Embossing can be used to change the shape of a ply from flat to shaped, so that there are areas that are raised and/or recessed from the rest of the surface
Implementation Method 3
A coreless roll of a tissue paper product, such as toilet paper, made of a spirally wound continuous web of tissue paper
Data Source
AI summary
Disclosed is a coreless roll of a tissue paper product having first and second ends, a web of absorbent material being wound to define an axially extending inner hole centrally positioned relative to the coreless roll, the product including at least two plies, at least one of which being an embossed ply, and the coreless roll has-having an outer diameter of 95-150 mm, an inner hole diameter being 20-50 mm, and a density of 110-160 kg/m3, the product including glued areas, and non-glued areas between the glued areas, at least some of the glued areas including embossments of the embossed ply, a sum of areas of all glued embossed areas being at least 6% of of all glued areas and all non-glued areas over at least 80% of the glued embossed areas, a maximum distance between adjacent embossments of the embossed ply being 2.5 mm or less.