Coreless Rolls of a Tissue Paper Product and Methods of Manufacturing Coreless Rolls
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Solution Overview
Problem
Existing coreless rolls of tissue paper products lack stability and do not meet customer satisfaction due to reduced strength and bulkiness, while also generating waste from cores.
Innovation Solution
A coreless roll design featuring a spirally wound continuous web with nested embossed plies made of Conventional Wet Press (CWP) paper, having a specific grammage, geometric mean tensile strength, and caliper ratio, with optional heating during embossing to enhance tensile strength and caliper without compromising softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If coreless rolls are used to eliminate waste from cores, then environmental friendliness is improved, but stability and strength are reduced
Solution Approach 1:
The patent applies nesting by placing one circumvolution inside another to form a compact coreless roll structure. The continuous web is wound in a spiral pattern where each turn is nested within the previous turn, creating a stable structure without requiring a separate core. This nesting arrangement provides structural integrity while eliminating the need for additional core materials that would generate waste.
Solution Approach 2:
The patent applies preliminary action through pre-embossing the tissue paper web before winding it into the coreless roll. The embossing process creates nested patterns and compresses the material in advance, which enhances the radial compression strength and stability of the final roll structure. This preliminary structural preparation ensures the coreless roll maintains its shape and strength during handling and storage.
2Device complexity
If coreless rolls are used to eliminate cores, then device complexity is reduced, but handling and storage properties deteriorate
Solution Approach 1:
The nested spiral winding structure creates a compact, self-supporting form that maintains structural integrity without complex core components. The nesting of circumvolutions provides natural structural support that improves handling properties while keeping the overall design simple and free of additional parts.
Solution Approach 2:
The patent applies parameter changes by modifying the physical properties of the tissue paper through pre-embossing and controlled winding tension. These parameter adjustments optimize the balance between structural stability and handling ease, creating a coreless roll that is both simple in design and practical for storage and operation.
3Strength
If pre-embossing is applied to enhance tensile strength and caliper, then strength and bulkiness are improved, but softness may be compromised
Solution Approach 1:
The patent applies partial action by using controlled embossing that provides sufficient structural enhancement without excessive compression. The embossing parameters are optimized to achieve the necessary tensile strength and caliper improvement while maintaining adequate softness for tissue paper functionality. This balanced approach avoids over-processing that would excessively reduce softness.
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 solution provides robust coreless rolls with high radial compression strength, improved handling, and storage properties, meeting customer expectations for strength and bulkiness without the need for additional cores.
Implementation Method 1
with optional heating during embossing to enhance tensile strength and caliper without compromising softness
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%.