Coreless Tissue Roll Structure for Stability Without Cardboard Cores
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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 absence of a cardboard core, while existing multi-ply tissue paper products require improvements in thickness, strength, softness, and absorption capacity.
Innovation Solution
A coreless roll design featuring a spirally wound continuous web of tissue paper with two, three, or four plies, where at least one ply is embossed with a heated embossing roll to enhance tensile strength and absorption properties, and a stabilizing coating composition is applied to improve radial and axial stability, while maintaining softness and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cardboard core is used in tissue paper rolls, then radial and axial stability is improved, but waste increases and manufacturing complexity increases
Solution Approach 1:
The invention removes the cardboard core from the tissue paper roll structure, extracting the problematic element that causes waste while redesigning the system to achieve stability through alternative means (spirally wound configuration with adhesive bonding between plies)
Solution Approach 2:
The tissue paper is divided into multiple plies that are spirally wound and adhesive-bonded together, creating a segmented structure that provides self-supporting stability without requiring a central core
2Strength
If a cardboard core is used in tissue paper rolls, then structural support is improved, but device complexity increases
Solution Approach 1:
The invention merges the functions of multiple plies into a single integrated spirally wound structure, where the combination of plies bonded together provides structural support that replaces the need for a separate core component, thereby simplifying the overall device
3Quantity of substance
If multi-ply tissue paper products are manufactured with increased thickness, then absorption capacity is improved, but tensile strength may be reduced
Solution Approach 1:
The invention uses composite construction with multiple plies of different tissue paper types (e.g., soft ply, absorbent ply, strength ply) bonded together, where each ply contributes specific properties that collectively provide both high absorption capacity and maintained tensile strength
Solution Approach 2:
Different plies are designed with different local qualities - some plies are optimized for softness, others for absorption, and others for strength - allowing the multi-ply product to achieve overall superior performance in all properties simultaneously
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 coreless rolls with improved radial compression strength, higher caliper, and enhanced absorption capacity, meeting customer satisfaction and reducing waste, while being cost-effective and maintaining softness and tensile strength.
Implementation Method 1
at least one ply is embossed with a heated embossing roll to enhance tensile strength and absorption properties
Implementation Method 2
a stabilizing coating composition is applied to improve radial and axial stability
Data Source
AI summary
Disclosed is a coreless roll of a tissue paper product made of a spirally wound continuous web having a first end and second end and an outer diameter in the range of 95 to 150 mm, the web of tissue paper product being wound to define an inner hole centrally positioned relative to the coreless roll such that the first end is located on the outer side of the coreless roll and the second end is located at the inner hole, a diameter of the inner hole being 20 to 50 mm, a density of the coreless roll being 80 to 150 kg/m3, and a caliper ratio of the roll being 10% to 80%, the tissue paper product including between two and four ply-bonded plies, at least one ply being Conventional Wet Press, and at least one ply being a structured ply.