Coreless Tissue Roll Design for Strength and Waste Reduction
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Solution Overview
Problem
Existing coreless rolls of tissue paper products, such as household towels, lack stability and do not meet customer satisfaction due to reduced strength and bulkiness, while also generating waste from cores.
Innovation Solution
The development of coreless rolls with a spirally wound continuous web of tissue paper, comprising two or three plies made of Conventional Wet Press (CWP) paper, embossed to be nested, with a specific grammage, caliper ratio, and density, and optionally using heated embossing rolls 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 cores and reduce waste, then environmental friendliness is improved, but stability and strength are worsened
Solution Approach 1:
The patent applies nesting by placing one ply inside another in a spiral configuration, where inner plies are nested within outer plies. This nested structure creates interlocking layers that provide mutual support, enhancing the overall strength and stability of the coreless roll while maintaining the waste-reducing benefit of eliminating separate cores.
Solution Approach 2:
The patent utilizes the spiral curvature of the wound plies to create a self-reinforcing structure. The curved, spiral arrangement of the tissue paper plies distributes mechanical stresses more effectively than flat layers, providing enhanced strength and stability to the coreless roll without requiring additional core materials.
2Loss of substance
If coreless rolls are used to eliminate cores, then waste reduction is improved, but handling and storage properties are worsened
Solution Approach 1:
The nested spiral structure of multiple plies creates a compact, space-efficient configuration that improves storage density. The interlocking nested layers prevent the roll from unspooling or deforming during handling, while the eliminated core reduces the overall footprint and weight for easier transportation and storage.
3Strength
If multiple plies are combined to increase strength and bulkiness, then roll strength is improved, but device complexity is worsened
Solution Approach 1:
The patent merges multiple plies into a single integrated spiral structure that functions as one unified roll. By combining the plies in a nested spiral configuration rather than as separate stacked layers, the design achieves enhanced strength and bulkiness while maintaining a simple, unified structure that is easier to manufacture and handle than multi-component alternatives.
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 results in coreless rolls with high radial compression strength, geometrical mean tensile strength, and improved handling and storage properties, addressing customer satisfaction and reducing waste by eliminating the need for cores.
Implementation Method 1
optionally using heated embossing rolls to enhance tensile strength and caliper without compromising softness
Implementation Method 2
embossed to be nested
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%.