Corrugated Fibrous Cores for Low-Basis-Weight Roll Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for fibrous cores for rolled products that offer reduced cost while maintaining sufficient strength properties, optimized for existing roll-forming equipment, and providing consumer awareness of branding before and after use.
Innovation Solution
The development of fibrous cores with a laminate material comprising a fluted layer and a non-fluted liner, forming a single-face corrugate material, which are wound and adhered to create a core with reduced basis weight while maintaining or exceeding the radial and axial strength of traditional cores, incorporating embossed or printed indicia for branding visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional paper cores are made with higher basis weight and denser material to increase strength, then radial and axial strength are improved, but manufacturing cost increases due to additional material and processing
Solution Approach 1:
The patent applies composite materials by combining a fluted layer and a liner layer to form a corrugated paperboard core. This composite structure provides enhanced radial and axial strength compared to traditional solid paper cores of the same basis weight, as the fluted configuration creates a more rigid structure that resists collapse and deformation while using less material.
Solution Approach 2:
The patent changes the structural parameters of the core by transitioning from a solid paper structure to a corrugated structure with specific flute configurations. This parameter change (from solid to fluted geometry) increases the moment of inertia and structural rigidity, thereby improving strength properties without proportionally increasing material quantity or cost.
2Strength
If core wall thickness is increased to improve strength, then radial and axial strength are improved, but the core basis weight increases
Solution Approach 1:
The corrugated composite structure allows the core to achieve higher strength with reduced basis weight. The fluted configuration provides structural reinforcement that enables thinner overall wall thickness while maintaining or improving strength properties, thus reducing the weight of the stationary core object.
Solution Approach 2:
The patent introduces a dimensional change by creating a three-dimensional fluted structure from a two-dimensional paper sheet. This geometric transformation distributes material more efficiently through the thickness direction, providing enhanced strength-to-weight ratio by utilizing the corrugation geometry rather than simply increasing material quantity.
3Strength
If stronger plies with more fibers are used to increase strength, then paper strength is improved, but processing cost increases due to mechanical refining and compression
Solution Approach 1:
The patent uses composite material construction with fluted and liner layers that can be manufactured through standard corrugated board processes. This approach achieves high strength without requiring extensive mechanical refining or high-pressure compression that would increase processing costs, as the structural integrity comes from the geometric configuration rather than extreme fiber densification.
Data Source
AI summary
The present invention is an array of sanitary tissue products. The array of sanitary tissue products comprises a first packaged article and a second packaged article. The first packaged article comprises a first rolled sanitary tissue product wound onto a first fibrous core. The second packaged article comprises a second rolled sanitary tissue product wound onto a second fibrous core. The second rolled sanitary tissue product is wound loosely relative to the first rolled sanitary tissue product. The second fibrous core has an axial strength greater than the first fibrous core.