Electrostatic Paper Reel Joining Without Adhesive Tape
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for joining a depleted reel of paper to a new reel in the production of toilet paper or domestic paper rolls are inefficient, requiring manual skill, time-consuming, and prone to errors due to the use of gluing means like double-sided tape, which can damage the product and require extensive preparation.
Innovation Solution
An automated method using electrostatic attraction to join the reels without gluing means, involving a tensioning unit, an electrostatic element to induce polarization, and a knurling unit with pins or rollers to secure the joined plies, eliminating the need for adhesive materials and reducing preparation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual joining methods (cutting, gluing band, knotting) are used to join depleted reel to new reel, then the joining operation can be performed, but it requires manual skill, takes long time, and risks incorrect positioning or product damage
Solution Approach 1:
The patent replaces manual mechanical operations (cutting, gluing, knotting) with an automated mechanical system comprising a cutting device, adhesive application device, and joining mechanism. This substitution eliminates the need for manual skill while maintaining joining functionality, directly resolving the contradiction between productivity and ease of operation.
Solution Approach 2:
The system performs preliminary actions by pre-positioning the new reel, pre-applying adhesive to the adhesive band, and pre-tensioning the paper ply before the actual joining moment. This preparation eliminates time-consuming manual operations during the critical joining phase, improving productivity without requiring manual skill.
2Reliability
If double-sided tape is used to join the reels, then adhesion is achieved, but adhesive residues can transfer onto the wound paper and machine components, damaging the end product
Solution Approach 1:
The adhesive is applied locally and precisely to the adhesive band in a controlled manner, ensuring adhesion only where needed. This localized application prevents adhesive from spreading to the wound paper or machine components, eliminating the harmful transfer effect while maintaining reliable adhesion at the joining point.
Solution Approach 2:
The adhesive band acts as an intermediary element between the depleted reel and new reel. The adhesive is contained on this intermediate band rather than being applied directly to the paper reels, preventing direct contamination of the paper product while still achieving reliable adhesion through the band.
3Reliability
If double-sided tape is arranged on the new reel to ensure adhesion, then the joining can be performed, but extensive preparation time is required and the operation is wasteful
Solution Approach 1:
The adhesive is pre-applied to the adhesive band in advance, allowing the band to be ready for immediate use during the joining operation. This preliminary preparation eliminates time-consuming on-site adhesive application while ensuring reliable adhesion is achieved when the joining occurs.
Solution Approach 2:
The system replaces manual adhesive preparation and application with an automated adhesive application device that precisely applies adhesive to the band. This mechanical substitution eliminates the wasteful and time-consuming manual preparation operation while maintaining adhesion reliability.
4Reliability
If the flap of new reel is made to adhere to support belts to prevent detachment, then adhesion is ensured, but the process becomes more complex and time-consuming
Solution Approach 1:
The adhesive band serves as an intermediary that simplifies the adhesion process. Instead of requiring complex arrangements of the flap with support belts, the pre-adhered band provides a straightforward joining mechanism that reduces device complexity while ensuring reliable adhesion between reels.
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 method enables faster, error-free, and automated joining of paper reels, preventing adhesive-related damages and reducing the time required for the process, ensuring continuous production with improved product quality.
Implementation Method 1
obtaining the adhesion of the plies of the two reels by electrostatic attraction
Implementation Method 2
arranging an electrostatic element able to accumulate an electrostatic charge; charging said electrostatic element with an electrostatic charge; moving said electrostatic element closer to the overlapping plies of said reels so as to induce a polarization state in said plies
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention concerns a method for joining the ply of a reel of paper in depletion with the initial flap of a new reel, as well as an apparatus adapted for carrying out such a method. Thanks to the method according to the present invention, and to the apparatus suitable for carrying it out, the joining of the reels takes place without using gluing means, like for example the double-sided tape used in known methods, avoiding the relative drawbacks, the adhesion between the plies of the reels to be joined taking place by electrostatic attraction.