Flexible Brace Dispenser for Coreless Web Material Roll Support
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Solution Overview
Problem
Conventional roll dispensers are not well-suited for coreless rolls of web material, as they require a hollow core for spindle insertion and support, leading to waste and increased restocking time, whereas coreless rolls lack a central conduit for spindle support, necessitating a dispenser that secures and rotates coreless rolls for incremental dispensing without a core.
Innovation Solution
A dispenser with a housing and roll brace system that compresses and secures coreless rolls, using inwardly directed protrusions to create a rotational axis and inhibit lateral movement, allowing for incremental dispensing without a core, featuring a flexible design to accommodate various roll sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional spindles are used to support rolls, then the roll can rotate and dispense material, but the dispenser requires a hollow core in the roll which increases waste and manufacturing cost
Solution Approach 1:
The invention extracts and eliminates the hollow core from the roll structure, transitioning from conventional rolls with cores to coreless rolls. The support mechanism is extracted from the roll itself and relocated to the dispenser's roll brace, allowing the roll to be solid throughout without requiring a central hollow space for spindle insertion.
Solution Approach 2:
The roll brace acts as an intermediary support structure between the dispenser housing and the coreless roll. It provides the necessary support and rotation capability that previously required the roll's own core structure, enabling coreless rolls to function in dispensers designed for conventional rolls.
2Ease of operation
If conventional spindles are used to support rolls, then the roll can rotate during dispensing, but the core must be removed and discarded during restocking, increasing restocking time
Solution Approach 1:
The core is extracted and eliminated from the roll structure, removing the need to remove and discard cores during restocking. The support function is extracted from the roll's core and transferred to the roll brace, which remains in the dispenser and does not require removal during restocking operations.
Solution Approach 2:
The roll brace provides self-retaining support within the dispenser housing, automatically maintaining the roll in position through compression forces. The inwardly directed protrusions self-align with the roll during insertion, eliminating the need for manual core removal and simplifying the restocking process.
3Reliability
If conventional spindles extend through the roll core, then the roll is supported at both sides, but coreless rolls lack a central conduit for spindle insertion and support
Solution Approach 1:
The roll brace is designed with universal adaptability to work with both conventional rolls and coreless rolls. The inwardly directed protrusions can engage with the roll structure regardless of whether a core is present, providing reliable support and rotation capability for both roll types through the same mechanism.
Solution Approach 2:
The roll brace serves as an intermediary support structure that replaces the need for core-based support. It provides the necessary mechanical interface between the dispenser housing and the roll, enabling reliable support and rotation for coreless rolls without requiring modifications to the roll structure itself.
4Reliability
If the roll brace is rigid to securely retain the coreless roll, then lateral movement is inhibited, but the roll cannot rotate freely for dispensing
Solution Approach 1:
The roll brace transitions from a static rigid structure to a dynamic flexible structure that can adapt its rigidity based on operational requirements. When compressed between the housing and cover, it becomes rigid enough to secure the roll laterally, yet maintains sufficient flexibility to allow rotational movement for dispensing through the friction engagement of its protrusions with the roll.
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
Enables secure retention and rotational dispensing of coreless rolls, reducing waste and restocking time by eliminating the need for core removal and accommodating different roll configurations, facilitating efficient and economical use of coreless web material.
Implementation Method 1
a roll brace to secure the coreless roll... When the housing is in a closed orientation, the at least one brace receives a compression force associated with interaction of the brace with the cover resulting in the compression of the at least one brace about the roll
Data Source
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AI summary
A coreless web material dispenser or dispensing apparatus (12) that includes a flexible brace (14) that is configured to support a roll of coreless web material relative to the dispenser (12). The flexible brace (14) is supported by the housing (18) such that closing a cover (22) of the dispensing apparatus biases a portion of the brace (14) into operative engagement with the roll of coreless web material. Preferably, the flexible brace (14) includes at least one protrusion (60, Figure 3) that extends inwardly relative to a roll facing side of the brace (14) and defines a rotational axis upon which the roll of the coreless web material may rotate while one or more side portions of the flexible brace (14) limit lateral movement of the roll during dispensing events.