Paper Towel Roll Lateral Groove Formed by Compression
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Solution Overview
Problem
Existing methods for creating annular grooves in paper rolls, such as toilet paper or kitchen towels, are limited by material removal techniques that are inefficient for high-rate manufacturing and result in reduced material width and unsatisfactory guidance, especially when using a mandrel.
Innovation Solution
A method involving a tool with a cylindrical central boss is used to deform and compress the paper roll's flank, forming a groove with a U-shaped cross-section, allowing for deeper and varied groove shapes that maintain the paper's width and improve guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material removal techniques are used to form grooves in paper rolls, then grooves can be formed, but manufacturing efficiency decreases and material width is reduced
Solution Approach 1:
The invention changes the fundamental parameter of groove formation from material removal to material deformation. By applying compression force through a grooving tool, the paper is deformed into the desired groove shape without removing any material, thereby maintaining manufacturing speed and material width while achieving the required groove geometry for proper dispenser engagement
Solution Approach 2:
The invention replaces the mechanical cutting system with a compression deformation system. Instead of using blades or cutting tools to remove material, a grooving tool applies localized compression to deform the paper into the groove shape, eliminating the limitations of material removal techniques and enabling high-speed manufacturing
2Manufacturing precision
If material removal techniques are used to form grooves, then grooves can be created, but the paper width is reduced and guidance is unsatisfactory
Solution Approach 1:
By changing from material removal to material deformation, the invention preserves the full paper width while creating grooves of any desired depth. The compression process maintains the paper's structural integrity and width, ensuring proper guidance in the dispenser without the material loss inherent in cutting methods
Solution Approach 2:
Instead of removing material to create the groove shape, the invention inverts the approach by deforming the material into the groove shape through compression. This inversion allows the groove to be formed while preserving the surrounding material structure, maintaining full paper width and improving guidance quality
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
This approach enables the formation of deeper grooves with greater projection height, enhancing guidance and allowing for the recovery of the paper's full width when unrolled, while accommodating various groove shapes, thus improving product quality and manufacturing efficiency.
Implementation Method 1
at least one of the flanks of the roll is deformed by compression using a tool comprising a rib
Implementation Method 2
the width of the sheet forming the turns at right of the groove being reduced by deformation and/or by compression parallel to the axis
Data Source
AI summary
The roll (1) has a continuous sheet rolled about a cardboard mandrel (5) around an axis (xx), and forming helical coils (8) leveled with an annular groove (7) comprising a curved bottom. The groove is provided on a side of the sheet near a central hole (3), and defines a closed contour around the axis. The sheet has a width reduced by deformation and compression of the coils in a direction parallel to the axis. An independent claim is also included for a method of manufacturing a roll.