Paper Roll Cut Pattern for Controlled Sheet Dispensing
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Solution Overview
Problem
Existing roll dispensers for disposable paper, especially in away-from-home use, suffer from overconsumption due to the need for users to manually control and cut sheets, which can lead to excessive paper usage and require complex or expensive electronic systems for control.
Innovation Solution
A roll design featuring sheets separated by alternating cuts and pre-cuts along the unwinding direction, allowing easy removal of ready-cut pieces with minimal force, and a manufacturing method using a rotating cutting tool with staggered cutting profiles to produce these patterns, enabling controlled and efficient dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sheets are connected by pre-cuts requiring manual cutting, then user control over sheet extraction is improved, but device complexity and cost increase due to required electronic control systems
Solution Approach 1:
The paper web is segmented into alternating cutting regions and non-cutting regions, allowing automatic separation at predetermined intervals. This mechanical segmentation eliminates the need for complex electronic control systems while maintaining ease of operation, as the alternating pattern enables simple mechanical or manual separation without requiring sophisticated electronics.
Solution Approach 2:
The paper web is pre-configured with alternating cutting and non-cutting regions during manufacturing. This preliminary action creates built-in separation points that enable easy sheet extraction without requiring complex real-time control systems, thus reducing device complexity while maintaining operational ease.
2Ease of operation
If complete cuts are made across the entire width of the roll, then sheet separation is improved, but paper waste increases due to loss of connecting regions
Solution Approach 1:
Instead of making complete cuts across the entire width, the invention applies cuts only to specific portions of the paper web width. This local quality approach maintains sheet separation functionality in the cut regions while preserving connecting regions in non-cut portions, thereby reducing paper waste while ensuring adequate sheet separation.
Solution Approach 2:
The invention uses partial cuts rather than complete cuts across the full width. This partial action is sufficient to achieve the desired sheet separation effect while minimizing the loss of paper material, as the connecting regions in non-cut portions remain intact and usable.
3Ease of operation
If alternating cuts and pre-cuts are implemented, then controlled dispensing with minimal force is improved, but manufacturing complexity increases
Solution Approach 1:
The cutting tool is configured to create a periodic pattern of alternating cutting and non-cutting regions along the paper web. This periodic action, established during manufacturing, enables controlled dispensing with minimal force during use, as the regular alternating pattern creates predictable separation points without requiring complex manufacturing processes.
Solution Approach 2:
The alternating cut pattern is designed to enable the paper roll to serve itself during dispensing. The periodic structure allows sheets to be easily separated and dispensed with minimal external force or complex control mechanisms, as the built-in alternating pattern facilitates automatic, controlled separation during normal use.
4Manufacturing precision
If staggered cutting profiles are used on rotating element, then cut alignment between superposed sheets is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention introduces a second dimension of staggering by offsetting cutting profiles not only along the rotation direction but also in the radial or axial dimension of the rotating element. This multi-dimensional staggering approach improves cut alignment between superposed sheets while distributing the complexity across multiple spatial dimensions, making the configuration more manageable.
Solution Approach 2:
The cutting profiles on the rotating element are configured with asymmetric staggering patterns, where successive knives have different angular positions and cutting depths. This asymmetric configuration improves alignment precision between sheets while avoiding the need for perfectly symmetric, equally complex arrangements, thus balancing precision requirements with device complexity.
Data Source
AI summary
A roll includes a succession of sheets of single-use absorbent paper, the succession of sheets includes a first sheet partially defined by a first line of perforations and a first cut arrangement partially defined by a first cut, a second cut, and a connecting region arranged between the first cut and the second cut and a second sheet partially defined by the first cut arrangement, and a second line of perforations.