Tubular Sheet Product Roll Core Forming for Void Diameter Stability
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Solution Overview
Problem
Tightly wound sheet products often have their central voids obstructed or deformed during manufacturing, making them difficult to use in dispensers, as the process of cutting the rolls can cause collapse and misalignment.
Innovation Solution
A method and system involving the use of mandrels with heated regions and fluid injection to dry and harden the central portion of the sheet product roll, forming a semi-rigid core that maintains the desired diameter and facilitates easy insertion into dispensers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sheet product is tightly wound to fit additional product on the roll, then the quantity of sheet product increases, but the void becomes obstructed or deformed
Solution Approach 1:
The patent applies preliminary action by forming a semi-rigid core portion in the void before the winding process completes. This pre-formed core structure prevents void deformation during subsequent handling and dispenser installation, allowing tight winding while maintaining void integrity. The core is created by injecting fluid into the void and allowing it to solidify, establishing a protective structure in advance.
Solution Approach 2:
The patent changes the physical state of the core material from liquid (injected fluid) to semi-rigid (solidified core). This parameter change transforms the void from a deformable space into a structurally supported cavity, enabling the roll to maintain its shape under tight winding conditions while still accommodating dispenser spindles.
2Ease of operation
If the void is maintained open for dispenser installation, then ease of operation improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies self-service by using the sheet product material itself to form the semi-rigid core structure. The fluid injected into the void is absorbed by the moistened sheet product layers, which then solidify to create the supporting core. This eliminates the need for separate core-forming equipment or additional components, achieving ease of installation without significant manufacturing complexity.
Solution Approach 2:
The patent discards the removable core used during winding and recovers the sheet product material by using it to form the semi-rigid core structure. The original core is removed, and the void space is utilized to create a new permanent core from the sheet product itself, simplifying the overall manufacturing process while maintaining installation ease.
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 effectively prevents deformation and ensures the sheet product rolls can be easily placed on dispenser spindles, maintaining their shape and functionality.
Implementation Method 1
heated regions to dry the moist core
Implementation Method 2
mandrels with heated regions
Implementation Method 3
fluid injection to dry and harden the moist core
Data Source
AI summary
A method for forming a tubular sheet product roll includes providing a sheet product roll having a first configuration and a void, centering a rotational axis of the sheet product roll on a longitudinal axis of a first tool, and inserting the first tool into the void of the sheet product roll to define an inner diameter of the void and to form the sheet product roll having a second configuration different from the first configuration.