Sheet Product Roll Semi-Rigid Core Formation
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Solution Overview
Problem
Existing methods for manufacturing tightly wound sheet products often result in voids that become obstructed or deformed, making it difficult to install the rolls in dispensers effectively.
Innovation Solution
A method and system involving the use of mandrels with heated regions and fluid injection to dry and harden the moist core of the sheet product roll, forming a semi-rigid core that maintains the desired void diameter and facilitates easy installation on dispenser spindles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sheet product is tightly wound to fit more product on the roll, then the quantity of sheet product increases, but the central void becomes obstructed or deformed making it difficult to use in dispensers
Solution Approach 1:
The patent applies preliminary action by forming a semi-rigid core structure in the central void during the winding process itself, before the roll is installed in the dispenser. This pre-formed core structure prevents the void from collapsing when the roll is later inserted into the dispenser, thus maintaining ease of operation while allowing tight winding to maximize product quantity.
2Manufacturing precision
If the roll is tightly wound to reduce outer diameter, then the manufacturing precision of the roll shape improves, but the central void becomes deformed and obstructed
Solution Approach 1:
The patent applies local quality by creating a semi-rigid core structure specifically in the central void region, while the outer layers of the roll maintain their tightly wound configuration. This localized structural modification preserves the overall roll shape precision and outer diameter control while preventing deformation of the central void, thus resolving the contradiction between manufacturing precision and void shape maintenance.
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 ensures that the sheet product rolls can be efficiently and effectively used in dispensers by maintaining the desired diameter and preventing telescoping, allowing for smooth operation and accurate fit.
Implementation Method 1
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
Implementation Method 2
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
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.