Doubled-Over Tail Seal for Tissue Rolls Without Ply Separation
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Solution Overview
Problem
Imperfect tail sealing in bath tissue rolls leads to issues such as ply separation and difficulty in removing tissue, due to inadequate adhesive penetration and strength, causing consumer complaints and manufacturing disruptions.
Innovation Solution
Controlling adhesive penetration to form even bonds between layers, using a doubled-over tail seal with controlled adhesive distribution to create a strong yet weak bond, ensuring the tail seal is spread over a wide area and avoids perforation lines, thereby preventing tearing and ply separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive penetration is increased to strengthen the tail seal bond, then bond strength between tail and roll is improved, but adhesive penetrates through an odd number of plies causing ply separation
Solution Approach 1:
The patent applies adhesive with controlled penetration characteristics specifically at the tail seal location, creating a localized bond that is strong enough to secure the tail tab to the roll body without penetrating through the entire multi-ply structure. This localized control prevents ply separation while maintaining necessary bond strength.
Solution Approach 2:
The patent modifies the adhesive penetration parameter to achieve optimal bonding. By controlling the penetration depth to an even number of plies rather than allowing it to penetrate through an odd number of plies, the invention prevents ply separation while maintaining adequate bond strength for tail seal attachment.
2Object-generated harmful factors
If adhesive penetration is decreased to prevent ply separation, then ply separation is reduced, but bond strength between tail and roll becomes insufficient
Solution Approach 1:
The patent optimizes the adhesive penetration parameter to a specific range that prevents ply separation while maintaining adequate bond strength. By controlling penetration to an even number of plies and distributing adhesive over a wide area, the invention achieves the necessary balance between preventing harmful ply separation and maintaining sufficient bonding strength.
Solution Approach 2:
The patent distributes adhesive over a wide area of the tail seal, transitioning from a concentrated bond to a distributed bond. This dimensional approach allows the adhesive to achieve sufficient total bond strength while maintaining low stress per unit area, preventing both ply separation and tail detachment.
3Reliability
If adhesive bond strength is increased to prevent tail detachment, then tail retention is improved, but tearing of the underlying tissue occurs
Solution Approach 1:
The patent distributes the adhesive bond over a wide area of the tail seal, transforming a concentrated high-stress bond into a distributed low-stress bond. This dimensional approach maintains adequate total bond strength for tail retention while reducing the stress per unit area to levels that do not cause tissue tearing.
Solution Approach 2:
The patent creates a localized adhesive application with controlled penetration characteristics that provides sufficient bond strength exactly where needed at the tail seal, while avoiding excessive strength that would cause tearing of the underlying tissue. The adhesive properties are tailored to the specific local requirements of the tail seal application.
4Reliability
If adhesive is applied to secure the tail tab, then tail attachment is achieved, but the bond creates difficulty in removing tissue from the roll
Solution Approach 1:
The patent applies adhesive with controlled penetration characteristics specifically at the tail seal location, creating a localized bond that is strong enough to secure the tail tab but weak enough to allow easy removal of tissue sheets. The adhesive properties are tailored to provide differential bonding: strong for tail retention, weak for sheet removal.
Solution Approach 2:
The patent optimizes adhesive penetration parameters to create a bond that is strong enough to prevent tail detachment during manufacturing and use, but weak enough to allow consumers to easily remove tissue sheets from the roll. By controlling penetration to an even number of plies and distributing over a wide area, the invention achieves the necessary balance.
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
Significantly reduces unwinding problems and ply separation issues, enhancing the ease of starting the roll and maintaining a neat, aesthetically pleasing appearance, as demonstrated by improved strength and caliper of the tail seal compared to existing products.
Implementation Method 1
if the penetration of the adhesive used for tail sealing is not properly controlled, the adhesive will penetrate through an odd number of plies on multi-ply products
Implementation Method 2
by spreading the adhesive over a large area, it is possible to control the strength of the bond per unit area between the inner surface of the inwardly folded portion of the tail and the underlying tissue
Implementation Method 3
forming an inward transverse fold across the projecting tail of the multi-ply tissue log
Data Source
AI summary
Easy starting rolls of perforated tissue product which have a reduced tendency to ply separate are formed with an adhesively secured doubled over tail tab folded against the roll. The strength and location of the bonds are controlled by controlling the penetration of the adhesive into the tissue. The dry tensile strength of the projecting folded over tail tab exceeds 400 g/3″ and the caliper thereof exceeds one mil The adhesive bonds are spaced away from lines of perforation joining sheets in the initial sheets of the roll.