The present disclosure relates to rolled absorbent products and, in certain embodiments, to compressed and hollow coreless rolls of absorbent paper products such as tissue and toweling, commonly referred to as tissue products including toilet paper and towel products including paper towels.
Certain rolled goods, including absorbent paper products, are inherently bulky, which can adversely impact cost and/or logistics when transporting these products in large volumes. It is known to compress rolled goods, including absorbent paper products, to reduce volume and/or increase density thereof for transportation and storage. When ready for use, the compressed rolled goods may be subjected to one or more forces to be re-formed or otherwise returned to (or nearly to) an original uncompressed state. Certain rolled goods, prior to and once compressed, include central cavities sized to receive a spindle or comparable component for roll-feed dispensing of the rolled goods once re-formed or uncompressed. While central cavities may contain a paperboard (or the like) core, it is also known to provided compressed rolled goods with a coreless central cavity. This, among other advantages, reduces waste product associated with the rolled good.
Conventional rolled products have sought to remedy the above-mentioned bulkiness and waste associated with their packaging and use by removing the paperboard core and/or compressing the rolled product. Despite these and other observed advantages, inefficiencies can also arise with certain compressed and coreless rolled products. For example, location of the central core (whether via use of a spindle or otherwise) can be time-consuming and/or inaccurate. Oftentimes, telescoping of an inner portion of the rolled product may occur, resulting in the inner portion being pushed outwardly due to unintended contact of the product with the spindle. Still further, an inner portion of the rolled product may bind or experience “locking up” around the spindle as the roll is used, rendering an inner portion of the rolled product unusable waste. Both phenomena negatively impact the ability of compressed coreless rolled products to deliver expected consumer performance, expected manufacturer performance, and expected environmental waste-avoidance. Thus, a need exists for compressed coreless rolled products that minimize and/or substantially avoid these phenomena.
To address the telescoping and locking-up phenomena, along with other technical considerations, there is described herein according to various embodiments a compressed coreless rolled product comprising: an inner surface defining a central cavity having an inner diameter; and an outer surface having an outer diameter larger than the inner diameter, wherein: the outer diameter is at least five inches; and a ratio of the inner diameter to the outer diameter is at least 0.35.
In certain embodiments, the inner diameter may be any of: at least 1.75 inches; from 1.75 to 4.0 inches; at least 2.0 inches; between 2.0 and 3.0 inches; or 2.5 inches. In certain embodiments, the inner diameter may be 2.0 inches and the outer diameter may be 5.0 inches. In these and other embodiments, the outer diameter may be 5.6 inches, with a ratio of 0.36. As another example, the outer diameter may be 7.0 inches and the ratio may be 0.40. In one embodiment, the outer diameter is between 7.0 and 12.0 inches.
There is also described herein according to various embodiments a compressed coreless rolled product comprising: an inner surface defining a central cavity having an inner diameter; and an outer surface having an outer diameter larger than the inner diameter, wherein: a difference between the outer diameter and the inner diameter defining a thickness of at least 2.9 inches; and a ratio of the inner diameter to the outer diameter is at least 0.35.
In certain embodiments, the thickness may be any of: at least 4.0 inches; between 3.0 and 12.0 inches; exactly 5.0 inches; or exactly 3.25 inches. In these and other embodiments, the ratio may be at least 0.40.
According to various embodiments there is also described a method of producing a compressed coreless rolled product, the method comprising the steps of: winding an absorbent sheet around a forming core member until a rolled product having an outer diameter of at least five inches is formed; removing the forming core member from the rolled product to form a coreless rolled product having a hollow central cavity with an inner diameter, a ratio of the inner diameter to the outer diameter being at least 0.35; and compressing the coreless rolled product such that the hollow central cavity is substantially collapsed.
In certain embodiments of the method, the forming core member is a tubular paperboard core, which may be re-usable. In these and other embodiments, wherein a difference between the outer diameter and the inner diameter defines a thickness, the thickness may be between 3.0 and 12.0 inches.
According to various embodiments there is also described a method of delivering a compressed coreless rolled product, the method comprising the steps of providing the compressed coreless rolled product described herein; re-forming the compressed roll by expanding the substantially collapsed central cavity; and mounting the re-formed compressed roll about a spindle.
In certain embodiments of this method a ratio between a diameter of the spindle and the inner diameter of the compressed coreless rolled product is between one and three. In these and other embodiments, the ratio may be between two and three. In still other embodiments, a ratio between a diameter of the spindle and the inner diameter of the compressed coreless rolled product may be at least one or at least two.
The invention is described in detail below with reference to the drawings wherein like numerals designate similar parts.
The invention is described in detail below in connection with the various figures and for purposes of illustration. The invention is also defined in the appended claims. It should be understood, though, that only some, but not all embodiments are shown and described herein. Indeed, the embodiments may take many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Still further, terminology used throughout herein is given its ordinary meaning, except as supplemented immediately below, and like numbers refer to like elements throughout.
“Tissue” rolls or similar terminology refers to cellulosic fiber tissue products, while “bath tissue” rolls must be flushable and are typically manufactured without a substantial amount of permanent wet strength resin; as opposed to paper toweling, or kitchen roll towel, which has a substantial amount of wet strength resin. Accordingly, the invention described herein may be employed with respect to absorbent papers in which the sheets are not spoiled or defaced, including with bath tissue, kitchen roll towel, other paper toweling formats, or even napkin stock.
Referring first to
As evident from
Although not a focus of the present disclosure, from
Turning now to
Collectively a difference between the outer and inner diameters 30, 32 define a thickness 34 of the compressed coreless rolled product 10. In certain embodiments, the thickness may range from approximately 2.5 inches to 8.0 inches. In at least one embodiment, the thickness may be 2.9 inches. In another embodiment, the thickness may be 7.8 inches. Combinations of these ranges may also be selected for the thickness 34.
According to various embodiments, the inner diameter 32 may range from approximately 0.5 inches to 6.0 inches. In at least one embodiment, the inner diameter 32 may range from approximately 1.5 to 2.0 inches. In another embodiment, the inner diameter 32 may be any of 1.625 inches, 1.75 inches, 1.83 inches, or 2.25 inches. Combinations of these ranges may also be selected for the inner diameter 32.
The outer diameter 30 may also vary across a range, dependent in part upon how much volume of material (i.e., paper) is desired for providing on rolled product. This volume may be quantified and/or calculated also based upon the thickness 34 of the product, representing a difference between the outer and inner diameters 30, 32. According to various embodiments, the outer diameter 30 may range from approximately 4.5 to 12.0 inches. In at least one embodiment, the outer diameter may range from 5.0 to 9.0 inches. In another embodiment, the outer diameter 30 is one of at least 5.0 inches, at least 6.0 inches, or at least 7.5 inches. Combinations of these ranges may also be selected for the outer diameter 30.
The difference between the outer and inner diameters 30, 32 is oftentimes expressed as a ratio (i.e., the inner diameter divided by the outer diameter, referred to elsewhere herein as the “I/O ratio”). According to various embodiments, the I/O ratio may range from 0.03 to 0.95. In at least one embodiment, the I/O ratio ranges from approximately 0.35 to 0.95. In another embodiment, the I/O ratio is at least 0.35. Combinations of these ranges may also be selected for the I/O ratio.
As a non-limiting example, consider a compressed coreless rolled product 10 having an outer diameter 30 of 5.0 inches and an inner diameter 32 of 1.75 inches. This exemplary product would have an I/O ratio of exactly 0.35. As another example, a compressed coreless rolled product 10 could have an outer diameter 30 of 6.0 inches and an inner diameter 32 of 2.0 inches, also resulting in an I/O ratio of 0.35. Yet another example with an I/O ratio of 0.45 could be achieved with a 5.0-inch outer diameter 30 and a 2.0-inch inner diameter 32. Various combinations can thus be envisioned, all within the scope of the present invention, noting that a minimal inner diameter of 1.75 inches is required to achieve an I/O ratio of 0.35 or higher with a 5.0-inch outer diameter. Still further, as the inner and outer diameters approach one another (i.e., become closer in values), the I/O ratio increases.
From a theoretical perspective, it is known that hoop stress is imposed upon compressed coreless rolled products like that of the present invention when re-forming of those products is attempted. This may be understood with reference to
The equation reproduced below calculates the imposed tangential hoop stress 38.
The tangential hoop stress 38 (denoted also as σ) based upon the outer diameter 30 dimension (denoted as ½ thereof in terms of a radius ro), the inner diameter 32 dimension (denoted as ½ thereof in terms of a radius ri), and the induced external stress 36 (denoted as P).
Notably, induced tangential hoop stress 38 governs, at least in part, how easily a compressed coreless rolled product 10 can be reformed. Specifically, the tangential hoop stress 38 is heightened as the difference between the inner diameter 32 and the outer diameter 30 decreases. Stated another way, the tangential hoop stress 38 is heightened as the I/O ratio increases. Thus, with an I/O ratio of at least 0.35, as provided in certain embodiments, a tangential hoop stress 38 is induced that is greater than that induced is the I/O ratio were, for example, 0.15.
As a result of the heightened tangential hoop stress 38 with a greater I/O ratio, re-forming of the compressed coreless rolled product 10 requires less externally induced stress 36. Stated otherwise, it is easier for consumers (or others) to re-form the compressed coreless rolled product according to various embodiments, as compared to conventional rolled products having a lower I/O ratio. As a non-limiting example, if a compressed coreless rolled product 10 according to the present invention comprises an outer diameter of about 5.6 inches and an I/O ratio of about 0.36, the tangential hoop stress induced increases by about 52%, as compared to conventional rolled products.
Notably, having an increased I/O ratio according to various embodiments (whether greater than 0.35 or otherwise), requires a certain degree of increase in the inner diameter 32 of the compressed coreless rolled product. For example, as compared to certain conventional rolled products having an inner diameter of 1.6 inches and an outer diameter of 4.75 inches, the I/O ratio is less than 0.35. Similarly, it is not possible to achieve an I/O ratio of greater than 0.35 with an outer diameter less than 5.0 inches without having an inner diameter that is larger than conventional inner diameters. An additional advantage due to this arises regarding telescoping.
Referencing now
Another recognized advantage from various embodiments is that, as the inner diameter increases (for purposes of increasing the I/O ratio, as previously described herein) a difference between the inner diameter and a diameter of an associated spindle, as may be used to mount the compressed coreless rolled product 10 is also potentially increased, dependent in part upon the diameter of the spindle itself.
As mentioned, though, as the inner diameter increases (to increase the I/O ratio), a ratio of spindle to inner (or central cavity) diameter increases. As this spindle/cavity ratio increases from 1 to 3, occurrences of telescoping are reduced. This is evident not only from chart 200 of
As illustrated above, it is also evident that a compressed coreless rolled product 10 according to various embodiments, having an inner diameter of 2.0 inches exhibits less telescoping (or a lowered risk thereof), as compared to conventional rolled products having an inner diameter of 1.625 inches. Above and beyond a spindle/central cavity ratio of 2-3, telescoping is virtually eliminated. And although this is true regardless of the inner diameter of the rolled product, occurrences are significantly lower with a larger inner diameter product (i.e., one also having a heightened I/O ratio, as previously described). For example, a 23% inner diameter increase to 2.0 inches reduces telescoping issues up to 67%, as compared to a conventional 1.625-inch cavity diameter.
Referencing now
Further data regarding reductions in telescoping and locking-up observed in various studies conducted is shown in Tables 3-6, provided below. The methodology employed in these studies, conducted to demonstrate certain non-limiting advantages achieved by one or more (or a combination of) increased I/O ratio, increased spindle to inner diameter (or central cavity diameter) ratio, and increased outer diameter, involved testing a hypothesis that properly finding the center of the compressed coreless rolled product is influential to alleviating telescoping and locking-up issues. For example, participants who indicated telescoping and locking-up issues were provided an additional compressed coreless rolled product to test. Those participants then exhibited a 45% decrease in telescoping and a 61% decrease in locking-up once the center of the compressed coreless rolled product 10 was properly located. Further, it was shown that an increased inner diameter improved participants' ability to reform and install the compressed coreless rolled product 10. It should be appreciated, though, that the studies conducted, including their results, are non-limiting examples and supportive of the further detailed disclosure provided elsewhere herein.
As can be seen in Tables 3-4 below, a first study involving a compressed coreless rolled product 10 having a 1.6″ inner diameter and a second studying involving a compressed coreless rolled product having a 2.0″ inner diameter was conducted. As observed, the increased inner core diameter engendered an increased consumer acceptance of the format. Stated another way, participants in the two studies felt they gained more benefits (i.e., reduced telescoping and locking-up) while using the 2.0″ inner diameter compressed coreless rolled product, and were willing to change their own behavior (e.g., more carefully find the center of the compressed coreless rolled product) to enjoy those benefits.
Observed in Table 5 below is data related to participants included in both the first study and the second study. As shown, 60% of participants successfully resolved their issues when given a second compressed coreless rolled product to try. Those participants who continued to experience difficulty were given a third compressed coreless rolled product. A comparison of this third study to the second study is observed in Table 6 still further below.
Table 6 below, shows that instances of telescoping continued to decrease when participants were given a third compressed coreless rolled product and successfully found the central cavity thereof. Moreover, fewer participants complained of sheets falling off at the end of the roll or improperly dispensing. Accordingly, the number of participants that perceived benefits, would change behavior for said benefits and try/purchase again increased.
Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/068,165, filed Aug. 20, 2020 and titled “Compressed Hollow Coreless Re-Formable Roll Products;” the contents of which (including Appendices attached therewith) as are hereby incorporated by reference in their entireties.
Number | Date | Country | |
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63068165 | Aug 2020 | US |