CENTRE FEED CORELESS ROLL

TECHNICAL FIELD

The present invention relates to a centre feed roll of a web material, preferably a tissue material such as paper or nonwoven material, said roll comprising a free innermost edge portion of web material in the vicinity of the centre of the roll. The invention also relates to methods for manufacturing such a roll.

BACKGROUND OF THE INVENTION Web material such as tissue or nonwoven material for household or industrial use is often provided in the form of centre feed rolls. Such rolls are advantageous in that the web material is fed out from the centre of the roll, thus abolishing the need for the roll to be rotated in order to successively feed the web material forward. Instead, the centre feed rolls are typically kept in dispensers having a central opening through which the web may be fed from the centre of the roll.

One type of centre feed rolls are referred to as "coreless" rolls, i.e. there is no core of cardboard material or the like in the centre of the roll. Instead, coreless rolls will have a free innermost edge portion of web material in the vicinity of the centre of the roll.

An advantage with coreless rolls is that the rolls may be relatively densely packed. As there is no need to provide space for a core, the centre of the roll may exhibit only a relatively small open space. Thus, as compared to a roll having a core of the same external diameter, the coreless roll comprises more web material. Coreless rolls have an area at the centre (which is generally open) from which the web can be pulled/drawn. During the manufacture of coreless rolls, the web material is wound around a support which is then removed to leave a hole, which usually collapses. This is in contrast to solid rolls, in which the inner web material is first joined in on itself to form a core, and then more web material is wound about this core.

For reference purposes, coreless rolls from which a support has been removed by collapsing the support (so-called "crack cores" or "spiral cores") have a central hole with an internal diameter of 32-80mm. Standard toilet rolls have an internal diameter for the

core which is usually around 34mm. The coreless rolls of the present invention have an internal diameter which is less than 25mm.

One problem that occurs with coreless rolls is related to the extraction of the first piece of material from the centre of the roll. Firstly, there is a problem of finding the end of the material web. If the end can be found, there is a further problem of grasping a portion of the web material. This is usually solved by attempting to pull at the lower material edge of the web in the vicinity of the centre of the roll. Thirdly, there is the problem that - if a user succeeds in grasping hold of the web - it is likely that several turns of rolled material will be extracted at once. The amount of web material thus extracted from the roll is normally superfluous to the needs of the user, so most of this material will be discarded. All of the above-mentioned problems are particularly pronounced in rolls which are relatively densely packed.

Hence, the above-mentioned problems constitute a practical inconvenience to persons handling the roll of material and cause unnecessary waste of material.

A known product attempts to solve the above-mentioned problems by providing a roll where the inner edge of the paper is already prepared to protrude from the roll. However, in order to prepare such a roll, the problem of extracting the first portion of material must be solved by the manufacturer instead of by the end user of the product, which places extra requirements on the manufacturing process. Thus, the above-mentioned inconveniences and possible waste of material contributes to the cost of the manufacturing process and hence to the price of the roll.

US 5,346,064 describes a coreless, center-pull roll product in a dispenser package having a central opening and a lead end connected to the innermost convolution. The dispenser package also includes a dispenser nozzle which is maintained in the roll product central opening until dispensing is desired.

Furthermore, it is known from EP 0 599 058 to provide centre feed rolls with a threading mandrel or threading lug which can be used for pulling a web through a dispensing opening. However, this threading mandrel is stiff, as it must project upwards through a dispensing opening of a tissue box and support its own weight. This leads to a bulge when such centre feed rolls are packaged.

In view of the above, there is a need for enhancing known centre feed rolls in order to facilitate the initial extraction of material from the roll, which enables use of a practical and cost-efficient manufacturing method. The rolls must maintain the ability to be stacked, packaged and handled effectively, so that storage and transport of the rolls is not disturbed.

SUMMARY OF THE INVENTION

The object of the invention is to provide a centre feed roll which meets the above- mentioned needs.

The above-mentioned object is achieved in accordance with the invention by a centre feed roll of a web material, preferably a tissue or nonwoven material, said roll having two opposing end surfaces and a continuous outer surface connecting the two end surfaces . The roll further comprises a free innermost edge portion of web material in the vicinity of the centre of the roll, wherein an extraction member not forming part of the web material is connected to the web material along the greater part of the total width W of said innermost edge portion. The extraction member has accession means extending from at least one end surface of said roll for accomplishing extraction of said innermost edge portion of material from the centre of the roll. The invention is primarily characterized in that the accession means is sufficiently flexible that, when the roll is placed on a flat horizontal surface, with the at least one end surface from which the accession means extends lying against said horizontal surface, the accession means lies substantially flat between said end surface and said horizontal surface.

In other words, the weight of the roll alone is sufficient to bend the flexible accession means so that it does not substantially disturb the contact between the entire end surface of the roll and the horizontal surface upon which the roll is placed.

In a further embodiment, the accession means is sufficiently flexible so that when the roll is placed on a flat horizontal surface, with the opposite end surface from which the accession means extends lying against said horizontal surface, the accession means lies substantially flat against the end surface from which it extends. In this case, the accession means is so flexible that it cannot support its own weight, and will lie substantially flat against the roll.

The provision of an extraction member not forming part of the web enables the extraction member as well as its connection to the web material to be designed such that sufficient strength of the extraction member and retention to the web material are achieved, so as to enable extraction of the innermost edge portion of material from the centre of the roll, even when using relatively densely packed rolls. The requirement that the extraction member is sufficiently flexible in the region of the accession means allows rolls to be packed or stacked in a stable conformation and in close contact with one another. In particular, rolls according to the invention can be stacked within a box without hindrance. Packaging, storage and transport of the rolls are therefore made more efficient.

With the term "innermost edge portion of material" is meant a portion of material at the centre of the roll, forming the innermost few windings thereof. Thus, the "innermost edge portion" extends a short distance from the innermost edge of the material.

In order to achieve said sufficient retention, the extraction member extends along the greater part of the total width of said innermost edge portion. Hence, the extraction force provided when pulling the extraction member out of the roll is distributed over the width of the edge of the web, which diminishes the risk that the web will rupture during extraction.

The extraction member being connected to the web along the greater part of the total width of the innermost edge portion also means that the extraction member is provided in the vicinity of the very edge. The extraction member could be provided extending along the edge itself. However, it is believed to be more advantageous that the extraction member is provided along the innermost edge portion, but at a certain distance from the very edge thereof. This is because the distance from the edge might contribute to the strength of the material web during extraction thereof. However, placement of the extraction member an excessive distance from the edge might lead to undesired waste of material. Optimally, the extraction member is placed at a distance of 3-10mm from the edge.

The total width of the innermost edge portion is conventionally the same as the total width of the roll.

That a free innermost edge portion of web material is positioned in the vicinity of the centre of the roll indicates that the roll is of the coreless type. In a roll having a core, e.g. of cardboard material, the innermost edge portion of edge material would instead be fastened to the core material.

The extraction member may advantageously be connected to the web material along at least 50%, preferably along at least 75%, most preferred along at least 90% of the total width of said innermost edge portion. The suitable connection length between the extraction member and the web material depends on the strength of the connection and the strength of the web material around the connection points In a weak web material, many connection points may be required to distribute the force evenly. In a relatively densely packed roll of a relatively weak web material, a longer connection length will be needed than in a less densely packed roll of a stronger web material. In smaller rolls, e.g. of toilet paper, the web material is not so wide, so that an extraction member need not be as strong as for larger rolls.

The extraction member may advantageously be continuously connected to the web material along the connection length. However, intermittent connection along the connection length may also be used. In another embodiment, the extraction member may be connected to the innermost edge portion using an adhesive. The adhesive is preferably distributed continuously along the extraction member. However, the adhesive may also be intermittently distributed as long as the desired strength in the connection to the web material is achieved.

In one embodiment, the extraction member may form a loop around the paper web at said innermost edge portion so as to accomplish the extension of the extraction member along the width of the edge portion of material.

In one embodiment, the extraction member may be generally string-shaped. This is particularly advantageous in combination with the extraction member forming a loop around the edge portion of the web material as described above. However, a string- shaped extraction member may also be connected to the web shaped material using other fastening means such as an adhesive.

In yet another embodiment, the extraction member may be a generally band-shaped material. The band-shaped extraction member could e.g. comprise a tape or the like, which is provided along the width of the innermost edge portion of web material.

The extraction member may be made of any suitable material, provided that the flexibility requirements set out above are met. Examples of such materials are plastic (e.g. tape or ribbon), textile, nonwoven materials, paper strings, fibrous materials (e.g. continuous threads, either singly, or intertwined) and metal materials. Preferably, the extraction member is easily visibly discernible from the roll, for example, by having a different colour, pattern or surface texture, to make it self-evident where the extraction member is located.

In one embodiment, the centre feed roll may have a density at the centre portion thereof being less than the density of the roll at an outer portion thereof. Hence, extraction of the extraction member and thus of the first edge portion of material may be still more facilitated.

In another aspect, the invention relates to a method for producing a centre feed roll according to the first aspect of the invention. The method comprises the steps of manufacturing a log of said web material, cutting the log into rolls, each roll comprising a free innermost edge portion of web material in the vicinity of the centre of the roll, and introducing an extraction member in the centre of said roll.

The method has the advantages of being relatively simple to perform, and not requiring any adjustments of existing equipment for production of coreless rolls.

In an alternative method, the method comprises the steps of manufacturing a log of said web material, introducing an extraction member in the centre of said roll and cutting the log into rolls, each roll comprising a free innermost edge portion of web material in the vicinity of the centre of the roll. Folds, pleats, loops or turns may be present in the extraction member, so that, after the log has been cut into rolls, the accession means extends from each roll. Preferably, there is no adhesive in the vicinity of the cuts, so that the cutting machinery remains adhesive-free.

In a preferred embodiment, the extraction member may be introduced via a hollow insertion device being introduced to the roll prior to or together with said extraction member.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in the following in greater detail by way of example and with reference to the accompanying drawings, in which:

Fig. 1 is a perspective view of a first embodiment of a roll according to the invention. Fig. 1a shows the roll of Fig. 1 when placed on a horizontal surface.

Fig. 2 is a side view from the end of the roll of the embodiment in Fig. 1

Fig. 3 is a cross-sectional view of the roll of the embodiment in Fig. 1

Fig. 4 illustrates an example of a position of an extraction member in a roll when the web of the roll is unwound. Fig. 5 illustrates an embodiment of a device for introduction of an extraction member in a roll.

Fig. 6 illustrates another embodiment of a roll according to the invention.

Fig. 7 illustrates a method of forming a roll according to the invention.

Fig. 8 illustrates an alternative method of forming a roll according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The invention will in the following be closer described with reference to some embodiments shown in the accompanying drawings. The same reference numerals generally denote the same features in the different drawings.

Fig. 1 illustrates a first embodiment of a centre feed roll 100 of a web material, in this case a paper material, according to the invention. Fig. 2 is a side view of the roll of Fig. 1, where the central portion has been enlarged for better visibility of the details of the centre portion of the roll 100. The roil 100 has two opposing end surfaces 110; 120 and a continuous outer surface 130 connecting the two end surfaces 110; 120.

The centre feed roll 100 being coreless, it comprises a free innermost edge 101 near or in the centre 103 of the roll 100. The portion of the web adjacent to the free edge 101 is

referred to as the free innermost edge portion 102 which is formed of the innermost few windings of the roll.

An extraction member 200, which does not form part of the web material, is connected to 5 the web material along the greater part of the total width W of the innermost edge portion 102 of the roll. In the illustrated embodiment, the extraction member 200 is provided in the very centre 103 of the roll close to the free edge 101 (see Fig. 2).

The extraction member 200 has accession means 140 extending from one end surface 10 110;120 of the roll 100 for accomplishing extraction of the innermost edge portion 102 of material from the centre 103 of the roll 100. Although it is possible that accession means 140 extends from both end surfaces 110; 120 of the roll, it is preferred for reasons of economy that the accession means 140 extends from only one end of the roll, as shown in Fig. 1. 15

The accession means 140 is sufficiently flexible that, when the roll 100 is placed on a flat horizontal surface, with the at least one end surface 110; 120 from which the accession means 140 extends lying against said horizontal surface, the accession means 140 lies substantially flat between said end surface 110;120 and said horizontal surface (i.e. flat 20 against the end surface 110; 120 from which it extends). This can be seen in Fig. 1a.

In effect, the weight of the roll 100 alone is sufficient to bend the flexible accession means 140 so that it does not substantially disturb the contact between the entire end surface 110;120 of the roll 100 and the horizontal surface upon which it rests. Coreless rolls such 25 as those used in the present invention generally have a weight of between 0.4 and 3.6kg.

In a further embodiment, the accession means is even more flexible. It is sufficiently flexible so that when the roll is placed on a flat horizontal surface, with the opposite end surface from which the accession means extends lying against said horizontal surface, 30 the accession means lies substantially flat against the end surface from which it extends. In this case, the accession means is so flexible that it cannot even support its own weight, and will lie substantially flat against the roll.

The accession means 140 may comprise the same material as the extraction member 35 200, and be of unitary construction with the extraction member 200. For example, the

extraction member may comprise a thread, the portion of which extends from one end surface of the roll being the accession means 140. Alternatively, the accession means 140 and the extraction member 200 may comprise different materials. However, this embodiment is less preferable, as the joint between the accession means 140 and the 5 extraction member 200 comprises a potential point of weakness in the extraction member, and manufacture of such rolls is more complicated. Preferably, the extraction member is easily visibly discernible from the roll, for example, by having a different colour, tint, pattern or surface texture, which indicates the location of the extraction member clearly to the user.

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The accession means 140 may be formed so that it is easier for the user to grasp. The figures show the accession means 140 comprising a straight string, but other forms are possible, e.g. a hook shape, a loop shape or a T-shape. The accession means 140 may also be folded back and glued upon itself.

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Fig. 3 is a cross-sectional view of the embodiment illustrated in Figs 1 and 2. In this view it may be seen how the extraction member 200 extends along the total width W of the innermost edge portion 102 in the illustrated embodiment. The extraction member 200 is connected to the innermost edge portion 102 along the greater part of its length, which

20 may be as a continuous line of adhesive, or with an intermittent line of adhesive, e.g. using subsequently following drops of glue.

Fig. 4 illustrates the inner part of the roll 100 when unwound. The innermost edge 101 is seen as the end of the unwound material. The dashed lines parallel to the innermost edge 25 101 each illustrates one winding of the roll when wound up. Hence, the innermost edge portion 102 extends a few windings from the very edge 101.

The extraction member 200 may be provided anywhere along the innermost edge portion 102. If provided exactly at the centre 103 of the roll, the extraction member 200 will be 30 connected to the innermost edge portion 102 somewhere along the first winding thereof.

The extraction member 200 of the embodiment in Figs 1 to 3 may be a string or a thread. In this case, manufacture of the rolls of the present invention is simplified, as such strings or threads can be easily inserted into the roll, or the log from which rolls are cut.

Advantageously, the extraction member may be coloured so as contrast against the tissue material, thus providing better visibility of the extraction member.

In the embodiment of Figs. 1 to 3, the extraction member is connected to the web material by an adhesive. The adhesive should extend along at least 50% of the width of the innermost edge portion 102, so as to ensure sufficient connection to enable extraction of the web without bursting thereof. In this embodiment, the adhesive extends along essentially the total width of the innermost edge portion 102. Also in this embodiment, the adhesive extends continuously along said length.

The adhesive can be any of a large number of pressure-sensitive adhesives that are commercially available, including the cold, pressure-sensitive adhesives such as the acrylate adhesives, generally combined with tackifiers such as polyterpenes, or the rapid- setting thermoplastic adhesives (or hot melt adhesives) such as styrene and butadiene copolymers. Other ingredients such as fillers, antioxidants and pigments may be included in the adhesive composition.

For manufacture of the embodiment of Figs. 1 to 3, the roll is preferably formed as is conventional from a log of web material. The extraction member 200 is introduced in the vicinity of the centre 103 of the finished roll 100.

Fig. 5 illustrates an embodiment of an insertion device 300 which may be used for the insertion of the extraction member 200. The insertion device 300 is hollow, so as to enable the extraction member 200 to be contained therein. Hence, the insertion device may be introduced into the roll 100, the extraction member 200 may be introduced into, or form a part of, the insertion device 300 while it remains in the roll, where after the insertion device 300 is extracted, leaving the extraction member 200 in the roll. Alternatively, the extraction member 200 may be present in the insertion device 300 already as the insertion device 300 is introduced into the roll 100. To ease insertion of the insertion device 300 into the roll 100, the end surface into which the insertion device 300 is inserted may be inclined slightly inwards.

Further, a glue pipe 301 may be introduced into the insertion device 300 for provision of the adhesive for connecting the insertion device 300 to the material web 100. The tip of the glue pipe 301 may protrude from the insertion device 300. As the insertion device 300

is drawn out of the roll 100, leaving the extraction member 20 behind, the glue pipe may be successively drawn out together with the insertion device 300, during which operation adhesive is fed out from the tip of the glue pipe 301. Hence, adhesive is applied along the extraction device 200 so as to connect it to the innermost edge portion 102 of the web material.

Depending on the type of adhesive, there is a possibility that the adhesive will migrate from the surface onto which it is applied and through some adjacent windings of the web material. As such, this may strengthen the connection between the extraction member 200 and the innermost edge portion 102 of the web material. In this case, the innermost windings - being glued together - will naturally be extracted together with the extraction member 200. However, the amount of material being discarded in this way is substantially less than the amount of material which is normally lost in prior art rolls not using any extraction member.

It is understood that gluing may be performed with a continuous line of adhesive as in the illustrated embodiment, or with an intermittent line of adhesive, e.g. using subsequently following drops of glue.

In the case of intermittent connection of the extraction member to the web material, regardless of the type of connection (adhesive, mechanical or other), the connection length is considered to be the length between the outermost points of connection. Regarding intermittent connection, it is believed that the best results are obtained if the intermittent connection is provided with a relatively large number of connections in relatively close relationship, i.e. with subsequently following connections, in contrast to scarcely provided connections. It is preferred that any intermittent connection begins with at least one connection at the edge of the web on the end surface of the roll 100 from which the accession means extends. In addition, a weaker web will require connections which are greater in number and lie closer to one another along the extraction member, whereas for stronger webs, a lower number of more sparse connections will suffice. In any case, the maximum distance between two adjacent connections should be no more than 5 cm.

Fig. 6 illustrates another embodiment of a roll according to the invention. In this case, the extraction member 200 forms a loop 204 around the material web at the innermost edge

portion 102. In this case, the extraction member is string- or band-shaped and may be made of plastic or metal or of a more conventional string material such as cord, twine or thread.

The two ends of the string material may extend from the same end surface of the roll so as to form accession means 140. Alternatively, the loop may be formed such that only one end of the string is accessible as accession means 140. To maintain the extraction means in the roll, the ends of the string material may be glued, intertwined or knotted together.

Preferably, the connection of the loop to the web material may be strengthened by the use of adhesive along the loop.

In all of the above-mentioned embodiments, density of the roll at a centre portion thereof may be less than the density of the roll at an outer portion thereof, so as to facilitate extraction of the first end portion 102 of web material using the extraction member 200, while maintaining a relatively high average density of the roll 100.

As illustrated in the embodiments above, the extraction member comprises an accession means 140 extending out of the roll. When the roll is placed in a conventional dispenser for centre feed rolls, having a central opening for feeding of the web material, the accession means 140 is positioned so as to extend out of said central opening. Hence, after extracting the extraction member 200 and disposing the extraction member 200 with attached web material, the roll is ready to use with a piece of web material extending through the centre opening of the dispenser.

Alternatives:

It is understood that a number of other embodiments and alternatives of the illustrated embodiments are possible without departing from the general idea of the invention.

For example, the extraction member could have a number of different shapes and designs, such as band-shaped, e.g. a tape, or shaped as a spiral extending along centre of the roll.

The extraction member could be formed in two pieces. For example, the rim or outer portion of the edge of the roll could be reinforced using e.g. a piece of reinforcement material forming a first part of the extraction member. A flap or the like may be fastened to an end of the reinforcement material and allowed to stick out of the roll so as to be 5 accessible. The flap would then constitute a second part of the extraction member. Hence, although provided in two parts, the extraction member as a whole will extend along essentially the full width of the innermost edge of the roll.

In the illustrated embodiments, the extraction member is generally applied parallel to the 10 edge of the material web. Nevertheless, it is understood that the extraction member could also be applied in an oblique angle across the width of the web, and still serve its purpose. However, a parallel or close to parallel relationship to the edge is preferred.

The extraction member could be connected to the web material using a number of 15 different connection methods. For example, a string-shaped extraction member may be stitched through the inner windings of the roll.

Figure 7 illustrates a method for producing a centre feed roll according to the invention. The method comprises a first step of manufacturing a log 400 of web material. This may

20 be achieved through standard rolling techniques. The log 400 is then cut into rolls 100. Each roll 100 comprises a free innermost edge portion 102 of web material in the vicinity of the centre of the roll. An extraction member 200 is then introduced into the centre of each roll 100. This may be in the form of a single long extraction member 200 which is introduced into more than one roll 100 and then cut into separate extraction members

25 200. Alternatively, individual extraction members can be introduced into each roll 100 separately.

Figure 8 illustrates an alternative method for producing a centre feed roll according to the invention. The method comprises a first step of manufacturing a log 400 of the web

30 material, as above. An extraction member 200 is inserted in the centre of said log 400 and the log 400 is cut into rolls. Each roll 100 comprises a free innermost edge portion of web material in the vicinity of the centre of the roll. Folds, pleats, loops or turns may be present in the extraction member 200, so that, after the log 400 has been cut into rolls, the accession means 140 extends from each roll 100. Preferably, there is no adhesive in the

35 vicinity of the cuts, so that the cutting machinery remains adhesive-free.

The method as described herein is believed to be advantageous for production of the inventive rolls, as it enables easy and cost-efficient manufacture. However, the rolls may be manufactured using other methods, e.g. by creating each roll one by one (instead of cutting them out of a log) and including an extraction member 200 at the start of each new roll or log.