US20160235260A1 - Bend to open flat poly-pack tissue cassette for use in over-shell dispensers - Google Patents
Bend to open flat poly-pack tissue cassette for use in over-shell dispensers Download PDFInfo
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- US20160235260A1 US20160235260A1 US15/041,319 US201615041319A US2016235260A1 US 20160235260 A1 US20160235260 A1 US 20160235260A1 US 201615041319 A US201615041319 A US 201615041319A US 2016235260 A1 US2016235260 A1 US 2016235260A1
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- 238000004806 packaging method and process Methods 0.000 claims description 10
- 230000001815 facial effect Effects 0.000 claims description 8
- 238000005452 bending Methods 0.000 claims description 6
- 230000007935 neutral effect Effects 0.000 claims 3
- 239000004033 plastic Substances 0.000 description 18
- 229920003023 plastic Polymers 0.000 description 18
- 239000011087 paperboard Substances 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- -1 polyethylene Polymers 0.000 description 6
- 239000004698 Polyethylene Substances 0.000 description 5
- 229920000573 polyethylene Polymers 0.000 description 5
- 230000001755 vocal effect Effects 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 2
- 210000004905 finger nail Anatomy 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000012217 deletion Methods 0.000 description 1
- 230000037430 deletion Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/42—Dispensers for paper towels or toilet-paper dispensing from a store of single sheets, e.g. stacked
- A47K10/421—Dispensers for paper towels or toilet-paper dispensing from a store of single sheets, e.g. stacked dispensing from the top of the dispenser
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/16—Paper towels; Toilet paper; Holders therefor
- A47K10/18—Holders; Receptacles
- A47K10/185—Holders for boxes of tissue
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
- B65D75/52—Details
- B65D75/58—Opening or contents-removing devices added or incorporated during package manufacture
- B65D75/5827—Tear-lines provided in a wall portion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
- B65D75/52—Details
- B65D75/58—Opening or contents-removing devices added or incorporated during package manufacture
- B65D75/5827—Tear-lines provided in a wall portion
- B65D75/585—Tear-lines provided in a wall portion the tear-lines being broken by deformation or bending
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K2010/3233—Details of the housing, e.g. hinges, connection to the wall
Definitions
- Facial tissue is often sold in a “boutique” format in which the tissue resides in an almost cubical paperboard carton with a top opening, usually an oval, through which the tissue is dispensed. As the paperboard carton adds significantly to the cost of the facial tissue, this format—even though widely used—is quite wasteful.
- the tissue in a boutique package is usually deployed in a folded or interfolded clip of folded tissues, wherein each of the longitudinal outer edges of each tissue is first folded inwardly so that they meet medially along the longitudinal center line of the sheet. Thereafter, a clip of roughly 100 of these tissues is formed by stacking one above the other, and the stacked clip is folded longitudinally with a central portion of the folded tissue clip protruding through an oval opening in the top of the boutique package. Inasmuch as facial tissue by its very nature should be soft, the tensile strength of the tissue must be limited.
- the footprint of the boutique carton is relatively small, it can be particularly advantageous for use in bathrooms where the space is limited, either in a free standing box or more commonly in a five sided plastic over-shell without a bottom, but the bottom of the typical conventional plastic over-shell is thus vulnerable to water thereby counteracting suitability.
- the bottom of the typical conventional plastic over-shell is thus vulnerable to water thereby counteracting suitability.
- guests are often very cavalier about splashing water on the counter leading to the need to replace a box of tissue merely because the bottom was spoiled by water even though a substantial amount of tissue remained un-used therein. Given the operating margins of motels and hotels, it can be appreciated that premature replacement of tissue can impose undue costs on the operator.
- both the presently used boutique boxes and long boxes present a storage and transport issue to the workers who prepare rooms for each guest as each box takes up a great deal of space on the cart used for transporting room preparation and cleaning supplies to and from the rooms as both the new boxes have to be transported to each room and the depleted and/or spoiled boxes have to be carried away. Further, if new boxes are cosmetically damaged prior to reaching the room, in many establishments, the damaged boxes are not considered suitable for use and thus are wasted.
- FIG. 1 is a schematic isometric perspective of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness in which the excess of material around the tissue clip is somewhat exaggerated.
- FIG. 2 is a schematic plan view of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness.
- FIG. 3 is a schematic sectional view taken along line 3 - 3 in FIG. 2 of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness.
- FIG. 4 is a schematic sectional view taken along line 4 - 4 in FIG. 2 of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette.
- FIG. 5 is another view of a capaciously sized loose fitting bend to open flat poly-pack tissue cassette.
- FIGS. 6 and 7 are schematic line drawings illustrating opening of a bend to open poly-pack tissue cassette of the present invention.
- FIG. 8 is a schematic isometric perspective of a plastic over-shell suitable for use with the capaciously sized loose fitting, bend-to-open, or flex-to-open, flat poly-pack tissue cassette with a transversely extending medial line of weakness.
- FIG. 9 is a schematic of a polyethylene sheet suitable for forming the capaciously sized loose fitting, bend-to-open, or flex-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness.
- FIG. 10 illustrates the dimensions of a prefolded sheet of tissue before it is stacked together with other sheets to form the tissue clip.
- FIGS. 11, 12 and 13 illustrate a long box over-shell also suitable for use with a bend to open poly-pack tissue cassette of the present invention.
- FIG. 14 is a sectional view taken along line 14 - 14 in FIG. 11 .
- FIG. 15 is a sectional view taken along line 15 - 15 in FIG. 12 .
- FIG. 16 is schematic isometric perspective illustrating a long box over-shell suitable for use with the poly-pack tissue cassette of the present invention.
- FIG. 17 illustrates where the transverse perimeter is measured on a clip of tissue.
- FIG. 18 illustrates a combo pack of the present invention comprising one plastic over-shell and a plurality of poly-pack tissue cassettes of the present invention.
- FIG. 19 illustrates a schematic of another polymeric sheet suitable for forming a capaciously sized loose fitting, flex-to-open flat poly-pack tissue cassette.
- FIG. 20 illustrates largely nonverbal, use instructions printed on a polymeric sheet suitable for forming a capaciously sized loose fitting, flex to open flat poly-pack tissue cassette.
- poly-pack tissue cassette 20 formed from polymeric sheet 21 having thickness of about 1-2 mils having a length of about 12.25 inches and a width of about 6 inches encompasses interfolded tissue clip 22 having a length of about 8.25 inches and a width of about 4 inches.
- each clip 22 will hold from about 75 to about 150, preferably from about 80-140, more preferably from about 85-135, still more preferably from around 90-130 and most preferably around 100, single or multi-ply tissues, preferably.
- 2-ply tissues having a basis weight of around 25-40 gsm (15-20 lb/3000 sq. ft. ream), or about 23-41 gsm (14-25 lb/3000 sq. ft.
- ream preferably 24-36 gsm (15-22 lb/3000 sq. ft. ream), more preferably about 26-34 gsm (16-21 lb/3000 sq. ft. ream) and most preferably about 29-33 gsm (18-20 lbs/3000 sq. ft. ream).
- clip 22 of 2-ply tissue will have a caliper of from about 40 to about 75 mils per 8 sheets, preferably from about 45 to 70 mils per 8 sheets, more preferably from about 50 to about 65 mils per 8 sheets and even more preferably from about 52 to about 60 mils per 8 sheets. Accordingly clip 22 will have a height of from about 0.75′′ to about 2.8′′, preferably from about 0.8′′ to about 2.5′′, more preferably from about 1′′ to about 2.2′′, still more preferably from about 1.1′′ to about 2′′ and even more preferably from about 1.2′′ to about 1.8′′.
- each clip 22 of tissue will contain between about 90 and 100 single ply or 2-ply sheets having a basis weight of from about 17 to 21 lbs/3000 sq. ft. ream with a caliper of 50 to 70 mils/8 sheets and a height of from about 1.2′′ to about 1.5′′-1.6′′.
- Transversely extending medial line of weakness 24 is formed by line 26 of perforations 28 extending across the poly surrounding tissue clip 22 in view of the disparity between the length and width of poly-pack tissue cassette 20 and the length and width of interfolded tissue clip 22 , it can be appreciated that poly-pack tissue cassette 20 is capaciously sized and loose fitting relative to tissue clip 22 therewithin.
- the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly is preferably between about 0.70 to about 0.95, more preferably between about 0.75 and 0.92, still more preferably between about 0.80 and 0.90.
- the ratio of the transverse perimeter of clip 22 to the interior transverse perimeter of poly-pack tissue cassette 20 may be between about 0.55 to about 0.85, between about 0.60 and 0.82, between about 0.65 and 0.8 and or about 0.70, the transverse perimeter being taken around the width of clip 22 as illustrated in FIG. 17 .
- the ratio of the longitudinal perimeter of tissue clip 22 to the interior longitudinal perimeter of the poly pack be in the range of from about 0.8 to about 0.96, more preferably from about 0.88 to about 0.96, still more preferably from about 0.92 to about 0.95. Most preferably, the ratio will lie between 0.90 and 0.95.
- the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly is preferably between about 0.70 to about 0.95, more preferably between about 0.75 and 0.92, still more preferably between about 0.80 and 0.90, and most preferably between about 0.82 and 0.89.
- the present invention is also suitable for use with napkin stock having a basis weight of 16 to 25 pounds per 3000 sq. ft. ream, a caliper of between 50 and 130 mils/8 sheets; towel having a basis weight of 20 to 40 pounds per 3000 sq. ft. ream, a caliper of 50 to 70 mils per 8 sheets; and, wipes having a basis weight of 15 to 30 pounds per 3000 sq. ft. ream and a caliper of between 30 and 70 mils per 8 sheets.
- the ratio of the transverse perimeter of the clip of paper product to the transverse interior perimeter of the polymeric overwrap be in the range of about 0.772 to about 0.92.
- the ratio of the longitudinal perimeter of the clip of paper product to the longitudinal interior perimeter polymeric overwrap should be between about 0.88 and 0.96.
- each perforation 28 has a length of 2.75 mm while the length of land 30 between perforations 28 is 0.915 mm and the total length of line of weakness 24 is 2.5 about 5 inches, although, in many cases, the length of the line of weakness will be as much as 7 inches or more.
- line of weakness 24 is formed of perforations 28 extending through the depth of polymeric sheet 21 overwrapping tissue cassette 20 .
- the perforations may also be formed sufficiently deeply to allow the release of entrained air in a cassette prior to dispensing without rupturing the cassette. This “flattening” may allow more cassettes to fit in a carton. This flattening can also be achieved by placing pin holes in the poly sheet itself. In many cases, only one or two perforations need extend entirely through the film with the other perforations being closer to score lines.
- poly- should be understood to include polyethylene in all of its variants that are suitable for packaging wrap, polypropylene, polyolefins suitable for packaging wrap as well as other suitably flexible, water impermeable polymeric material commonly used as overwraps.
- polypropylene polypropylene
- polyolefins suitable for packaging wrap
- other suitably flexible, water impermeable polymeric material commonly used as overwraps.
- FIG. 4 the schematic sectional view taken along line 4 - 4 in FIG. 2 of the capaciously sized loose fitting, bend-to-open/flex-2-open flat poly-pack tissue cassette 20 further illustrates the generous amount of polymeric wrap used to envelop interfolded tissue clip 22 .
- overlap fin seam 34 depends therefrom.
- Transversely extending lip 36 is visible as well.
- FIG. 5 illustrates the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette 20 with transversely extending medial line of weakness 24 formed in polymeric sheet 21 encompassing tissue clip 22 .
- Transversely extending lip 36 is visible as well.
- FIGS. 6 and 7 illustrate opening of poly-pack tissue cassette 20 of the present invention with FIG. 6 representing the poly-pack tissue cassette 20 just prior to rupture along line of weakness 24 and FIG. 7 just after.
- FIG. 8 illustrates schematic isometric perspective of a plastic over-shell 38 having an oval opening 40 in top surface 42 thereof, plastic over-shell 38 being suitable for use with capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette 20 (not shown) with a transversely extending medial line of weakness 24 .
- FIG. 9 is a schematic of polymeric sheet 21 illustrating dimensions thereof suitable for forming capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness 24 illustrating dimensions suitable for use with a 96 sheet clip of 2-ply tissue sheets, 8.85′′ in length by 7.65′′ in width having longitudinal folds therein resulting in a folded width of 4 inches, each 2-ply tissue sheet having a basis weight of approximately 20 lbs/3000 sq. ft. ream when each sheet is folded into the configuration illustrated in FIG. 10 .
- FIG. 10 illustrates the approximate dimensions of each sheet of tissue when prefolded prior to being incorporated into clip 22 (illustrated in FIG. 1 ).
- FIGS. 14 and 15 (with reference to FIG. 2 ), the disposition of poly-pack tissue cassette 20 within long box over-shell 39 is illustrated, while FIG. 16 is an isometric perspective of long box over-shell 39 with oval dispensing opening 41 and FIG. 17 illustrates where the transverse perimeter of tissue clip 22 is measured.
- FIG. 18 illustrates a starter pack of several poly-pack tissue cassettes 20 and a plastic over-shell 38 inside a poly overwrap 45 to acquaint consumers with this packaging format.
- FIG. 19 illustrates the dimensions of a polymeric overwrap sized to accommodate a 96 sheet clip of 2-ply tissue where each sheet is 8.4 in. ⁇ 8 in (213 mm ⁇ 203 mm), while FIG. 20 illustrates a combination of verbal and non-verbal instructions suitable for printing on an overwrap used in the practice of the present invention.
- the internal width of the completed tissue pack exceed the width of the tissue clip 22 by at least about 1.75 inches, more preferably by at least about 2 inches, more preferably by at least about 2.25 inches, still more preferably by at least about 2.5 inches and most preferably by at least about 2.75 inches.
- the interior length of the overwrap exceed the length of tissue clip 22 by at least about 0.75 inches, more preferably by at least about 1.0 inches, more preferably by at least about 1.25 inches and most preferably by at least about 1.35 inches.
- the ratio of the interior periphery of the polymeric sheet 21 to the transverse periphery of tissue clip 22 will be in the ranges prescribed above.
- use and opening instructions be printed directly onto the poly film for each cassette in a graphic form not requiring ability to read so that these instructions can be easily understood by all workers no matter what their background.
- FIG. 20 illustrates a suitable combination of verbal instructions 66 and nonverbal pictorial instructions 68 .
- the last 15-20 sheets in the cassette vary from the color of the upper sheets in clip 22 or include a colored stripe and/or logo, so that workers can quickly determine whether the inner pack should be replaced.
- Tendency for tissue to fall back into the dispenser can be largely alleviated by provision of a lip at each end of the cassette of at least about 0.5 inches in length by heat sealing two layers of film together.
- the lip is at least about 0.7 inches in length, more preferably at least about 0.75 inches in length, still more preferably at least about 0.85 inches in length and most preferably at least about 1.0 inches in length.
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Abstract
Description
- This application is based on U.S. Provisional. Patent Application No. 62/116,719, filed Feb. 16, 2015, and U.S. Provisional Patent Application No. 62/153,236, filed Apr. 27, 2015, which are incorporated herein by reference in their entirety.
- Packaging can make a crucial difference in the success, or lack of it, for many consumer products, often constituting a significant portion of the cost that the consumer must ultimately bear for the product. Facial tissue is often sold in a “boutique” format in which the tissue resides in an almost cubical paperboard carton with a top opening, usually an oval, through which the tissue is dispensed. As the paperboard carton adds significantly to the cost of the facial tissue, this format—even though widely used—is quite wasteful. Further cartoning a large number of boutique cubes inside corrugate is rather wasteful as the amount of boxed boutique tissue that can be placed in a given corrugate container is rather small in relation to the volume of the corrugate as, when the tissue is folded over into a folded clip, it occupies a significantly greater volume than the volume of the flat clip before folding. Since the amount of tissue that can be effectively trucked is limited by volume rather than weight, this adds significantly to cartoning expense as well as to transportation cost.
- To reconcile the almost cubic boutique format with standard tissue sizes preferred by consumers, the tissue in a boutique package is usually deployed in a folded or interfolded clip of folded tissues, wherein each of the longitudinal outer edges of each tissue is first folded inwardly so that they meet medially along the longitudinal center line of the sheet. Thereafter, a clip of roughly 100 of these tissues is formed by stacking one above the other, and the stacked clip is folded longitudinally with a central portion of the folded tissue clip protruding through an oval opening in the top of the boutique package. Inasmuch as facial tissue by its very nature should be soft, the tensile strength of the tissue must be limited. Therefore, if the packaging is not well suited to the particular tissue format, it can be difficult to easily remove sheets from the boutique package without tearing the sheet or lifting the package from its desired location. To this end, boutique carton designs have been used in which the interior of the boutique carton is partially lined with polyethylene to reduce the friction between the tissue sheet and the interior of the carton. Provision of the polyethylene interlining adds to the cost of the carton thereby aggravating an already wasteful format. See for example, U.S. Pat. No. 6,672,475, to Ho et al., and U.S. Pat. No. 4,411,374, to Hotchkiss. In many cases, particularly in hotel and motel rooms, boutique cartons are placed within reusable 5-sided plastic or metallic over-shells without any bottom to better suit the customer's aesthetic preferences. In other cases, long boxes of tissue may also be placed within plastic over-shells sized to accommodate the more conventional rectangular prism carton packaging often used for facial tissue.
- Because the footprint of the boutique carton is relatively small, it can be particularly advantageous for use in bathrooms where the space is limited, either in a free standing box or more commonly in a five sided plastic over-shell without a bottom, but the bottom of the typical conventional plastic over-shell is thus vulnerable to water thereby counteracting suitability. In particular, when facial tissue is presented in hotel/′motel applications, guests are often very cavalier about splashing water on the counter leading to the need to replace a box of tissue merely because the bottom was spoiled by water even though a substantial amount of tissue remained un-used therein. Given the operating margins of motels and hotels, it can be appreciated that premature replacement of tissue can impose undue costs on the operator.
- Thus it can be understood that boutique packaging of boxed facial tissue inside a re-usable plastic over-shell presents several distinct issues:
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- Cost of the paperboard carton as well as the polyethylene interlining and overwrap binding the boutique boxes together in aggregates that are easily handled;
- Cost of the corrugate overwrap in relation to the amount of tissue containable within a given volume of corrugate as well as the associated environmental impact of manufacture and disposal of the paperboard carton;
- Transportation costs for the format;
- Susceptibility to water and concomitant spoilage;
- Loading issues; and
- Dispensing of the tissue from the container.
Similar issues are presented when long boxes of tissue are placed in a plastic over-shell. We have found that we can alleviate many of these difficulties by eliminating the paperboard carton. In particular, in many cases as much as 75% more tissue that can be shipped if the paperboard boxes are eliminated. However, mere deletion of the paperboard carton does not alleviate all of the problem as the tissue still must be packed both for transportation and sale to the customer, and a simple close fitting polymeric overwrap over a folded or unfolded clip of tissue can not only cause difficulty in dispensing but also can make loading of the plastic over-shell non-trivial for the consumer. In particular, we have found that a conventional close fitting polymeric overwrap can severely impede proper dispensing of tissue in a boutique format—in many cases preventing proper dispensing unless the overwrap has a size substantially exceeding that of the clip. We have found that we can alleviate many of these difficulties associated with the current boutique format by packing unfolded stacked clips of tissues in a capaciously sized overwrap with a transversely extending line of weakness placed medially across one face of the overwrap, so that when it is desired to replace the tissue within a plastic shell, the replacement clip can be folded longitudinally to place the transversely extending line of weakness in tension, rupturing it and then inserting the tissue into the over-shell although, in many cases, the user will start the opening by running a finger nail or other suitable object along the line of weakness. This boxless design also alleviates issues experienced with nearly empty boxes of conventional boxed tissues in that when a conventional box of tissues becomes depleted, it becomes more and more likely that the user will have difficulty removing tissue from the box, particularly when the tissue becomes sufficiently depleted that the tissue clip can fall back into the box. Using the boxless tissue cassettes of the present invention, the tendency for tissues to fall back into the box is largely alleviated.
- We have found that we can achieve excellent results by providing a capaciously sized, loose fitting, bend-to-open, or flex-to-open, flat poly-pack tissue cassette with a transversely extending medial line of weakness which, when capaciously sized, eases dispensing from inside a five-sided plastic over-shell. In our inventive packaging format, the facial tissue can be packed and shipped flat, conserving space. In preparation for use, the consumer can simply bend or flex the flat poly-pack along the transversely extending medial line of weakness, thereby placing that line of weakness in tension and opening up the poly-pack to make its contents accessible upon inserting the folded pack into the plastic over-shell. In many cases, consumers will prefer to run a fingernail along the line of weakness to ease opening or at least partially open the poly pack prior to bending or flexing. Even though the plastic over-shell is bottomless, susceptibility to water damage is alleviated, if not almost entirely obviated, since the lower ends of the clip remain ensconced in poly, while the tissue can be easily withdrawn through the top of the plastic over-shell. Thus, not only are the excess costs associated with the paperboard boutique carton eliminated, but it is also possible to store more tissue in a given space while avoiding the environmental impact of disposal of the paperboard carton as well as the wastage which results when water seeps into the bottom of conventionally boxed boutique tissues. Surprisingly, we have found that the very same configuration of over-wrapped tissue that functions well inside of boutique over-shells also functions well when used in conjunction with the rectangular prismatic over-shell usually used with long boxes.
- When used in hotel/motel applications, both the presently used boutique boxes and long boxes present a storage and transport issue to the workers who prepare rooms for each guest as each box takes up a great deal of space on the cart used for transporting room preparation and cleaning supplies to and from the rooms as both the new boxes have to be transported to each room and the depleted and/or spoiled boxes have to be carried away. Further, if new boxes are cosmetically damaged prior to reaching the room, in many establishments, the damaged boxes are not considered suitable for use and thus are wasted.
-
FIG. 1 is a schematic isometric perspective of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness in which the excess of material around the tissue clip is somewhat exaggerated. -
FIG. 2 is a schematic plan view of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness. -
FIG. 3 is a schematic sectional view taken along line 3-3 inFIG. 2 of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness. -
FIG. 4 is a schematic sectional view taken along line 4-4 inFIG. 2 of the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette. -
FIG. 5 is another view of a capaciously sized loose fitting bend to open flat poly-pack tissue cassette. -
FIGS. 6 and 7 are schematic line drawings illustrating opening of a bend to open poly-pack tissue cassette of the present invention. -
FIG. 8 is a schematic isometric perspective of a plastic over-shell suitable for use with the capaciously sized loose fitting, bend-to-open, or flex-to-open, flat poly-pack tissue cassette with a transversely extending medial line of weakness. -
FIG. 9 is a schematic of a polyethylene sheet suitable for forming the capaciously sized loose fitting, bend-to-open, or flex-to-open flat poly-pack tissue cassette with a transversely extending medial line of weakness. -
FIG. 10 illustrates the dimensions of a prefolded sheet of tissue before it is stacked together with other sheets to form the tissue clip. -
FIGS. 11, 12 and 13 illustrate a long box over-shell also suitable for use with a bend to open poly-pack tissue cassette of the present invention. -
FIG. 14 is a sectional view taken along line 14-14 inFIG. 11 . -
FIG. 15 is a sectional view taken along line 15-15 inFIG. 12 . -
FIG. 16 is schematic isometric perspective illustrating a long box over-shell suitable for use with the poly-pack tissue cassette of the present invention. -
FIG. 17 illustrates where the transverse perimeter is measured on a clip of tissue. -
FIG. 18 illustrates a combo pack of the present invention comprising one plastic over-shell and a plurality of poly-pack tissue cassettes of the present invention. -
FIG. 19 illustrates a schematic of another polymeric sheet suitable for forming a capaciously sized loose fitting, flex-to-open flat poly-pack tissue cassette. -
FIG. 20 illustrates largely nonverbal, use instructions printed on a polymeric sheet suitable for forming a capaciously sized loose fitting, flex to open flat poly-pack tissue cassette. - In
FIGS. 1-5 , poly-pack tissue cassette 20 formed frompolymeric sheet 21 having thickness of about 1-2 mils having a length of about 12.25 inches and a width of about 6 inches encompassesinterfolded tissue clip 22 having a length of about 8.25 inches and a width of about 4 inches. Typically, eachclip 22 will hold from about 75 to about 150, preferably from about 80-140, more preferably from about 85-135, still more preferably from around 90-130 and most preferably around 100, single or multi-ply tissues, preferably. 2-ply tissues having a basis weight of around 25-40 gsm (15-20 lb/3000 sq. ft. ream), or about 23-41 gsm (14-25 lb/3000 sq. ft. ream), preferably 24-36 gsm (15-22 lb/3000 sq. ft. ream), more preferably about 26-34 gsm (16-21 lb/3000 sq. ft. ream) and most preferably about 29-33 gsm (18-20 lbs/3000 sq. ft. ream). - In the most preferred embodiments,
clip 22 of 2-ply tissue will have a caliper of from about 40 to about 75 mils per 8 sheets, preferably from about 45 to 70 mils per 8 sheets, more preferably from about 50 to about 65 mils per 8 sheets and even more preferably from about 52 to about 60 mils per 8 sheets. Accordingly clip 22 will have a height of from about 0.75″ to about 2.8″, preferably from about 0.8″ to about 2.5″, more preferably from about 1″ to about 2.2″, still more preferably from about 1.1″ to about 2″ and even more preferably from about 1.2″ to about 1.8″. In the most preferred embodiments, eachclip 22 of tissue will contain between about 90 and 100 single ply or 2-ply sheets having a basis weight of from about 17 to 21 lbs/3000 sq. ft. ream with a caliper of 50 to 70 mils/8 sheets and a height of from about 1.2″ to about 1.5″-1.6″. Transversely extending medial line ofweakness 24 is formed byline 26 ofperforations 28 extending across the poly surroundingtissue clip 22 in view of the disparity between the length and width of poly-pack tissue cassette 20 and the length and width ofinterfolded tissue clip 22, it can be appreciated that poly-pack tissue cassette 20 is capaciously sized and loose fitting relative totissue clip 22 therewithin. To ease removal of tissue sheets, the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly is preferably between about 0.70 to about 0.95, more preferably between about 0.75 and 0.92, still more preferably between about 0.80 and 0.90. In other cases, the ratio of the transverse perimeter ofclip 22 to the interior transverse perimeter of poly-pack tissue cassette 20 may be between about 0.55 to about 0.85, between about 0.60 and 0.82, between about 0.65 and 0.8 and or about 0.70, the transverse perimeter being taken around the width ofclip 22 as illustrated inFIG. 17 . Similarly, we prefer that the ratio of the longitudinal perimeter oftissue clip 22 to the interior longitudinal perimeter of the poly pack be in the range of from about 0.8 to about 0.96, more preferably from about 0.88 to about 0.96, still more preferably from about 0.92 to about 0.95. Most preferably, the ratio will lie between 0.90 and 0.95. In the case of polymeric overwraps wherein the length of the transverse opening formed from the line of perforations exceeds W+H, approaching W+2 H, the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly is preferably between about 0.70 to about 0.95, more preferably between about 0.75 and 0.92, still more preferably between about 0.80 and 0.90, and most preferably between about 0.82 and 0.89. - The present invention is also suitable for use with napkin stock having a basis weight of 16 to 25 pounds per 3000 sq. ft. ream, a caliper of between 50 and 130 mils/8 sheets; towel having a basis weight of 20 to 40 pounds per 3000 sq. ft. ream, a caliper of 50 to 70 mils per 8 sheets; and, wipes having a basis weight of 15 to 30 pounds per 3000 sq. ft. ream and a caliper of between 30 and 70 mils per 8 sheets. For these products, it is preferred that the ratio of the transverse perimeter of the clip of paper product to the transverse interior perimeter of the polymeric overwrap be in the range of about 0.772 to about 0.92. Similarly, the ratio of the longitudinal perimeter of the clip of paper product to the longitudinal interior perimeter polymeric overwrap should be between about 0.88 and 0.96.
- In
FIGS. 1-5 , eachperforation 28 has a length of 2.75 mm while the length ofland 30 betweenperforations 28 is 0.915 mm and the total length of line ofweakness 24 is 2.5 about 5 inches, although, in many cases, the length of the line of weakness will be as much as 7 inches or more. In this embodiment, line ofweakness 24 is formed ofperforations 28 extending through the depth ofpolymeric sheet 21overwrapping tissue cassette 20. The perforations may also be formed sufficiently deeply to allow the release of entrained air in a cassette prior to dispensing without rupturing the cassette. This “flattening” may allow more cassettes to fit in a carton. This flattening can also be achieved by placing pin holes in the poly sheet itself. In many cases, only one or two perforations need extend entirely through the film with the other perforations being closer to score lines. - For
tissue cassette 20 varying in size from those most preferred herein, the length, L, of the line of perforations will desirably be at least: L=W+H up to about L=W+2H. - Throughout the specification and claims, the terms “poly-”, “poly” and “polymeric” should be understood to include polyethylene in all of its variants that are suitable for packaging wrap, polypropylene, polyolefins suitable for packaging wrap as well as other suitably flexible, water impermeable polymeric material commonly used as overwraps. In this specification, all measurements are taken according to the applicable TAPPI standard unless otherwise specified.
- In
FIG. 4 , the schematic sectional view taken along line 4-4 inFIG. 2 of the capaciously sized loose fitting, bend-to-open/flex-2-open flat poly-pack tissue cassette 20 further illustrates the generous amount of polymeric wrap used to envelopinterfolded tissue clip 22. Along the lower longitudinally extendingmedial line 32 oftissue cassette 20, overlapfin seam 34 depends therefrom.Transversely extending lip 36 is visible as well. -
FIG. 5 illustrates the capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette 20 with transversely extending medial line ofweakness 24 formed inpolymeric sheet 21 encompassingtissue clip 22.Transversely extending lip 36 is visible as well. -
FIGS. 6 and 7 illustrate opening of poly-pack tissue cassette 20 of the present invention withFIG. 6 representing the poly-pack tissue cassette 20 just prior to rupture along line ofweakness 24 andFIG. 7 just after. -
FIG. 8 (with reference toFIG. 1 ) illustrates schematic isometric perspective of a plastic over-shell 38 having anoval opening 40 intop surface 42 thereof, plastic over-shell 38 being suitable for use with capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette 20 (not shown) with a transversely extending medial line ofweakness 24. -
FIG. 9 is a schematic ofpolymeric sheet 21 illustrating dimensions thereof suitable for forming capaciously sized loose fitting, bend-to-open flat poly-pack tissue cassette with a transversely extending medial line ofweakness 24 illustrating dimensions suitable for use with a 96 sheet clip of 2-ply tissue sheets, 8.85″ in length by 7.65″ in width having longitudinal folds therein resulting in a folded width of 4 inches, each 2-ply tissue sheet having a basis weight of approximately 20 lbs/3000 sq. ft. ream when each sheet is folded into the configuration illustrated inFIG. 10 . In many cases, it may be expedient to lengthen a total perforated area to as much as about 7 inches or more to ease opening as there is really no penalty associated with use of longer score lines. SeeFIGS. 19 and 20 . -
FIG. 10 illustrates the approximate dimensions of each sheet of tissue when prefolded prior to being incorporated into clip 22 (illustrated inFIG. 1 ). - In
FIGS. 11-13 long box over-shell 39 withoval dispensing opening 41 will accepttissue cassettes 20 which will also fit boutique size plastic over-shell 38 (FIG. 8 ) without however requiring folding. In most cases, poly pack tissue cassette 20 (FIG. 1 ) will still be opened by bending, flexing or folding as described above, then unfolded to lie withlong box over-shell 39. - In
FIGS. 14 and 15 (with reference toFIG. 2 ), the disposition of poly-pack tissue cassette 20 withinlong box over-shell 39 is illustrated, whileFIG. 16 is an isometric perspective oflong box over-shell 39 withoval dispensing opening 41 andFIG. 17 illustrates where the transverse perimeter oftissue clip 22 is measured. -
FIG. 18 illustrates a starter pack of several poly-pack tissue cassettes 20 and aplastic over-shell 38 inside apoly overwrap 45 to acquaint consumers with this packaging format. -
FIG. 19 illustrates the dimensions of a polymeric overwrap sized to accommodate a 96 sheet clip of 2-ply tissue where each sheet is 8.4 in.×8 in (213 mm×203 mm), whileFIG. 20 illustrates a combination of verbal and non-verbal instructions suitable for printing on an overwrap used in the practice of the present invention. In general, for easy dispensing, we prefer that the internal width of the completed tissue pack exceed the width of thetissue clip 22 by at least about 1.75 inches, more preferably by at least about 2 inches, more preferably by at least about 2.25 inches, still more preferably by at least about 2.5 inches and most preferably by at least about 2.75 inches. We further prefer that the interior length of the overwrap exceed the length oftissue clip 22 by at least about 0.75 inches, more preferably by at least about 1.0 inches, more preferably by at least about 1.25 inches and most preferably by at least about 1.35 inches. For optimum dispensing, the ratio of the interior periphery of thepolymeric sheet 21 to the transverse periphery oftissue clip 22 will be in the ranges prescribed above. We also prefer that use and opening instructions be printed directly onto the poly film for each cassette in a graphic form not requiring ability to read so that these instructions can be easily understood by all workers no matter what their background.FIG. 20 illustrates a suitable combination ofverbal instructions 66 and nonverbalpictorial instructions 68. Preferably the last 15-20 sheets in the cassette vary from the color of the upper sheets inclip 22 or include a colored stripe and/or logo, so that workers can quickly determine whether the inner pack should be replaced. Tendency for tissue to fall back into the dispenser can be largely alleviated by provision of a lip at each end of the cassette of at least about 0.5 inches in length by heat sealing two layers of film together. Preferably the lip is at least about 0.7 inches in length, more preferably at least about 0.75 inches in length, still more preferably at least about 0.85 inches in length and most preferably at least about 1.0 inches in length.
Claims (24)
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/041,319 US20160235260A1 (en) | 2015-02-16 | 2016-02-11 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
MX2017010573A MX2017010573A (en) | 2015-02-16 | 2016-02-12 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers. |
JP2017542870A JP2018505104A (en) | 2015-02-16 | 2016-02-12 | Bent open flat polypack tissue cassette for use in overshell feeders |
CA2976222A CA2976222A1 (en) | 2015-02-16 | 2016-02-12 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
EP16752849.6A EP3259206A4 (en) | 2015-02-16 | 2016-02-12 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
PCT/US2016/017765 WO2016133819A1 (en) | 2015-02-16 | 2016-02-12 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
TW105104279A TW201637954A (en) | 2015-02-16 | 2016-02-15 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
HK18104478.3A HK1245207A1 (en) | 2015-02-16 | 2018-04-04 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201562116719P | 2015-02-16 | 2015-02-16 | |
US201562153236P | 2015-04-27 | 2015-04-27 | |
US15/041,319 US20160235260A1 (en) | 2015-02-16 | 2016-02-11 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
Publications (1)
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US20160235260A1 true US20160235260A1 (en) | 2016-08-18 |
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US15/041,319 Abandoned US20160235260A1 (en) | 2015-02-16 | 2016-02-11 | Bend to open flat poly-pack tissue cassette for use in over-shell dispensers |
Country Status (8)
Country | Link |
---|---|
US (1) | US20160235260A1 (en) |
EP (1) | EP3259206A4 (en) |
JP (1) | JP2018505104A (en) |
CA (1) | CA2976222A1 (en) |
HK (1) | HK1245207A1 (en) |
MX (1) | MX2017010573A (en) |
TW (1) | TW201637954A (en) |
WO (1) | WO2016133819A1 (en) |
Cited By (2)
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WO2019089002A1 (en) * | 2017-10-31 | 2019-05-09 | Kimberly-Clark Worldwide, Inc. | Package of volumetrically stable, wet consumer product having microvent |
US20220183514A1 (en) * | 2019-03-29 | 2022-06-16 | Daio Paper Corporation | Film packaging tissue |
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- 2016-02-12 JP JP2017542870A patent/JP2018505104A/en active Pending
- 2016-02-12 EP EP16752849.6A patent/EP3259206A4/en not_active Withdrawn
- 2016-02-12 WO PCT/US2016/017765 patent/WO2016133819A1/en active Application Filing
- 2016-02-12 CA CA2976222A patent/CA2976222A1/en not_active Abandoned
- 2016-02-15 TW TW105104279A patent/TW201637954A/en unknown
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2018
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Also Published As
Publication number | Publication date |
---|---|
MX2017010573A (en) | 2018-04-13 |
EP3259206A1 (en) | 2017-12-27 |
TW201637954A (en) | 2016-11-01 |
JP2018505104A (en) | 2018-02-22 |
WO2016133819A1 (en) | 2016-08-25 |
HK1245207A1 (en) | 2018-08-24 |
EP3259206A4 (en) | 2019-02-27 |
CA2976222A1 (en) | 2016-08-25 |
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