Abstract:
A tissue dispensing system with a rigid overshell having 5 sides and an opened bottom with a tissue withdrawal opening in the top is adapted to receive a bend-to-open pack containing a clip of tissue sheets enwrapped in a capaciously sized overwrap having a medial line of weakness formed therein and situated to allow withdrawal of tissue through the tissue withdrawal opening after the line of weakness is ruptured and the tissue pack is placed in the overshell.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    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. 
     
    
     SUMMARY OF THE INVENTION 
       [0002]    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. 
         [0003]    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&#39;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. 
         [0004]    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. 
         [0005]    Thus it can be understood that boutique packaging of boxed facial tissue inside a re-usable plastic over-shell presents several distinct issues:
       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.
       
 
         [0012]    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. 
         [0013]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      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. 
           [0015]      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. 
           [0016]      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. 
           [0017]      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. 
           [0018]      FIG. 5  is another view of a capaciously sized loose fitting bend to open flat poly-pack tissue cassette. 
           [0019]      FIGS. 6 and 7  are schematic line drawings illustrating opening of a bend to open poly-pack tissue cassette of the present invention. 
           [0020]      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. 
           [0021]      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. 
           [0022]      FIG. 10  illustrates the dimensions of a prefolded sheet of tissue before it is stacked together with other sheets to form the tissue clip. 
           [0023]      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. 
           [0024]      FIG. 14  is a sectional view taken along line  14 - 14  in  FIG. 11 . 
           [0025]      FIG. 15  is a sectional view taken along line  15 - 15  in  FIG. 12 . 
           [0026]      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. 
           [0027]      FIG. 17  illustrates where the transverse perimeter is measured on a clip of tissue. 
           [0028]      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. 
           [0029]      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. 
           [0030]      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. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    In  FIGS. 1-5 , 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. Typically, 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). 
         [0032]    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, 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. 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 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 . Similarly, we prefer that 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. 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. 
         [0033]    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. 
         [0034]    In  FIGS. 1-5 , 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. In this embodiment, 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. 
         [0035]    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. 
         [0036]    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. 
         [0037]    In  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 . Along the lower longitudinally extending medial line  32  of tissue cassette  20 , overlap fin seam  34  depends therefrom. Transversely extending lip  36  is visible as well. 
         [0038]      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. 
         [0039]      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. 
         [0040]      FIG. 8  (with reference to  FIG. 1 ) 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 . 
         [0041]      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 . 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. See  FIGS. 19 and 20 . 
         [0042]      FIG. 10  illustrates the approximate dimensions of each sheet of tissue when prefolded prior to being incorporated into clip  22  (illustrated in  FIG. 1 ). 
         [0043]    In  FIGS. 11-13  long box over-shell  39  with oval dispensing opening  41  will accept tissue 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 with long box over-shell  39 . 
         [0044]    In  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. 
         [0045]      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. 
         [0046]      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. In general, for easy dispensing, we prefer that 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. We further prefer that 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. For optimum dispensing, 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. 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 of verbal instructions  66  and nonverbal pictorial instructions  68 . Preferably 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. 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.