Stack of folded paper products

A stack of folded paper products. The stack can include first and second paper products, each having first and second centerlines and first and second fold lines. The first fold line can be substantially parallel to, and offset from, the first centerline. The second centerline can be substantially perpendicular to the first centerline. The second fold line can be substantially parallel to the second centerline. The first and second paper products can each be folded about the first fold line prior to being folded about the second fold line, thereby forming first and second larger panels and first and second smaller panels. At least one of the panels of the second paper product can be at least partially disposed between at least two of the panels of the first paper product.

BACKGROUND

Embodiments described herein generally relate to folded paper products. More particularly, such embodiments relate to folded paper napkins that are arranged to form a stack.

2. Description of the Related Art

Paper products, such as napkins, are folded and then placed one on top of another to form a stack. Each fold is generally about a centerline of the napkin such that the surface area of the napkin is reduced by a factor of two. For example, a napkin can be folded a first time to form two evenly sized panels. The napkin can then be folded a second time to form four evenly sized panels. The napkins can be placed one on top of another and inserted into a dispenser.

Withdrawing a single napkin from a dispenser can inadvertently lead to two or more napkins being inadvertently withdrawn. To overcome this, a panel from each napkin can be inserted between at least two panels of the adjacent napkin prior to loading the napkins into the dispenser. This is referred to as “interfolding.” If a user desires to load additional napkins into the dispenser before the dispenser is empty, however, one of the new napkins must be interfolded with one of the napkins already disposed within the dispenser. This can be difficult and time consuming. There is a need, therefore, for an improved method for folding paper products and stacking same.

SUMMARY

Stacks of folded paper products and methods for making same are provided. The stack of folded paper products can include first and second paper products, each having first and second centerlines and first and second fold lines. The first fold line can be substantially parallel to, and offset from, the first centerline. The second centerline can be substantially perpendicular to the first centerline. The second fold line can be substantially parallel to the second centerline. The first and second paper products can each be folded about the first fold line prior to being folded about the second fold line, thereby forming first and second larger panels and first and second smaller panels. At least one of the panels of the second paper product can be at least partially disposed between at least two of the panels of the first paper product.

The method for forming a stack of folded paper products can include folding a first paper product about a first fold line that is substantially parallel to, and offset from, a first centerline extending therethrough. The first paper product can then be folded about a second fold line that is substantially perpendicular to the first fold line after the first paper product is folded about the first fold line, thereby forming first and second larger panels and first and second smaller panels. A second paper product can be folded about a first fold line that is substantially parallel to, and offset from, a first centerline extending therethrough. The second paper product can then be folded about a second fold line that is substantially perpendicular to the first fold line after the second paper product is folded about the first fold line, thereby forming first and second larger panels and first and second smaller panels. At least one of the panels of the second paper product can be inserted at least partially between at least two of the panels of the first paper product.

A stack of folded paper napkins is also disclosed. The stack can include first and second paper napkins, each having first and second centerlines and first and second fold lines. The first fold line can be substantially parallel to, and offset from, the first centerline. The second centerline can be substantially perpendicular to the first centerline. The second fold line can be substantially parallel to, and substantially aligned with, the second centerline. The first and second paper napkins can each be folded about the first fold line prior to being folded about the second fold line, thereby forming first and second larger panels that are each at least partially disposed between first and second smaller panels. The first and second larger panels of the first and second paper napkins can each include an offset section that extends a distance beyond the first and second smaller panels. At least one of the panels of the second paper napkin can be at least partially disposed between at least two of the panels of the first paper napkin.

DETAILED DESCRIPTION

FIG. 1shows a top view of an illustrative paper product100prior to folding, according to one or more embodiments. As shown, the paper product100can have a length L, a width W, and a thickness T. The paper product100can be any one or more napkins, tissues, paper towels, or other consumable paper products, and any one or more combinations thereof. The paper product100can have any suitable shape or size and if more than one type, each paper product100can vary in shape or size or both shape and size. Illustrative shapes can include squares, rectangles, polygons, ovals, elliptical, and circles, to name a few. For simplicity and ease of illustration, however, the paper product100will be further described with reference to a rectangular shape having a length (L) that is greater than a width (W).

The paper product100can also have at least two centerlines that are substantially perpendicular to one another. As shown inFIG. 1, the paper product100can have two centerlines (first and second centerlines102,104). The first centerline102can be equidistant or substantially equidistant between first and second opposing sides112,114of the paper product100. The second centerline104can be equidistant or substantially equidistant between third and fourth opposing sides116,118of the paper product100.

The paper product100can have a first fold line106about which the paper product100can be folded to form two portions, sections, or panels122,124. The first fold line106can be substantially parallel to the first centerline102. The first fold line106can be on the first centerline102or can be spaced apart (i.e., offset) from the first centerline102by a distance109. The distance109can be about 0.05 in (1.27 mm), about 0.10 in (2.54 mm), about 0.20 in (5.08 mm), about 0.30 in (7.62 mm), about 0.40 in (10.2 mm), or about 0.50 in (12.7 mm) to about 0.60 in (15.2 mm), about 0.80 in (20.3 mm), about 1.0 in (25.4 mm), about 1.5 in (38.1 mm), about 2.0 in (50.8 mm), about 3.0 in (76.2 mm), or more. For example, the distance109can be about 0.10 (2.54 mm) in to about 3.0 in (76.2 mm), about 0.2 in (5.08 mm) to about 2.0 in (50.8 mm), or about 0.3 in (7.62 mm) to about 1.0 in 25.4 mm).

The length L of the paper product100can be about 2 in (5.08 cm), about 4 in (10.2 cm), about 6 in (15.2 cm), about 8 in (20.3 cm), or about 10 in (25.4 cm) to about 15 in (38.1 cm), about 20 in (50.8 cm), about 25 in (63.5 cm), about 30 in (76.2 cm), about 35 in (88.9 cm), or more. For example, the length L can be from about 2 in (5.08 cm) to about 30 in (76.2 cm), about 4 in (10.2 cm) to about 20 in (50.8 cm), or about 6 in (15.2 cm) to about 15 in (38.1 cm).

The width W of the paper product100can be about 2 in (5.08 cm), about 4 in (10.2 cm), about 6 in (15.2 cm), about 8 in (20.3 cm), or about 10 in (25.4 cm) to about 15 in (38.1 cm), about 20 in (50.8 cm), about 25 in (63.5 cm), about 30 in (76.2 cm), about 35 in (88.9 cm), or more. For example, the width W can be from about 2 in (5.08 cm) to about 30 in (76.2 cm), about 4 in (10.2 cm) to about 20 in (50.8 cm), or about 6 in (15.2 cm) to about 15 in (38.1 cm).

A ratio of the distance109to the width W can be about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, or about 1:15 to about 1:10, about 1:8, about 1:6, about 1:4, or about 1:2. For example, the ratio can be about 1:4 to about 1:8; about 1:4 to about 1:12; about 1:6 to about 1:10; about 1:6 to about 1:14; about 1:8 to about 1:12; about 1:8 to about 1:16; about 1:10 to about 1:15; about 1:10 to about 1:20; about 1:15 to about 1:20; about 1:15 to about 1:25; about 1:20 to about 1:25; about 1:20 to about 1:30; about 1:to about 1:40; about 1:40 to about 1:50; or about 1:50 to about 1:60.

FIG. 2shows a top view of the paper product100after being folded about the first fold line106, according to one or more embodiments. The first panel122can be on top of the second panel124, or the first panel122can be beneath the second panel124. As depicted, the first and second panels122,124rest one on top of the other. The first and second sides112,114of the paper product100can be offset from one another by a distance110(“offset distance”). The offset distance110will be twice as much as the distance109. As such, one panel, (e.g., the first panel122) has a smaller surface area than the other panel (e.g., the second panel124). As a result, the second panel124has an offset section126that does not overlap with the first panel122, as depicted inFIG. 3.

The offset distance110can be about 0.10 in (2.54 mm), about 0.20 in (5.08 mm), about 0.30 in (7.62 mm), about 0.40 in (10.2 mm) or about 0.50 in (12.7 mm) to about 0.75 in (19 mm), about 1.0 in (25.4 mm), about 1.5 in (38.1 mm), about 2.0 in (50.8 mm), about 3.0 in (76.2 mm), about 4.0 in (102 mm), about 5.0 in (127 mm), or more. For example, the offset distance110can be from about 0.10 in (2.54 mm) to about 2.0 in (50.8 mm), from about 0.20 in (5.08 mm) to about 1.0 in (25.4 mm), or from about 0.30 in (7.62 mm) to about 0.75 in (19 mm).

A ratio of the offset distance110to the width W (or length L) can be about 1:40, about 1:35, about 1:30, about 1:25, about 1:20, about 1:15, about 1:10, or about 1:7.5 to about 1:5, about 1:4, about 1:3, or about 1:2. For example, the ratio can be about 1:2 to about 1:40; about 1:2 to about 1:4; about 1:2 to about 1:6; about 1:3 to about 1:5; about 1:3 to about 1:7; about 1:4 to about 1:6; about 1:4 to about 1:8; about 1:5 to about 1:7.5; about 1:5 to about 1:10; about 1:7.5 to about 1:10; about 1:7.5 to about 1:12.5; about 1:10 to about 1:12.5; about 1:10 to about 1:15; about 1:15 to about 1:20; about 1:15 to about 1:25; about 1:20 to about 1:30, about 1:25 to about 1:35, or about 1:30 to about 1:40.

The paper product100can have a second fold line108about which the paper product100can be folded to split, separate, or otherwise divide each of the two panels122,124into two other panels, thereby forming four panels132,134,136,138, as shown inFIG. 4. The second fold line108can be substantially parallel to the second centerline104.

As shown, the second fold line108can be aligned or coaxial with the second centerline104and perpendicular to the first fold line106. Although not shown, the second fold line108could also be spaced apart or offset from the second centerline104. Such offset could be about 0.05 in (1.27 mm), about 0.10 in (2.54 mm), about 0.20 in (5.08 mm), about 0.30 in (7.62 mm), about 0.40 in (10.2 mm), or about 0.50 in (12.7 mm) to about 0.60 in (15.2 mm), about 0.80 in (20.3 mm), about 1.0 in (25.4 mm), about 1.5 in (38.1 mm), about 2.0 in (50.8 mm), about 3.0 in (76.2 mm), or more, depending on the design of the dispenser into which the paper product100can be loaded.

FIG. 3shows an end view of the paper product100after being folded about the first fold line106, according to one or more embodiments. The thickness T of the paper product100can be about 0.0005 in (0.013 mm), about 0.0010 in (0.025 mm), about 0.0025 in (0.064 mm), about 0.0050 in (0.13 mm), about 0.0075 in (0.19 mm), or about 0.010 in (0.25 mm) to about 0.025 in (0.64 mm), about 0.050 in (1.27 mm), about 0.075 in (1.90 mm), about 0.10 in (2.54 mm), or more. For example, the thickness T can be from about 0.0005 in (0.013 mm) to about 0.10 in (2.54 mm), from about 0.0025 in (0.064 mm) to about 0.050 in (1.27 mm), or from about 0.0050 in (0.13 mm) to about 0.025 in (0.64 mm).

FIG. 4shows a top view of the paper product100after being folded about the second fold line108, according to one or more embodiments. After the paper product100is folded about the first fold line106, the paper product100can then be folded about the second fold line108to form four stacked panels.

FIG. 5shows a cross-sectional view of the paper product100taken along the line5-5inFIG. 4, andFIG. 6shows an end view of the paper product100that is perpendicular to the view shown inFIG. 5, according to one or more embodiments. Folding the paper product100about the second fold line108forms two smaller panels132,134and two larger panels136,138. Once folded about the second fold line108, the two larger panels136,138will be positioned at least partially between the two smaller panels132,134. After the second fold about the second fold line108, the order of the panels132,134,136,138from top to bottom will be: the first smaller panel132, the first larger panel136, the second larger panel138, and the second smaller panel134.

Two or more folded paper products100can be inserted into one another or otherwise assembled together to form a stack. At least one paper product100can be flipped about its horizontal (x-axis) or vertical axis (y-axis) and/or rotated about its horizontal axis prior to assembly. For instance, the folded paper product100ofFIG. 6can be flipped about its x-axis and/or its y-axis so that the panel132is oriented on the bottom. The paper product100can also be rotated, about its horizontal axis, 90°, 180°, or 270°, or any other angle therebetween. The rotation can occur before or after flipping. Similarly, the paper product100can be flipped before or after being rotated. The flipping and/or rotation moves the orientation of the fold lines106,108, which rearranges the panels132,134,136,138to provide varying stacked arrangements. Some examples of differing stacked arrangements are depicted inFIGS. 7-18and described in more detail below, although other and equally effective arrangements can be used.

FIG. 7, for example, shows a perspective view of three paper products being assembled to form a first illustrative stack410, according to one or more embodiments. To form the first stack410, any portion of the panels232,234,236,238of the second paper product200can be inserted at least partially between any two of the panels132,134,136,138of the first paper product100. Likewise, any portion of the panels332,334,336,338of the third paper product300can be inserted at least partially between any two of the panels232,234,236,238of the second paper product200, and so on. The offset sections126(seeFIG. 4) of the paper products100,200,300can be aligned.

In another embodiment, at least one of the panels232,234,236,238of the second paper product200can be positioned between any two of the panels132,134,136,138of the first paper product100during the folding process, as opposed to after the paper products100,200have been folded. Although three paper products100,200,300are shown in the first stack410, it may be appreciated that any number of paper products can be used. For example, the number can be from about 2, about 5, about 10, about 20, or about 50 to about 100, about 250, about 500, about 1000, about 5000, or more.

FIG. 8shows a cross-sectional view of the first stack410, andFIG. 9shows an end view of the first stack410that is perpendicular to the view shown inFIG. 8, according to one or more embodiments described. The first stack410can be assembled as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the second smaller panel234of the second paper product200, (4) the second larger panel238of the second paper product200, (5) the second larger panel138of the first paper product100, (6) the second smaller panel134of the first paper product100, (7) the first smaller panel332of the third paper product300, (8) the first larger panel336of the third paper product300, (9) the first larger panel236of the second paper product200, (10), the first smaller panel232of the second paper product200, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

FIG. 10shows a perspective view of the paper products100,200,300after being assembled to form a second illustrative stack420, according to one or more embodiments. Similar to the first stack410, the offset sections126(seeFIG. 4) of the paper products100,200,300can be aligned in the second stack420. To form the second stack420, any portion of the panels232,234,236,238of the second paper product200can be inserted at least partially between any two of the panels132,134,136,138of the first paper product100. Likewise, any portion of the panels332,334,336,338of the third paper product300can be inserted at least partially between any two of the panels232,234,236,238of the second paper product200, and so on.

FIG. 11shows a cross-sectional view of the second stack420, andFIG. 12shows an end view of the second stack420that is perpendicular to the view shown inFIG. 11, according to one or more embodiments. The second stack420can be assembled as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the second larger panel138of the first paper product100, (4) the second smaller panel234of the second paper product200, (5) the second larger panel238of the second paper product200, (6) the second smaller panel134of the first paper product100, (7) the first larger panel236of the second paper product200, (8) the first smaller panel332of the third paper product300, (9) the first larger panel336of the third paper product300, (10) the first smaller panel232of the second paper product200, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

FIG. 13shows a perspective view of the paper products100,200,300after being assembled to form a third illustrative stack430, according to one or more embodiments. In contrast to the first and second stacks410,420above, the offset section126(seeFIG. 4) of the second paper product200can be opposed to the offset sections126of the first and third paper products100,300. To form the third stack430, any portion of the panels232,234,236,238of the second paper product200can then be inserted at least partially between any two of the panels132,134,136,138of the first paper product100. Likewise, any portion of the panels332,334,336,338of the third paper product300can be inserted at least partially between any two of the panels232,234,236,238of the second paper product200, and so on.

FIG. 14shows a cross-sectional view of the third stack430, andFIG. 15shows an end view of the assembled stack430that is perpendicular to the view shown inFIG. 14, according to one or more embodiments. The third stack430can be assembled as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the first smaller panel232of the second paper product200, (4) the first larger panel236of the second paper product200, (5) the second larger panel138of the first paper product100, (6) the second smaller panel134of the first paper product100, (7) the first smaller panel332of the third paper product300, (8) the first larger panel336of the third paper product300, (9) the second larger panel238of the second paper product200, (10), the second smaller panel234of the second paper product200, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

FIG. 16shows a perspective view of the paper products after being assembled to form a fourth illustrative stack440, according to one or more embodiments. Similar to the third stack430above, the offset section126(seeFIG. 4) of the second paper product200can be opposed to the offset sections126of the first and third paper products100,300. To form the fourth stack440, any portion of the panels232,234,236,238of the second paper product200can be inserted at least partially between any two of the panels132,134,136,138of the first paper product100. Likewise, any portion of the panels332,334,336,338of the third paper product300can be inserted at least partially between any two of the panels232,234,236,238of the second paper product200, and so on.

FIG. 17shows a cross-sectional view of the fourth stack440, andFIG. 18shows an end view of the fourth stack440that is perpendicular to the view shown inFIG. 17, according to one or more embodiments. The fourth stack440can be assembled as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the second larger panel138of the first paper product200, (4) the first smaller panel232of the second paper product200, (5) the first larger panel236of the second paper product200, (6) the second smaller panel134of the first paper product100, (7) the second larger panel238of the second paper product200, (8) the first smaller panel332of the third paper product300, (9) the first larger panel336of the third paper product300, (10) the second smaller panel234of the second paper product200, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

Although not shown, the paper products100,200,300can be assembled into a fifth stack. Similar to the first and second stacks410,420, the offset sections126of the paper products100,200,300in the fifth stack can be aligned. After the paper products100,200,300are assembled to form the fifth stack, the order from top to bottom can be as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the second smaller panel234of the second paper product200, (4) the second larger panel138of the first paper product100, (5) the second smaller panel134of the first paper product100, (6) the second larger panel238of the second paper product200, (7) the first smaller panel332of the third paper product300, (8) the first larger panel236of the second paper product200, (9) the first smaller panel232of the second paper product200, (10), the first larger panel336of the third paper product300, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

Although not shown, the paper products100,200,300can be assembled into a sixth stack. Similar to the third and fourth stacks430,440, the offset section126of the second paper product200can be opposed to the offset sections126of the paper products100,300above and below it. As used herein, the terms “above” and “below” and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. After the paper products100,200,300are assembled to form the sixth stack, the order from top to bottom is as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the first smaller panel232of the second paper product200, (4) the second larger panel138of the first paper product100, (5) the second smaller panel134of the first paper product100, (6) the first larger panel236of the second paper product200, (7) the first smaller panel332of the third paper product300, (8) the second larger panel238of the second paper product200, (9) the second smaller panel234of the second paper product200, (10) the first larger panel336of the third paper product300, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

Although not shown, the paper products100,200,300can be assembled into a seventh stack. Similar to the third, fourth, and sixth stacks, the offset section126of the second paper product200can be opposed to the offset sections126of the paper products100,300above and below it. After the paper products100,200,300are assembled to form the seventh stack, the order from top to bottom is as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the first smaller panel232of the second paper product200, (4) the second larger panel138of the first paper product100, (5) the first larger panel236of the second paper product200, (6) the second smaller panel134of the first paper product100, (7) the first smaller panel332of the third paper product300, (8) the second larger panel238of the second paper product200, (9) the first larger panel336of the third paper product300, (10) the second smaller panel234of the second paper product200, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

Although not shown, the paper products100,200,300can be assembled into an eighth stack. Similar to the third, fourth, sixth, and seventh stacks, the offset section126of the second paper product200can be opposed to the offset sections126of the paper products100,300above and below it. After the paper products100,200,300form the eighth stack, the order from top to bottom is as follows: (1) the first smaller panel132of the first paper product100, (2) the first larger panel136of the first paper product100, (3) the second larger panel138of the first paper product100, (4) the first smaller panel232of the second paper product200, (5) the second smaller panel134of the first paper product100, (6) the first larger panel236of the second paper product200, (7) the second larger panel238of the second paper product200, (8) the first smaller panel332of the third paper product300, (9) the second smaller panel234of the second paper product200, (10) the first larger panel336of the third paper product300, (11) the second larger panel338of the third paper product300, and (12) the second smaller panel334of the third paper product300.

FIG. 19shows a perspective view of an illustrative paper product dispenser500, according to one or more embodiments. The dispenser500can include a housing502, a face plate504, a movable support plate (not shown), and a biasing spring (not shown). The housing502and the face plate504can define a storage chamber that is adapted to receive a stack of paper products (e.g., stacks410,420,430, and/or440). The face plate504can include an opening506formed therethrough, and one or more paper products (e.g., paper products100,200,300) can be removed one at a time from the chamber through the opening506. The biasing spring can move the support plate within the chamber to bias the stack410,420,430, and/or440toward the face plate504and the opening506. Other illustrative dispensers400can include those discussed and described in U.S. Pat. Nos. 7,938,294; 7,568,593; 7,546,934; 7,341,166; 6,892,898; 6,874,653; 6,622,888; 6,585,129; and 4,679,703.

Each of the eight stacks described above can be repeating for the desired number of paper products100,200,300in the paper product dispenser500. In another embodiment, two or more stacks can be used in the paper product dispenser500. Placing the paper products100,200,300in one of the eight stacks described above can reduce the space taken up by the stack when the stack is loaded into the chamber of the dispenser500, thereby increasing the number of paper products100,200,300that can be loaded into the chamber. In addition, placing the paper products100,200,300in one of the eight stacks described above can allow a user to withdraw one paper product100,200,300at a time, and prevent the user from inadvertently withdrawing multiple paper products100,200,300with a single pull when multiple paper products100,200,300are not desired.