Abstract:
An improved stacked sheet material assembly is disclosed. A carton or container for reliably releasing stacked tissues also is disclosed. The assembly includes at least a first web and a second web on the top of the assembly where dispensing is started. The first and second webs are shown using various efficient starter folding patterns, for releasing sheet material webs, or tissues, more reliably and consistently. Folding patterns preferably achieve dispensing of one tissue at a time, from the beginning of the carton to the end of the carton, with relative ease, no tissue tearing, and no package induced fallback.

Description:
BACKGROUND OF THE INVENTION 
     Pop-up style dispensers have been used for some time to release individual folded sheet products such as facial tissues and the like. Such dispensers typically include a container and a stack, or “clip”, of interfolded tissues disposed within the container. The tissues may be folded so that once the top tissue in the clip is withdrawn, subsequent sheets are individually presented above the top plane of the container for individual use. 
     It is known for an uppermost or starter web of a stack of longitudinally folded webs to be folded back upon itself so as to provide a centrally located longitudinally folded edge on a top of the stack as described, for example, in U.S. Pat. No. 3,401,927 to Frick. The folded edge, and overlying folds of the starter web, may be provided so as facilitate easy grasping and withdrawing of the uppermost web from the stack. 
     It is also known in the art to provide a next lower web interfolded with the uppermost web so that a portion of the next lower web is withdrawn from the stack at the time that the uppermost web is withdrawn. In this way, the next lower web is exposed to the user for successive removal from the stack. Typically, the overlying folds of the starter web are arranged so that a single uppermost fold extends away from the centrally located longitudinally folded edge and terminates in a free edge proximate the side edge of the stack as shown, for example, in U.S. Pat. No. 3,401,927. 
     A problem consumers sometimes experience is the tearing of one or more of the first few sheets dispensed. The earliest (usually top) sheets dispensed sometimes encounter excess friction, which causes the sheets to break or tear if the structure of the sheet is weaker than the frictional forces holding the tissue in place in the fold. When a container is nearly empty, tissue fallback sometimes occurs, so that the succeeding tissue is not pulled far enough through the container opening, and it falls back into the container. If this occurs, the tissue may fail to present itself for grasping. It sometimes has proven difficult to devise a tissue packaging method that will avoid tearing the first few tissues dispensed, and also at the same time avoid tissue fallback as the container is depleted. 
     Furthermore, many tissue dispensers include a plastic film that covers the opening of the container. Once the top tissue has been raised through a dispensing slit in the plastic film, subsequent tissues are held in an upright position by the plastic film for individual use. If the user must search with his or her fingers to identify the proper location to grasp the top sheet, the plastic film may become distorted, causing further dispensing problems. 
     Several other recent patents disclose methods of folding and arranging tissues in a stack, for pop-up style dispensing. See, for example, U.S Pat. Nos. 5,868,276 and 5,740,913 to McFarland (i.e.: “the McFarland patent”), as examples. The McFarland patent discloses a commercially known “double pop” tissue stacking arrangement. The “double pop” refers to the first two tissues of a clip being folded together in a common manner such that both tissues are removed from the carton at the same time to initiate dispensing of tissues from the carton. 
     The “double pop” arrangement sometimes avoids tearing, since two sheets folded together in unison may be strong enough to avoid tearing. However, many consumers dislike the fact that the first pull provides two sheets, which many consumers view as wasteful and unnecessary. 
     What is needed in the industry is an improved pop-up sheet material dispenser, sheet assembly, and related method for improving the dispensing of tissues. A tissue assembly and dispensing system that is capable of releasing one tissue at a time, from beginning to end, with relative ease, minimal tissue tearing, and with minimal tissue fallback would be desirable. Folding arrangements that provides for reliable and efficient dispensing are needed. 
     SUMMARY OF THE INVENTION 
     An improved stacked sheet material assembly, method, and pop-up dispenser is provided by way of the invention. The assembly includes at least a first web and a second web on top of the assembly where dispensing is to begin. The first and second webs may employ various efficient and reliable starter folding patterns, for releasing sheet material webs or tissues more reliably and consistently. Folding patterns may be deployed to reliably dispense only one tissue at a time, from the beginning of the carton to the end of the carton, with relative ease, minimal tissue tearing, and minimal package-induced fallback. 
     In one embodiment, the stacked sheet material assembly comprises a first web and a second web. The first web may be folded into four panels (or “folds”) with creases between each. The first fold of the first web is positioned between the second and third folds. The second fold of the first web overlies the first fold, the third fold overlies the second web. Furthermore, the fourth fold is positioned beneath at least a portion of the second web. In one embodiment, the first and second folds of the first web join at a crease, the crease being positioned is and adapted for gripping of said first web. The second and third folds of the first web may join at a crease, the crease being positioned and adapted for gripping said first web. 
     In another embodiment, a stacked sheet material assembly provides a first web and a second web. The first web is folded and comprises a first fold, second fold, a third fold and a fourth fold. The first fold of the first web underlies the second web, and the fourth fold of the first web underlies the second web. The stacked sheet material assembly also may provide second and third folds positioned above the second web. 
     In yet another application of the invention, a stacked sheet material assembly provides a first web and a second web. The first web is folded, and comprises a first fold, a second fold, a third fold and a fourth fold. The first, second, and third folds of the first web each are positioned above the second web. The second web is quarter folded. In one embodiment, an insert or visual indicator is provided adjacent the first web. 
     In yet another embodiment of the invention, a stacked sheet material assembly is provided having a first web and a second web. The first web is folded, and includes a first fold, a second fold, a third fold and a fourth fold. The first fold of the first web underlies the second web, and the fourth fold of the first web underlies the second web. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A full and enabling disclosure of this invention, including the best mode shown to one of ordinary skill in the art, is set forth in this specification. The following Figures illustrate the invention: 
     FIG. 1 is a perspective view of a carton of interfolded tissues illustrating one embodiment of the present invention; 
     FIG. 2 shows one embodiment of the invention having a particular folding arrangement; 
     FIG. 2A shows a perspective view of the folding pattern of the embodiment shown in FIG. 2; 
     FIG. 3 shows another embodiment of the invention having a particular folding arrangement; 
     FIG. 4 reveals a further embodiment of the invention having a particular folding arrangement; 
     FIG. 5 shows yet another embodiment of the invention; 
     FIG. 6 shows a further embodiment of the invention having a particular folding arrangement; and 
     FIG. 7 illustrates yet another embodiment of the invention having a particular folding arrangement. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference now will be made to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not as a limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in this invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features and aspects of the present invention are disclosed in or are obvious from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. 
     In one embodiment of the invention, a pop-up tissue dispenser includes a carton and a clip of tissues disposed within the carton. The carton includes a plurality of walls that define a carton opening through which the tissues may be removed from the carton. The clip includes tissues having a folding pattern with a starter fold that will efficiently provide tissues to the consumer, with minimal tearing or fallback into the container. 
     The clip of tissues may be interfolded, prefolded interfolded, or non-interfolded. As used herein, the phrase “prefolded interfolded” or “interfolded” tissues means that the tissues are folded and interleaved with neighboring tissues immediately above and/or below in the clip of tissues. The tissues can be interleaved by any suitable means, including the use of an interfolder as employed in the papermaking arts. If an interfolder is used, consecutive tissues will be attached to each other at perforation lines. In such cases, the unperforated segments of the perforation lines should be sufficiently weak to permit the consecutive tissues to separate from each other upon removal from the carton. This can be controlled by the degree of perforation of the tissue sheet. Tissues that may be employed in a non-interfolded clip which are not interleaved with neighboring tissues are releasably attached to neighboring tissues so that upon dispensing one tissue, the next adjacent tissue is ready for dispensing. 
     Surprisingly, new patterns of folding have been discovered that provide remarkable additional benefits in pop-up style dispensers. In several embodiments of the invention, a pop-up tissue dispenser includes a clip of interfolded tissues disposed within a carton. A series of webs are provided with a plurality of folds to achieve various degrees of strength and pop-up characteristics. That is, some interfolding patterns provide increased amounts of friction. Frictional contact between tissues assists in pulling the next successive tissue into the window opening, for “pop-up” dispensing. Other patterns provide somewhat less friction, which tend to avoid tearing of the tissue when extracted from the container. 
     Webs or sheets may be folded in a stacked arrangement. Each web or sheet, when laid flat, may assume a square or rectangular shape, in many instances. Many different folds may be employed, and several embodiments of the invention are shown in the attached Figures. Folds are defined as first folds, second folds, third folds, and the like by reference to their respective position on the sheet. That is, a sheet or web having four folds, for example, typically would have a first fold, second fold, third fold, and fourth fold in that order, respectively, as when moving from one edge of the sheet to the opposite edge of that sheet. 
     A folded sheet, for example, would have four panels or folds and three creases. One crease appears at the junction of each fold. For example, a first crease is at the junction of the first fold and a second fold, as will be further described below. A bifolded sheet, for example, would have two folds two folded panels and one crease, while a trifolded sheet would have three folded panels and two creases. 
     It should be understood that the term “web,” as used herein, is meant to include a sheet material made of one or more plies of material so that a multiple-ply sheet material is considered to be a “web” of sheet material, regardless of the number of plies. 
     Alternatively, the lower webs can be formed as upwardly opening C-shaped webs having a base fold, and two wing folds. In such an arrangement, the lower webs are not interfolded, but rather are stacked one upon the other. An interfolded stack of sheet material webs is produced by interfolding webs using a preceding succession of conventional alternate right-hand and left-hand folding boards, as taught, for example, in U.S. Pat. No. 3,401,927 to Frick and U.S. Pat. No. 5,868,276 to Loppnow, et. al. 
     In some applications of the invention, as shown for example in FIG. 6, a visually distinctive insert or tissue may be employed. In the case of a visually distinctive tissue, the tissue would be oriented within the carton such that a visual indicator may be observed through the carton opening prior to removal of tissues from the carton. 
     The term “visual indicator” is used herein to mean a continuous or intermittent pattern disposed on or in a tissue to visually identify for the user the best location to grasp a tissue to initiate dispensing. The pattern may consist of designs or symbols, such as alphanumeric characters, that are visually distinguishable to the human eye from surrounding regions of the tissue. The pattern can consist of an insert web or tissue, and is desirably formed of a color that stands out from the surrounding portions of the tissue and is clearly identifiable through any plastic film covering the opening to the container. 
     Turning to FIG. 1, a pop-up dispenser formed according to one embodiment of the present invention is shown as an upright, pop-up facial tissue dispenser  20 . The invention may also be utilized to dispense other types of folded sheet products. Thus, the term “tissue” is not intended to be limited to facial tissues, but is used herein to include any individual sheet product, such as dry or moistened wipes, household or industrial wipes, soap or fabric softening sheets, and the like. Thus, the term “tissue” is used herein in its broadest sense as known in the art. 
     The tissue dispenser  20  includes a clip  21  of prefolded interfolded tissues disposed within the dispenser  20 . Sometimes, the dispenser  20  is described herein as a “carton”. The clip  21  of tissues is inside the dispenser  20 , and therefore is not shown in FIG. 1 but its location is referenced as clip  21 . A top wall  22  forms part of a rectangular parallel structure comprising also an opposite bottom wall (not shown in FIG.  1 ). Furthermore, a plurality of sidewalls  23   a-b  (as two examples) are provided around the sides of the dispenser  20 . The sidewalls that are visible in FIG. 1 have been provided with reference numerals  23   a  and  23   b . The dispenser  20  may be constructed in a variety of sizes and shapes from material such as paper board, plastic and the like. For example, in an alternate embodiment the dispenser  20  may include a single cylindrical shaped sidewall extending between the top and bottom walls (not shown). Furthermore, as further illustrated in FIG. 1, any of the sidewalls such as sidewalls  23   a  or  23   b  may be constructed of one or more panels that are bonded together by adhesives, thermal bonds, or other suitable means. 
     The top wall  22  of the dispenser  20  defines a carton opening  24  in the form of an aperture through which tissues may be individually removed from the dispenser  20 . The dispenser  20  optionally includes a plastic film  26  overlaying the carton opening  24  and incorporating intersecting dispensing slits  25   a  and  25   b . The use of the plastic film  26  is desirable, particularly for larger carton openings, in order to protect the tissues within the carton and to provide sufficient resistance to prevent multiple tissue dispensing. The plastic film  26  may be bonded to the top wall  22  by adhesives or other suitable means, and the dispensing slits  25   a  and  25   b  may assume other forms such as a single slit, an aperture, or the like. The dispenser  20  may optionally be provided with a removable panel (not shown) that creates a carton opening when the panel is removed. FIG. 1 further shows the tissue  27  standing upright from the top wall  22  of the dispenser  20 . 
     An individual clip  21  of prefolded interfolded tissues is illustrated in FIG. 2A, which will be described further below. FIG. 2A shows a clip of tissues laid flat for purposes of illustration, but would be curved from end to end and placed within the dispenser  20  in the manufacture of the invention. 
     In FIG. 2A, a stacked sheet material assembly  35  comprising a series of tissues of webs stacked upon each other in a particular pattern. For purposes of this specification, the term “web” may be used in a manner that is more broad than “tissue”. 
     A first web  36  is shown at the top of the stacked sheet material assembly  35  in FIG. 2A. A second web  37  is below first web  36 , and a third web  38  is further below second web  37 . Finally, a fourth web  39  is even further below, and the remaining webs are not numbered in FIG.  2 A. Hundreds of webs could be applied in a stacked sheet material assembly  35 , and FIG. 2A illustrates the top few webs or sheets which would be utilized at the top of the stacked sheet material assembly  35 . A crease  40  also is shown in FIG. 2A, which forms a reference point for the consumer to grasp the first web  36  and pull it upwards as shown by the arrow in FIG. 2A out through the carton opening  24  of FIG. 1 as shown. 
     FIG. 2 shows a cross section of the stacked sheet material assembly  35  shown also in FIG.  2 A. In FIG. 2, a first web  36  comprises a first fold  36   a , a second fold  36   b , a third fold  36   c , and fourth fold  36   d.    
     For purposes of identification in this specification, folds are identified as “first fold”, “second fold”, “third fold” and the like by reference to their respective position on the sheet, from one edge of the sheet to an opposite of the sheet, respectively. 
     Likewise, a second web  37  is shown having a first fold  37   a , a second fold  37   b , and a third fold  37   c  as shown in FIG.  2 . The first fold  36   a  of the first web  36  is positioned between the second fold  36   b  and the third fold  36   c . This results from the folding pattern in which the first web  36  is multiple folded as shown in FIG.  2 . Furthermore, the second fold  36   b  overlies the first fold  36   a . Further, the third fold  36   c  overlies the second web  37 . Also, the fourth fold  36   d  of the first web  36  is positioned beneath at least a portion of the second web  37 . The folding pattern as shown in FIG. 2 provides significant advantages in the pop-up dispensing of the stacked sheet material assembly  35  when loaded into a dispenser  20  (See FIG.  1 ). 
     Creases are formed at the junction of each fold of each web in the stacked sheet material assembly  35 . For example, the first fold  36   a  forms a crease where it meets the second fold  36   b . That crease is indicated at crease  42 . Likewise, a crease  40  is shown between second fold  36   b  and third fold  36   c . The crease  40  forms a position for grasping by the consumer to remove the first web  36  (i.e., first tissue) from the dispenser  20  when the stacked sheet material assembly  35  is loaded into a dispenser  20  (See dispenser  20  in FIG.  1 ). 
     In FIG. 2, the second web  37  is comprised of a first fold  37   a , second fold  37   b , and third fold  37   c . A third web  38  and a fourth web  39  also are shown in FIG.  2 . Only the top few webs are shown in FIG. 2, which are critical to the start-up dispensing from a dispenser  20 . The folding pattern shown in FIG. 2 is sometimes called an “S Fish Hook” configuration, in part because the first web  36  forms an S shape, and the second web  37  forms in a “fish hook” shape. 
     FIG. 3 provides a flat sheet material assembly  45  which includes a first web  46  having a first fold  46   a , second fold  46   b , third fold  46   c , and fourth fold  46   d . A crease  47  is formed at the junction of second fold  46   b  and third fold  46   c . A second web  48  is also provided, as shown in FIG.  3 . The second web  48  comprises a first fold  48   a , a second fold  48   b , and a third fold  48   c . A third web  49  is shown with first fold  49   a , second fold  49   b , and third fold  49   c . The second web  48  is shown partially beneath the third web  49 . The third web  49  is also partially beneath a third web  50 . A fourth web  51  is shown as well. 
     The folding arrangement in FIG. 3 is sometimes referred to as the “E Fish Hook” design, because the first web  46  resembles the shape of the letter “e”, and the second web  47  is in the shape of a fish hook. In this particular arrangement, the second fold  46   b  and third fold  46  join at crease  47 , the crease  47  being positioned and adapted for gripping of said first web  46  by a consumer. 
     In FIG. 4, another web folding pattern is shown. This pattern is sometimes known as the “Double Fish Hook” design. A stacked sheet material assembly  60  is above first web  61 , with a first fold  61   a , second fold  61   b , and third fold  61   c . Crease  64  is formed at the junction of the second fold  61   b  and the third fold  61   c . A second web  62  comprises of a first fold  62   a , second fold  62   b , and third fold  62   c . A third web  63  also is shown. 
     FIG. 5 shows a stacked sheet material assembly  69  with a first web  70  having first fold  70   a , second fold  70   b , third fold  70   c  and fourth fold  70   d . A second web  71  further comprises first fold  71   a , second fold  71   b , third fold  71   c  and fourth fold  71   d . A third web  72  and a fourth web  73  also are shown in FIG.  5 . This alternate embodiment of the invention provides an efficient folding pattern that is suited for pop-up dispensers. 
     In FIG. 6, a stacked sheet assembly  80  is provided having a first web  81  with first fold  81   a , second fold  81   b , third fold  81   c , and fourth fold  81   d . A visual indicator  82  is shown in FIG. 6, which may be employed in at least one embodiment of the invention. In some applications, the visual indicator  82  could comprise a gold ribbon or other selected color with a sheet or web of tissue laminated to the edge of the first web  81 , as one example. In other examples a ribbon or colored tapestry portion could be provided. Some applications may include a differently colored first web  81 , to notify the user in a visual manner that the user is to grasp the first web  81  when commencing the release of tissues. 
     The first web  81  comprises first fold  81   a , second fold  81   b , third fold  81   c  and fourth fold  81   d . A second web  83  comprises a first fold  83   a , second fold  83   b , third fold  83   c  and fourth fold  83   d . Furthermore, a third web  84  and a fourth web  85  also are shown in FIG.  6 . This particular embodiment of the invention is sometimes known as “Ribbon W Fold” The fold shown in FIG. 6 is similar to the fold shown in FIG. 5, with the exception that the fold pattern of FIG. 6 provides the visual indicator  82  as shown. 
     FIG. 7 provides a folding pattern sometimes known as “Double C-W”. In FIG. 7, a first web  86  is comprised of a first fold  86   a , second fold  86   b , third fold  86   c  and fourth fold  86   d . A second web  87  having first fold  87   a , second fold  87   b , third fold  87   c , and fourth fold  87   d  is shown. A third web  88  also is shown. Fourth web  88  and fifth web  89  are further provided at lower points in the stack. 
     In FIG. 7, this arrangement results in the first web  86  being multiple folded, wherein the first fold  86   a  of the first web  86  underlies the second web  87 . Furthermore, the fourth fold  86   d  of the first web  86  underlies the second web  87 . In some instances, the stacked sheet material assembly  91  of FIG. 7 may provide a second fold  86   b  and a third fold  86   c  of the first web  86  which are positioned above the second web  87 . Furthermore, the second fold  86   b  and the third fold  86   c  of the first web  86  may join at a crease  92  as shown in FIG.  7 . The crease  92  may provide the point at which consumers may grasp the first web  86  and pull it from a container  20  (See FIG.  1 ). 
     The invention may include the various embodiments of the application which may be provided in a pop-up style tissue dispenser which comprises a carton and a clip of facial or bath tissues having the folding patterns as previously described. Furthermore, other embodiments of the invention may not relate to facial or bathroom tissues at all, but instead be directed to stacked sheet material assemblies for releasing wet wipes, dry wipers for industrial applications, napkins, towels, or other varieties of stacked sheets. Thus, the invention may provide an improved stacked sheet material assembly. In other embodiments, the invention may provide an improved product, in which the product comprises a container with a stacked sheet material assembly provided within the container. FIG. 1 shows one example of such a container, but other types of containers which are not disposable, but instead are permanent, could be used. 
     For example, some industrial applications could provide stacked wipers or other folded web products wherein the stacked assembly is provided as a refill, and the dispenser is a permanent fixture in a factory, or other commercial setting. There is no limit to the uses to which the invention may be applied, and the examples shown in the Figures and described above are merely exemplary embodiments of the invention. 
     In the case of tissues, all of the tissues may be generally uniformly white in color and substantially identical. In other applications, a visual indicator may be printed upon the top tissue that is adjacent to the secondary fold. A visual indicator as described may comprise any of the indicators as previously discussed, or in other applications could provide an optional textual message oriented at a convenient location on the top tissue. 
     It is understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. The invention is shown by example in the appended claims.