Abstract:
By interfolding or interleaving at least a portion of the dispensing panel of a dispenser with the first sheet in a stack of sheet material such that a leading edge of the first sheet is exposed, it is no longer necessary to reach into the dispenser to dispense the first sheet. To dispense the first sheet, the optional removable panel is torn from the dispenser, and then the already exposed leading edge of the first sheet protruding from the dispensing panel is grasped and pulled to withdraw the first sheet from the dispenser.

Description:
BACKGROUND 
   Dispensers for sheet materials, such as facial tissue, are often provided with the sheets in the dispenser interfolded or interleaved with adjacent sheets such that the withdrawal of one sheet partially exposes the subsequent sheet in the dispensing opening of the dispenser. Partially exposing the next sheet enables a person needing a facial tissue to easily grab the exposed end to quickly dispense the sheet. Frequently, this type of dispensing is referred to as pop-up dispensing. Often, to prevent debris from entering the dispenser, to reduce multiple sheets from dispensing, or to assist with retaining the partially exposed sheet within the dispensing opening, a dispensing window constructed from a clear film or plastic material is provided. Typically, a slit or other restricted opening is present in the dispensing window to retain the partially exposed sheet within the opening. While a narrow slit in the dispensing window can assist with presenting tissue sheets for subsequent removal, it is sometimes difficult to remove the initial sheet from the dispenser due to the narrowness of the slit. For instance, the narrow slit can interfere with the ability of a person opening a new tissue carton to locate and find the leading edge of the first tissue sheet in the stack. Furthermore, the narrow slit may get distorted or damaged by inserting a portion of one&#39;s hand inside of the dispenser to retrieve the first sheet. 
   In order to assist with dispensing of the first tissue sheet, U.S. Pat. No. 4,574,952, entitled Box Containing Facial Tissue which granted Mar. 11, 1986, to Masui discloses a carton containing facial tissues in which double sided tape is attached to the undersurface of a removable panel of the carton and, in turn, attached to the uppermost sheet in the stack of facial tissues inside the dispenser. In this manner, when the carton is opened and the removable panel is detached along a perforated line, the uppermost facial tissue sheet is automatically removed from the container along with the removable panel. 
   U.S. Pat. No. 6,715,633, entitled Interfolded Sheet Dispenser Having a Starter Sheet Pull-Out System which granted Apr. 6, 2004, to Thoms describes a dispenser for dispensing a stack of disposable sheets having a removable panel that is releasably attached to the first sheet in the stack. When the removable panel is pulled off the dispenser, the first sheet in the stack is partially withdrawn from the container. After being partially withdrawn, the sheet releases from the removable panel. 
   Finally, pending U.S. patent application Ser. No. 11/216,468, entitled Tissue Sheet Dispenser And Process For Making Same filed Aug. 31, 2005, discloses a dispenser having the first sheet adhesively attached to a removable panel with the adhesive located in a recess in the removable panel. By placing the adhesive in a recess, the adhesive material is prevented from adhering to other portions of the dispensing container before the first sheet is attached. 
   Although the above references assist with dispensing the first tissue sheet, they can be difficult to implement in some embodiments. For example, if the dispensing window utilizes a narrow slit to dispense the tissue sheets, the dispensing window with the narrow slit disposed between the removable carton panel and the first tissue sheet can interfere with attaching the first tissue sheet to the removable panel. The adhesive or tape needs to attach the first tissue sheet to the removable panel while at the same time not sticking to the dispensing window. 
   Therefore, a need exists for quickly dispensing the first sheet of a stack of sheets in a dispenser that overcomes the above problems. More particularly, a need exists for locating and quickly dispensing the first sheet that is compatible with dispensing windows having a small opening or narrow slit. 
   SUMMARY 
   The inventors have discovered that the above needs can be met by interfolding or interleaving at least a portion of a dispensing panel with the first sheet in the stack such that a leading edge of the first sheet is exposed. To dispense the first sheet, the optional removable panel or surfboard is torn from the dispenser, and then the already exposed leading edge of the first sheet protruding from the dispensing panel is grasped and pulled to withdraw the first sheet from the dispenser. It is no longer necessary to insert a portion of one&#39;s hand through the dispensing panel to locate, grasp, and withdraw the first sheet. 
   Hence, in one aspect, the invention resides in a product comprising a stack of sheets and at least one dispensing panel placed adjacent to the stack, and a portion of the at least one dispensing panel interleaved with the stack. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above aspects and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings in which: 
       FIG. 1  is a perspective view of one embodiment of the invention. 
       FIG. 1A  is a partial cross-section view of  FIG. 1 . 
       FIG. 2  is a perspective view of another embodiment of the invention. 
       FIG. 2A  is a partial cross-section view of  FIG. 2 . 
       FIG. 3  is a perspective view of another embodiment of the invention. 
       FIG. 3A  is a partial cross-section view of  FIG. 3 . 
       FIG. 4  is a perspective view of another embodiment of the invention. 
       FIG. 4A  is a partial cross-section view of  FIG. 4 . 
       FIG. 4B  is a perspective view of another embodiment of the invention. 
       FIG. 4C  is a partial cross-section view of  FIG. 4B . 
       FIG. 5  is a perspective view of another embodiment of the invention. 
       FIG. 5A  is a partial cross-section view of  FIG. 5 . 
       FIG. 6  is a perspective view of another embodiment of the invention. 
   

   Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the invention in different embodiments. 
   DEFINITIONS 
   As used herein, forms of the words “comprise”, “have”, and “include” are legally equivalent and open-ended. Therefore, additional non-recited elements, functions, steps or limitations may be present in addition to the recited elements, functions, steps, or limitations. 
   As used herein, “top”, “bottom”, “left”, or “right” are used for convenience when describing the particular structure involved in the illustrations and do no imply that the dispenser or stack must be orientated in a particular manner. For example, the dispenser could be invented for use under a shelf or table and the top could become the bottom. 
   As used herein “dispensing panel” is one or more thin pieces of material that have or form a dispensing orifice, such as a slit, that is generally secured to the dispenser&#39;s surface adjacent an opening into the dispenser. The dispensing panel provides assistance with dispensing the sheets located within the dispenser, such as preventing debris from entering the dispenser, reducing multiple sheets from dispensing, or assisting with retaining the partially exposed sheet within the dispensing opening. The dispensing panel can be made from any suitable film, plastic, paper, nonwoven, or cloth material. The film can be a polypropylene, polystyrene, polyester, polyvinylchloride, or polyethylene material. The film material can be uniaxially oriented, a multilayer material, clear, opaque, or printed. Suitable paper dispensing panels are disclosed in U.S. Pat. No. 5,316,177 entitled Facial Tissue Dispensing Carton that issued May 31, 1994 to Boldt. Suitable film and nonwoven dispensing panels are disclosed in U.S. patent application 2006/0151516 entitled Lint-Reducing Container published Jul. 13, 2006, by Etheridge et al. 
   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 construction. 
   Referring to  FIGS. 1 and 1A , one embodiment of the invention is illustrated. A stack  20  of a plurality of interfolded sheets  21 , such as facial tissue, napkins, paper towels, and wet wipes, is illustrated. Interleaved with the first sheet  22  of the stack  20  is at least one dispensing panel  24 . The dispensing panel  24  can be a single piece of material as best seen in  FIG. 3A , or multiple pieces that together form the dispensing panel. 
   In the illustrated embodiment, a first side dispensing panel  26  is placed over at least a portion of the right side of the first sheet  22 . A second side dispensing panel  28  is placed over at least a portion of the left side of the first sheet  22  and interleaved with at least a portion of the first sheet  22  such that a leading edge  30  of the first sheet  22  is exposed between the first side and the second side dispensing panels ( 26 ,  28 ). The first sheet  22  in this embodiment is J-folded such that the leading edge  30  is formed where the first sheet is doubled back on itself. Such a folding configuration for the first sheet is disclosed in U.S. Pat. No. 5,868,276 entitled Folded Sheet Material Web and Assembly and Method and Apparatus Therefore and issued to Loppnow et al. on Feb. 9, 1999. Other folding configurations for the first sheet can be used. 
   The second side dispensing panel  28  is interleaved between a doubled over portion  31  of the first sheet  22  and a trailing panel  33  of the first sheet. The trailing panel  33  of the first sheet  22  is interleaved between the V-fold of the next sheet in the stack  20  and thereafter the interfolded sheets  21  are interleaved V-folded sheets to enable pop-up dispensing. The interfolded sheets within the stack  20  could be interleaved in another manner such as Z-folded or W-folded, fan folded and separated by perforated lines, adhesively attached, or otherwise constructed such that the withdrawal of one sheet from the stack partially withdraws or exposes the next sheet from the dispenser&#39;s opening. 
   After placing the first and the second side dispensing panels ( 26 ,  28 ) onto the stack  20 , an adhesive  32  can be applied to the dispensing panels prior to inserting the stack into a dispenser  34 . After insertion of the stack  20 , the dispenser  34  can be inverted to attach the first side and the second side dispensing panels ( 26 ,  28 ) to an interior surface  35  of the dispenser such as the top interior surface  37  of the dispenser. The right and the left side dispensing panels ( 26 ,  28 ) are attached to the top interior surface  37  such that a portion of each panel extends into a dispensing opening  50  located in the dispenser  35 . As such, to a consumer the dispenser  34  will appear and function similar to existing dispensers having a single piece of film adhered to the dispenser&#39;s top interior surface, having a small slit that forms the dispensing window; however, it will have a significant advantage in that the leading edge  30  of the first sheet  22  is exposed between the first and the second dispensing panels ( 26 ,  28 ), enabling the first sheet  22  to be easily grabbed and dispensed without having to search, reach-in or find it inside of the dispenser as previously required. 
   In previous dispensers, the dispensing window is attached by adhesive to the top interior surface of the dispenser while producing the carton blank that ultimately becomes the dispenser. After folding and gluing the carton blank with the attached dispensing window into a parallelepiped, the stack is inserted into an open end of the dispenser. As such, the leading edge of the stack is not exposed by the prior process since the dispensing window is not interleaved or interfolded with the stack. The leading edge remains within the interior of the dispenser until retrieved by a user to start the dispensing process. 
   To produce the product of  FIG. 1 , the material used for the first and the second dispensing panels ( 26 ,  28 ) can be provided in large rolls similar to the material that forms the interfolded sheets  21 . The first and the second dispensing panel rolls can be unwound, guided, placed, and interleaved using folding boards in a process similar to interfolding the sheets  21 . The resulting continuous sausage of interfolded sheets having the first and the second dispensing panels ( 26 ,  28 ) located at the top of the stack can then be cut to length using an orbital saw to form the stack  20  of  FIG. 1 . 
   One advantage of the new process is the interfolded sheets  21 , the first side dispensing panel  26 , and the second side dispensing panel  28  can be placed, folded or interleaved using a multi-folder converting line. Therefore, it is possible to guide the first and the second dispensing panels ( 26 ,  28 ) to form either an overlap distance O, a slit with no gap, or to provide a gap G between the dispensing edge  36  of each dispensing panel to create differently shaped or sized dispensing orifices  38  for the dispenser  34 . 
   In another embodiment, since the leading edge  30  of the first sheet  22  is exposed, it is also possible to apply adhesive  32  to the leading edge  30  in order to attach the first sheet  22  to a removable panel  40  of the dispenser  34 . In this manner, the first sheet can be fully or partially withdrawn when the removable panel  40  is detached from the dispenser  34 . However, with at least one dispensing panel  24  interleaved with the stack  20 , it is possible to attach the first sheet  22  to the removable panel  40  and have either a gap G or an overlap O for the dispensing orifice  38 . In the various embodiments, the removable panel  40  covers at least a portion of the dispensing opening  50 . Preferably, the removal panel extends the length of the dispensing opening  50  and covers the dispensing edges  36  and the leading edge  30  of the first sheet  22 . In order to more easily remove the removable panel  40 , preferably a cutout  48  is present on opposing sides of the removable panel. 
   Referring now to  FIGS. 2 and 2A , another embodiment of the invention is illustrated. This embodiment is similar to the embodiment of  FIG. 1  except that the first and the second dispensing panels ( 26 ,  28 ) cover at least a portion of the top  44  and the sides  42  of the stack  20 . The first side dispensing panel  26  is placed over a portion of the top  44  and a portion of the right side of the stack  20 . The second side dispensing panel  28  is placed over a portion of the top  44  of the stack and a portion of the left side of the stack  20 . In one embodiment, the first and the second dispensing panels ( 26 ,  28 ) cover the sides  42  of the stack  20  from the top  44  to the bottom  46  of the stack. The ends of the stack  20  can be exposed if the stack is cut to length with the dispensing panel positioned about the continuous stack. Substantially the entire top  44  of the stack  20  is covered by the dispensing panels. A small portion of the top  44  may be uncovered if a gap G is present between the dispensing edges  36  of the first and the second dispensing panels ( 26 ,  28 ) rather than an overlap O. The dispensing orifice  38  can have a gap G, an overlap O, or a slit with no gap between the dispensing edges  36  of the dispensing panels. 
   This embodiment can provide more surface area to glue the dispensing panels to the interior surface  35  of the dispenser  34  and can reduce the dispensing force needed to remove the first sheet  22 . Often the coefficient of friction for a tissue sheet on a film surface can be less than for a tissue sheet on a paperboard surface. Since all or a significant portion of the interfolded sheets  21  in the stack are mostly in contact with the first and the second dispensing panel ( 26 ,  28 ), it can be easier to remove them from the dispenser  34 ; especially, when the dispenser is full or nearly full. 
   Referring now to  FIGS. 3 and 3A , another embodiment of the invention is illustrated. This embodiment is similar to the embodiment of  FIG. 1  except that the dispensing panel  24  is wrapped completely around the stack  20  covering the top  44 , sides  42  and bottom  46  of the stack  20 . The ends of the stack  20  can be exposed if the stack is cut to length with the dispensing panel wrapped about the continuous stack. The dispensing edges  36  are located above and below the leading edge  30  of the first sheet  22  to expose the leading edge with the lower dispensing edge interleaved with the first sheet. A gap G, a slit with no gap, or an overlap O can be provided to form the dispensing orifice  38  depending on the length of the dispensing panel  24  and the perimeter of the stack  20 . This embodiment entirely wraps the stack  20  in the dispensing panel  24  and can provide an advantage in transporting the stack  20  with the interleaved dispensing panel on a high speed assembly line with a lower likelihood of the dispensing panel being moved out of position. 
   Referring now to  FIGS. 4 and 4A , another embodiment of the invention is illustrated. For clarity, the optional removable panel  40  has been omitted to see details of the dispensing orifice  38 . This embodiment is similar to the embodiment of  FIG. 1  except that the first side dispensing panel  26  is already attached to the top interior surface  37  of the dispenser  34 . It can be provided as a portion of the carton blank that is assembled into the dispenser  34 . Thus, only the second side dispensing panel  28  is placed onto the top  44  of the stack  20  and interleaved with the first sheet  22 . However, once the stack  20  is inserted into the dispenser  34 , a dispensing panel is formed substantially covering the top  44  of the stack. By varying the size and/or location of the first and the second side dispensing panels ( 26 ,  28 ), either a gap G, a slit with no gap, or an overlap O can be present between the dispensing edges  36  of the dispensing panels to form the dispensing orifice  38 . This embodiment has the advantage that the non-interleaved first side dispensing panel  26  is attached to the interior surface of the dispenser  34  where it is less likely to be dislodged or moved out of position during high speed conveying of the stack  20  or during insertion of the stack into the dispenser  34 . This embodiment can also be easier to implement since only the second side dispensing panel  28  is placed and interfolded with the stack  20  requiring fewer changes to the manufacturing process. 
   Referring now to  FIGS. 4B and 4C , another embodiment of the invention is illustrated. For clarity, the optional removable panel  40  has been omitted to see details of the dispensing orifice  38 . This embodiment is similar to the embodiment of  FIG. 4A  except that the first side dispensing panel  26  that is already attached to the top interior surface  37  of the dispenser  34  has an opening or cutout  49 . The first side dispensing panel  26  can be provided pre-attached to a portion of the carton blank that is assembled into the dispenser  34  and has a U shape. By placing a cutout  49  in the first side dispensing panel  26 , the dispensing edge  36  is made effectively shorter. As a result, the interfolded sheets  21  as they are dispensed are gathered or bunched together more as they are forced through the cutout  49 . This can improve sheet-to-sheet adhesion or friction resulting in less fallback or occurrences where the next sheet in the stack is not partially withdrawn through the dispensing orifice  38 . The cutout  49  can be located in either the first side dispensing panel  26  or the second side dispensing panel  29 . The size or the shape of the cutout  49  can be varied in order to promote either more or less gathering of the sheet material as it is dispensed from the dispenser. 
   As with the embodiment of  FIG. 4A , only the second side dispensing panel  28  is placed onto the top  44  of the stack  20  and interleaved with the first sheet  22 . However, once the stack  20  is inserted into the dispenser  34 , a dispensing panel is formed substantially covering the top  44  of the stack. By varying the size and/or location of the first and the second side dispensing panels ( 26 ,  28 ), either a gap G, a slit with no gap, or an overlap O can be present between the dispensing edges  36  of the dispensing panels to form the dispensing orifice  38 . 
   Referring now to  FIGS. 5 and 5A , another embodiment of the invention is illustrated. This embodiment is similar to the embodiment of  FIGS. 4B  and C except that the second side dispensing panel  28  is V-folded about the leading edge  30  of the first sheet  22 . The first side dispensing panel  26  is pre-attached to the interior surface  35  of the dispenser  34  leaving the cutout  49  that functions as a dispensing orifice  38  between the dispensing edge  36  of the first side dispensing panel  26  and a dispensing opening  50  in the top of the dispenser  34 . In this embodiment, the second side dispensing panel  28  is a sacrificial piece that is initially grabbed to start the first sheet  22  and then is discarded. While this embodiment requires the user to insert their fingers into the dispenser to find the leading edge  30 , the V-folded second side dispensing panel  28  that is wrapped about the leading edge  30  makes it far less likely that the leading edge will tear as the first sheet is withdrawn. The tear strength of a film material can be much greater than a typical tissue sheet. In order to enhance the ability of easily locating the leading edge  30 , the second side dispensing panel  28  can be formed from a contrasting color with regard to the first sheet  22  and/or the first side dispensing panel  26 . Additionally, the second side dispensing panel  28  can be printed with coupons, promotional messages, trademarks or brand names, motivational messages, wellness or health information, recipes, or other information to enhance the user&#39;s interaction and usage of the product; especially to promote the usage of facial tissue. 
   Referring now to  FIG. 6 , another embodiment of the invention is illustrated. This embodiment is similar to the embodiment of  FIG. 1  except that the stack  20  is folded into a U-shaped stack  51  and inserted into an upright dispenser  52 . As such, any of the previous embodiments discussed or illustrated are compatible with either flat or upright dispensers and the invention is not limited to the size or shape of the dispenser  34  and/or the stack  20 . 
   In the various embodiments described, the adhesive  32  can be a pressure sensitive adhesive, hot melt adhesive, radio frequency activated adhesive, two-part adhesive, contact cement, tape, double sided adhesive tape, or other suitable adhesive as known. In the various embodiments of the invention, the adhesive can be applied to the dispensing panel  24 , the interior surface  35  of the dispenser  34 , or to both surfaces. The adhesive  32  can be located in a recess or depression  54  on the interior surface  35  of the dispenser  34 , such as in a recess fully or partially surrounding the dispensing opening  50  as shown in  FIGS. 2 and 2A . Locating the adhesive in a recess can prevent the carton sleeves from sticking in a flattened position, yet allow the dispensing panel  24  to contact the adhesive  32  to attach the dispensing panel(s) to the interior surface  35  of the dispenser  34 . The dispensing panel  24  can be made from a more flexible material allowing for contact with the adhesive whereas the stiffer carton blank material does not touch the adhesive in the recess. In the embodiment shown in  FIG. 2 , a trough or recess  54  surrounds the dispensing opening  50  on the top interior surface  37  of the dispenser  34  and an adhesive  32  is located in the trough. 
   The dispensing panel  24  can be electrostatically charged. By charging the dispensing panel, dust or lint may tend to stick to the dispensing panel reducing the amount of lint created during dispensing. Additionally, by charging the dispensing panel  24  either positively or negatively with regard to the stack  20 , or by creating a charge potential between the stack and the dispensing panel, the dispensing panel can stick, cling, or be attracted to the stack. This can assist with keeping the dispensing panel  24  positioned as the stack  20  is conveyed during manufacturing or while the stack  20  is inserted into the dispenser  34 . For example, the dispensing panel  24  can be charged either positively or negatively as it is unwound by using a static induction device such that it clings to or is attracted to the stack  20 . 
   In various embodiments of the invention, the gap G can be between about 0.5 mm to about 20 mm, or between about 0.5 mm to about 10 mm, or between about 0.5 mm to about 5 mm, or between about 0.5 mm to about 2 mm. In various embodiments of the invention, the overlap distance O can be between about 0.5 mm to about 20 mm, or between about 0.5 to about 10 mm, or between about 0.5 to about 5 mm. Alternatively, the dispensing edges  36  can be adjusted such that they touch or meet and the gap G is 0 mm. The dispensing edges  36  can be linear, wavy, curved, zigzag or have a cutout. 
   In various embodiments of the invention, the dispensing panel  24  can be interleaved with any of the sheets in the stack  20  such as with the second, third, or fourth sheet in the stack, including the first sheet  22 . For example, the first sheet and second sheet in the stack can be folded together into a J-fold as shown in FIG. 2 of U.S. Pat. No. 5,868,276 such that the first and second sheets are both dispensed when the leading edge  30  is grasped. For such an embodiment, the dispensing panel  24  could be interleaved between the first and third sheets in the stack to expose the leading edge  30 . 
   The leading edge  30  can be a single thickness of a sheet, a doubled over thickness of a sheet such as the folded edge shown in  FIG. 1 , or a triple or quadruple or other folded thickness of the sheet. The leading edge  30  can be a single thickness of two or more sheets or the folded edge of two or more sheets as shown in FIG. 2 of U.S. Pat. No. 5,868,276. The leading edge is the portion of the sheet(s) that can be exposed from the dispensing panel  24  used to start the dispensing process. 
   The dispenser  34  can be made from paperboard, cardboard, coated paperboard, carton stock, or other paper materials comprising cellulose. Alternatively, the dispenser can be made from plastic, films, metallic foils, wood or other materials. In one embodiment, the dispenser  34  comprised six panels including a top panel  56 , a bottom panel  58 , a left side panel  60 , a right side panel  62 , a left end panel  64 , and a right end panel  66  forming a parallelepiped shape. The dispensing opening  50  can be located in the top panel  56  or another panel of the dispenser  34 . The dispensing opening  50  can be any suitable size or shape such as rectangular, oval, or circular. As previously described, the dispensing orifice  38  is created by the gap, overlap, or slit with no gap created by the dispensing panel  24  which can be attached to the interior surface  35  of the dispenser  34  after being interleaved with the stack  20 . To facilitate filling the dispenser on an automated cartoner, the left and right end panels ( 64 ,  66 ) can comprise a plurality of flaps  68  which are folded shut and glued to seal the dispenser. For clarity in the drawings, the top flap has been cut away to illustrate more of the top panel  56 . 
   Other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. It is understood that aspects of the various embodiments may be interchanged in whole or part. All cited references, patents, or patent applications in the above application for letters patent are herein incorporated by reference in a consistent manner. In the event of inconsistencies or contradictions between the incorporated references and this application, the information present in this application shall prevail. The preceding description, given by way of example in order to enable one of ordinary skill in the art to practice the claimed invention, is not to be construed as limiting the scope of the invention, which is defined by the claims and all equivalents thereto.