Patent Publication Number: US-2022218163-A1

Title: Out indicator sheets

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Continuation application that claims the benefit of and priority to U.S. Non-Provisional application Ser. No. 16/868,812, filed May 7, 2020, which application itself is a Divisional application that claims the benefit of and priority to U.S. Non-Provisional application Ser. No. 15/897,213, filed Feb. 15, 2018, which application itself further claims the benefit of and priority to U.S. Provisional Application No. 62/468,442 filed Mar. 8, 2017; the contents of all of which as are hereby incorporated by reference in their entireties. 
    
    
     BACKGROUND 
     The present invention relates in general to tissue and paper fabrication methods and resulting devices. More specifically, the present invention relates to fabrication methods and resulting structures for a dispensed folded tissue having an image printed across the center of the tissue fold indicating the amount of tissue remaining in a dispenser. 
     Tissue and paper sheets for household use are well known in the art. It is often desired to decorate such sheets, such as by printing or embossing an image onto the sheets. The image imparts an aesthetically pleasing pattern to the sheet. Such sheets are typically made in continuous form and then later cut to discrete lengths as desired. Such cutting to discrete lengths may occur at the point of use, such as is caused by the consumer detaching one sheet from the balance thereof at a line of termination. For this purpose, the line of termination typically comprises a line of weakness, such as a perforation. Alternatively, the continuous sheet can be cut into discrete portions prior to the point of use. Such arrangement often occurs in individual napkins or facial tissues that are cut during manufacture and purchased by the consumer as discrete units. Where tissue is packaged within a dispenser and is used by pulling sheets of tissue out of the dispenser a visual indicator that the dispenser has reached different stages of advancement towards the end of the product is useful. 
     SUMMARY 
     According to an embodiment of the present invention, a dispensing device having an improved out indicator is provided. The device can include a housing having a cavity. A tissue stack is disposed within the cavity, the tissue stack including a plurality of tissue sheets folded along a crease. An aperture is formed in a top surface of the housing such that a tissue sheet is removable from the cavity through the aperture. A portion of the tissue sheets includes an out indicator formed along a centerline of each tissue sheet and across the crease. 
     According to another embodiment, a method for forming a tissue is provided. The method includes receiving a first sheet from a first parent roll. The first sheet is transported via a first roller beneath a surface of a first print head. The first print head is positioned above the first sheet and directly over the first roller. The method includes spraying, from the first print head, wax ink onto a surface of the first sheet to form a first out indicator on the surface of the first sheet. A second sheet is received from a second parent roll and transported via a second roller beneath a surface of a second print head. The second print head is positioned above the second sheet and directly over the second roller. The method includes spraying, from the second print head, wax ink onto a surface of the second sheet to form a second out indicator on the surface of the second sheet. The first sheet and the second sheet are interfolded to form a tissue stack. 
     According to another embodiment, an apparatus for forming a tissue having an out indicator is provided. The apparatus includes a first parent roll comprising a first tissue sheet and a second parent roll comprising a second tissue sheet. The apparatus further includes a first printing apparatus comprising eight print heads and a second printing apparatus comprising eight print heads. The apparatus further includes a first plurality of rollers for transporting the first tissue sheet beneath a surface of each print head of the first printing apparatus. Each print head is positioned above a surface of the first tissue sheet and directly over a roller of the first plurality of rollers. The apparatus further includes a second plurality of rollers for transporting the second tissue sheet beneath a surface of each print head of the second printing apparatus. Each print head is positioned above a surface of the second tissue sheet and directly over a roller of the second plurality of rollers. The apparatus further includes an interfolding apparatus for interfolding the first sheet and the second sheet to form a tissue stack. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter of the present invention is particularly pointed out and distinctly defined in the claims at the conclusion of the specification. The foregoing and other features and advantages are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  depicts a top-down view of a folded tissue stack having an improved out indicator according to one or more embodiments of the present invention; 
         FIG. 2  depicts a view of a dispenser for housing the folded tissue stack of  FIG. 1  according to one or more embodiments of the present invention; 
         FIG. 3  depicts a top-down view of out indicator sheets having an improved out indicator formed across a crease and centered on a centerline of each sheet according to one or more embodiments of the present invention; 
         FIG. 4  depicts a cross-sectional view of an apparatus during an intermediate operation for forming an out indicator on a tissue sheet according to one or more embodiments of the present invention; and 
         FIG. 5  depicts a cross-sectional view of an interfolding apparatus during an intermediate operation for forming a tissue stack according to one or more embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments of the present invention are described herein with reference to the related drawings. Alternative embodiments can be devised without departing from the scope of this invention. It is noted that various connections and positional relationships (e.g., over, below, adjacent, etc.) are set forth between elements in the following description and in the drawings. These connections and/or positional relationships, unless specified otherwise, can be direct or indirect, and the present invention is not intended to be limiting in this respect. Accordingly, a coupling of entities can refer to either a direct or an indirect coupling, and a positional relationship between entities can be a direct or indirect positional relationship. As an example of an indirect positional relationship, references in the present description to forming layer “A” over layer “B” include situations in which one or more intermediate layers (e.g., layer “C”) is between layer “A” and layer “B” as long as the relevant characteristics and functionalities of layer “A” and layer “B” are not substantially changed by the intermediate layer(s). 
     The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus. 
     Additionally, the term “exemplary” is used herein to mean “serving as an example, instance or illustration.” Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. The terms “at least one” and “one or more” are understood to include any integer number greater than or equal to one, i.e. one, two, three, four, etc. The terms “a plurality” are understood to include any integer number greater than or equal to two, i.e. two, three, four, five, etc. The term “connection” can include an indirect “connection” and a direct “connection.” 
     References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described can include a particular feature, structure, or characteristic, but every embodiment may or may not include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. 
     For purposes of the description hereinafter, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” and derivatives thereof shall relate to the disclosed structures and methods, as oriented in the drawing figures. The terms “overlying,” “atop,” “on top,” “positioned on” or “positioned atop” mean that a first element, such as a first structure, is present on a second element, such as a second structure, wherein intervening elements such as an interface structure can be present between the first element and the second element. The term “direct contact” means that a first element, such as a first structure, and a second element, such as a second structure, is connected without any intermediary elements at the interface of the two elements. 
     As used herein, a “unit” is defined as that portion of the sheet that is discrete as delivered to the consumer. For example, this would include, but not be limited to, a single table napkin, a single roll of paper toweling, a single facial tissue, or a single roll of bath tissue. 
     As used herein, the terms “about,” “substantially,” “approximately,” and variations thereof are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value. 
     As used herein, “continuous” means a relatively long product produced in a mostly continuous manufacturing process. An example of a continuous product for use in the present process or apparatus is a rolled sheet where the length of the sheet on the roll is very long in relation to its width. 
     For the sake of brevity, conventional techniques related to tissue paper fabrication may or may not be described in detail herein. Moreover, the various tasks and process steps described herein can be incorporated into a more comprehensive procedure or process having additional steps or functionality not described in detail herein. In particular, various steps employed in the manufacture of tissue paper are well known and so, in the interest of brevity, many conventional steps will only be mentioned briefly herein or will be omitted entirely without providing the well-known process details. 
     As previously noted herein, household tissue and paper sheets are often decorated with printed or embossed images. In many cases, these images conventionally serve as product logos or advertisements meant to be seen by the consumer during use. One disadvantage of using printed or embossed images on a tissue sheet as logos or pure advertisements is that the images provide no additional information to the consumer. In some cases, images can be used to indicate that the unit (e.g., a box of tissue within a dispenser) will soon need to be replaced. In this manner, the image serves as an “out indicator” and the sheet having the image serves as an “out indicator sheet.” Out indicator sheets are typically patterned with a stripe of ink across the width of the sheet. In some cases, the entire out indicator sheet is colored to distinguish the out indicator sheet from other sheets. 
     There are disadvantages associated with the conventional use of out indicator sheets. Tissue sheets are deformed when placed into a dispenser. Consequently, the size and placement of the out indicator often results in the image being difficult to see from multiple vantage points once the product is placed within the dispenser. Moreover, conventional out indicator stripes or fully colored out indicator sheets inform consumers that replacement of the unit is required, but do not provide the consumer with any additional information, such as, for example, how many sheets remain within the dispenser. Thus, an improved out indicator sheet is desired. 
     One or more embodiments of the present disclosure relate to fabrication methods and resulting structures for a dispensable folded tissue having improved out indicator sheets. Each out indicator sheet includes an image printed or embossed across the center of a tissue fold. Placing the image across the center of the tissue fold greatly improves the visibility of the image once the out indicator sheet is pulled out of the dispenser. The image serves as a visual indication of the relative or actual amount of tissue remaining in a dispenser. The image can simultaneously serve as both an advertising logo and as an out indicator. A tissue product and associated manufacturing methods in accordance with embodiments of the present invention are described in detail below by referring to the accompanying drawings in  FIGS. 1-5 . 
       FIG. 1  illustrates a top-down view of a folded tissue stack  100  having an improved out indicator  102  according to one or more embodiments of the present invention. The folded tissue stack  100  includes a plurality of tissue sheets folded along a crease  104 . A portion of the tissue sheets are out indicator sheets (as depicted in  FIG. 2 ). Each out indicator sheet in the folded tissue stack  100  includes a sheet width W 1  and an out indicator width W 2 . The sheets can be of any dimensions known in the art. In some embodiments, the sheet width W 1  is about 7 inches to about 9 inches. In some embodiments, the sheet width W 1  is about 7.8 inches. It is understood that the sheets can be of other dimensions suitable for tissue or paper. In some embodiments, the out indicator width W 2  is about 1.5 to about 3.5 inches. In some embodiments, the out indicator width W 2  is about 2 inches. In some embodiments, the out indicator width W 2  is sized proportionally to the sheet width W 1 . In some embodiments, the out indicator width W 2  is sized such that about 20%, about 25%, or about 30% of the sheet surface is covered by the out indicator  102 . 
     The out indicator  102  is formed along a centerline CL of each out indicator sheet across the crease  104 . In some embodiments, the out indicator  102  is not perfectly centered about the centerline CL and is instead formed within a top tolerance  106  or bottom tolerance  108  of the centerline CL. The top and bottom tolerances  106  and  108  depict a maximum acceptable drift from the centerline CL of the out indicator  102 . If the out indicator  102  is printed on a sheet above the top tolerance  106  or below the bottom tolerance  108  the sheet is discarded. In some embodiments, the top tolerance  106  and the bottom tolerance  108  is about 0.5 inches. It is understood that the top and bottom tolerances  106  and  108  can be increased or decreased to relax or tighten, respectfully, the process for forming the out indicator  102  (e.g., printing or embossing). In some embodiments, the out indicator  102  includes a logo. In this manner, the out indicator  102  serves a dual purpose as both an advertisement and as a visual indicator. 
       FIG. 2  illustrates a view of a dispenser  200  according to one or more embodiments of the present invention. The dispenser  200  includes a top surface  202 , a sidewall  204 , a bottom (not depicted), and a cavity  206 . In some embodiments, the dispenser  200  is rectangular in shape (e.g., as depicted in  FIG. 2 ). In other embodiments, the dispenser is square shaped or circular shaped. It is understood that the shape of the dispenser  200  can be any suitable shape known for dispensing tissue. A folded tissue stack  208  is disposed within the cavity  206 . In some embodiments, the folded tissue stack  208  is the folded tissue stack  100  (as depicted in  FIG. 1 ). The folded tissue stack  208  includes a plurality of stacked tissue sheets (i.e., tissues). Each tissue is folded along a crease (e.g., the crease  104  of  FIG. 1 ). An aperture  210  is formed in the top surface  202  of the dispenser  200 . The aperture  210  allows for one or more tissues  218  to be removed from the cavity  206 . In some embodiments, a dispensing insert  214  having a bottom liner  216  is disposed within the cavity  206  on top of the folded tissue stack  208  such that the aperture  210  is at least partially covered. In this manner, the dispensing insert  214  limits the extent of the container which is open to contamination, yet allows one or more tissues  218  to be dispensed. In some embodiments, the dispensing insert  214  is designed to remain in place within the dispenser  200  until all tissues of the folded tissue stack  208  have been dispensed. 
     In some embodiments, a portion  212  of the tissue sheets in the folded tissue stack  208  includes an out indicator (e.g., the out indicator  102  of  FIG. 1 ) while the remaining tissue sheets in the folded tissue stack  208  do not include an out indicator. The tissue sheets in the portion  212  (i.e., those tissues having an out indicator) are known as out indicator sheets. In some embodiments, the portion  212  includes about 5% to about 10% of the total number of tissues in the folded tissue stack  208 . In some embodiments, the portion  212  includes less than about 35%, 25%, 20%, 15%, 10%, or 5% of the total number of tissues in the folded tissue stack  208 . In some embodiments, the portion  212  includes 1 to 15 tissues. In some embodiments, the portion  212  includes 6 to 8 tissues. In some embodiments, the portion  212  includes every tissue in the folded tissue stack  208 . In some embodiments, the portion  212  includes a first indicator sheet  220  and a last indicator sheet  222 . The last indicator sheet  222  is the bottom sheet of the folded tissue stack  208 . 
     As discussed previously herein, the out indicator  102  is formed along a centerline CL of each out indicator sheet across the crease  104  (as depicted in  FIG. 1 ). Locating the out indicator  102  in this way allows for at least a portion of the out indicator  102  to be viewable from multiple angles after pulling an out indicator sheet from the dispenser  200 . In some embodiments, the out indicator  102  visually indicates that the dispenser  200  has reached different stages of advancement towards the end of the folded tissue stack  208 . In this manner, a consumer can look at the out indicator  102  and determine whether the folded tissue stack  208  will soon need to be replaced. In some embodiments, each tissue of the folded tissue stack  208  includes a first color and the out indicator  102  includes a second color. In some embodiments, the first color and second color are complementary colors. 
     In some embodiments, the out indicator  102  progressively changes in a characteristic between adjacent out indicator sheets. In some embodiments, the characteristic is a color intensity, color saturation, hue, physical size, positioning, or transparency of the out indicator  102 . In some embodiments, the change in the characteristic between adjacent out indicator sheets is about 1% to about 75%. In some embodiments, the change is linear. For example, a change in the characteristic between a pair of adjacent out indicator sheets is the same for all pairs of adjacent out indicator sheets). In some embodiments, the linear change in the characteristic between adjacent out indicator sheets is about 5% or about 2%. For example, a change in color intensity between the first indicator sheet  220  and a second indicator sheet can be about 2% and consequently, a change in color intensity between the second indicator sheet and a third indicator sheet is also 2%. 
     In some embodiments, the change in characteristic is exponential. In some embodiments, the rate of change accelerates or decelerates between the first indicator sheet  220  and the last indicator sheet  222 . For example, the change in color intensity between the first indicator sheet  220  and a second indicator sheet can be about 2% and a change in color intensity between a penultimate indicator sheet and the last indicator sheet  222  can be greater than about 2%, such as 5%, 10%, 20%, or 40%. In this manner, the out indicator  102  provides consumers with an initial visual indicator that the folded tissue stack  208  will need to be replaced in the near future that quickly escalates as the last sheets of the folded tissue stack  208  are used and replacement becomes imminent. 
     In some embodiments, the change in characteristic decreases from a high value on the first indicator sheet  220  to a relatively lower value on the last indicator sheet  222 . For example, the transparency of the out indicator  102  can be highest on the first indicator sheet  220  and lowest on the last indicator sheet  222 . In this manner, the out indicator  102  is barely visible on the first indicator sheet  220 , but is easily noticed on the last indicator sheet  222 . In some embodiments, the change in characteristic increases from a low value on the first indicator sheet  220  to a relatively higher value on the last indicator sheet  222 . For example, the color intensity of the out indicator  102  can be lowest on the first indicator sheet  220  and highest on the last indicator sheet  222 . In this manner, the out indicator  102  is less noticeable on the first indicator sheet  220  than on the last indicator sheet  222 . In some embodiments, the change in characteristic is stepwise such that the characteristic is the same between some pairs of adjacent out indicator sheets. For example, the color intensity of the out indicator  102  can increase between the first indicator sheet  220  and the last indicator sheet  222  while remaining the same between one or more pairs of adjacent out indicator sheets (e.g., the color intensity is the same for the first indicator sheet  220  and a second indicator sheet and the color intensity increases between the second indicator sheet and a third indicator sheet). 
       FIG. 3  illustrates a top-down view of out indicator sheets  300 A,  300 B,  300 C, and  300 D having an improved out indicator  302  formed across a crease  304  and centered on a centerline CL according to one or more embodiments of the present invention. The out indicator sheets  300 A,  300 B,  300 C, and  300 D depict different topmost out indicator sheets of the same folded tissue stack (i.e., the folded tissue stack  208  depicted in  FIG. 2 ) as the tissues are used over time. The change in characteristic (i.e., the pattern of the out indicator  302 ) progressively increases from a relatively low value on the out indicator sheet  300 A to a relatively high value on the out indicator sheet  300 D according to one or more embodiments. 
       FIG. 4  illustrates a cross-sectional view of an apparatus  400  during an intermediate operation for forming a tissue stack  402  (also referred to as a tissue “log” or interfolded tissue) having an out indicator according to one or more embodiments. In some embodiments, the apparatus  400  includes a first parent roll  404  having a first tissue sheet  406  and a second parent roll  408  having a second tissue sheet  410 . The first tissue sheet  406  moves through the apparatus  400  in a machine direction D M  by way of a first plurality of rollers  412 . The actual number of rollers is not meant to be particularly limited and it is understood that the apparatus  400  can include any number of rollers known in the art. In some embodiments, the first tissue sheet  406  includes one or more tissue sheet “wads” (i.e., the first tissue sheet  406  can be portioned along a cross direction Dc perpendicular to the machine direction D M  into one or more parallel lines or “wads”). 
     The first tissue sheet  406  is transported via the first plurality of rollers  412  beneath a surface of a print module  414 . In a similar manner, the second tissue sheet  410  is transported via a second plurality of rollers  416  beneath a surface of a print module  418 . In some embodiments, each of the print modules  414  and  418  includes dual print modules, each controlling four print heads (i.e., the apparatus  400  includes eight print heads per parent roll). In some embodiments, each print head sprays wax ink onto a surface of the first or second tissue sheets  406  and  410 , respectively, to form an out indicator on the surface of each sheet according to one or more embodiments. 
     In some embodiments, the print heads are located about 0.125 inches to about 0.200 inches above the first and second tissue sheets  406  and  410  and directly over a roller of the first or second plurality of rollers  412  and  416 , respectively. In some embodiments, each print head is mounted over the first and second tissue sheets  406  and  410  in a specified location relative to the center of a tissue wad. In some embodiments, the print heads can be moved from left to right in the cross direction Dc to center the out indicator relative to each respective tissue wad. In some embodiments, print delay settings within apparatus  400  can be increased or decreased to adjust when or for how long printing will begin and end for a particular portion of first and second tissue sheets  406  and  410 . 
     Mounting the print heads directly over a roller at a distance of about 0.125 inches to about 0.200 inches above the first and second tissue sheets  406  and  410  provides several advantages over mounting the print heads just off or above the roller (i.e., at positions less than about 0.125 inches or more than about 0.200 inches above or below the first and second tissue sheets  406  and  410 ). Positioning the print heads less than about 0.125 inches above a roller causes a static induction on each print head which results in charged dust accumulating on each print head. The charged dust interferes with the print application, causing dust contamination and an increase in plugged print heads. Conversely, locating the print heads within about 0.125 to 0.200 inches of a roller neutralizes the static charge in the narrow contact zone (i.e., a portion of the surface of the first or second tissue sheets  406  and  410  directly under a print head). Positioning the print heads more than about 0.200 inches above a roller causes a loss in print quality. In some cases, portions of the out indicator can contain streaks rendering the out indicator unreadable. In other cases, portions of the out indicator can be entirely missing. In some embodiments, the print heads are periodically purged to further increase the print quality. 
     Once out indicators are printed onto surfaces of the first and second tissue sheets  406  and  410 , the first and second tissue sheets  406  and  410  are transported to an interfolding apparatus  420 . The interfolding apparatus  420  interfolds the first and second tissue sheets  406  and  410  into the single tissue stack  402 . 
       FIG. 5  illustrates a cross-sectional view of an interfolding apparatus  420  during an intermediate operation for forming a tissue stack  402  according to one or more embodiments. From this view it is apparent that the interfolding apparatus  420  receives the first tissue sheet  406  from a roller of the first plurality of rollers  412  and the second tissue sheet  410  from a roller of the second plurality of rollers  416 . In some embodiments, opposite surfaces of the first and second tissue sheets  406  and  410  are interfolded into a single tissue stack  402 . In some embodiments, the tissue stack  402  is cut to a specified length. The tissue stack  402  can be cut using, for example, a saw or other known apparatus for cutting tissue stacks. 
     The descriptions of the various embodiments of the present invention have been presented for purposes of illustration but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The terminology used herein was chosen to best explain the principles of the embodiment, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.