WO2023113767A1

WO2023113767A1 - Sustainable dispenser for sheet materials

Info

Publication number: WO2023113767A1
Application number: PCT/US2021/063051
Authority: WO
Inventors: Stephen SAY; Brandon M. HOKANSON; Julie A. Paveletzke; Reginald Charles HURST
Original assignee: Kimberly-Clark Worldwide, Inc.
Priority date: 2021-12-13
Filing date: 2021-12-13
Publication date: 2023-06-22

Abstract

The present disclosure relates to dispensing containers for storing and dispensing folded sheet material. The dispensing container of the present disclosure can be constructed so as to be free of any polymer films and without the use of a tearaway surfboard. The dispensing container includes a unique dispensing opening that is integral with the top panel of the container. The dispensing opening includes two biasing flaps that are configured to hold a sheet material in an upright position for pop-up dispensing without the sheet material falling back into the container.

Description

SUSTAINABLE DISPENSER FOR SHEET MATERIALS

BACKGROUND

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 The tissues may be folded so that once the top tissue in the clip is withdrawn, subsequent sheets are individually presented above the top plane of the container for individual use.

The above dispensers typically include a dispensing window. The dispensing window comprises a dispensing slit or cutout portion that may be configured to hold tissues for pop-up type dispensing. For example, conventional pop-up style dispensers include a plastic film that covers the dispensing window. The plastic film includes the dispensing slit. Once the top tissue has been raised through the dispensing slit in the plastic film, subsequent tissues are held in an upright position by the plastic film for individual use. More particularly, once one tissue is removed from the dispenser, the following tissue is partially pulled out and is held in a substantially upright position by the slit in the plastic film.

Conventional dispensers for tissue products, such as facial tissues, industrial wipers, and the like, are made from a paperboard material to which the plastic film is adhered. Prior to use of the container, the dispensing window is typically covered with a perforated flap. In order to access the tissue product, the perforated flap is removed from the dispenser and discarded, thereby exposing the dispensing window and the underlying plastic film.

The above dispenser configuration has enjoyed tremendous success. The plastic film has been found well suited for applying a suitable amount of feree to an individual tissue so that the tissue will remain in an upright position and not fall back into the interior of the dispenser.

Although plastic films have performed well in tissue dispensers, the plastic films create various problems and drawbacks. For instance, incorporating a plastic film into a carton made from paperboard significantly complicates the ability to recycle the paperboard material. The presence of the plastic film, for instance, can prevent the paperboard carton from entering paper recycling streams and from being able to easily place the used dispensing carton back into a repulping process. In addition, the flap that must be initially removed from the dispenser in order to expose the plastic dispensing window represents waste that is typically not recaptured in the recycling stream but, instead, is disposed separately from the used container.

In addition, previous attempts to replace slit plastic films with more environmentally friendly materials have not been entirely successful. For example, U.S. Patent No. 5,316,177, which discloses a pop-up facial tissue carton with a paper window having an elongated opening with two or more slits emanating from its two ends, created a large degree of friction between the dispensed tissue sheet and the paper window. While the high degree of friction prevented fallbacks, it was noisy and caused tearing of the paper window. German Utility model G9108036 also discloses a carton having a paper dispensing window. To reduce the degree of friction between the dispensed sheet and the paper dispensing window, the window is provided with an opening that extends all the way to the carton opening at two or more points. While such designs may reduce the amount of friction, they are susceptible to fallbacks and the window is easily deformed, bent, or torn.

In view of the above, a need currently exists for an improved dispenser opening configuration that can hold a tissue sheet in an upright position for facilitating pop-up dispensing while minimizing fallback of the tissues into the dispenser. A need also exists for a sustainable tissue dispenser that can enter the paper recycling stream after all the tissues have been dispensed. In addition, a need exists for a tissue dispenser that does not include a tearaway top flap that must be removed prior to dispensing a tissue product and/or a tissue dispenser that does not include a plastic film that covers a dispensing window.

SUMMARY

The present disclosure is generally directed to an improved dispenser for individual sheet materials, such as tissue products, that can fulfill one or more of the above needs. The tissue dispenser of the present disclosure, for instance, can be made exclusively from a paperboard material and, in one aspect, from a single piece blank. The dispenser can be formed without the use of a plastic film making the dispenser or container sustainable and well suited for entering the paper recycling stream and/or for being fed to a repulping process and converted back into new product. In this regard, the dispenser or container of the present disclosure defines a dispensing opening that can be formed exclusively from the top panel of the container that is suitably configured to facilitate pop-up dispensing of tissue sheets while minimizing fallback.

For example, in one embodiment, the present disclosure is directed to a container for holding and dispensing a plurality of individual sheets, such as tissue sheets. In one aspect, the container is formed from a single piece blank comprising a top panel, a bottom panel, two opposing side panels, and two opposing end panels. The top panel defines a dispensing surface for dispensing sheets therethrough. The dispensing surface defines a dispensing axis that extends along a direction of the dispensing surface. The dispensing surface further includes a dispensing pathway extending along the dispensing axis that is in an initially closed position. A first crease line and a second crease line both extend along the dispensing axis and are both spaced from each other. The dispensing surface can further comprise a first perforated side line that extends from the first end of the first crease line to the first end of the second crease line and a second perforated side line that extends from the second end of the first crease line to the second end of the second crease line. Opening the first perforated side line and the second perforated side line produces a dispensing opening on the top panel that is surrounded by first and second biasing flaps. The first and second biasing flaps are formed between the first crease line and the second crease line. The first and second biasing flaps are biased towards the dispensing opening for contacting sheets dispensed therethrough. For example, the biasing flaps can be configured to apply sufficient pressure to a sheet emerging from the dispensing opening for holding the sheet in a partially extended position while preventing the sheet from falling back into the container. Through the use of the biasing flaps, in one aspect, no polymer film is needed or located below the dispensing opening and attached to the container. For example, the container can be made only from a single piece of material.

In one embodiment, the single piece blank can be made from a paperboard. For example, the paperboard can comprise a coated paper having a basis weight of from about 40 gsm to about 80 gsm.

In one aspect, the container further includes a perforated dispensing line extending along the dispensing axis and positioned between the first crease line and the second crease line. Opening the perforated dispensing line in conjunction with the first perforated side line and the second perforated side line creates the first biasing flap and the second biasing flap and produces the dispensing opening.

The dispensing line, the first side line, and the second side line can all be perforated. The perforations that form the dispensing line can be different than the perforations that form the side lines. For instance, the perforations that form the dispensing line can include longer perforated portions than the perforated portions found on the first and second side lines. In one aspect, for instance, the perforated dispensing line includes perforated portions and non-perforated portions. The perforated portions can have a length of from about 8 mm to about 20 mm and the non-perforated portions can have a length of from about 0.5 mm to about 2 mm. Similarly, the first and second perforated side lines can include perforated portions and non-perforated portions. The perforated portions can have a length of from about 0.5 mm to about 3 mm and the non-perforated portions can have a length of from about 0.5 mm to about 2 mm. The first and second perforated side lines can be, in one embodiment, perpendicular to the dispensing axis. The first and second crease lines can be formed by scoring the top panel. In one aspect, the first and second perforated side lines and the first and second crease lines can form a rectangular-like shape.

In one embodiment, the top panel of the container is formed from a first top panel section and a second top panel section. For instance, the first top panel section and the second top panel section can overlap to form the top panel. Each of the different panel sections can also contain one of the biasing flaps. In one embodiment, the biasing flaps can overlap when arranged in the closed position. When the top panel is formed from first and second top panel sections, the first and second perforated side lines can extend across both sections.

In one embodiment, the container can also include an attachment mechanism for closing the biasing flaps after the container has been opened. Any suitable attachment mechanism can be used. For instance, one biasing flap can include a tab that is inserted on a complementary slot located on the opposing biasing flap for closing the flaps. Alternatively, the attachment mechanism can be a reclosable adhesive or can be the combination of an extending tab and a reclosable adhesive.

The present disclosure is also directed to a product for dispensing a plurality of individual sheets, one at a time. The product includes a stack of individual sheets, such as sheets of a facial tissue, an industrial wiper, or the like. The product further includes a container defining a hollow enclosure. The stack of individual sheets are positioned within the hollow enclosure. The container includes a dispensing surface defining a dispensing opening. The dispensing opening comprises a dispensing slit bordered by a first biasing flap on one side and a second biasing flap located on the opposite side. The first and second biasing flaps are biased towards the dispensing opening for contacting one of the sheets emerging from the dispensing opening with sufficient force to hold the sheet in an extended position without the sheet falling back into the hollow enclosure of the container.

Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

Figure 1 is a perspective view of one embodiment of a dispensing container in accordance with the present disclosure;

Figure 2 is a perspective view of the dispensing container illustrated in Figure 1 prior to opening the container;

Figure 3 is one embodiment of a blank that may be used to construct the dispensing container illustrated in Figures 1 and 2;

Figure 4 is a perspective view of another embodiment of a dispensing container in accordance with the present disclosure;

Figure 5 is a perspective view of still another embodiment of a dispensing container made in accordance with the present disclosure;

Figure 6 is a perspective view of the dispensing container illustrated in Figure 5 shown in an open configuration; Figure 7 is one embodiment of a blank that may be used to construct the dispensing container illustrated in Figures 5 and 6;

Figure 8 is a perspective view of another embodiment of a dispensing container in accordance with the present disclosure; and

Figure 9 is a plan view of another embodiment of a blank that may be used to construct a dispensing container in accordance with the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DEFINITIONS

As used herein, the term "dispensing opening” generally refers to an opening formed in one or more walls or panels of a dispensing container through which sheet materials are dispensed such as, for example, facial tissues.

As used herein the term "paper” or "paperboard” generally refers to a fibrous structure in sheet format. Paper useful in the present invention may be manufactured from a variety of paper-making fibers, such as, for example, natural fibers or synthetic fibers, or any other suitable fibers, and any combination thereof. Papermaking fibers useful in the present invention include cellulosic fibers commonly known as wood pulp fibers. Applicable wood pulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps, as well as mechanical pulps including, for example, groundwood, thermomechanical pulp and chemically modified thermomechanical pulp.

As used herein the term "slit” generally refers to a cut where no material is removed. In certain embodiments a tissue carton of the present invention may be provided with a top panel having a slit that is used to form a dispensing opening.

As used herein the term "tissue” generally refers to any individual sheet product, such as facial tissue, dry or moistened wipes, for example household or industrial wipes, soap or fabric softening sheets, or the like. Normally, the basis weight of sheet products to be dispensed by the cartons of the present invention is less than about 80 grams per square meter (gsm), in some embodiments less than about 60 gsm, and in some embodiments, between about 10 to about 60 gsm.

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 disclosure.

In general, the present disclosure is directed to a dispensing container for sheet materials, such as facial tissues, wipers, and the like. Of particular advantage, the container of the present disclosure can be sustainable and made entirely from biodegradable, compostable, and/or repulpable materials, such as a paper or paperboard. In one aspect, for instance, the container made according to the present disclosure, once emptied, can be collected and processed through the recycling stream, such as the paper recycling stream. In one embodiment, the container can be constructed without containing any polymer films. In fact, the empty container, in one embodiment, can be repulpable for making other cellulose fiber-based products.

In accordance with the present disclosure, the dispensing container includes a combination of unique creases and biasing flaps formed into a top panel of the container that are designed to hold a sheet material, such as a facial tissue, in an upright position extending from a dispensing opening while preventing the sheet material from falling back into the interior enclosure of the container. The biasing flaps are formed from perforated slits that are perforated at particular locations for facilitating the opening of the container and the formation of the biasing flaps. In this manner, a dispensing opening is formed that is integral with a top panel of the container in a way so as to present and hold a sheet material in place while preventing fallback issues. In addition, the dispensing opening can be formed into the container without the use of any polymer films. Further, the dispensing opening can be formed into the container without having to first remove a portion or flap of the top panel of the container.

Referring to FIGS. 1 and 2, for instance, a pop-up dispensing container 10 according to one embodiment of the present disclosure is shown for purposes of illustration. Generally, a clip of tissues is disposed within the container or carton. While the container of the present invention is particularly well suited for dispensing tissue sheets, such as folded facial tissue sheets, the invention is not so limited. The invention may also be utilized to dispense other types of 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, for example household or industrial wipes, soap or fabric softening sheets, or the like.

The stack 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 may 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. Particularly preferred folding patterns include interfolding patterns that provide somewhat less friction, which tend to avoid tearing of the tissue when extracted from the container.

As shown in FIGS. 1 and 2, the container 10 includes a top panel 12 opposite a bottom panel 14. The container 10 further includes a pair of opposing end panels 16 and 18 and a pair of opposing side panels 20 and 22. In the embodiment illustrated in FIG. 1 , the dispensing container 10 has dimensions that allow for the sheet material to lay flat within the container. Thus, the dispensing container 10 as shown in FIGS. 1 and 2 generally has a rectangular shape. In other embodiments, however, the dispensing container 10 can have a more square, elevated configuration that holds the sheet materials in an upside down “U” shape. In particular, the stack of sheet materials can be folded and placed into the dispensing container for dispensing the sheet materials one at a time. The unique dispensing opening of the present disclosure can be used in all different types of dispensing containers and the embodiment illustrated in FIGS. 1 and 2 are provided for exemplary purposes only.

The dispensing container 10 can be constructed from any rigid material. For example, the dispensing container 10 can be made from any suitable paper, such as cardboard, carton stock, paperboard, or the like. Alternatively, the dispensing carton 10 can be made from a polymer material, particularly a recyclable polymer material. The polymer material can comprise a polypropylene, a polyethylene, a polystyrene, or any other suitable plastic. In one particular embodiment, the dispensing container 10 is made from a paper, such as paperboard, that is capable of entering the paper recycling stream and/or is capable of being repulped into new products. For example, in one embodiment, the dispensing container 10 is made from a fiber sheet containing pulp fibers. The pulp fibers can comprise softwood fibers, hardwood fibers, bast fibers, recycled fibers, any other suitable cellulosic fibers, and mixtures thereof. The paper can be coated on one side with a polymer and/or clay material in order to provide some moisture resistance. The paper can have a basis weight of greater than about 40 gsm, such as greater than about 50 gsm, such as greater than about 60 gsm, such as greater than about 70 gsm, such as greater than about 80 gsm, such as greater than about 90 gsm, such as greater than about 100 gsm. The basis weight of the paper is generally less than about 150 gsm, such as less than about 120 gsm, such as less than about 100 gsm. In one embodiment, the basis weight of the paper is from about 40 gsm to about 80 gsm.

Not shown in the figures, the material used to produce the dispensing container 10 can also be designed to receive printed matter, such as text, trademarks, designs, and the like. For example, paper substrates are well suited for receiving printed matter. The printed matter can be applied to the paper substrate using any suitable technique, including flexographic printing, inkjet printing, and the like. In one embodiment, printed matter can be applied to the paper substrate and the paper substrate can then be coated with a polymer coating. The polymer coating can be transparent and can be repulpable. For instance, the polymer coating can be made from a natural gum or any suitable polysaccharide-based coating material.

In FIG. 1 , the dispensing container 10 is shown in an open configuration. More particularly, the dispensing container 10 includes a dispensing surface 24 on the top panel 12 through which sheet materials 30 are dispensed. The dispensing surface 24 defines a dispensing opening 26 that not only permits dispensing of individual sheet materials 30 but does so in a pop-up dispensing style. More particularly, the dispensing opening 26 is designed to permit dispensing of an individual sheet material 30 that can be interfolded with a subsequent sheet of material. When one individual sheet material is removed from the dispensing container 10, the subsequent sheet material remains partially withdrawn from the container 10 through the dispensing opening 26 as shown in FIG. 1. Consequently, once the top sheet material is withdrawn, subsequent sheets are individually presented above the dispensing surface 24 for facilitating removal of subsequent sheets. The dispensing opening 26 of the present disclosure is particularly configured to maintain the sheet material 30 in an upright position once a previous sheet of material has been removed while preventing the sheet material 30 from falling back into the dispensing container 10.

Referring to FIG. 2, the dispensing container 10 is shown in a closed, unopened configuration. As shown in FIG. 2, the dispensing surface 24 includes a perforated dispensing line 32. In the embodiment illustrated in FIG. 2, the dispensing line 32 is linear and parallel with a dispensing axis that extends in one direction along the dispensing surface 24. For example, in the embodiment illustrated in FIG. 2, the dispensing axis extends along the length of the dispensing surface 24. In addition to being linear or straight, the perforated dispensing line 32 can have any suitable shape. For instance, the dispensing line 32 can have a wave-like pattern including a plurality of alternating arc-like shapes. For instance, the perforated dispensing line 32 can include greater than about 2 arc-like shapes, such as greater than about 3 arc-like shapes, such as greater than about 4 arc-like shapes, such as greater than about 5 arc-like shapes, such as greater than about 6 arc-like shapes, such as greater than about 7 arc-like shapes, such as greater than about 8 arc-like shapes, and generally less than about 20 arc-like shapes, such as less than about 15 arc-like shapes, such as less than about 10 arc-like shapes. Alternatively, instead of alternating arc-like shapes, the dispensing line 32 can include alternating rectangular-like shapes that appear as alternating teeth. In still another embodiment, the perforated dispensing line 32 can have a zig-zag-like shape. In still another aspect, the perforated dispensing line 32 can include a random-like shape that may improve the aesthetic appearance of the dispensing container 10.

In one embodiment, the perforated dispensing line 32 can have a curved shape. For example, referring to FIG. 4, one embodiment of a container 10 made in accordance with the present disclosure is shown. Like reference numerals have been used to indicate similar elements. The container 10, for instance, includes a top panel 12 defining a dispensing surface 24. The dispensing surface includes a first crease line 34 spaced from a second crease line 36. Connecting the ends of each crease line 34 and 36 is a first perforated side line 38 and a second perforated side line 40. In addition, the dispensing surface 24 defines a perforated dispensing line 32 that has a curved shape and, once opened, forms a first biasing flap 42 opposite a second biasing flap 44. As shown in FIG. 4, the curved dispensing line 32 can extend from the first perforated side line 38 to the second perforated side line 40.

As shown in FIG. 2, on one side of the perforated dispensing line 32 is a first crease line 34. On the opposite side of the perforated dispensing line 32 is a second crease line 36. The first and second crease lines 34 and 36 are spaced from the perforated dispensing line 32. In the embodiment illustrated, the crease lines 34 and 36 are each equidistant from the perforated dispensing line 32. The first and second crease lines 34 and 36 are parallel or substantially parallel with the dispensing axis of the dispensing surface 24. When the perforated dispensing line 34 is linear as shown in FIG. 2, the crease lines 34 and 36 can also be parallel with the dispensing line 32.

The crease lines 34 and 36 can be formed into the dispensing surface 24 in various different ways. In one embodiment, for instance, the top panel 12 can be scored for forming the crease lines 34 and 36. Alternatively, the crease lines 34 and 36 can be formed by a user when the dispensing container 10 is opened.

As illustrated in FIG. 2, the dispensing surface 24 further includes a first perforated side line 38 opposite a second perforated side line 40. As shown, the perforated side lines 38 and 40 can be positioned so as to be perpendicular to the dispensing axis of the dispensing surface 24. The first perforated side line 38 extends from a first end of the first crease line 34 to a first end of the second crease line 36. The second perforated side line 40, on the other hand, extends from a second end of the first crease line 34 to the second end of the second crease line 36. In the embodiment illustrated, each of the perforated side lines 38 and 40 are generally linear and then have a curved portion that intersects with the respective crease lines. The curved corners, however, are optional and, in an alternative embodiment, the perforated side lines 38 and 40 can intersect with the crease lines 34 and 36 to form a more pointed corner. The perforated dispensing line 32 extends from the first perforated side line 38 to the second perforated side line 40.

Overall, the first and second perforated side lines 38 and 40 in combination with the first and second crease lines 34 and 36 generally form a rectangular-like shape or structure. The perforated dispensing line 32 in combination with the crease lines 34 and 36 and the perforated side lines 38 and 40 form two opposing biasing flaps, namely a first biasing flap 42 and a second biasing flap 44. In order to open the dispensing container 10 as shown in FIG. 2, the perforated dispensing line 32 is broken open in combination with breaking open the first and second perforated side lines 38 and 40. After breaking apart the perforated dispensing line 32 and the first and second perforated side lines 38 and 40, the dispensing opening 26 as shown in FIG. 1 is formed.

In one aspect, the perforations along the perforated dispensing line 32 and the perforations along the first and second perforated side lines 38 and 40 can be designed for opening the container 10, especially when made from a paperboard material, in a manner that facilitates formation of the dispensing opening 26 without causing the container to tear or rip in an undesired manner. For example, as shown in FIG. 2, in one aspect, the perforated dispensing line 32 can include longer perforations than the perforations present on the first and second perforated side lines 38 and 40.

More particularly, in one embodiment, the perforated dispensing line 32 includes perforated portions and unperforated portions. The perforated portions can have a length of greater than about 8 mm, such as greater than about 10 mm, such as greater than about 12 mm, such as greater than about 14 mm. The perforated portions can have a length of generally less than about 20 mm, such as less than about 18 mm, such as less than about 16 mm. The non-perforated portions located between the perforated portions, on the other hand, can have a length of greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, and generally less than about 2 mm, such as less than about 1 .5 mm, such as less than about 1 .3 mm, such as less than about 1.1 mm.

The first perforated side line 38 and the second perforated side line 40 can also include perforated portions and non-perforated portions. The perforated side lines 38 and 40, for instance, can have perforated portions that have a length of greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, and generally less than about 3 mm, such as less than about 2.5 mm, such as less than about 2 mm, such as less than about 1 .5 mm, such as less than about 1 .3 mm. The non-perforated portions positioned between the perforated portions can have a length of greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, and generally less than about 2 mm, such as less than about 1 .6 mm, such as less than about 1 .4 mm, such as less than about 1 .2 mm.

The perforated portions of the dispensing line 32 and the first and second side lines 38 and 40 can extend through the entire thickness of the material that is used to construct the dispensing container 10. The perforated dimensions as described above have been found to greatly facilitate ease of opening the container 10. In particular, the above perforations have been found to easily open the container without causing the material used to make the container from tearing or delaminating when the perforated portions are torn open. As described above, in one embodiment, various parts of the container, such as the top panel 12 of the container, can be coated with a polymer coating. The polymer coating can increase moisture resistance, increase strength, and be receptive to printed matter. In one aspect, the polymer coating can contain a film-forming polymer in combination with clay particles to produce a clay coating. In one embodiment, a clay coating can be applied to the top panel 12 of the container 10 prior to forming the perforated dispensing line 32 and the first and second perforated side lines 38 and 40. Forming the perforations through a clay coating can help prevent tearing when the perforated portions are opened and can also prevent the propagation of tears or cuts.

As shown in FIG. 1, the biasing flaps 42 and 44 are biased towards the dispensing opening 26. The biasing flaps 42 and 44 formed into the top panel 12 of the dispensing container 10 are constructed in a unique way such that the biasing flaps 42 and 44 contact a sheet material 30 emerging from the container 10 with sufficient force to hold the sheet material 30 in an extended position as shown in FIG. 1 without falling back into a hollow enclosure defined by the container 10. In order to apply sufficient force to the sheet material 30, various factors can be varied and altered in constructing the dispensing opening 26. For example, the length of the dispensing line 32, the manner in which the crease lines 34 and 36 are formed, the width of the biasing flaps 42 and 44, and the width of the biasing flaps 42 and 44 in relation to the length of the perforation line 32 can all be manipulated and adjusted for optimizing the configuration. The size and shape of the container 10 can also impact the particular dimensions of each of the different components.

In one embodiment, when producing a dispensing container 10 for facial tissues as shown in FIG. 1 , the dispensing line 32 and the length of the flaps 42 and 44 can generally be greater than about 4 inches, such as greater than about 5 inches, such as greater than about 6 inches, and generally less than about 7 inches, such as less than about 6 inches. The width of the biasing flaps 42 and 44 can generally be greater than about 0.5 inches, such as greater than about 1 inch, such as greater than about 1 .5 inches, and generally less than about 2.5 inches, such as less than about 2 inches, such as less than about 1 .75 inches. The ratio between the length of the biasing flaps 42 and 44 and the width of the biasing flaps 42 and 44 can be generally from about 1 :2 to about 1 :8, such as from about 1 :3 to about 1 :6.5, such as from about 1 :3.5 to about 1 :5. When producing more squareshaped dispensers, however, the above ratios and dimensions can change and be varied.

The dispensing opening 26 as shown in FIG. 1 is not only well suited for facilitating pop-up dispensing while minimizing fallback, but also offers various advantages and benefits. For instance, as shown in FIG. 1, the unique dispensing opening 26 is well suited to maintaining the sheet material 30 in an extended position without the use of a polymer film as used conventionally. In addition, another significant advantage is that the dispensing opening 26 can be formed directly into the top panel 12 or the dispensing surface 24 of the container 10 without having to first remove a perforated flap or "surfboard” in order to access an opening or dispensing window.

In this regard, the dispensing container 10 of the present disclosure can be formed from a single piece of material. For example, referring to FIG. 3, one embodiment of a single piece blank 50 that may be used to construct the dispensing container 10 as shown in FIG. 1 is illustrated. The blank 50 includes a top panel 12 that defines a dispensing surface 24. The blank 50 also includes two side panels 20 and 22, a bottom panel 14, and two opposing end panels 16 and 18. In addition, the blank 50 can include various construction tabs 52 that are configured to receive an adhesive for assembling the blank into the container 10 as shown in FIG. 1. The blank 50 can be made from any suitable material and particularly a paper, such as a paperboard. The blank can be first formed and then printed with text and/or decorations as desired. The blank can then be scored in order to define the different panels 12, 14, 16, 18, 20, and 22 and to facilitate folding of the tabs 52. In addition, the blank 50 can be scored to create the first and second crease lines 34 and 36. The blank 50 can also be perforated to create the perforated dispensing line 32 and the first perforated side line 38 and the second perforated side line 40.

In producing the product as shown in FIG. 1 , a stack of sheet materials can be loaded into the blank 50 when in a partially assembled state or, alternatively, the blank 50 can be formed into a container around a stack of sheet materials. The sheet material can be in the form of individual sheets that are interfolded together to facilitate pop-up dispensing. The sheet material contained within the dispenser product of the present disclosure can vary. In one particular application, for instance, the product of the present disclosure can be configured to dispense facial tissues. In alternative embodiments, however, the dispensing container 10 can be configured to dispense other dry wipers, wet wipes, napkins, paper towels, or the like. In one embodiment, the dispensing container 10 is configured to dispense individual sheet materials formed from cellulosic fibers that have a bulk of greater than about 3 cc/g to about 20 cc/g and have a basis weight of from about 10 gsm to about 120 gsm, such as from about 20 gsm to about 60 gsm.

Referring to FIGS. 5 and 6, another embodiment of a container 110 made in accordance with the present disclosure is shown. The container 110 includes a top panel 112 opposite a bottom panel 114, two opposing end panels 116 and 118, and two opposing side panels 120 and 122. In this embodiment, the top panel 112 is formed from a first top panel section 160 that, in this embodiment, overlaps with a second top panel section 162.

In accordance with the present disclosure, the container 110 includes a unique dispensing pathway formed into the top panel 112. More particularly, as shown in FIG. 5, the top panel 112 defines a dispensing surface 124. Located on the dispensing surface are a pair of opposing crease lines, including a first crease line 134 spaced from a second crease line 136. The crease lines 134 and 136 extend along the dispensing axis from a first end to a second end. A first perforation side line 138 extends from a first end of the first crease line 134 to the first end of the second crease line 136. Similarly, a second perforated side line 140 extends from the second end of the first crease line 134 to the second end of the second crease line 136. The first and second perforated side lines 138 and 140 extend over both of the first and second top panel sections 160 and 162.

As shown in FIG. 6, by opening the first and second perforated side lines 138 and 140, a first biasing flap 142 and a second biasing flap 144 are formed that are pliable along the respective crease lines 134 and 136 in order to create a dispensing opening and pathway through which sheet product can be dispensed.

In the embodiments illustrated in FIGS. 5 and 6, the first biasing flap 142 and the second biasing flap 144 overlap in a closed position. Once placed in an open position, the biasing flaps 142 and 144 are configured to facilitate pop-up dispensing while minimizing fallback. The first and second biasing flaps 142 and 144, for instance, are biased towards the dispensing opening for contacting sheets dispensed through the dispensing pathway.

Referring to FIG. 7, one embodiment of a single piece blank 150 that may be used to construct the dispensing container 110 as shown in FIGS. 5 and 6 is illustrated. The blank 150 includes a top panel 112 formed from a first top panel section 160 and a second top panel section 162. The blank 150 also includes two side panels 120 and 122, a bottom panel 114, and two opposing end panels 116 and 118. In addition, the blank 150 can include various construction tabs 152 that are configured to receive an adhesive for assembling the blank into the container 110 as shown in FIG. 5. In this embodiment, the construction tabs 152 can also form portions of the end panels 116 and 118.

The blank 150 can be formed and cut to shape and then scored in order to form crease lines, including fold lines, for facilitating assembly of the container.

In one embodiment, the blank 150 or at least the exterior surfaces of the resulting container can be coated with a coating that, for instance, can improve moisture resistance, strength, and be capable of receiving printed matter. In one embodiment, for instance, the coating can be a clay coating comprised of a film-forming polymer combined with clay particles. The clay coating can create opaque and smooth panels.

As shown in FIG. 7, the blank 150 further includes first and second biasing flaps 142 and 144 that are each located on a corresponding top panel section 160 and 162. The biasing flap 142 is defined by a first crease line 134 on one side and by first and second perforated side lines 138 and 140. Similarly, the biasing flap 144 is defined by a second crease line 136 and by the first and second perforated side lines 138 and 140. As shown, the perforated side lines 138 and 140 extend over both of the first top panel section 160 and the second top panel section 162. In one embodiment, the perforated side lines 138 and 140 are formed into the blank 150 after a clay coating has been applied to the blank. Perforating the clay coating, for instance, can provide various advantages and benefits. For instance, perforating the clay coating helps prevent the paperboard material from tearing when the perforated portions are opened.

Referring to FIG. 8, another embodiment of a container 110 made in accordance with the present disclosure is shown. Like reference numerals from the embodiment illustrated in FIGS. 5 and 6 have been used to indicate similar elements. As shown, the container 110 in FIG. 8 includes a top panel 112 that is formed from a first top panel section 160 that overlaps a second top panel section 162 and defines a dispensing surface 124. The container 110 further includes a bottom panel 114, two opposing end panels 116 and 118, and two opposing side panels 120 and 122.

Further, the container 110 includes a unique opening structure that defines a dispensing pathway. The opening structure includes a first biasing flap 142 opposite a second biasing flap 144. The biasing flaps are movable along corresponding crease lines, namely a first crease line 134 and a second crease line 136. In the embodiment illustrated, the biasing flaps 142 and 144 include an attachment mechanism that allows the flaps to assume a closed position after the container 110 has been opened. In general, any suitable attachment mechanism can be used. The attachment mechanism, for instance, can include a mechanical interlocking structure, can include a resealable adhesive, or can include a combination of both. In FIG. 8, the attachment mechanism includes a tab 170 located on the second biasing flap 144 and a corresponding slot 172 located on the first biasing flap 142. In order to close the container 110, the tab 170 can be inserted into the slot 172.

Referring to FIG. 9, another embodiment of a blank that may be used to construct a container in accordance with the present disclosure is shown. Like reference numerals from the embodiment illustrated in FIG. 7 have been used to indicate similar elements. The blank 150 includes first and second biasing flaps 142 and 144 that are each located on a corresponding top panel section 160 and 162. The biasing flap 142 is defined by a first crease line 134 on one side and by first and second perforated side lines 138 and 140. Similarly, the biasing flap 144 is defined by a second crease line 136 and by the first and second perforated side lines 138 and 140. As shown, the perforated side lines 138 and 140 extend over both of the first top panel section 160 and the second top panel section 162. The blank 150 shown in FIG. 7 can be used to construct a container, similar to the container 110 shown in FIG. 8. The blank 150 illustrated in FIG. 7, however, has a different attachment mechanism for interlocking the first biasing flap 142 and the second biasing flap 144. More particularly, the first biasing flap 142 includes a tab 170. Once the first and second perforated side lines 138 and 140 are opened, the first biasing flap 142 can overlap the second biasing flap 144 and the tab can be inserted below the second top panel section 162 for interlocking the biasing flaps 142 and 144.

These and 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. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.

Claims

What Is Claimed:

1 . A container for holding and dispensing a plurality of individual sheets comprising: a single piece blank comprising a top panel, a bottom panel, two opposing side panels, and two opposing end panels, the top panel defining a dispensing surface for dispensing sheets therethrough, the dispensing surface defining a dispensing axis that extends along a direction of the dispensing surface, the dispensing surface further comprising:

(a) a dispensing pathway extending along the dispensing axis in an initially closed position;

(b) a first crease line and a second crease line that both extend along the dispensing axis and are spaced from each other, the dispensing pathway being located between the first crease line and the second crease line, each of the first crease line and the second crease line including a first end and a second and opposite end;

(c) a first perforated side line that extends from the first end of the first crease line to the first end of the second crease line;

(d) a second perforated side line that extends from the second end of the first crease line to the second end of the second crease line and wherein the dispensing pathway is located between the first perforated side line and the second perforated side line; and wherein opening the first perforated side line and the second perforated side line produces a dispensing opening on the top panel that is surrounded by first and second biasing flaps, the first and second biasing flaps being biased towards the dispensing opening for contacting sheets dispensed therethrough.

2. A container as defined in claim 1 , wherein the biasing flaps apply sufficient pressure to a sheet emerging from the dispensing opening for holding the sheet in a partially extended position while preventing the sheet from falling back into the container.

3. A container as defined in any of the preceding claims, wherein there is no polymer film located below the dispensing opening and attached to the container.

4. A container as defined in any of the preceding claims, wherein the container is made from a single piece of material.

5. A container as defined in claim 1 , wherein the container further includes a perforated dispensing line extending along the dispensing axis and positioned between the first crease line and the second crease line and wherein opening the perforated dispensing line in conjunction with the first perforated side line and the second perforated side line produces the dispensing opening and creates the first and second biasing flaps.

6. A container as defined in claim 1 , wherein the top panel is formed from a first top panel section and a second top panel section.

7. A container as defined in claim 6, wherein, when in the closed position, the first and second biasing flaps overlap.

8. A container as defined in claim 6, wherein the first perforated side line and the second perforated side line extend across both of the first and second top panel sections.

9. A container as defined in claim 1 , wherein the container further includes an attachment mechanism for closing the first and second biasing flaps together after the container has been opened.

10. A container as defined in any of the preceding claims, wherein the container comprises a paperboard.

11. A container as defined in claim 10, wherein the paperboard comprises a coated paper having a basis weight of from about 40 gsm to about 80 gsm.

12. A container as defined in claim 5, wherein the dispensing opening is created by opening the perforated dispensing line, the first perforated side line, and the second perforated side line and without having to remove a portion of the top panel from the container.

13. A container as defined in claim 5, wherein the perforated dispensing line comprises perforated portions and non-perforated portions, the perforated portions having a length from about 8 mm to about 20 mm and the non-perforated portions having a length from about 0.5 mm to about 2 mm.

14. A container as defined in any of the preceding claims, wherein the first and second perforated side lines comprise perforated portions and non-perforated portions, the perforated portions having a length from about 0.5 mm to about 3 mm, the non-perforated portions having a length from about 0.5 mm to about 2 mm.

15. A container as defined in any of the preceding claims, wherein the first and second perforated side lines are perpendicular to the dispensing axis.

16. A container as defined in any of the preceding claims, wherein the first and second crease lines have been formed by scoring the top panel.

17. A container as defined in any of the preceding claims, wherein the first and second perforated side lines and the first and second crease lines form a rectangular-like shape.

18. A container as defined in claim 5, wherein the perforated dispensing line is linear or curved.

19. A product for dispensing a plurality of individual sheets one at a time comprising: a stack of individual sheets; and a container defining a hollow enclosure, the stack of individual sheets being positioned within the hollow enclosure, the container including a dispensing surface defining a dispensing opening, the dispensing opening being bordered by a first biasing flap on one side of the dispensing opening and a second biasing flap located on the opposite side of the dispensing opening, the first and second biasing flaps being biased towards the dispensing opening for contacting one of the sheets emerging from the dispensing opening with sufficient force to hold the sheet in an extended position without the sheet falling back into the hollow enclosure of the container.

20. A product as defined in claim 19, wherein there is no polymer film located below the dispensing opening and attached to the container.

21 . A product as defined in claim 19 or 20, wherein the container is only formed from a single piece blank comprising a paperboard.

22. A product as defined in claim 21 , wherein the paperboard comprises a coated paper having a basis weight of from about 40 gsm to about 80 gsm.

23. A product as defined in any of claims 19-22, wherein the dispensing opening is accessed on the container without removing a portion of the dispensing surface from the container.

24. A product as defined in any of claims 19-23, wherein the container includes a dispensing axis that extends along a length of the dispensing surface and wherein a dispensing slit extends along the dispensing axis between the first and second biasing flaps.

25. A product as defined in claim 19, wherein the slit is linear or curved.

26. A product as defined in claim 19, wherein the dispensing surface is formed from a first top panel section and a second top panel section.

27. A product as defined in claim 26, wherein the first biasing flap overlaps with the second biasing flap when in a closed position.

18