Packaging for paper products

Abstract

Sheets of a paper product are arranged in a compact package. Each sheet has a primary panel and at least one secondary panel. When packaged, the primary panel and one or more secondary panels are disposed in overlying relation to each other in various arrangements according to several embodiments. When each sheet is removed and separated from the package, the panels can be unfolded to enlarge the sheet. In several embodiments, the panels are separable from each other along perforated seams to selectively provide smaller individual sheets. The package may be in the form of a roll, either coreless or on a tubular core. Alternatively, the sheets may be packaged in a stacked array.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to packaging of paper products and, more particularly, to a compact package having a plurality of sheets wherein each of the sheets includes a plurality of panels disposed in overlying relation to one another.

[0003] 2. Discussion of the Related Art

[0004] Certain paper products, such as toilet tissue and paper towels, have for long been packaged on a roll with a hollow tubular core for the convenience of mounting the roll package on a holder or dispenser. Typically, individual sheets are attached to one another, end-to-end, along perforated seams. The individual sheets are separable from the next adjacent sheet and the remainder of the roll by tearing along the perforated seam. The sheet, once attached, typically comprises a single square or rectangular panel. When packaged in this manner, the size of the panel directly correlates to the size of the roll. In other words, the height of each single panel sheet, measured from the bottom edge to the top edge, is the same as the height or length of the roll. And, because the roll length of paper products, such as toilet tissue and paper towels, is typically limited to standard dimensions due to shelf space requirements and standard roll holder sizes, the size of each individual sheet package on the roll is limited. For example, the individual sheet size of toilet tissue is directly related to the standard toilet tissue roll size in the industry. And, while a larger sheet may be more desirable to the user, a larger roll would require additional shelf space and larger holders in bathrooms. For these reasons, a larger roll size is not acceptable to industry standards Other paper products, such as paper towels, may be more conveniently packaged on a smaller roll size. However, this would limit the size of each individual sheet, when packaged in the conventional manner. Reducing the size of a paper towel sheet is certainly not desirable.

[0005] To address the needs of packaging paper products, such as toilet tissue, paper towels and wipes, in a compact package, the present invention provides for individual sheets having multiple panels, including a primary panel and at least one secondary panel. When packaged, the panels of each sheet are disposed in overlying relation to one another by folding along seams. In several embodiments of the invention, the seams are perforated to enable separation of each of the individual panels from one another once the sheet is separated from the package.

[0006] In the past, others have proposed packaging paper sheet products having multiple panels on either a roll or in a stacked array. For example, the U.S. patent to Bonk, U.S. Pat. No. 4,101,026 discloses a roll package of pre-moistened towelettes, wherein individual sheets are separable from one another along perforated seams, and further wherein the individual sheets include multiple panels folded in a Z configuration. The individual sheets in Bonk, however, do not provide for perforated seams between the panels so that the individual panels of each sheet can be separated from one another. Moreover, the panels of each sheet are disposed in a Z-configured overlying relation so that the ends of the side panels extend outwardly beyond the seams between the side panels and the center panel. This causes the outer edges of the roll package to sag in comparison to the central portion of the roll which is bulged due to the greater thickness of material created by the three overlying panels of each sheet.

[0007] It has also been known to package pre-moistened wipes, such as hand wipes and baby wipes, in a stacked array, wherein each sheet includes a plurality of panels folded in overlying relation. Notwithstanding, it has not heretofore been known to provide individual sheets in a paper package, either in roll form or in a stacked array, wherein the individual sheets include a plurality of panels disposed in overlying relation to one another and wherein the panels are separable from one another along perforated seams.

SUMMARY OF THE INVENTION

[0008] The present invention provides a plurality of sheets of a paper product arranged in a compact package. Each sheet has a primary panel and at least one secondary panel. When packaged, the primary panel and one or more secondary panels are disposed in overlying relation to each other in various arrangements according to several embodiments. When each sheet is removed and separated from the package, the panels can be unfolded to enlarge the sheet. In several embodiments, at least one of the panels is separable from the remainder of the sheet along a perforated seam to selectively provide smaller individual sheets. The package may be in the form of a roll, either coreless or on a tubular core. Alternatively, the sheets may be packaged in a stacked array.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

[0010] FIG. 1 is a partially exploded perspective view showing a roll of toilet tissue and a hollow tubular core of the roll removed for purposes of illustration, in accordance with one preferred embodiment of the invention;

[0011] FIG. 2 is a partially exploded perspective view showing the roll of toilet tissue of FIG. 1 supported on a dowel of a holder or dispensing device, and wherein the dowel is also shown removed for purposes of illustration;

[0012] FIG. 3 is an isolated top perspective view showing a portion of a sheet of paper according to one preferred embodiment of the present invention, and wherein the sheet includes a primary panel and opposite secondary panels folded and overlying opposite side faces of the primary panel;

[0013] FIG. 4 is an isolated top perspective view of the folded sheet of FIG. 3 wherein one of the side panels is shown partially lifted in an unfolding movement;

[0014] FIG. 5 is an isolated top perspective view of a sheet of paper in accordance with another preferred embodiment of the present invention, wherein opposite side panels are separable from a primary panel along perforated seams;

[0015] FIG. 6 is a front perspective view of a roll of paper having a plurality of interconnecting sheets, in accordance with yet another preferred embodiment of the present invention, and wherein the individual interconnecting sheets each include a primary panel and opposite side panels folded in overlying relation on opposite sides of the primary panel;

[0016] FIG. 7 is an isolated front perspective view of a sheet of paper taken from the embodiment of FIG. 6, wherein the opposite side panels are shown overlying opposite side faces of the primary panel with the free side edges of the secondary panels positioned along the center of the primary panel;

[0017] FIG. 8 is an isolated front perspective view of the sheet of FIG. 7 showing one of the side panels being lifted in an unfolding movement from the primary panel;

[0018] FIG. 9 is an isolated front perspective view of a further embodiment of the sheet of paper shown in FIG. 6-8, wherein the side panels are separable from the primary panel along perforated seams;

[0019] FIG. 10 is a front perspective view of a roll of paper containing a plurality of interconnecting sheets, wherein each of the sheets includes a primary panel and secondary panels folded in overlying relation to the primary panel in accordance with yet another preferred embodiment of the present invention;

[0020] FIG. 11 is an end elevational view of a sheet taken from the embodiment of FIG. 10 showing the secondary panels folded in overlying relation on opposite side faces of the primary panel in a generally Z configuration;

[0021] FIG. 12 is an end elevational view of a further embodiment of the sheet of FIGS. 10 and 11, wherein the edges of the secondary panels extend beyond the seams interconnecting the secondary panels to the primary panel when the panels are folded in the Z configuration;

[0022] FIG. 13 is an end elevational view of a further embodiment of the sheet of FIGS. 10 and 11, wherein the side edges of the secondary panels terminate inboard of the seams interconnecting the secondary panels to the primary panel when the panels are folded in the Z configuration;

[0023] FIG. 14 is an isolated top perspective view showing the sheet of the embodiments of either FIGS. 11, 12 or 13, and wherein the secondary panels are separable from the primary panel along perforated seams;

[0024] FIG. 15 is a front perspective view of a roll of paper containing a plurality of interconnecting sheets, wherein the secondary panels are folded in overlying relation to the top face of the primary panel with the free side edges of the secondary panel disposed in spaced relation to provide a zone between the secondary panels to facilitate grasping the edges or corners of the secondary panels in order to lift and separate the sheet from the roll and to further open and separate the secondary panels from the primary panel;

[0025] FIG. 16 is an isolated top perspective view of the sheet taken from the embodiment of FIG. 15 wherein the secondary panels are separable from the primary panel along perforated seams;

[0026] FIG. 17 is a front perspective view of a roll of paper containing a plurality of interconnecting sheets, wherein each sheet includes a primary panel and one secondary panel disposed in overlying relation to the primary panel, and wherein the secondary panel is separable from the primary panel along a perforated seam;

[0027] FIG. 18 is an isolated top perspective view of the sheet taken from the embodiment of FIG. 17 showing the secondary panel disposed in overlying relation to the primary panel and wherein the free side edges of the primary panel and secondary panel are disposed in aligned relation;

[0028] FIG. 19 is an isolated top perspective view of an alternative embodiment of the sheet taken from FIG. 17 wherein the secondary panel is shown in overlying relation to the primary panel and further wherein the free side edge of the secondary panel is disposed inboard of the free side edge of the primary panel when the panels are folded in overlying relation;

[0029] FIG. 20 is an isolated top perspective view of the embodiment of FIG. 19 showing the secondary panel being separated from the primary panel along a perforated seam;

[0030] FIGS. 21-26 show top plan views of various embodiments of the sheets, including varying configurations of the sheets and perforated seams interconnecting the sheets or panels of each sheet; and

[0031] FIG. 27 is a front perspective view of a roll of paper containing a plurality of interconnecting sheets, and wherein the roll has a coreless center.

[0032] Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Referring to the several views of the drawings, numerous embodiments of a paper product and packaging for the paper product are shown, wherein the paper package is generally indicated as 10.

[0034] In each of the embodiments shown throughout the drawings, the paper product of the package 10 includes a plurality of sheets 19 each having two or more panels. Specifically, each sheet 19 includes a primary panel 20 having a top face 22 and a bottom face 23. The primary panel 20 further includes a top edge 24, a bottom edge 25, a right side edge 26 and a left side edge 27. In multiple embodiments of the invention, the paper package 10 is in the form of a roll. In this instance, the sheets 19 are interconnected to one another along perforated seams 28. In this manner, one or more of the sheets 19 may be pulled from the roll and separated from a remainder of the roll along the respective perforated seam 28.

[0035] In addition to the primary panel 20, the sheets 19 further include one or more secondary panels. In several embodiments, the secondary panels include two panels, namely a right panel 30 and a left panel 40. The right panel 30 is joined along a side edge 37 to the right side edge 26 of the primary panel 20 along a folded seam which may be perforated. The right side panel further includes a top face 32, a bottom face 33, a top edge 34 and a bottom edge 35. A free side edge 36 extends from the top edge 34 to the bottom edge 35, opposite of the seam joining the right panel 30 to the primary panel 20.

[0036] The left side panel 40 is joined along a side edge 47 to the left side edge 27 of the primary panel 20 along a folded seam which may be perforated. The left side panel further includes a top face 42, a bottom face 43, a top edge 44 and a bottom edge 45. A free side edge 46 of the left panel 40 extends from the top edge 44 to the bottom edge 45 opposite of the seam 47 joining the left panel 40 to the primary panel 20.

[0037] As seen in several figures of the drawings, the package 10 of the paper product may be in the form of a roll. In particular, the roll may be of the type which includes a tubular core 12, wherein the interconnecting sheets 19 are wound about the core 12 in a manner similar to that of conventional toilet tissue. In this instance, the tubular core 12, which may be formed of a cardboard material, includes an outer surface 14 having means thereon for grabbing the first sheet(s) which contact the outer surface 14. The means for grasping the sheet(s) may include bumps 16, glue or other means which hold the first sheet(s) on the roll to thereby allow the length of interconnecting sheets 19 to be wound onto the core 12 with slight tension applied so that the sheets are wound in a compact uniform roll package. The roll package 10 may be supported on a dowel 60. Pegs 61 at the opposite ends of the dowel 60 are adapted for keyed receipt within a holder for holding the dowel and supported roll package 10 in a manner which permits removal of individual sheets by pulling the sheet from the roll as the roll rotates about the dowel.

[0038] Various embodiments of the paper package 10 of the present invention are shown throughout the drawings, wherein at least one secondary panel is folded along a seam to overly or underlie the primary panel 20 when contained in the package. Once the sheet 19 is removed from the package, the one or more secondary panels may be unfolded relative to the primary panel 20 to thereby enlarge the overall size of the removed sheet 19. In several embodiments, the at least one secondary panel is separable from the primary panel along the adjoining seam which is perforated. The varying embodiments of the present invention further contemplate alternative sizes and configurations of bulky primary panel and secondary panels, as well as the configuration of the perforated seams adjoining the sheets 19 as well as the perforated seams adjoining the secondary panels to the primary panel of each sheet. In the instance there are multiple secondary panels, such as a right side panel 30 and a left side panel 40, either of the secondary panels, or both, may be separable from the primary panel along a perforated seam. For example, only one seam adjoining the secondary panels to the primary panels may be perforated, so that only one of the secondary panels is separable from the primary panel. Alternatively, both seams adjoining the secondary panels to the primary panel may be perforated, so that each of the secondary panels may be separated from the primary panel, thereby providing three independent smaller sheets taken from the larger sheet 19.

[0039] Referring to FIGS. 1-5, the sheets 19 on the roll package 10 are shown in accordance with one preferred embodiment thereof. In this particular embodiment, each sheet 19 includes the primary panel 20, along with secondary panels including the right panel 30 and left panel 40. In this embodiment, the opposite secondary panels are folded in overlying relation on opposite sides of the primary panel 20. Specifically, the right side panel 30 is folded along seam 52 defining the joining side edges 26, 37 of the primary panel 20 and right panel 30, respectively. The left side panel 40 is folded along seam 54 defining the edges 27, 47 of the primary panel 20 and left panel 40, respectively. Moreover, the right side panel 30 is folded in overlying relation to the top face 22 of the primary panel 20 so that the free side edge 36 of the right panel 30 extends between the top edge 24 and bottom edge 25 of the primary panel on the top face 22. Likewise, the left panel 40 is folded under the primary panel 20 so that the left panel 40 is disposed in underlying relation to the bottom face 23 of the primary panel 20 with the free side edge 46 of the left panel 40 extending between the top edge 24 and bottom edge 25 of the primary panel. In this particular embodiment, the widths of the respective right and left side panels 30, 40, are less than half the width of the primary panel 20 so that the free edges 36, 46 of the respective side panels 30, 40 are spaced from the center of the primary panel 20, and spaced in relation to one another to define a zone 50 along the center of the primary panel extending from the top edge 24 to the bottom edge 25. This zone 50 forms a dimple or recess on the center of the package 10, allowing the corner or free side edge of the respective side panels overlying the top face of the primary panel to be more easily grasped and lifted when separating the sheet 19 from the roll 10. As seen in FIG. 9, either or both of the seams joining the side panels to the primary panel may be perforated. Specifically, the seam joining the right panel 30 to the primary panel may be perforated as at 56, joining the side edge 37 of the right panel 30 to the side edge 26 of the primary panel 20. This permits separation and removal of the right panel 30 from the primary panel 20 once the sheet 19 has been separated from the roll package. Likewise, the seam between the left side panel 40 and primary panel 20 may be perforated as at 58 to permit separation of the left panel 40 from the primary panel 20 once the sheet 19 is removed from the roll.

[0040] Referring to FIGS. 6-9, a further embodiment of the invention is shown wherein the side edges 36, 46 of the respective right and left side panels 30, 40 are arranged along the center of the primary panel 20, on the opposite side faces 22, 23, respectively. In this particular embodiment, the sheet 19, when packaged, is of uniform thickness throughout its width. It is noted that, while the right side panel 30 is shown in overlying relation to the top face 22 of the primary panel 20 and the left side panel 40 is shown underlying the bottom face 23 of the primary panel 20, the arrangement may be reversed. Specifically, as seen in FIG. 6, the left panel 40 may be folded and disposed in overlying relation to the top face 22 of the primary panel 20 while the right side panel 30 may be folded in underlying relation to the bottom face 23 of the primary panel 20. Again, either or both of the respective left and right side panels 30, 40 may be separated from the primary panel 20 along a perforated seam 56, 58, respectively.

[0041] Referring to FIGS. 10-14, yet another embodiment of the package 10 is shown, wherein the sheets 19 include the three panels, namely the primary panel 20, the right panel 30 and the left panel 40. In this particular embodiment, the right and left panels 30, 40 are folded and disposed in overlying relation to the opposite side faces 22, 23 of the primary panel 20 and are sized and configured to substantially cover and overly the entire respective top or bottom surface of the primary panel 20. In this particular embodiment, the thickness of the sheet 19 is three layers when packaged on the roll 10.

[0042] Referring to FIG. 11, the arrangement of the three panels of the sheet 19 are shown in a generally Z configuration, wherein the respective free side edges 36, 46 of the right and left panels 30, 40 are disposed in aligned relation with the seams joining the respective left and right side panels to the primary panel. In FIG. 12, the three panels of the sheet are shown in the Z configuration wherein the free side edges 36, 46 of the respective right 30 and left 40 panels extend beyond the seams joining the side panels to the primary panel 20. In FIG. 13, the three panels of the sheet 19 are shown in the Z-fold configuration wherein the free side edges 36, 46 of the respective right 30 and left 40 side panels are shown inboard of the seams joining the respective side panels to the primary panel 20. In each of the arrangements shown in FIGS. 11-13, either or both of the seams joining the right 30 and left 40 side panels to the primary panel 20 may be perforated, such as at 56 and 58, thereby permitting selective removal of either or both of the right side panel 30 and/or left side panel 40 from the primary panel 20.

[0043] Referring to FIGS. 15 and 16, yet another embodiment of the invention is shown, wherein the left and right panels 30, 40 respectively, are shown folded in overlying relation on the top face 22 of the primary panel 20, with the free side edges 36, 46 respectively, terminating in spaced relation to define the zone 50, similar to the embodiment of FIGS. 1-5. Again, the seams joining the right and/or left side panels to the primary panel may be perforated, such as at 56 and 58.

[0044] Referring to FIGS. 17-20, yet a further embodiment of the present invention is shown, wherein only one secondary panel 70 is provided in addition to the primary panel 20. In this particular embodiment, the secondary panel 70 is sized and configured to be generally the same as the primary panel 20 and may be folded in overlying relation to either the top face 22 or bottom face 23 of the primary panel 20. The secondary panel 70 includes a top face 72, a bottom face 73, a top edge 74 and a bottom edge 75. The secondary panel 70 further includes opposite side edges 76, 77. One of the side edges 76, 77 is joined to the respectively positioned side edges 26, 27 of the primary panel 20 along either a fold or a perforated seam. As seen in FIGS. 18-20, the secondary panel 70 is joined to the primary panel 20 along a perforated seam 79 to permit selective removal and separation of the secondary panel 70 from the primary panel 20 once the sheet 19 is removed from the roll package 10. As seen in FIGS. 18 and 19, the side edge 77 of the secondary panel 70 may be disposed either in aligned relation with the side edge 26 of the primary panel 20 or, inboard of the side edge 26 when the panels are folded in overlying relation on the package.

[0045] Referring to FIGS. 21-26, various embodiments of the sheets 19 of the invention are shown. Specifically, the shape and configuration of the panels, including the primary panel 20 and secondary panels 30, 40 may be of various configurations. Further, the perforated seam 28 joining the sheets 19 to one another may be either straight, angled or curved, and of various configurations, as shown throughout FIGS. 21-26. The sheets 19 may be of a single primary panel, as seen in FIGS. 21-24 and 26 or, alternatively, as described above, the sheets 19 may include the primary panel 20 and one or more secondary panels. Further, the perforated seams joining the secondary panels to the primary panel may be of various configurations so that when the individual panels are separated, a desired peripheral edge configuration may be achieved, such as a zig-zag configuration or scalloped configuration, as seen in FIGS. 25 and 26.

[0046] FIG. 27 shows an alternative embodiment of the roll package and is indicated as 10′. In this particular embodiment, the roll package 10′ includes a coreless center 11. The sheets 19 contained on the roll package 10′ may be structured, arranged and configured in accordance with any of the embodiments previously discussed.

[0047] While the instant invention has been shown and described in accordance with preferred and practical embodiments thereof, it is recognized that departures from the instant disclosure are contemplated within the spirit and scope of the present invention which, therefore, should not be limited except as defined in the following claims as interpreted under the doctrine of equivalents.

Claims

1. A package of paper comprising:

a plurality of sheets of paper detachably connected to one another along perforations and wound onto a hollow tubular core to form a roll;

each of said plurality of sheets including a plurality of panels including a primary panel and at least one secondary panel, said plurality of panels being disposed in folded, overlying relation to one another and said sheets including at least one seam between said plurality of panels.

2. The package of paper as recited in claim 1 wherein said at least one seam between said plurality of panels is perforated for selectively detaching and separating said at least one secondary panel from said primary panel.

3. The package of paper as recited in claim 1 wherein said plurality of panels includes said primary panel and a plurality of secondary panels, and said sheets including a seam between each of said plurality of panels.

4. The package of paper as recited in claim 3 wherein said plurality of secondary panels includes a right panel and a left panel, and wherein said primary panel is disposed between said right panel and said left panel, and further wherein said plurality of sheets include a seam between said right panel and said primary panel and a seam between said left panel and said primary panel.

5. The package of paper as recited in claim 4 wherein said right panel and said left panel are folded along said seams and disposed in overlying relation on the same side of said primary panel.

6. The package of paper as recited in claim 4 wherein said right panel and said left panel are folded along said seams and disposed in overlying relation to opposite sides of said primary panel.

7. The package of paper as recited in claim 4 wherein at least one of the seams between said left and right panels and said primary panel is perforated for selectively detaching and removing said at least one of said right and left panels.

8. A package of paper comprising:

a plurality of sheets of paper;

each of said plurality of sheets including a plurality of panels including a primary panel and at least one secondary panel, said plurality of panels being disposed is folded, overlying relation to one another and said sheets including at least one seam between said plurality of panels, and said at least one seam being perforated for selectively detaching and separating said at least one secondary panel from said primary panel.

9. The package of paper as recited in claim 8 wherein said plurality of panels includes said primary panel and a plurality of secondary panels, and said sheets including a seam between each of said plurality of panels.

10. The package of paper as recited in claim 9 wherein said plurality of secondary panels includes a right panel and a left panel, and wherein said primary panel is disposed between said right panel and said left panel, and further wherein said plurality of sheets each include a seam between said right panel and said primary panel and a seam between said left panel and said primary panel.

11. The package of paper as recited in claim 10 wherein said right panel and said left panel are folded along said seams and disposed in overlying relation on the same side of said primary panel.

12. The package of paper as recited in claim 10 wherein said right panel and said left panel are folded along said seams and disposed in overlying relation to opposite sides of said primary panel.

13. The package of paper as recited in claim 10 wherein at least one of said seams between said left and said right panels and said primary panel is perforated for selectively detaching and removing said at least one of said right and left panels.

14. The package of paper as recited in claim 8 wherein said plurality of sheets of paper are wound in a form of roll.

15. The package of paper as recited in claim 14 wherein said roll includes a hollow tubular core.

16. The package of paper as recited in claim 14 wherein said roll is coreless.

17. The package of paper as recited in claim 8 wherein said plurality of sheets of paper are arranged in a stacked array.