OFF-FOLDED ABSORBENT SHEET PRODUCTS INTERFOLDABLE IN A STACK FOR DISPENSEMENT FROM A DISPENSER

Abstract

Exemplary embodiments are disclosed of off-folded absorbent sheet products (e.g., paper napkins, etc.) that are interfoldable or interfolded in a stack for dispensement from a dispenser.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of PCT International Application No. PCT/US2013/033569 filed Mar. 22, 2013 (published as WO2013/162803 on Oct. 31, 2013), which, in turn, claimed priority to and benefit of U.S. provisional patent application No. 61/639,193 filed Apr. 27, 2012. The entire disclosures of the applications identified in this paragraph are incorporated herein by reference in their entirety.

FIELD

The present disclosure relates to off-folded absorbent sheet products (e.g., paper napkins, etc.), which are interfoldable or interfolded in a stack for dispensement from a dispenser.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Generally, napkins are pieces of doth or absorbent paper that are typically at a table to protect the clothes and/or wipe the lips and fingers of the user. Paper napkins are commonly loaded into a dispenser for removal by users.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

Exemplary embodiments are disclosed of off-folded absorbent sheet products (e.g., paper napkins, etc.) that are interfoldable or interfolded in a stack for dispensement from a dispenser.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 shows an exemplary embodiment of an off-folded napkin shown in an open or unfolded configuration;

FIG. 2 shows the off-folded napkin of FIG. 1 in a partially folded configuration in which the napkin is folded along one of its two folds and also illustrating the napkin's off-fold between the edges of the front and back parts;

FIG. 3 shows the off-folded napkin of FIGS. 1 and 2 in a fully folded, closed position in which the napkin is folded along both folds;

FIG. 4 shows a stack of interfolded napkins in which the napkins have an off-fold as shown in FIGS. 1 through 3 according to an exemplary embodiment;

FIG. 5 shows a dispenser loaded with a stack of interfolded napkins as shown in FIG. 4 according to an exemplary embodiment; and

FIG. 6 shows an exemplary embodiment of an off-folded napkin with a tape measure illustrating an exemplary dimension of one-half inch for the napkin's off-fold.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

With reference now to the figures, FIGS. 1 through 3 illustrate an exemplary embodiment of an off-folded napkin 100 embodying one or more aspects of the present disclosure. As shown in FIGS. 2 and 3, the off-folded napkin 100 includes an off-fold 102 between the opposite edges 112, 116 of the front and back parts. The front portion or part of the napkin 100 shown on top in FIG. 2 is shorter than the back portion or part of the napkin 100 on the bottom.

By way of example, the napkin 100 may be configured such that the off-fold 102 is about one-half inch such that the off-fold 102 is either exactly one-half inch or about one-half inch where the difference above or below one-half inch is within manufacturing tolerances. By way of further example, the napkin 100 may be configured such that the off-fold 102 is about one centimeter such that the off-fold 102 is either exactly one centimeter or about one centimeter where the difference above or below one centimeter is within manufacturing tolerances. As yet another example, the napkin 100 may be configured such that the off-fold 102 falls within a range from about four-tenths of an inch to about six-tenths of an inch, etc.

The inventor hereof has recognized that purposefully and controllably providing a sufficiently large off-fold 102 (e.g., one-half inch, one centimeter, within a range from four-tenths of an inch to six-tenths of an inch, etc.) allows a user to more easily grasp and separate the opposing front and back parts of the napkin 100 at the off-fold 102. This, in turn, allows the user to more easily open the napkin 100.

As shown in FIG. 1, the napkin 100 is single ply and foldable about first and second folds 104, 108. The first and second folds 104, 108 are generally perpendicular to each other. For example, the first and second folds 104, 108 may be perpendicular. Or, the first and second folds 104, 108 may be close to perpendicular with the variance falling within manufacturing tolerances.

The first fold 104 extends in a first linear direction between a first pair of opposite edges 120, 124 of the napkin 100. The first fold 104 may also be generally referred to as longitudinal fold or interfold that extends longitudinally in a machine direction as described hereinafter. The second fold 108 extends in a second linear direction generally perpendicular to the first linear direction. The second fold 108 extends between a second pair of opposite edges 112, 116 of the napkin 100. The second fold 108 may also be generally referred to as a cross fold described hereinafter. The napkin 100 is thus foldable twice (cross-folded or quarter folded) once about each of the two generally perpendicular axes or folds 104, 108. For example, the napkin 100 may first be foldable about the first fold 104 into a single-folded configuration with the off-fold 102 between the first pair of opposite edges 112, 116, and thereafter foldable about the second fold 108 into a quarter-folded or cross-folded configuration having the off-fold 102 between the first pair of opposite edges.

The napkin 100 includes four panels or parts 128, 132, 136, and 140 cooperatively defined by the first and second folds 104, 108. The napkin 100 is configured such that the first and second folds 104, 108 do not bisect the napkin 100 into four equal parts. In this exemplary embodiment, the first fold 104 is not along a centerline axis of the napkin 100. Instead, the first fold 104 is located closer to the edge 112 than to the edge 116 as shown in FIG. 1. Accordingly, the napkin 100 is off-folded and includes the off-fold 102 as shown in FIGS. 2 and 3.

In one particular example, the panels or parts 128, 132 are one-half inch longer (from top to bottom in FIG. 1) than the panels 136, 140 in order to provide the one-half inch off-fold 102. The first fold 104 is one-half inch closer to the edge 112 than it is to the edge 116 in this example shown in FIG. 1. Therefore, and as shown in FIG. 2, the napkin 100 may thus be folded along the first fold 104 into unequal parts such that the napkin 100 has a one-half inch off-fold 102 in this example.

Continuing with this example, the panels or parts 128, 132, 136, 140 may all have about the same width (from left to right in FIG. 1). And, the second fold 108 may be along or coincident with a centerline axis of the napkin 100 such that the second fold 108 is equidistant from the edges 120, 124 in this example shown in FIG. 1. As shown in FIG. 3, the napkin 100 may be folded a second time along the second fold line 108 after it has been folded along the first fold line 104. The folding of the napkin 100 along the second fold 108 may align or substantially align the edges 120, 124 such that there is not a significantly sized off-fold (e.g., no off-fold, relatively small off-fold less than one-half inch, etc.) between the edges 120, 124.

FIGS. 1 through 3 show the exemplary manner by which the unfolded napkin 100 may be folded. First, the napkin 100 (FIG. 1) is folded about the first fold 104 (FIG. 2) and then folded about the second fold 108 (FIG. 3). Conversely, the closed, folded napkin 100 may also be opened by the reverse. That is, the folded, closed napkin 100 (FIG. 3) may first be unfolded about the second fold 108 (FIG. 2) and then unfolded about the first fold 104 to thereby fully open the napkin 100 as shown in FIG. 1.

Exemplary embodiments of the off-folded napkins may be manufactured and interfolded by using conventional in-line converting machines for manufacturing and interfolding napkin products after modifying the same. By way of example, exemplary embodiments may include using and/or modifying the web interfolding equipment such as that disclosed in U.S. Pat. No. 3,291,479 and/or U.S. Pat. No. 3,285,599 to provide off-folded napkin products. The entire contents of U.S. Pat. Nos. 3,291,479 and 3,285,599 are incorporated herein by reference.

An exemplary embodiment of a napkin disclosed herein (e.g., 100, 200, etc.) may first be folded in a first direction longitudinally or parallel in the machine direction, and then folded transversely in a cross direction. The machine direction, longitudinal folding may be accomplished by using a technique generally referred to as plow folding. In this exemplary method, a paper web is pulled or drawn (e.g., via driven feed rolls, etc.) from a roll over a stationary plow (e.g., fold pan or former, folding rods or guide bars, etc.). As the paper web travels (e.g., under tension, etc.) over the plow, the plow folds the paper web longitudinally along a line that is parallel to the direction of travel of the paper web.

With conventional plow folding, the paper roll, the stationary plow, and feeding mechanism are specifically configured (e.g., located relative to each other, etc.) such that the plow folds the paper web in half into equal parts along the paper web's centerline, which centerline bisects the paper web and is parallel to the direction of travel of the paper web. In contrast, the inventor hereof has developed and discloses exemplary embodiments of modified plow folding processes for making his off-folded napkins. In an exemplary embodiment of one such modified plow folding process, the plow, paper roll, and/or feed line are configured (e.g., intentionally misaligned, positioned relative to each other, etc.) such that the plow is not located along the centerline of the paper roll. Instead, the plow is spaced apart from the centerline of the paper roll so that the plow off-folds the paper web (e.g., off-folded by one half inch, one centimeter, etc.) as the paper web travels over the stationary plow.

In another exemplary embodiment, the off-fold is accomplished by intentionally misaligning the paper roll relative to the plow so that the longitudinal fold line created by the plow is not centered relative to the paper web. Additionally, or alternatively, the feeding process (e.g., rollers, edge guide tracks, etc.) may be configured to controllably steer the paper web (e.g., controllably steer the paper off-course and not merely due to some uncontrollable or uncertain variation or manufacturing tolerance, etc.) so that the paper web arrives at the plow un-centered. Because the paper web is un-centered at the plow, the plow off-folds the paper web in an exemplary embodiment. As yet a further example, the plow itself may be geometrically configured (e.g., shaped, sized, etc.) to off-fold the paper web without having to reposition or realign the paper roll or plow in an exemplary embodiment.

After the paper web has been off-folded by one of the exemplary processes described above, the off-folded paper web may then be cut (e.g., via a paper cutter, etc.) to form individual or discreet sheets in an exemplary embodiment. Then, the sheets may be transferred to a folding section that includes mechanical folding cylinders or drums. The sheets are folded transversely in the cross direction as the sheets are transferred from one cylinder to another, thereby providing the sheets with second fold lines or cross folds. Transfer of the folded sheets may take place by grippers, pushers, and/or vacuum. The folded sheets may be grabbed by mechanical grippers and tuckers that overlap the sheets from each line of the machine and create an interfold at the interfold line.

The overlapped and interfolded sheets may be provided in a stacked arrangement. For example, FIG. 4 illustrates a stack 144 of off-folded napkins 100, which have been interfolded to form the stack 144. The napkins 100 in the stack 144 may each be off-folded to have an off-fold of one-half inch or about one-half inch. Each napkin 100 in the stack 144 may or may not have the same off-fold equal to the off-fold of each other napkin 100 in the stack 144. For example, there may be some manufacturing tolerance and variability in the manufacturing process (e.g., a repeating drift in the folding operation, etc.), such that each napkin 100 does not include exactly the same off-fold. Instead, the napkins 100 in the stack 144 may have off-folds falling within a range, e.g., four-tenths of an inch to six-tenths of an inch, etc.

Within the stack 144 of interfolded napkins 100, each napkin 100 includes at least one pair of panels or parts that are disposed or sandwiched between a pair of adjacent panels or parts of another one of the napkins 100 in the stack 144. More specifically, this exemplary embodiment includes each napkin 100 within the stack 144 receiving between its two inwardly facing adjacent parts or panels a pair of adjacent parts or panels from each of two napkins 100 disposed immediately above and below it in the stack 144. Preferably, each napkin 100 is detachable and/or entirely detached from the other napkins 100 in the stack 144. Each napkin 100 is also oriented oppositely from each preceding and succeeding napkin 100 with the stack 144.

FIG. 5 illustrates a stack 144 of interfolded napkins 100 loaded into a dispenser 148. Preferably, the napkins 100 and dispenser 148 are configured such that the napkins 100 will be dispensed or drawn one at a time during regular use. While a user may be able to remove more than a single napkin by improperly using the dispenser 148, the configuration of the napkins 100 and dispenser 148 inhibits users from removing more than one napkin 100 at a time from the dispenser 148. As shown in FIG. 5, only a portion of a single napkin 100 extends or protrudes out of the dispensing opening 152 in the faceplate 156 of the dispenser 148 at a given time. When that protruding portion is grabbed by a user and the napkin 100 is pulled out of the dispenser 148, a portion of the next succeeding napkin 149 immediately below in the stack 144 is repositioned so that it extends or protrudes out of the dispensing opening 152.

Exemplary embodiments of the present disclosure may provide one or more (but not necessarily any or all) of the following advantages. For example, the dispenser 148 and interfolded napkins 100 may be configured to provide one napkin-at-a-time dispensing, which, in turn, may provide up to a fifty percent reduction in napkin usage when compared to usage of smaller tall fold styles and up to a thirty percent reduction in napkin usage when compared to usage of larger standard styles. This exemplary one-at-a-time napkin dispensing configuration may help ensure that patrons use fewer napkins and touch only the napkin they use, thus improving personal hygiene. This exemplary one-at-a-time dispensing may help decrease consumption, thus reducing the number of napkins needed to be stored at a restaurant, etc.

By way of example only, the napkins 100 may be provided in a case, such as six thousand napkins per case in which there are twelve stacks or packs each with five hundred interfolded napkins. The napkins 100 may be configured such that one thousand five hundred fifty of such cases may fit within a standard forty foot container. Dimensionally, the napkin 100 may be configured with a rectangular configuration having a long side measuring 12.5 inches (or thereabout) and a short side measuring 8.25 inches (or thereabout) when unfolded and opened. When fully folded and closed, the napkin 100 may still have a rectangular configuration and have a long side measuring 6.5 inches (or thereabout) and a short side measuring 4.125 inches (or thereabout). Accordingly, this exemplary embodiment of the napkin 100 when folded includes one fold 108 that bisects the napkin 100 into equal (or about equal) parts where the fold 108 is equidistant or equally spaced from each of the napkin's edge 120, 124. In one example embodiment, the fold 108 is 4.125 inches (or thereabout) from each of the napkin's edges 120, 124 parallel to that fold 108. The other fold 104, however, is an off-fold that does not bisect the napkin 100 into equal parts. Instead, this off-fold 102 is 6 inches (or thereabout) from one napkin edge 112 parallel to the off-fold 102 and 6.5 inches (or thereabout) from the opposite edge 116, thus creating an off-fold of one-half inch (or thereabout). For example, FIG. 6 illustrates an exemplary embodiment of an off-folded napkin 200 having an off-fold 202 of one-half inch.

These specific dimensions and other specific numerical values provided in this paragraph (and elsewhere in this application) are exemplary in nature and do not limit the scope of the present disclosure. Alternative embodiments may include napkins or other absorbent sheet products that are configured differently (e.g., larger, smaller, made from different materials, etc.).

A wide range of materials may be used for the napkins or other absorbent sheet products disclosed herein. By way of example only, exemplary embodiments include off-folded napkins formed from Virgin Sugarcane-Bagasse/Bright White or Natural/Kraft. Alternative embodiments may include napkins or other absorbent sheet products formed from other suitable paper and non-paper materials.

Exemplary embodiments are disclosed herein of paper napkins. But other exemplary embodiments may include other absorbent sheet products, such as facial tissues, paper towels, among other paper and non-paper products, cloth products, etc.

In an exemplary embodiment, a system generally includes means (e.g., a plow, etc.) for forming a first fold in an absorbent sheet product that extends in a first linear direction between a first pair of opposite edges of the absorbent sheet product and that is about one-half inch closer to one edge of the first pair of opposite edges than to the other edge. The system also generally includes means (e.g., mechanical folding cylinders or drums, etc.) for forming a second fold in the absorbent sheet product that extends in a second linear direction between a second pair of opposite edges of the absorbent sheet product. The second linear direction is generally perpendicular to the first linear direction. The first and second folds are configured to allow the absorbent sheet to be foldable about the first and second folds such that there is an off-fold of about one-half inch between the first pair of opposite edges.

The means for forming a first fold may comprise a plow configured to fold a paper web as the paper web travels over the plow. The plow may form the first fold in the paper web plow longitudinally along a line that is parallel to the direction of travel of the paper web. The plow may be intentionally misaligned with a centerline of the paper web such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or the paper web may be controllably steered to arrive at the plow un-centered such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or the plow may be geometrically configured to create the off-fold without having to reposition or realign the paper roll relative to the plow.

The system may further include means for cutting (e.g., paper cutter, etc.) the off-folded paper web into sheets; means for transferring (e.g., grippers, pushers, and/or vacuum, etc.) the sheets to a folding section including first and second mechanical folding cylinders; and means for folding (e.g., mechanical folding cylinders or drums, etc.) the sheets transversely in a cross direction as the sheets are transferred from the first mechanical folding cylinder to the second mechanical folding cylinder to thereby form the second fold in the sheets.

The absorbent sheet products may comprise off-folded paper napkins each having an off-fold of about one-half inch. A stack of absorbent sheet products may be loaded into a dispenser from which the absorbent sheet products are dispensable one-at-a-time.

In an exemplary embodiment, a system generally includes means (e.g., a plow, etc.) for folding an absorbent sheet product about a first fold into a single-folded configuration. The first fold extends in a first linear direction between a first pair of opposite edges of the absorbent sheet product. The first fold is about one-half inch closer to one edge of the first pair of opposite edges than to the other edge. The system also generally includes means (e.g., mechanical folding cylinders or drums, etc.) for folding the absorbent sheet product having the single-folded configuration about a second fold such that the absorbent sheet product has a quarter-folded or cross-folded configuration. The second fold extends in a second linear direction between a second pair of opposite edges of the absorbent sheet product. The second linear direction is generally perpendicular to the first linear direction. The second pair of opposite edges is substantially aligned. There is an off-fold of about one-half inch between the first pair of opposite edges.

The means (e.g., a plow, etc.) for folding an absorbent sheet product about a first fold may comprise a plow configured to fold a paper web as the paper web travels over the plow. The plow may form the first fold in the paper web plow longitudinally along a line that is parallel to the direction of travel of the paper web. The plow may be intentionally misaligned with a centerline of the paper web such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or the paper web may be controllably steered to arrive at the plow un-centered such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or the plow may be geometrically configured to create the off-fold without having to reposition or realign the paper roll relative to the plow.

The system may further include means for cutting (e.g., paper cutter, etc.) the off-folded paper web into sheets; and means for transferring (e.g., grippers, pushers, and/or vacuum, etc.) the sheets to a folding section including first and second mechanical folding cylinders. The means for folding the absorbent sheet product having the single-folded configuration about a second fold may comprise a first mechanical folding cylinder and a second mechanical folding cylinder that are operable for folding the sheets transversely in a cross direction as the sheets are transferred from the first mechanical folding cylinder to the second mechanical folding cylinder.

The system may be operable for folding a plurality of absorbent sheet products about the first and second folds; and for forming a stack of the plurality of absorbent sheet products in which the absorbent sheet products are interfolded to form the stack. The plurality of absorbent sheet products may comprise off-folded paper napkins each having an off-fold of about one-half inch. The stack of absorbent sheet products may be loaded into the dispenser from which the absorbent sheet products are dispensable one-at-a-time.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1 - 2, 2-10, 2-8, 2-3, 3-10, and 3-9.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally,” “about,” and “substantially,” may be used herein to mean within manufacturing tolerances. Whether or not modified by the term “about,” the claims include equivalents to values or quantities.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. An absorbent sheet product comprising:

a first pair of opposite edges;

a second pair of opposite edges;

a first fold extending in a first linear direction between the first pair of opposite edges, the first fold about one-half inch closer to one edge of the first pair of opposite edges than to the other edge; and

a second fold extending in a second linear direction between the second pair of opposite edges where the second linear direction is generally perpendicular to the first linear direction;

whereby the absorbent sheet product is foldable about the first and second folds such that there is an off-fold of about one-half inch between the first pair of opposite edges.

2. The absorbent sheet product of claim 1, wherein the first fold is one-half inch closer to one edge of the first pair of opposite edges than to the other edge such that the off-fold between the first pair of opposite edges is one-half inch.

3. The absorbent sheet product of claim 1, wherein the off-fold between the first pair of opposite edges is one inch, one centimeter, or within a range from four-tenths of an inch to six-tenths of an inch.

4. The absorbent sheet product of claim 1, wherein the absorbent sheet product is foldable about the first and second folds into a quarter-folded or cross-folded configuration having the off-fold of about one-half inch between the first pair of opposite edges.

5. The absorbent sheet product of claim 1, wherein:

the first fold is an interfold that extends longitudinally in a machine direction; and

the second fold is a cross fold that is perpendicular to the interfold.

6. The absorbent sheet product of claim 1, wherein:

the absorbent sheet product is a single ply paper napkin; and

the single ply paper napkin is foldable about the first fold into a single-folded configuration with the off-fold between the first pair of opposite edges and thereafter foldable about the second fold, which is equidistant from the second pair of opposite edges, into a quarter-folded or cross-folded configuration in which the second pair of opposite edges are substantially aligned and where the off-fold between the first pair of opposite edges allows a user to more easily grasp and separate the first pair of opposite edges, thereby allowing the user to more easily open the paper napkin.

7. The absorbent sheet product of claim 1, wherein:

the absorbent sheet product includes four panels cooperatively defined by the first and second folds; and

the first and second folds do not bisect the absorbent sheet product into four equally sized panels;

the second fold is equidistant from the second pair of opposite edges; and

the absorbent sheet product when unfolded and opened has a rectangular configuration having a long side that is 12.5 inches, a short side that is 8.25 inches, and the off-fold is one-half inch.

8. A stack comprising a plurality of absorbent sheet products interfolded with each other in the stack, wherein each of the plurality of absorbent sheet products comprises an absorbent sheet product of claim 1.

9. A dispenser loaded with the stack of absorbent sheet products of claim 8, wherein the absorbent sheet products are dispensable one-at-a-time from the dispenser.

10. A method comprising:

folding an absorbent sheet product about a first fold into a single-folded configuration, the first fold extending in a first linear direction between a first pair of opposite edges of the absorbent sheet product, the first fold is about one-half inch closer to one edge of the first pair of opposite edges than to the other edge; and

folding the absorbent sheet product having the single-folded configuration about a second fold such that the absorbent sheet product has a quarter-folded or cross-folded configuration, the second fold extending in a second linear direction between a second pair of opposite edges of the absorbent sheet product where the second linear direction is generally perpendicular to the first linear direction;

whereby the second pair of opposite edges is substantially aligned and there is an off-fold of about one-half inch between the first pair of opposite edges of about one-half inch.

11. The method of claim 10, wherein folding an absorbent sheet product about a first fold includes using a plow to fold a paper web as the paper web travels over the plow, whereby the first fold is formed by the plow in the paper web longitudinally along a line that is parallel to the direction of travel of the paper web, and wherein:

the paper web travels un-centered over the plow due to intentional misalignment of the plow and a centerline of the paper web to thereby create the off-fold; and/or

the paper web is controllably steered to arrive at the plow un-centered such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or

the plow is geometrically configured to create the off-fold without having to reposition or realign the paper roll relative to the plow.

12. The method of claim 11, wherein after folding the absorbent sheet product about the first fold, the method includes:

cutting the off-folded paper web into sheets;

transferring the sheets to a folding section including first and second mechanical folding cylinders; and

folding the sheets transversely in a cross direction as the sheets are transferred from the first mechanical folding cylinder to the second mechanical folding cylinder to thereby fold the absorbent sheet product having the single-folded configuration about the second fold.

13. The method of claim 10, wherein

folding the absorbent sheet product about the first and second folds comprises folding a plurality of absorbent sheet products about the first fold and about the second fold, which is equidistant from the second pair of opposite edges, such that the plurality of absorbent sheet products each has a quarter-folded or cross-folded configuration; and

the method further includes forming a stack of the plurality of absorbent sheet products in which the absorbent sheet products are interfolded to form the stack.

14. The method of claim 13, wherein:

the absorbent sheet products comprise off-folded paper napkins each having an off-fold of about one-half inch; and

the method further includes loading the stack of absorbent sheet products into a dispenser in which the absorbent sheet products are dispensable one-at-a-time from the dispenser.

15. A system comprising:

means for folding an absorbent sheet product about a first fold into a single-folded configuration, the first fold extending in a first linear direction between a first pair of opposite edges of the absorbent sheet product, the first fold about one-half inch closer to one edge of the first pair of opposite edges than to the other edge; and

means for folding the absorbent sheet product having the single-folded configuration about a second fold such that the absorbent sheet product has a quarter-folded or cross-folded configuration, the second fold extending in a second linear direction between a second pair of opposite edges of the absorbent sheet product where the second linear direction is generally perpendicular to the first linear direction;

whereby the second pair of opposite edges is substantially aligned and there is an off-fold of about one-half inch between the first pair of opposite edges.

16. The system of claim 15, wherein the system comprises a paper web, and the means for folding an absorbent sheet product about a first fold comprises a plow configured to fold the paper web as the paper web travels over the plow whereby the first fold is formed by the plow in the paper web longitudinally along a line that is parallel to the direction of travel of the paper web.

17. The system of claim 16, wherein:

the plow is intentionally misaligned with a centerline of the paper web such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or

the paper web is controllably steered to arrive at the plow un-centered such that the paper web travels un-centered over the plow to thereby create the off-fold; and/or

the plow is geometrically configured to create the off-fold without having to reposition or realign the paper roll relative to the plow.

18. The system of claim 16, wherein:

the system includes means for cutting the off-folded paper web into sheets, and means for transferring the sheets to a folding section including first and second mechanical folding cylinders; and

the means for folding the absorbent sheet product having the single-folded configuration about a second fold comprises a first mechanical folding cylinder and a second mechanical folding cylinder that are operable for folding the sheets transversely in a cross direction as the sheets are transferred from the first mechanical folding cylinder to the second mechanical folding cylinder.

19. The system of claim 15, wherein the system is operable for:

folding a plurality of absorbent sheet products about the first fold and about the second fold, which is equidistant from the second pair of opposite edges; and

forming a stack of the plurality of absorbent sheet products in which the absorbent sheet products are interfolded to form the stack.

20. The system of any one of claim 19, wherein:

the plurality of absorbent sheet products comprise off-folded paper napkins each having an off-fold of about one-half inch; and

the stack of absorbent sheet products are loaded into a dispenser from which the absorbent sheet products are dispensable one-at-a-time.