BEND TO OPEN FLAT POLY-PACK TISSUE CASSETTE FOR USE IN OVER-SHELL DISPENSERS
A tissue dispensing system with a rigid overshell having 5 sides and an opened bottom with a tissue withdrawal opening in the top is adapted to receive a bend-to-open pack containing a clip of tissue sheets enwrapped in a capaciously sized overwrap having a medial line of weakness formed therein and situated to allow withdrawal of tissue through the tissue withdrawal opening after the line of weakness is ruptured and the tissue pack is placed in the overshell.
This application is based on U.S. Provisional. Patent Application No. 62/116,719, filed Feb. 16, 2015, and U.S. Provisional Patent Application No. 62/153,236, filed Apr. 27, 2015, which are incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTIONPackaging can make a crucial difference in the success, or lack of it, for many consumer products, often constituting a significant portion of the cost that the consumer must ultimately bear for the product. Facial tissue is often sold in a “boutique” format in which the tissue resides in an almost cubical paperboard carton with a top opening, usually an oval, through which the tissue is dispensed. As the paperboard carton adds significantly to the cost of the facial tissue, this format—even though widely used—is quite wasteful. Further cartoning a large number of boutique cubes inside corrugate is rather wasteful as the amount of boxed boutique tissue that can be placed in a given corrugate container is rather small in relation to the volume of the corrugate as, when the tissue is folded over into a folded clip, it occupies a significantly greater volume than the volume of the flat clip before folding. Since the amount of tissue that can be effectively trucked is limited by volume rather than weight, this adds significantly to cartoning expense as well as to transportation cost.
To reconcile the almost cubic boutique format with standard tissue sizes preferred by consumers, the tissue in a boutique package is usually deployed in a folded or interfolded clip of folded tissues, wherein each of the longitudinal outer edges of each tissue is first folded inwardly so that they meet medially along the longitudinal center line of the sheet. Thereafter, a clip of roughly 100 of these tissues is formed by stacking one above the other, and the stacked clip is folded longitudinally with a central portion of the folded tissue clip protruding through an oval opening in the top of the boutique package. Inasmuch as facial tissue by its very nature should be soft, the tensile strength of the tissue must be limited. Therefore, if the packaging is not well suited to the particular tissue format, it can be difficult to easily remove sheets from the boutique package without tearing the sheet or lifting the package from its desired location. To this end, boutique carton designs have been used in which the interior of the boutique carton is partially lined with polyethylene to reduce the friction between the tissue sheet and the interior of the carton. Provision of the polyethylene interlining adds to the cost of the carton thereby aggravating an already wasteful format. See for example, U.S. Pat. No. 6,672,475, to Ho et al., and U.S. Pat. No. 4,411,374, to Hotchkiss. In many cases, particularly in hotel and motel rooms, boutique cartons are placed within reusable 5-sided plastic or metallic over-shells without any bottom to better suit the customer's aesthetic preferences. In other cases, long boxes of tissue may also be placed within plastic over-shells sized to accommodate the more conventional rectangular prism carton packaging often used for facial tissue.
Because the footprint of the boutique carton is relatively small, it can be particularly advantageous for use in bathrooms where the space is limited, either in a free standing box or more commonly in a five sided plastic over-shell without a bottom, but the bottom of the typical conventional plastic over-shell is thus vulnerable to water thereby counteracting suitability. In particular, when facial tissue is presented in hotel/′motel applications, guests are often very cavalier about splashing water on the counter leading to the need to replace a box of tissue merely because the bottom was spoiled by water even though a substantial amount of tissue remained un-used therein. Given the operating margins of motels and hotels, it can be appreciated that premature replacement of tissue can impose undue costs on the operator.
Thus it can be understood that boutique packaging of boxed facial tissue inside a re-usable plastic over-shell presents several distinct issues:
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- Cost of the paperboard carton as well as the polyethylene interlining and overwrap binding the boutique boxes together in aggregates that are easily handled;
- Cost of the corrugate overwrap in relation to the amount of tissue containable within a given volume of corrugate as well as the associated environmental impact of manufacture and disposal of the paperboard carton;
- Transportation costs for the format;
- Susceptibility to water and concomitant spoilage;
- Loading issues; and
- Dispensing of the tissue from the container.
Similar issues are presented when long boxes of tissue are placed in a plastic over-shell. We have found that we can alleviate many of these difficulties by eliminating the paperboard carton. In particular, in many cases as much as 75% more tissue that can be shipped if the paperboard boxes are eliminated. However, mere deletion of the paperboard carton does not alleviate all of the problem as the tissue still must be packed both for transportation and sale to the customer, and a simple close fitting polymeric overwrap over a folded or unfolded clip of tissue can not only cause difficulty in dispensing but also can make loading of the plastic over-shell non-trivial for the consumer. In particular, we have found that a conventional close fitting polymeric overwrap can severely impede proper dispensing of tissue in a boutique format—in many cases preventing proper dispensing unless the overwrap has a size substantially exceeding that of the clip. We have found that we can alleviate many of these difficulties associated with the current boutique format by packing unfolded stacked clips of tissues in a capaciously sized overwrap with a transversely extending line of weakness placed medially across one face of the overwrap, so that when it is desired to replace the tissue within a plastic shell, the replacement clip can be folded longitudinally to place the transversely extending line of weakness in tension, rupturing it and then inserting the tissue into the over-shell although, in many cases, the user will start the opening by running a finger nail or other suitable object along the line of weakness. This boxless design also alleviates issues experienced with nearly empty boxes of conventional boxed tissues in that when a conventional box of tissues becomes depleted, it becomes more and more likely that the user will have difficulty removing tissue from the box, particularly when the tissue becomes sufficiently depleted that the tissue clip can fall back into the box. Using the boxless tissue cassettes of the present invention, the tendency for tissues to fall back into the box is largely alleviated.
We have found that we can achieve excellent results by providing a capaciously sized, loose fitting, bend-to-open, or flex-to-open, flat poly-pack tissue cassette with a transversely extending medial line of weakness which, when capaciously sized, eases dispensing from inside a five-sided plastic over-shell. In our inventive packaging format, the facial tissue can be packed and shipped flat, conserving space. In preparation for use, the consumer can simply bend or flex the flat poly-pack along the transversely extending medial line of weakness, thereby placing that line of weakness in tension and opening up the poly-pack to make its contents accessible upon inserting the folded pack into the plastic over-shell. In many cases, consumers will prefer to run a fingernail along the line of weakness to ease opening or at least partially open the poly pack prior to bending or flexing. Even though the plastic over-shell is bottomless, susceptibility to water damage is alleviated, if not almost entirely obviated, since the lower ends of the clip remain ensconced in poly, while the tissue can be easily withdrawn through the top of the plastic over-shell. Thus, not only are the excess costs associated with the paperboard boutique carton eliminated, but it is also possible to store more tissue in a given space while avoiding the environmental impact of disposal of the paperboard carton as well as the wastage which results when water seeps into the bottom of conventionally boxed boutique tissues. Surprisingly, we have found that the very same configuration of over-wrapped tissue that functions well inside of boutique over-shells also functions well when used in conjunction with the rectangular prismatic over-shell usually used with long boxes.
When used in hotel/motel applications, both the presently used boutique boxes and long boxes present a storage and transport issue to the workers who prepare rooms for each guest as each box takes up a great deal of space on the cart used for transporting room preparation and cleaning supplies to and from the rooms as both the new boxes have to be transported to each room and the depleted and/or spoiled boxes have to be carried away. Further, if new boxes are cosmetically damaged prior to reaching the room, in many establishments, the damaged boxes are not considered suitable for use and thus are wasted.
In
In the most preferred embodiments, clip 22 of 2-ply tissue will have a caliper of from about 40 to about 75 mils per 8 sheets, preferably from about 45 to 70 mils per 8 sheets, more preferably from about 50 to about 65 mils per 8 sheets and even more preferably from about 52 to about 60 mils per 8 sheets. Accordingly clip 22 will have a height of from about 0.75″ to about 2.8″, preferably from about 0.8″ to about 2.5″, more preferably from about 1″ to about 2.2″, still more preferably from about 1.1″ to about 2″ and even more preferably from about 1.2″ to about 1.8″. In the most preferred embodiments, each clip 22 of tissue will contain between about 90 and 100 single ply or 2-ply sheets having a basis weight of from about 17 to 21 lbs/3000 sq. ft. ream with a caliper of 50 to 70 mils/8 sheets and a height of from about 1.2″ to about 1.5″-1.6″. Transversely extending medial line of weakness 24 is formed by line 26 of perforations 28 extending across the poly surrounding tissue clip 22 in view of the disparity between the length and width of poly-pack tissue cassette 20 and the length and width of interfolded tissue clip 22, it can be appreciated that poly-pack tissue cassette 20 is capaciously sized and loose fitting relative to tissue clip 22 therewithin. To ease removal of tissue sheets, the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly is preferably between about 0.70 to about 0.95, more preferably between about 0.75 and 0.92, still more preferably between about 0.80 and 0.90. In other cases, the ratio of the transverse perimeter of clip 22 to the interior transverse perimeter of poly-pack tissue cassette 20 may be between about 0.55 to about 0.85, between about 0.60 and 0.82, between about 0.65 and 0.8 and or about 0.70, the transverse perimeter being taken around the width of clip 22 as illustrated in
The present invention is also suitable for use with napkin stock having a basis weight of 16 to 25 pounds per 3000 sq. ft. ream, a caliper of between 50 and 130 mils/8 sheets; towel having a basis weight of 20 to 40 pounds per 3000 sq. ft. ream, a caliper of 50 to 70 mils per 8 sheets; and, wipes having a basis weight of 15 to 30 pounds per 3000 sq. ft. ream and a caliper of between 30 and 70 mils per 8 sheets. For these products, it is preferred that the ratio of the transverse perimeter of the clip of paper product to the transverse interior perimeter of the polymeric overwrap be in the range of about 0.772 to about 0.92. Similarly, the ratio of the longitudinal perimeter of the clip of paper product to the longitudinal interior perimeter polymeric overwrap should be between about 0.88 and 0.96.
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For tissue cassette 20 varying in size from those most preferred herein, the length, L, of the line of perforations will desirably be at least: L=W+H up to about L=W+2H.
Throughout the specification and claims, the terms “poly-”, “poly” and “polymeric” should be understood to include polyethylene in all of its variants that are suitable for packaging wrap, polypropylene, polyolefins suitable for packaging wrap as well as other suitably flexible, water impermeable polymeric material commonly used as overwraps. In this specification, all measurements are taken according to the applicable TAPPI standard unless otherwise specified.
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Claims
1. A package comprising:
- a plurality of boutique sized capacious loose fitting, bend-to-open flat low density polymeric sheet tissue cassettes, each tissue cassette comprising a clip of tissue having a heat sealed polymeric film overwrap thereabout with a transversely extending medial line of perforations forming a line of weakness in said polymeric overwrap; and
- a rigid re-usable generally cubic over-shell having at least four upwardly extending side walls defining an interior cavity having a height of at least about 4.5 inches, and lateral dimensions of about 4.25 inches, said interior cavity being capped by a horizontally extending upper wall having a dispensing opening formed therein;
- each said low density polymeric sheet tissue cassette having an interior span length of at least about 9.5 inches, and an interior span width of at least about 6.0 inches;
- each said tissue in said clip being prefolded along its length into a configuration chosen from C-shaped (C-fold) or interfolded configuration having a length of about 7 to 9.5 inches; a width of about 3.5 to 5.75 inches, and comprising from about 50 to 150 2-ply sheets having a basis weight of from at least about 15 lbs/3000 sq. ft. ream.
2. The package of claim 1, wherein the cubic over-shell has an interior height of at least about 4.75 inches and internal lateral dimensions of at least about 4.25 inches.
3. The package of claim 1, wherein the cubic over-shell has an interior height of at least about 4.85 inches and internal lateral dimensions of at least about 4.5 inches.
4. The package of claim 1, wherein the cubic over-shell has an interior height of at least about 5 inches and internal lateral dimensions of at least about 4.75 inches.
5. The package of claim 4, wherein each polymeric tissue cassette has interior span width of at least about 6.5 inches and said tissue clip has a width of from about 3.5 to about 5.75 inches.
6. The package of claim 1, wherein each polymeric tissue cassette has interior span width of at least about 6.5 inches and said tissue clip has a width of from about 3.5 to about 5.75 inches.
7. A bend to open polymeric sheet tissue cassette, having a transversely extending medial line of perforations forming a line of weakness; said bend to open poly-pack tissue cassette encompassing a prefolded clip of tissue sheets, wherein said poly-pack sheet tissue cassette has an interior span width of at least about 5.75 inches and comprises about 75 to 125 sheets of tissue having at least 2 plies having a width of no more than about 5.15 inches and a basis weight of from about 14 lbs/3000 sq. ft. ream up to about 25 lbs/3000 sq. ft. ream, said bend to open polymeric sheet tissue cassette having a transversely extending medial line of weakness formed thereacross capable of forming an opening having a width of at least about 5 inches, such that upon bending the line of weakness is placed in tension.
8. The bend to open polymeric sheet tissue cassette of claim 7 wherein said poly-pack sheet tissue cassette has an interior span width of at least about 6 inches and comprises about 75 to 125 sheets of tissue having at least 2 plies having a width of no more than about 5 inches and a basis weight of from about 14 lbs/3000 sq. ft. ream up to about 25 lbs/3000 sq. ft. ream.
9. The bend to open polymeric sheet tissue cassette of claim 8 wherein said clip of tissue has a height of between about 1″ and about 2.2″.
10. A tissue dispensing system comprising a rigid re-usable generally cubic over-shell having at least four upwardly extending side walls defining an interior cavity, said interior cavity being capped by a horizontally extending upper wall having a dispensing opening formed therein; and having disposed therewithin a bend to open poly pack sheet tissue cassette with a transversely extending medial line of perforations forming a line weakness; said bend to open poly-pack sheet tissue cassette encompassing a prefolded clip of tissue sheets, wherein each said low density polymeric sheet tissue cassette has a transversely extending medial line of weakness formed thereacross capable of forming an opening upon bending as the line of weakness is placed in tension.
11. The tissue dispensing system of claim 10 wherein said poly pack forms a water-tight seal around the lower portion of the prefolded clip of tissues encompassed therein.
12. The tissue dispensing system of claim 10, wherein language neutral pictorial use and opening instructions are printed onto the polymeric.
13. The tissue dispensing system of claim 10, wherein language neutral pictorial use and opening instructions are printed onto packaging associated with said bend to open poly-pack sheet tissue cassette.
14. The tissue dispensing system of claim 10, wherein the tissue sheets in the clip are interfolded.
15. The tissue dispensing system of claim 10, wherein the tissue sheets in the clip are C-folded.
16. The tissue dispensing system of claim 10, wherein:
- said poly-pack sheet tissue cassette has an interior span width of at least about 6 inches and comprises about 75 to 125 sheets of tissue having at least 2 plies having a width of no more than about 5 inches and a basis weight of from about 14 lbs/3000 sq. ft. ream up to about 25 lbs/3000 sq. ft. ream;
- said clip of tissue has a height of between about 1″ and about 2.2″;
- each said tissue in said clip is prefolded along its length into a C-shaped configuration having a length of about 7 to 9.5 inches;
- the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly of between about 0.55 to about 0.85;
- said poly pack forms a water-tight seal around the lower portion of the prefolded clip of tissues encompassed therein; and
- language neutral pictorial use and opening instructions are printed onto packaging associated with said bend to open poly-pack sheet tissue cassette.
17. The tissue dispensing system of claim 10, wherein the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly of between about 0.55 to about 0.85.
18. The tissue dispensing system of claim 17, wherein said poly pack forms a water-tight seal around the lower portion of the prefolded clip of tissues encompassed therein.
19. A bend to open polymeric sheet tissue cassette, having a transversely extending medial line of perforations forming a line of weakness; said bend to open poly-pack tissue cassette encompassing a prefolded clip of tissue sheets, wherein said poly-pack sheet tissue cassette has an interior span width of at least about 5.75 inches and comprises about 75 to 125 sheets of tissue having at least 2 plies having a width of no more than about 5.15 inches and a basis weight of from about 13 lbs/3000 sq. ft. ream up to about 30 lbs/3000 sq. ft ream, said bend to open polymeric sheet tissue cassette having a transversely extending medial line of weakness formed thereacross capable of forming an opening having a width of at least about 5 inches, such that upon bending the line of weakness is placed in tension.
20. The bend to open polymeric sheet tissue cassette of claim 19 wherein said poly-pack sheet tissue cassette has an interior span width of at least about 6 inches and comprises about 75 to 125 sheets of tissue having at least 2 plies having a width of no more than about 5 inches and a basis weight of from about 15 lbs/3000 sq. ft. ream up to about 27 lbs/3000 sq. ft. ream.
21. The bend to open polymeric sheet tissue cassette of claim 19 wherein said clip of tissue has a height of between about 1″ and about 2.2″.
22. The bend to open polymeric sheet tissue cassette of claim 21, wherein the ratio of the transverse perimeter of the clip to the interior transverse perimeter of the poly of between about 0.7 to about 0.95.
23. A bend to open polymeric sheet tissue cassette, having a transversely extending medial line of perforations forming a line of weakness; said bend to open poly-pack tissue cassette encompassing a prefolded clip of about 75 to 125 tissue sheets of tissue having a basis weight of from about 13 lbs/3000 sq. ft. ream up to about 40 lbs/3000 sq. ft. ream, and a caliper of between about 30 to 130 mils per 8 sheets, wherein the transverse perimeter of said clip is between about 0.77 and 0.92 of the interior transverse perimeter of said poly-pack and said bend to open polymeric sheet tissue cassette has a transversely extending medial line of weakness formed thereacross capable of forming an opening having a length of at least about the sum of the width and height of said tissue clip, such that upon bending, the line of weakness is placed in tension.
24. The bend to open polymeric sheet tissue cassette of claim 23 wherein said tissue product is chosen from the group consisting of;
- (a) napkin stock having a basis weight of about 16 to 25 pounds per 3000 sq. ft. ream and a caliper of between about 50 and 130 mils per 8 sheets;
- (b) facial tissue stock having a basis weight of between about 14 to 25 lbs/3000 sq. ft. ream and a caliper of between about 40 to 70 mils per 8 sheets;
- (c) towel stock having a basis weight of between about 20 to 40 pounds per 3000 sq. ft. ream and a caliper of between about 50 and 70 mils per 8 sheets; and
- (d) wiper stock having a basis weight of between about 15 to 30 pounds per 3000 sq. ft. ream and a caliper of between about 30 to 70 mils per 8 sheets.
Type: Application
Filed: Feb 11, 2016
Publication Date: Aug 18, 2016
Inventors: Donald C. McCarthy (Appleton, WI), William G. Burr (Scandinavia, WI), Jared S. Felix (Fenton, MI)
Application Number: 15/041,319