Container for Dispensing Sheet Materials

BACKGROUND

Pop-up style dispensers have been used for some time to release individual folded sheet products such as facial tissues and the like. Such dispensers typically include a container and a stack, or “clip”, of interfolded tissues disposed within the container. The tissues may be folded so that once the top tissue in the clip is withdrawn, subsequent sheets are individually presented above the top plane of the container for individual use.

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

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

The above dispenser configuration has enjoyed tremendous success. The plastic film has been found well suited for applying a suitable amount of force to an individual tissue so that the tissue will remain in an upright position and not fall back into the interior of the dispenser and without applying too much force that unreasonably restricts dispensing of the tissues and causes tears.

Although plastic films have performed well in tissue dispensers, the plastic films create various problems and drawbacks. For instance, incorporating a plastic film into a carton made from paperboard can complicate the process for recycling the used container. The presence of the plastic film, for instance, can create the necessity of separating the film from the paperboard carton during the recycling process. In many cases, the waste plastic film is collected and disposed of in the waste stream with little chance for recycling or upcycling. Ideally, the container is designed such that the entire carton can be reclaimed in a repulping process and used to make new fiber-based products.

In view of the above, a need currently exists for an improved dispenser opening configuration that can hold a tissue sheet in an upright position for facilitating pop-up dispensing while minimizing fallback of the tissues into the dispenser. A need also exists for a sustainable tissue dispenser that can easily enter a recycling stream after all the tissues have been dispensed. A need also exists for a dispenser design that can be produced solely from a fiber-based material so that the used dispenser can be wholly recycled in the paper recycling stream. In addition, a need exists for a tissue dispenser that does not include a plastic film that covers a dispensing window.

SUMMARY

The present disclosure is generally directed to an improved dispenser for individual sheet materials, such as tissue products, which can fulfill one or more of the above needs. The tissue dispenser of the present disclosure, for instance, can be made exclusively from a paperboard material. The dispenser can be formed without the use of a plastic film making the dispenser or container sustainable and well suited for entering the paper recycling stream and/or for being fed to a repulping process and converted back into new product. The dispenser of the present disclosure can also include an access opening separate from a baffle that dispenses sheets in a pop-up style. The access opening can be used to initiate dispensing of the sheet material and can also be used to re-thread the sheet material through the baffle should fallback of the sheet material into the dispenser occur.

For example, in one embodiment, the present disclosure is directed to a container for holding and dispensing a plurality of individual sheets. The container includes a carton having at least one carton wall and defining a hollow enclosure for receiving a stack of interfolded sheets. An access opening is disposed on the at least one carton wall. The access opening has a size sufficient to receive the fingers and/or hand of a user. The access opening is positioned such that a user can grasp a top sheet of the stack of interfolded sheets received within the hollow enclosure. A baffle is in communication with the access opening. The baffle comprises a non-linear slit. When a top sheet of the stack of interfolded sheets is grasped by a user through the access opening, an adjacent interfolded sheet is partially withdrawn from the container and is engaged by the non-linear slit of the baffle.

In one aspect, the baffle can be integral with a carton wall of the container. Alternatively, the baffle can be made from a flexible member that is attached to a carton wall. The flexible member, for instance, can be made from a paperboard material that is more flexible than the carton wall. The baffle can be located on any suitable carton wall, such as the top carton wall. In one aspect, the non-linear slit of the baffle comprises a sinusoidal pattern. The sinusoidal pattern can include a pattern of peaks and valleys having an amplitude defined by a distance extending from a peak to an adjacent valley. The amplitude can be constant or can vary over the length of the slit. In one aspect, the amplitude of the sinusoidal pattern can be from about 2 mm to about 50 mm and the peak-to-peak distance of the sinusoidal pattern can be from about 8 mm to about 90 mm. The non-linear slit can initially comprise a perforation line that is then opened by the user to gain access to the stack of sheet materials contained in the container.

In one aspect, the access opening can be located on a first carton wall and the baffle can be located on a second and adjacent carton wall. The first carton wall, for example, can be perpendicular to the second carton wall. Alternatively, the access opening can extend between the first carton wall and the second carton wall. In this embodiment, the access opening can intersect the non-linear slit of the baffle in various ways. For instance, the portion of the access opening located on the first carton wall can have an hourglass-like shape where the access opening intersects the non-linear slit in order to better hold and direct the sheet material into the baffle. Alternatively, the access opening can include a spacer slit that extends between the access opening and the baffle for providing indirect communication between the access opening and the baffle. The spacer slit can intersect the non-linear slit at an angle and can be used to not only direct sheet materials into the baffle, but also prevent fallback of a partially extended sheet material back into the container.

In still another embodiment, the access opening and the non-linear slit of the baffle can both be located on the same carton wall. For example, the access opening can be located at one end of the non-linear slit. Alternatively, the access opening can be placed along the non-linear slit and the non-linear slit can extend from opposite ends of the access opening. In this regard, the baffle can comprise only a single non-linear slit or can comprise two non-linear slits.

The stack of interfolded sheets contained in the container can have a length and a width. The length can be greater than the width. The non-linear slit of the baffle can be perpendicular to the length of the stack of interfolded sheets. In an alternative embodiment, the non-linear slit of the baffle can be parallel with the length of the stack of interfolded sheets. In still another embodiment, the non-linear slit of the baffle can extend at a diagonal (e.g. skew) to the length of the sheets.

The container of the present disclosure can be made from any suitable material that is preferably capable of being recycled. In one embodiment, the entire container can be made from a polymer material. Alternatively, the entire container can be made from a paper material. For example, the paper can be a coated paper having a basis weight of from about 40 gsm to about 500 gsm. In one embodiment, the container does not include a polymer film associated with the baffle or the access opening. In one aspect, the access opening can be created by removing a perforated dispensing flap. In this manner, the user can decide whether the access opening is needed for dispensing the sheet materials.

The container of the present disclosure can be used to dispense all different types of sheets, including facial tissues, premoistened wipes, industrial wipes, paper towels, and the like.

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a perspective view of one embodiment of a container made in accordance with the present disclosure;

FIG. 2 is a perspective view of the container illustrated in FIG. 1 showing a sheet material held in an upright position ready for dispensing;

FIG. 3 is a perspective view of another embodiment of a container made in accordance with the present disclosure;

FIG. 4 is a perspective view of still another embodiment of a container made in accordance with the present disclosure;

FIG. 5 is one embodiment of a blank that may be used to form the container illustrated in FIG. 1;

FIG. 6 is another embodiment of a blank and a container made in accordance with the present disclosure;

FIG. 7 is another embodiment of a blank and a container made in accordance with the present disclosure;

FIG. 8 is another embodiment of a blank and a container made in accordance with the present disclosure;

FIG. 9 is another embodiment of a blank and a container made in accordance with the present disclosure;

FIG. 10 is another embodiment of a blank and a container made in accordance with the present disclosure;

FIG. 11 is a perspective view of another embodiment of a container made in accordance with the present disclosure.

FIG. 12 is a perspective view of another embodiment of a container made in accordance with the present disclosure.

FIG. 13 is a perspective view of another embodiment of a container made in accordance with the present disclosure.

FIG. 14 is a perspective view of another embodiment of a container made in accordance with the present disclosure; and

FIG. 15 is a perspective view of another embodiment of a container made in accordance with the present disclosure.

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

DEFINITIONS

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

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

As used herein the term “slit” generally refers to a cut where no material is removed. In certain embodiments a tissue carton of the present invention may be provided with a top wall having slits that are used to form or assist a dispensing opening. As used herein, a slit is to be distinguished from a slot. A slot is a narrow opening that has a defined width. In the embodiments of the present disclosure, a slit can be replaced with a slot.

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

DETAILED DESCRIPTION

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

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

In accordance with the present disclosure, the dispensing container includes a unique dispensing system formed into one or more walls of the container. The dispensing system includes a baffle that is designed to hold a sheet material, such as a facial tissue, in an upright position while preventing the sheet material from falling back into the interior enclosure of the container. The baffle can optionally be placed in communication with an access opening. The access opening on the container can have a size sufficient to receive the hand of a user in order for the user to grasp the top sheet of a stack of interfolded sheets received within the container. In this manner, the access opening can be used to facilitate threading of sheet materials through the baffle for upright, pop-up style dispensing. The access opening can also be used to re-thread the sheet materials should the top sheet fall back into the container or placed intentionally back into the container. In one aspect, the access opening can be formed into the walls of the container and defined by a perforation line. In this manner, the user can decide whether to remove a flap and create the access opening or to dispense sheet materials from the container using only the baffle.

In one aspect, the baffle can be defined by one or more non-linear slits. The non-linear slits have a length sufficient to dispense individual sheet materials and have a shape that applies sufficient force to a sheet material for maintaining the sheet material in an upright position once an adjoining sheet material has been dispensed.

Referring to FIGS. 1, 2, and 5, for instance, a pop-up dispensing container or carton 10 according to one embodiment of the present disclosure is shown for purposes of illustration. Generally, a stack of interfolded sheet materials 11, such as a clip of tissues, is disposed within the container or carton. While the container of the present invention is particularly well suited for dispensing tissue sheets, such as folded facial tissue sheets, the invention is not so limited. The invention may also be utilized to dispense other types of sheet products. Thus, the term tissue is not intended to be limited to facial tissues but is used herein to include any individual sheet product, such as dry or moistened wipes, for example household or industrial wipes, soap or fabric softening sheets, or the like.

The stack of tissues may be interfolded, such as prefolded interfolded, or non-interfolded. As used herein, the phrase “prefolded interfolded” or “interfolded” tissues means that the tissues are folded and interleaved with neighboring tissues immediately above and/or below in the clip of tissues. The tissues can be interleaved by any suitable means, including the use of an interfolder as employed in the papermaking arts. Alternatively, non-interfolded sheets may be used, such as consecutive tissues attached to each other at perforation lines. In such cases, the unperforated segments of the perforation lines should be sufficiently weak to permit the consecutive tissues to separate from each other upon removal from the carton. This can be controlled by the degree of perforation of the tissue sheet. Tissues that may be employed in a non-interfolded clip which are not interleaved with neighboring tissues are releasably attached to neighboring tissues so that upon dispensing one tissue, the next adjacent tissue is ready for dispensing. Particularly preferred folding patterns include interfolding patterns that provide somewhat less friction, which tend to avoid tearing of the tissue when extracted from the container.

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

The dispensing container 10 can be constructed from any rigid material. For example, the dispensing container 10 can be made from any suitable paper, such as cardboard, carton stock, paperboard, or the like. Alternatively, the dispensing carton 10 can be made from a polymer material, particularly a recyclable polymer material. The polymer material can comprise a polypropylene, a polyethylene, a polystyrene, or any other suitable plastic. In one particular embodiment, the dispensing container 10 is made from a paper, such as paperboard, which is capable of entering the paper recycling stream and/or is capable of being repulped into new products. For example, in one embodiment, the dispensing container 10 is made from a fiber sheet containing pulp fibers. The pulp fibers can comprise softwood fibers, hardwood fibers, bast fibers, recycled fibers, any other suitable cellulosic fibers, and mixtures thereof. The paper can be coated on one side with a polymer and/or clay material in order to provide moisture resistance. The paper can have a basis weight of greater than about 40 gsm, such as greater than about 100 gsm, such as greater than about 250 gsm, such as greater than about 300 gsm, such as greater than about 350 gsm, such as greater than about 400 gsm. The basis weight of the paper is generally less than about 500 gsm, such as less than about 450 gsm, such as less than about 400 gsm. In one embodiment, the basis weight of the paper is from about 250 gsm to about 500 gsm.

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

In FIGS. 1 and 2, the container 10 is shown in an opened state, while FIG. 5 illustrates the container 10 in an unopened state. As shown in FIG. 1, the container 10 includes a baffle 24 located on one wall of the container 10, such as the top wall 12. The baffle 24 defines a non-linear slit 26. The stack of sheet materials 11 can be dispensed one at a time through the non-linear slit 26 of the baffle 24. The baffle 24 is generally made from a flexible material, while the non-linear slit 26 has a size and shape that applies friction and a force to sheet materials being dispensed through the baffle. More particularly, the non-linear slit 26 is imparted with a particular shape that exerts sufficient pressure on an emerging sheet 30 as shown in FIG. 2 for holding the sheet in a partially extended position while preventing the sheet from falling back into the container 10.

In the embodiment illustrated in FIGS. 1, 2 and 5, the container 10 includes only one non-linear slit 26. The non-linear slit 26 has a sinusoidal pattern defined by peaks and valleys. The amplitude of the sinusoidal pattern, which is defined by a distance extending from a peak to an adjacent valley, can be constant over the length of the slit or can vary over the length of the slit. Further, the sinusoidal pattern can define a peak-to-peak distance determined by measuring the distance from one peak to an adjacent peak (e.g. measured from the highest point of the peak which can be the midpoint of the peak). The amplitude and the peak-to-peak distance of the sinusoidal pattern of the non-linear slit 26 can be varied depending upon the particular type of sheet material being dispensed and various other factors. Particularly when dispensing tissue products, for instance, in one embodiment, at least a portion of the sinusoidal pattern can have an amplitude of greater than about 2 mm, such as greater than about 5 mm, such as greater than about 10 mm, such as greater than about 15 mm, such as greater than about 20 mm, such as greater than about 25 mm, and generally less than about 50 mm, such as less than about 40 mm, such as less than about 30 mm. The peak-to-peak distance over at least a portion of the non-linear pattern can generally be greater than about 8 mm, such as greater than about 12 mm, such as greater than about 15 mm, such as greater than about 20 mm, such as greater than about 25 mm, such as greater than about 30 mm, such as greater than about 40 mm, such as greater than about 50 mm, and generally less than about 90 mm, such as less than about 80 mm, such as less than about 70 mm, such as less than about 60 mm, such as less than about 50 mm, such as less than about 40 mm.

The shape and design of the non-linear slit 26 can also be configured to prevent friction from damaging the sheet material while the sheet material is being dispensed through the baffle 24. For instance, the design of the non-linear slit can prevent tearing of the sheet material during the dispensing process. The sinusoidal pattern of the non-linear slit 26 as shown in FIG. 1 produces a tortuous path for the sheet materials to be dispensed. Each section of the sine wave, for example, can move freely and independently of the other sections during dispensing to provide optimum forces for pop-up style dispensing without causing tears or rips in the sheet material. In this manner, the non-linear slit can dispense sheet materials in a pop-up style manner without having to include a conventional polymer film within the baffle.

In the embodiment illustrated in FIG. 1, the stack of interfolded sheet materials 11 has a length and a width. In the embodiment illustrated in FIG. 1, the non-linear slit 26 is positioned perpendicular to the length. This particular configuration has been found to be well suited for preventing individual sheets from falling back into the container once partially emerged through the baffle 24. In other embodiments, however, the non-linear slit can be parallel to the length or can be diagonal to the length direction of the stack of sheet materials 11.

As shown in FIGS. 1 and 2, the dispensing system of the present disclosure can further include an access opening 28. In the embodiment illustrated in FIGS. 1 and 2, the access opening 28 is positioned on the side wall 20, while the baffle 24 is positioned on the adjacent top wall 12. The access opening 28 is in communication with the non-linear slit 26. In the embodiment illustrated in FIGS. 1 and 2, for instance, the non-linear slit 26 intersects the access opening 28 for providing direct communication between the two structures. As shown, the access opening 28 has a size sufficient to receive the fingers or a portion of the hand of a user. In this manner, a user can access the top sheet in the stack of sheet materials 11 and thread the sheet through the baffle 24. If desired, the access opening 28 can also be used to dispense the sheet material. In addition, the access opening 28 can be used to re-thread the sheet material through the baffle 24 in case the sheet purposely or accidentally falls back into the container. In this manner, the sheet material can be re-thread through the baffle 24 without damaging the non-linear slit 26.

Referring to FIG. 5, one embodiment of a blank 70 that can be used to construct the container 10 is shown. As illustrated in FIG. 5, the blank 70 includes a top wall 12 that includes a baffle 24 that defines a non-linear slit 26. When the blank 70 is constructed into the container 10, the top wall 12 is positioned opposite a bottom wall 14. The blank 70 further includes a first side wall 20 and a second side wall 22.

The blank 70 includes side tabs 72, 74, 76, and 78. During construction of the container 10, the tabs 72 and 76 combine with the tabs 74 and 78 to form the end walls 16 and 18. The tabs 72 and 76 can be attached to the tabs 74 and 78 using any suitable means, such as using an adhesive.

In FIG. 5, the blank 70 illustrates the container in an unopened state. In this regard, the blank 70 includes a first perforation line 34 that defines a first tearaway flap 36 and a second perforation line 38 that defines a second tearaway flap 40. The tearaway flaps 36 and 40 are to be removed by the consumer or user in order to expose the non-linear slit 26 of the baffle 24 and/or to expose the access opening 28. Although the container 10 can include a single tearaway flap for exposing both the baffle 24 and the access opening 28, in one embodiment, the container 10 is provided with two tearaway flaps 36 and 40 as shown in FIG. 5. In this manner, the user can decide whether to remove both tearaway flaps 36 and 40 or to just remove one of the flaps in order to dispense the individual sheet materials.

In the embodiment illustrated in FIGS. 1, 2, and 5, the baffle 24 is formed from a separate piece of material that is adhered to the underside of the top wall 12. For example, the baffle 24 can be formed from a flexible member 42 that has been perforated to form the non-linear slit 26.

The flexible member 42 of the baffle 24 can be made from any suitable material that is capable of forming the non-linear slit, is capable of dispensing sheet materials one at a time, and is capable of maintaining a sheet material in an upright position for pop-up style dispensing. In one aspect, the flexible member 42 is made from the same material that is used to form the container 10 or the blank 70. For example, the walls of the container 10 and the flexible member 42 can both be made from a paperboard material. Alternatively, the container 10 and the flexible member 42 can be made from the same polymer material. By being made from the same material as the container 10, the flexible member 42 can be recycled with the container once the stack of sheet materials 11 has been dispensed.

In one aspect, the flexible member 42 is made from a material that has greater flexibility than the material that is used to form the walls of the container 10. In this manner, the properties of the flexible member 42 in conjunction with the shape of the non-linear slit 26 can be designed and controlled for optimum dispensing of the sheet materials. For instance, the flexibility of the flexible member 42 can be varied while the shape of the non-linear slit 26 can be varied based upon the properties of the sheet material being dispensed, such as the stiffness of the sheet material, the strength of the sheet material, and the like.

The blank 70 can be made from any suitable material. In one aspect, the blank 70 can be made from a paper, such as a paperboard. The paperboard can comprise a coated paper having a basis weight of from about 80 gsm to about 500 gsm. For instance, the paperboard can be coated with a polymer coating, especially a coating that does not interfere with a recycling and/or a repulping process. The polymer coating can increase moisture resistance, increase strength, and be receptive to printed matter and/or protect printed matter. In one aspect, the polymer coating can contain a film-forming polymer in combination with clay particles to produce a clay coating. In one aspect, the polymer coating can be sustainable and can be biodegradable. Sustainable polymer coatings can be made from natural film forming materials that can be water-based. These coatings break-up in the repulping process and thus can be recycled with the paperboard material. Some of these coating can even be applied to the inside of the container. The polymer coating containing the clay particles can be applied to the different walls of the container prior to forming the perforations, such as perforations 34 and 38. Forming the perforations through a clay coating can help prevent tearing when the perforated portions are opened and can also prevent the propagation of tears or cuts.

In forming the blank 70, the paperboard or other material can be cut to a desired shape and coated. Various score lines can then be formed into the blank in order to facilitate folding of the walls and tabs.

In producing the product as shown in FIG. 1, a stack of sheet materials 11 can be loaded into the blank 70 when in a partially assembled state or, alternatively, the blank 70 can be formed into a container around a stack of sheet materials. The sheet materials can be in the form of individual sheets that are interfolded together to facilitate pop-up dispensing. The sheet materials contained within the dispenser product of the present disclosure can vary. In one particular application, for instance, the product of the present disclosure can be configured to dispense facial tissues. In alternative embodiments, however, the dispensing container 10 can be configured to dispense other dry wipers, wet wipes, napkins, paper towels, or the like. In one embodiment, the dispensing container 10 is configured to dispense individual sheet materials formed from cellulosic fibers that have a bulk of greater than about 3 cc/g to about 20 cc/g and have a basis weight of from about 10 gsm to about 120 gsm, such as from about 20 gsm to about 60 gsm.

In the embodiment illustrated in FIGS. 1 and 2, the container 10 has a rectangular-like shape. In particular, the container 10 has a top wall 12 and a bottom wall 14 that generally match the length and width dimensions of a stack of interfolded sheets loaded into the container. In this manner, the sheets lay flat in the container as they are dispensed one at a time. Alternatively, the container can have more of a cube-like shape. In this embodiment, the stack of interfolded sheet materials may be in the form of a U-shaped clip that is inserted into the container. The dispensing system of the present disclosure can be used in either type of the containers described above.

As shown in FIG. 5, the blank 70 can further include a bottom tab 78. As shown in FIG. 1, the bottom tab 78 can be used to attach to the side wall 20. The bottom tab 78 can be used to reinforce the side wall 20 and provide stability where the access opening 28 is located.

Referring now to FIG. 3, another embodiment of a container 10 made in accordance with the present disclosure is shown. Like reference numerals have been used to indicate similar elements. As shown, the container includes a top wall 12, a bottom wall 14, two end walls 16 and 18, and two side walls 20 and 22. Similar to the embodiment illustrated in FIG. 1, the container 10 includes an access opening 28 in communication with a baffle 24 that defines a non-linear slit 26. In this embodiment, the baffle 24 further includes a baffle tab 46 that is positioned on an adjacent wall, namely the side wall 20. The baffle tab 46 defines a spacer slit 48. The baffle tab 46 is to not only help reinforce the container but also prevent sheet materials from falling back into the container once threaded through the non-linear slit 26. In order to thread the sheet materials through the baffle 24, the spacer slit 48 is provided that provides indirect communication between the access opening 28 and the non-linear slit 26.

Referring to FIG. 4, another embodiment of a container 10 made in accordance with the present disclosure is shown. Like reference numerals have been used to indicate similar elements. The container 10 includes a top wall 12 opposite a bottom wall 14, a first end wall 16 opposite a second end wall 18, and a first side wall 20 opposite a second side wall 22. In accordance with the present disclosure, the container 10 includes a dispensing system comprising a dispensing baffle 24 in conjunction with an access opening 28.

As shown in FIG. 4, the baffle 24 includes a non-linear slit 26 that is positioned perpendicular to a lengthwise direction of a stack of sheet materials 11 received within the container 10. In alternative embodiments, however, the non-linear slit 26 can be parallel with the lengthwise direction of the sheet materials 11 or can be diagonal to the lengthwise direction of the sheet materials 11. In the embodiment of FIG. 4, the baffle 24 is formed directly into the top wall 12 of the container 10. In this manner, the baffle 24 and the non-linear slit 26 are integral with the top wall 12. Consequently, no separate piece of material needs to be adhered to the container for creating the baffle 24 and no tear away flap is needed to cover the baffle. In addition, the container 10 as shown in FIG. 4 can be made from a blank that is a single piece of material.

Referring to FIG. 6, another embodiment of a container or carton for dispensing sheet materials is illustrated. Like reference numerals have been used to indicate similar elements. As shown, the container 10 is made from a blank 70. The blank 70 includes a top wall 12 opposite a bottom wall 14, and a pair of opposing side walls 20 and 22. The blank 70 further includes tabs 72, 74, 76, and 78 which are assembled together to form opposing end walls.

In accordance with the present disclosure, the blank 70 includes a dispensing system comprised of a baffle 24 in communication with an access opening 28. As shown, the baffle 24 is initially covered by a first tearaway flap 36 that can be removed along a perforation line 34. Similarly, the access opening 28 is covered by a second tearaway flap 40 defined by a perforation line 38. In this embodiment, the access opening 28 extends from the side wall 20 onto a portion of the top wall 12 where the access opening 28 intersects with a non-linear slit 26 of the baffle 24. Consequently, the baffle 24 and/or the non-linear slit 26 extend across only a portion of the width of the top wall 12.

The non-linear slit 26 is defined by a sinusoidal pattern. In this embodiment, the amplitude of the sine wave of the sinusoidal pattern increases from an end of the sinusoidal pattern to the middle of the sinusoidal pattern. The changing amplitude of the sinusoidal pattern can affect the amount of force applied to sheet materials being dispensed through the baffle 24. For instance, the non-linear slit 26 may apply less holding force at the center of a sheet material being dispensed through the baffle as opposed to the ends of the non-linear slit 26. It is believed that the design illustrated in FIG. 6 may provide various advantages and benefits. For instance, in one aspect, the changing amplitude of the sinusoidal pattern may prevent multiple sheet materials from being dispensed at once and may better promote one sheet at a time dispensing.

Referring to FIG. 7, another embodiment of a container 10 made in accordance with the present disclosure is illustrated. The container 10 is illustrated in the form of a blank 70 that can be assembled into the container defining a hollow enclosure for receiving a stack of sheet materials. As shown, the blank 70 includes a top wall 12 opposite a bottom wall 14 and a pair of opposing side walls 20 and 22. Tabs 72, 74, 76, and 78 are for forming opposing end walls. Optionally, the blank 70 can include an end tab 78 for reinforcing the side wall 20 where an optional access opening can be formed.

As shown, an access opening 28 can be formed into the side wall 20 by removing a tearaway flap 40 along a perforation line 38. In this embodiment, the access opening extends from the side wall 20 onto the top wall 12. The top wall 12 includes a tearaway flap 36 that can be removed along the perforation line 34 for exposing a baffle 24 that defines a non-linear slit 26. The baffle 24 can be formed into a flexible member 42 attached to the top wall 12 or can be formed directly into the surface of the top wall 12.

In the embodiment illustrated in FIG. 7, the baffle 24 includes a first non-linear slit 26 and a second non-linear slit 27 that extend from a second access opening 50. More particularly, in this embodiment, the second access opening 50 is generally positioned in the center of the baffle 24. The first non-linear slit 26 extends from the second access opening 50 to one edge of the baffle 24, while the second non-linear slit 27 extends from the second access opening 50 to the opposite edge of the baffle 24.

The second access opening 50 may provide various advantages and benefits. For instance, the second access opening 50 may allow a user to have access to and grab a top sheet of a stack of sheets contained within the container 10 and begin dispensing the sheets through the baffle 24. Should a sheet fall back within the container 10 or be purposely put back into the container 10, the access opening 50 can also be used to re-thread the sheet material through the non-linear slits 26 and 27. Including the second access opening 50 can also, in one embodiment, eliminate the need for the first access opening 28. Thus, in one embodiment, the only access opening present in the container can be the access opening 50.

Referring to FIG. 8, still another embodiment of a container 10 made in accordance with the present disclosure is shown that can be constructed from the blank 70. As shown, the blank 70 includes a top wall 12 opposite a bottom wall 14 and a pair of opposing side walls 20 and 22. Tabs 72, 74, 76, and 78 can be used to construct opposing end walls. The blank 70 further includes a dispensing system comprising an access opening 28 in conjunction with a baffle 24. The access opening 28 can be created by the user by removing a tearaway flap 40 defined by the perforation line 38.

The baffle 24 can be exposed by removing a tearaway portion 36 along a perforation line 34. The baffle 24 includes a non-linear slit 26 in the shape of a sinusoidal pattern. In this embodiment, the baffle 24 further includes transverse slits 52 that are perpendicular to the non-linear slit 26. In the embodiment illustrated, the transverse slits 52 are equally spaced along the non-linear slit 26 and are positioned after each curvature of the sine wave. In this manner, the transverse slits form leg members opposite each curvature of the sine wave. The transverse slits can be added to the baffle 24 for controlling and changing the force that is exerted against a sheet material that is partially extended from the container 10.

The transverse slits 52 as shown in FIG. 8 can also be included within the baffle 24 according to a different pattern or design. For instance, transverse slits 52 may only be positioned after each cycle of the sine wave or can be positioned along the non-linear slit in a more random fashion.

Referring to FIG. 9, still another embodiment of a container 10 made in accordance with the present disclosure is illustrated. The container 10 can be made from a blank 70 that includes a top wall 12 opposite a bottom wall 14 and two opposing side walls 20 and 22. Tabs 72, 74, 76, and 78 can be used to construct opposing end walls. During assembly of the container 10 from the blank 70, a stack of interfolded sheet materials can be received within a hollow enclosure defined by the container 10.

Similar to FIGS. 6, 7, and 8, the blank 70 as shown in FIG. 9 includes an access opening 28 defined by a perforation line 38. In order to form the access opening 28, a tearaway flap 40 can be removed.

In accordance with the present disclosure, the blank 70 further defines a baffle 24 positioned below a tearaway flap 36 that is defined by a perforation line 34. The baffle 24 includes a non-linear slit that is in the shape of a sinusoidal pattern. More particularly, in the embodiment illustrated in FIG. 9, the sinusoidal pattern is in the form of a square sine wave as opposed to a curved sine wave.

FIG. 10 discloses still another embodiment of a container 10 and blank 70 made in accordance with the present disclosure. The embodiment illustrated in FIG. 10 is very similar to the embodiment illustrated in FIG. 9 and like reference numerals have been used to indicate similar elements. In FIG. 10, however, the baffle 24 further includes transverse slits 52 that are positioned along the square sine wave pattern of the non-linear slit 26. As shown, the transverse slits are positioned after each one-half cycle of the sinusoidal pattern. The transverse slits 52 form leg or finger members that can be used to control the amount of force applied against a sheet material being dispensed from the container 10.

Referring to FIGS. 11-14, further embodiments of dispensing containers made in accordance with the present disclosure are shown. In the embodiments illustrated in FIGS. 11-14, the non-linear slit of the baffle is positioned parallel with the lengthwise direction of the stack of sheet materials received within the container.

Referring to FIG. 11, for instance, a container 110 is illustrated including a top wall 112 and a side wall 120. The container includes an access opening 128 through which a stack of sheet materials 11 can be seen. In this embodiment, the access opening extends over the side wall 120 and the top wall 112.

The container 110 further includes a baffle 124 that defines a non-linear slit 126. The non-linear slit 126 is in the shape of a curved sinusoidal pattern. The container further defines a spacer slit 148 that intersects with the non-linear slit 126. The spacer slit 148 provides indirect communication between the access opening 128 and the non-linear slit 126. In this manner, a user can access the top sheet in the stack of sheet materials 11 and thread the sheet through the baffle 124 using the spacer slit 148.

Referring to FIG. 12, another embodiment of a container 110 made in accordance with the present disclosure is shown. The container 110 includes a top wall 112 that is adjacent to and perpendicular with a side wall 120. An access opening extends over both the side wall 120 and the top wall 112. The container 110 further includes a baffle 124 that defines a non-linear slit 126 for pop-up style dispensing of the stack of sheet materials 11 received within the container 110.

In the embodiment illustrated in FIG. 12, the access opening 128 intersects the non-linear slit 126. Having the access opening 128 extend all the way to the non-linear slit 126 provides better visibility to the stack of sheet materials 11 received within the container 110. Further, a user can access the top sheet in the stack of sheet materials 11 either from the top wall 112 or from the side wall 120.

In order to prevent partially emerged sheet materials from falling back into the container, the access opening 128 further defines a constriction 56. The constriction or narrow section 56 can prevent individual sheet materials engaged by the non-linear slit 126 from slipping back into the container 110. As shown in FIG. 12, the constriction or narrow section 56 provides the access opening 128 with an hourglass-like shape.

Referring to FIG. 13, still another embodiment of a container 110 made in accordance with the present disclosure is shown. The container 110 illustrated in FIG. 13 is very similar to the container 110 illustrated in FIG. 12. In the embodiment illustrated in FIG. 13, however, the access opening 128 includes a greater flared section where the access opening 128 intersects with the non-linear slit 126 of the baffle 124. Again, the access opening 128 in the embodiment illustrated in FIG. 13 includes a constriction or narrow section 56 that provides the access opening with an hourglass-like shape.

Referring to FIG. 14, still another embodiment of a container 110 made in accordance with the present disclosure is shown. The container 110 includes a top wall 112 that defines an access opening 128 which intersects with a baffle 124. The baffle 124 includes a non-linear slit 126 for dispensing sheet materials one at a time.

In the embodiment illustrated in FIG. 14, the access opening 128 is only located on the top wall or the same wall as the non-linear slit 126. In this embodiment, the access opening is positioned on one side of the top wall 112 of the container 110, and the non-linear slit 126 extends from the access opening 128 to the other side of the top wall. The access opening 128 can be initially covered by a tearaway flap defined by a perforation line. When a user desires to dispense sheet materials from the container 110, the tearaway flap can be removed for creating the access opening 128. A user can then insert one's hand into the access opening for accessing the top sheet in a stack of sheet materials for threading the sheet materials through the non-linear slit 126. As shown in FIG. 14, the non-linear slit 126 extends parallel with the lengthwise direction of the stack of sheet materials.

Referring to FIG. 15, another embodiment of a container 110 for dispensing sheet materials in accordance with the present disclosure is shown. The container 110 includes a top wall 112 opposite a bottom wall 114. The container further includes two opposing side walls 120 and 122 and two opposing end walls 116 and 118.

In accordance with the present disclosure, the container 110 further includes an access opening 128 which can provide access to a stack of sheet materials 11. The container 110 further includes a baffle 124 defining a non-linear slit 126 that can be in the shape of a sinusoidal pattern. As shown, the non-linear slit 126 intersects with the access opening 128.

In the embodiment illustrated in FIG. 15, the baffle 124 and the non-linear slit 126 extend from the access opening 128 at an angle to the lengthwise direction of the stack of sheet materials 11 received within the container 110. The baffle can form an angle with an axis running the lengthwise direction of anywhere from about 10° to about 80°, including all increments of 1° therebetween.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so further described in such appended claims.

Container for Dispensing Sheet Materials

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