BACKGROUND

[0001] The present disclosure is directed to a sheet dispenser, in particular, a paper towel dispenser that can dispense sheets when the dispenser is positioned on a horizontal surface or towel bar.

[0002] Singly used paper towels are more sanitary than cloth towels that are used multiple times. Bacteria may grow on damp, used towels. However, paper towel dispensers are not typically used where they are most needed, in the bathroom. Existing paper towels are typically seen in commercial facilities, but they require permanent attachment to the wall and may not be aesthetically pleasing for a residential setting. Paper towel dispensers available for residential use are designed for roll-style paper towels, not interfolded paper towels. There remains a need for a sheet dispenser that is versatile enough to be used in conjunction with a towel bar. Further, there is a need for a sheet dispenser that is differentiated from other sheet dispensers, e.g. facial tissue dispensers.

BRIEF SUMMARY

[0003] In response to the aforementioned needs, a sheet dispenser is disclosed.

The sheet dispenser includes a carton defining an interior volume. The carton includes six outwardly -facing surfaces. The six outwardly -facing surfaces defined by three pairs of panels. The pairs of panels include a face panel substantially parallel to and spaced apart from a contact panel, a first side-panel substantially parallel to and spaced apart from a second side-panel, and a dispensing panel substantially parallel to and spaced apart from an obscure panel. The dispensing panel includes a dispensing opening and a bearing panel extending from the dispensing panel. The bearing panel extends from a first edge defined between the dispensing panel and the face panel. [0004] Also provided are methods for dispensing sheets from the disclosed dispenser. The method includes providing a dispenser disclosed herein; identifying a wall having a towel bar mounted thereon at a distance from the floor; extending the bearing panel on the dispensing panel; facing the contact panel toward the wall; and sliding the sheet dispenser between the towel bar and the wall such that the bearing panel rests on the towel bar and the dispensing panel is oriented toward the floor. [0005] Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure will be more fully understood and further features will become apparent when reference is made to the following detailed description of the disclosure and the accompanying drawings. The drawings are merely representative and are not intended to limit the scope of the claims. Like parts of the containers depicted in the drawings are references by the same reference numerals. [0007] FIG. 1 is a front perspective of a sheet dispenser in accordance with example embodiments of the present disclosure.

[0008] FIG. 2 is a side perspective view of a sheet dispenser in accordance with example embodiments of the present disclosure.

[0009] FIG. 3 is a side perspective view of a sheet dispenser in accordance with example embodiments of the present disclosure.

[0010] FIG. 4 is a plan view of a carton blank used to form a sheet dispenser according to example embodiments of the present disclosure.

[0011] FIG. 5 is a plan view of a carton blank used to form a sheet dispenser according to example embodiments of the present disclosure.

[0012] FIG. 6 is a side elevation view of a sheet dispenser with the stack of towel substrates visible through the sheet panel according to example embodiments of the present disclosure.

[0013] FIG. 7 is a side elevation of a pair of sheets demonstrating a fold and overlap configuration according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION

[0014] 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. [0015] The present disclosure is directed to a sheet dispenser, in particular, a paper towel dispenser that can dispense sheets when the dispenser is positioned on a horizontal surface or towel bar.

[0016] Singly used paper towels are more sanitary than cloth towels that are used multiple times. Bacteria may grow on damp, used towels. However, paper towel dispensers are not typically used where they are most needed, in the bathroom. Existing paper towels are typically seen in commercial facilities, but they require permanent attachment to the wall and may not be aesthetically pleasing for a residential setting. Paper towel dispensers available for residential use are designed for roll-style paper towels, not interfolded paper towels. There remains a need for a sheet dispenser that is versatile enough to be used in conjunction with a towel bar. However, many residential paper towel dispensers suitable to be mounted in some manner on a user’s bathroom towel bar can suffer from drawbacks such as falling between the towel bar and the wall during removal of towels from the dispenser. For example, during use, the force exerted by the user to remove the towel can dislodge or displace the dispenser from its location on the towel bar, causing the dispenser to fall between the towel bar and the wall and on to the floor. The sheet dispenser of the present disclosure, however, incorporates a bearing panel configured to help secure the dispenser in place between the wall and the towel bar and to prevent the dispenser from slipping off the towel bar and falling to the floor during use.

[0017] Referring now to FIGS. 1-3, the sheet dispenser 10 is a quadrilateral carton 12 defined by four surfaces each having a rectangular area, and two surfaces each having a rhomboid area. The carton 12 has six outwardly-facing surfaces defined by three pairs of panels. One panel pair is a face panel 20 which is substantially parallel to and spaced apart from a contact panel 22. Another panel pair is a first side-panel 24 substantially parallel to and spaced apart from a second sidepanel 26. The last panel pair is a dispensing panel 28 substantially parallel to and spaced apart from an obscure panel 30.

[0018] In embodiments, the panels 20-30 can be rectangles or trapezoids. For instance, at least four of the panels can be rectangular and at least two of the panels can be trapezoidal. For instance, the face panel 20, contact panel 22, dispensing panel 28 and contact panel can be rectangular panels, while the two side panels 24 and 26 are trapezoidal. For instance, one rectangular panel pair is a face panel 20 which is substantially parallel to and spaced apart from a contact panel 22. The trapezoidal panel pair is a first-side panel 24 substantially parallel to and spaced apart from a second-side panel 26. The rectangular dispensing panel 28 is spaced apart from a rectangular obscure panel 30. Obscure panel 30 has a right-angle orientation with respect to panels 20, 22, 24, and 26. In other embodiments, all of the panels 20-30 can be rectangular and can have right-angle orientation with respect to each other.

[0019] The dispenser 10 includes an opening 15 disposed in the dispensing panel 28. The opening 15 is defined by an edge 14. The location of the opening 15 defined by edge 14 can be important for proper dispensing of sheets 16. When the carton 12 is placed between a structure such as a towel bar 42 and a wall 44, it is necessary to prevent the towel bar 42 from obstructing the opening 15. Therefore, the opening 15 defined by edge 14 is located at a particular region of the dispensing panel 28, and may or may not be covered by a surfboard 41. Referring in particular to FIG. 2, the dispensing panel 28 has a longitudinal axis 17 bisecting the dispensing panel 28 surface area. It is noted that for the purpose of this discussion the dispensing panel 28 surface area is the entire surface area of the outwardly -facing surface of the dispensing panel 28, regardless of whether or not there is an opening 15 or surfboard 41. Desirably, the edge 14 is located on the dispensing panel 28 entirely between the longitudinal axis 17 and the edge between the dispensing panel 28 and the contact panel 22, referred to as acute edge 200. Acute edge 200 is opposite the edge located between the dispensing panel and face panel, and is referred to as the obtuse edge 202.

[0020] The edge 14 defines a shape having its own longitudinal axis. In some embodiments of the present disclosure, this opening longitudinal axis is located between the longitudinal axis 17 and the acute edge 200 so that the opening 15 is offset toward the acute edge 200.

[0021] The sheets 16 may be removed from the opening 15 by pulling the sheets 16 in a substantially downward direction 48 or a substantially outward direction 49. [0022] A bearing region area 204 is defined as the dispensing panel 28 area located between the obtuse edge 202 and the longitudinal axis 17 on which a structure such as a towel bar can apply force to dispenser 10. In one embodiment of the present disclosure, the bearing region area 204 is about 38 to about 60 percent of the dispensing panel 28 area. In yet another embodiment, the bearing region area 204 is about 39 to about 45 percent of the dispensing panel 28 surface area. It is possible that a portion of the opening edge 14 crosses over the longitudinal axis 17 of the dispensing panel 28, yet the opening edge 14 never crosses into the bearing region area 204.

[0023] A bearing panel 27 is disposed on the dispensing panel 28. The bearing panel 27 extends from the obtuse edge 202 defined between the dispensing panel 28 and the face panel 20. In certain embodiments, the bearing panel 27 is separate from the bearing region area 204 of the dispensing panel 28. For instance, the bearing panel 27 can be a separate panel coupled to the dispensing panel 28 along the obtuse edge 202. However, in other embodiments, the bearing panel 28 can be removed from the dispensing panel 28, namely from the bearing region area 204. In such embodiments, perforations 29 can be cut into the dispensing panel 28, such that the user can tear the perforations 29 in order to form the bearing panel 27. For example, upon installation of the dispenser 10 on a towel bar 42, the user can break the perforations 29 to remove at least a portion of the dispensing panel 28 therefrom to form the bearing panel 27. As previously noted, the bearing panel 27 remains coupled to the dispenser 10 along the obtuse edge 202 between the dispensing panel 28 and the face panel 20. The bearing panel 27 provides more surface area over the towel bar 42 when the dispenser 10 is mounted between the towel bar 42 and the wall 44. Accordingly, the bearing panel 27 can prevent slipping or movement of the dispenser 10 on the towel bar 42 or between the wall 44 and the towel bar 42, thus preventing the dispenser 10 from slipping between the towel bar 42 and the wall 44 and falling to the floor.

[0024] In operation, the contact panel 22 may contact the wall 44, and the dispensing panel 28 may be oriented toward the floor underneath the towel bar 42, while maintaining contact with towel bar 42. The face panel 20 and the contact panel 22 are spaced far enough apart so that when a sheet 16 is pulled in a substantially downward/outward direction 48/49, the dispenser 10, including the bearing panel 27 disposed on the towel bar 42 will not slide down between the towel bar 42 and the wall 44 such that the face panel 20 makes contact with the towel bar 42. [0025] Referring now to FIGS. 4-5, blanks 13 for the carton 12 are illustrated. As shown, the panels 20-30 may be integrally connected and differentiated from one another by fold lines 32. However, it is contemplated that the panels 20-30 may be distinct and separate parts that are connected together to form a three-dimensional carton 12 such as sheet dispenser 10. For example, it can be seen that panel 22 is separated from panel 30 by a fold-line 32.

[0026] A margin 33 may extend from a panel to provide a structure to which other panels may be attached such as by glue, or the like. Each margin 33 may be separated from its neighboring panel by a fold-line 34, though it is contemplated that margins 33 may be non-integral parts, such as a tape or the like. For example, it can be seen that two margins 33 extend from panel 22 at adjacent sides, separated by a fold-line 34. The margins 33 may be folded and attached to the interior surfaces of panels 20-30 once the carton 12 is folded to form an interior volume for containing sheets 16. The margins 33 may be attached to the interior surfaces with an adhesive or the like.

[0027] Without regard to margins 33, each of the panels in a panel pair are desirably identical in size and shape. For instance, panels 20 and 22 are identical to not only each other, but also panels 28 and 30. Rhomboid shaped panels 24 and 26 are also identical in size and shape.

[0028] Referring now to FIG. 5, a blank 13 is depicted. Fold-lines 32 separate panels 22, 24, 20, 26, and 28. Margins 33 may extend from one or two sides of panels 22, 24, and 26. Carton 12 may be folded such that either panel 30 or 30' is an outwardly facing surface. Panels 31 a and 31 6 may not be visible from the exterior surface of carton 12 when carton 12 is fully assembled. It is noted that blank 13 is only one possible configuration that could be used to create carton 12.

[0029] Desirably, the blank 13, including panels 20-30, is cut from a sheet material. Depending on the embodiment of the present disclosure, the sheet dispenser 10 may be rigid (like a sheet of 4 mm thick acrylic), or semi-rigid (like an 80 lb basis weight paper board). Thus, the sheet material may be that typically used in paperboard box construction, such as a facial tissue box (e.g. a KLEENEX® Facial Tissue box) or a cereal box. It is further contemplated that the sheet material used to form the carton 12 may be formed from a semi-rigid plastic sheet, or the like. The sheet material may have the characteristics of being scoreable, foldable, and cuttable using a die or by other sheet cutting techniques.

[0030] As noted, the blank 13 may be folded about the various fold lines 32 to form a carton with an interior volume for containing a stack of sheets, such as towel substrates. The sheets may have a V-fold (“inter-fold”) or a Z-fold (“multi-fold”) as is known in the art of tissue folding. There are other possible panel arrangements that may be used other than those illustrated. For example, side panel 26 could be attached to contact panel 22 instead of face panel 20. Other variations are possible.

[0031] As shown in FIGS. 2 and 5 the opening 15 defined by edge 14 may not be created until the optional surfboard 41 is removed from the dispensing panel 28. The surfboard 41 can be defined by at least one line of perforations surrounding the opening 15. For example, as seen in FIG. 5, a pair of spaced apart perforation lines 56 and a pair of spaced apart apertures 58 define the shape of surfboard 41. Perforation lines 56 may be straight or curved, or a combination thereof, as shown. Apertures 58 may be replaced by perforation lines 56, but are desirable because they allow a gap for a consumer to grasp the surfboard 41 for removal. Desirably, the machine direction 39 of blank 13 coincides with the longitudinal axis of the surfboard 41 so that it is easier to remove the surfboard 41 without tearing the panel 28.

[0032] Regardless of embodiment, the opening as defined by edge 14 of the previously described dispensing panels 28 may be a rectangular shape. However, opening edge 14 may define other shapes such as oval, “smile,” dog-bone, or other such elongated shapes. Desirably, a sheet of flexible, smooth material, referred to as a baffle 40, is used to make the opening smaller to provide some tension on the sheets 16 as they are pulled from the dispenser 10. The baffle 40 prevents more than one sheet being pulled from the opening at one time. Further, baffle 40 helps to protect the sheets 16 from the surrounding environment where there is a potential for water splashing or the like. Desirably, the baffle 40 is made from a sheet of clear polyethylene or the like, and is attached around its perimeter to the inwardly-facing surface (not shown) of panel 28. It is, however, contemplated that the baffle could be made from an opaque material, a paper or non-woven material, or have an aesthetic and/or informative indicia thereon. For example, to further differentiate the dispenser 10 from a facial tissue dispenser, the baffle may have a logo such as KLEENEX® HAND TOWELS printed thereon. The carton 12 can include a slitted baffle 40 located underneath surfboard 41.

[0033] Referring now to FIG. 6, a side elevation of carton 12 may be seen. From this vantage point, obscure panel 30 is substantially parallel to the X-direction 78, while face panel 20 and contact panel 22 are substantially parallel to the Y- direction 79. Dispensing panel 28 may be oriented at a 20 to 60° angle 80 with respect to X-direction 78. It is further contemplated that panel 28 may be oriented at a 30° to 50° angle 80 with respect to the X-direction 78. Most desirably, dispensing panel 28 is oriented at a 45° angle 80 with respect to X-direction 78. The 45° angle 80 orientation allows cartons 12 to be packed into a shipping package most efficiently as there will be no significant gaps between the cartons 12. Not only is this more efficient, it may protect the packaging from significantly rubbing against one another and potentially damaging the outwardly facing surfaces of carton 12 or any graphics thereon.

[0034] The sheet dispenser 10 includes a stack of folded sheet material (e.g., sheets 16) disposed within the interior volume of the carton 12. The sheets 16 may be made from paper, woven, or nonwoven substrates, or composites thereof. Most desirably, a towel substrate in any of the carton 12 embodiments described herein is made from a paper substrate that has a relatively high bulk and wet-strength ratio. One example of such a substrate is a paper towel that has a dry, specific modulus less than 0.0040 kilograms, a bulk greater than 10 cubic centimeters per gram, and a wet strength ratio greater than 0.40. Further details regarding the most desired sheet 16 substrates and the various test methods used to determine the aforementioned physical properties may be found in U.S. Pat. No. 6,423,180; U.S. Pat. No. 6,565,707; and U.S. Pat. No. 7,297,231; each incorporated herein in their entirety to the extent they are consistent with the present disclosure. One non-limiting example of a sheets 16 is paper or nonwoven toweling.

[0035] As mentioned previously, the stack 76 of sheets 16 may be comprised from multi -folded or inter-folded sheets. When sheets 16 are stacked in a multi -folded or inter-folded configuration, there is a portion between each consecutive sheet that overlaps, namely the overlap 75 (see FIG. 7).

[0036] Desirably, the stack 76 has a single towel closest to the opening defined by edge 14. Most desirably, the leading edge of this single towel is visible from the opening to prevent a user from having to reach inside the container to find the leading edge.

[0037] When stack 76 is viewed from the side as in FIGS. 6 and 7, the length 77 of overlap 75 may be observed. Length 77 can become important when the substrate from which sheet 16 is made is subject to blocking. “Blocking” occurs when the towel substrate sticks to itself either chemically or mechanically. Blocking usually happens as the stack of substrate is shipped or moved repeatedly. Blocking can be problematic as it may cause more than one towel to be dispensed from carton 12 at one time. However, blocking can be an advantage when the dispensing panel is facing upward, so the towels do not fall down into the cavity 102, away from the opening. This allows dispensing of the last few towels without having to shake carton 12 or turn it upside down. By controlling length 77, the tendency for more than one towel to be dispensed at one time is greatly reduced, if not completely diminished. Blocking can also facilitate continuous downward dispensing of the towels without having to perforate the towel material.

[0038] For the desired paper towel substrate described above, multi-folded towels have an overlap length 77 of about 2.75 inches to about 3.25 inches, and the interfolded towels have an overlap length 77 of about 4.75 inches to 5.25 inches. In another embodiment of the present disclosure, multi-folded towels may have an overlap length 77 of about 3 inches, and the inter-folded towels may have an overlap length 77 of about 5 inches.

[0039] Regardless of embodiment, it may be desirable to maximize the number of towels contained within the interior volume of carton 12. Accordingly, there is an opportunity to utilize some of the volume located underneath dispensing panel 28. While sheets 16 may not dispense easily if the entire volume located under the dispensing panel 28 is occupied by a stack 76, it is reasonable to occupy a portion of that space. For example, as seen in FIG. 6, a front side 90 of stack 76 is lower in height than the opposite rear side 92 of stack 76. Specifically, front side 90 may be shorter than second side 92 by about 10 mm to about 30 mm. It is further contemplated that front side 90 may be shorter than second side 92 by about 10 mm to about 15 mm. It is noted that the height of front side 90 and second side 92 is measured at each side from the obscure panel 30 to the uppermost sheet 96 of stack 76.

[0040] Referring back to FIGS. 1-3, indicia 100 may be used to indicate how the towel substrate is to be utilized. For example, a towel substrate that is used to dry hands may be referred to as “hand towels.” Indicia help to differentiate the towel substrate from other similarly packaged sheets such as facial tissue. Because dispenser 10 may be oriented more than one way, it is desirable to have the indicia be properly oriented regardless of dispenser orientation. For example, indicia 100 may be read in at least two different directions, such as when dispenser 10 is sitting on a countertop or inverted and used between a wall and a towel bar, as described herein. [0041] Special inks or other coatings may be used on the outwardly facing surfaces of carton 12. These inks or her coatings may serve a functional and/or an aesthetic purpose. In one embodiment, an expandable ink is applied to one or more outwardly facing surfaces of carton 12. Expandable ink expands in three dimensions when heated, thereby forming a raised body with respect to the surface on which it is applied. One non-limiting example of an expandable ink is AQUAPUFF, obtained from Polytex Environmental Inks ltd., Bronx, N.Y. When the expandable ink is applied to an outwardly facing surface of carton 12, it may have a thickness from about 1 mm to about 3 mm from the surface. Indicia 100 may be made using expandable ink. Further, it is contemplated that an aesthetic design may be applied to more than one outwardly facing surface using the expandable ink. In particular, expandable ink may be applied to any of the outwardly facing surfaces so that when dispenser 10 is in use, the expandable ink protects a surface such as the wall, or protects carton 12 from water damage. Raising carton 12 off of a wall or towel bar by 1 mm to about 3 mm may prevent water from making contact and soaking into a panel of carton 12, such as the dispensing panel 28 or contact panel 22. It is contemplated that several dots of expandable ink may be placed on dispensing panel 28 or contact panel 22 to function as feet.

[0042] When introducing elements of the disclosure or the preferred aspect(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0043] These and other modifications and variations to the present disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure, 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 disclosure so further described in such appended claims.