Tissue Product Dispenser

Description

BACKGROUND

Tissue products (e.g., facial tissues) are commonly sold in prepackaged cardboard boxes in either a flat carton or an upright carton containing a stack of tissues. The tissues can be interfolded for pop-up dispensing or merely laid on top of one another for reach-in dispensing. When interfolded, the tissues are dispensed through an opening in the top of the box that can contain a polymeric film to facilitate separation of the top tissue from the rest of the stack while retaining the popped-up tissue. However, some consumers are reluctant to buy such products because they do not think the large, bulky boxes of tissues are appealing. For example, some consumers think the boxes create an eye sore when present on countertops and tables, particularly in modern design spaces which tend to promote open design concepts, a lack of coffee tables, and decluttered surfaces. Many consumers view toilet tissue as a suitable alternative to facial tissue and forego buying facial tissue due to the lack of an aesthetic dispenser with a small footprint. Additionally, such existing dispensers can suffer from “fall back,” which occurs when the uppermost tissue sheet falls back into the box rather than being retained in its popped-up position.

While some dispensers have been designed to be more aesthetically pleasing, they are still typically variations on the box design and suffer from some of the same problems, but use materials like wood, plastic, or ceramic rather than the typical cardboard and still require a large space on a countertop or table surface. As such, there is a need for an improved tissue product dispenser.

SUMMARY

In general, the present disclosure is directed to a dispenser for a rolled tissue product. The dispenser comprises a base and a top. The base has a lower portion with a generally flat surface and an upper portion. The top has a lower portion interfitting detachably with the upper portion of the base. The top further has an upper portion comprising an opening. The spindle is detachably retained by the upper portion of the base and/or the lower portion of the top, for example, by a slot configured to detachably retain the spindle.

In some embodiments, the top and base are both generally hemispherical in shape and connect together to form a generally spherical body. The upper portion of the base may be rotatably connected to the lower portion of the base (e.g., by a ball-and-socket joint), such that the generally spherical body of the dispenser can rotate relative to the lower portion of the base.

In some embodiments, the generally flat surface of the base has a generally circular cross-section. Additionally, the generally flat surface of the base can have a mounting mechanism attached thereto, such as an adhesive strip, to facilitate mounting the dispenser on a surface, such as a wall or table.

In some embodiments, the opening in the top is circular and the opening further contains an insert with an aperture, such as a silicone insert, which facilitates separation of the first tissue sheet while retaining the next one in a popped-up position.

The top can interlock with the base via a tab and slot connection. For example, in some embodiments, the upper portion of the base comprises a rim and at least one L-shaped slot and the lower portion of the top comprises a rim and at least one tab extending below the rim, the tab having a protrusion extending outwardly therefrom which can slide into the bottom groove of the L-shaped slot on the base. As such, when the top is rotated with respect to the base, the protrusion on the tab can be locked into the L-shaped slot.

The dispenser can also include a spindle configured to hold a rolled tissue product. In some embodiments, the spindle is a cylindrical rod. The spindle can be retained in a slot having comprising a recess having a rounded bottom portion and two sidewalls. In such an embodiment, the bottom portion of the recess can be wider than the diameter of the spindle such that the spindle can rest in the bottom of the recess. In order to detachably retain the spindle in the bottom of the recess, the middle portion of the recess can have the same width as, or be slightly narrower than, the diameter of the spindle. Alternatively, the slot can be an L-shaped recess which retains the spindle in the bottom groove of the L-shaped recess.

The dispenser can further comprise a rolled tissue product comprising a tissue sheet spirally wound to form a roll, the roll defining an axial passageway that extends from a first end of the roll to a second and opposite end of the roll in a direction perpendicular to the length of the tissue sheet, wherein the spindle extends through the passageway. The passageway may be lined only by the tissue sheet or in certain embodiments may be lined with core about which the tissue sheet is spirally wound.

For example, the roll can comprise a plurality of individual (i.e., separated) tissue sheets, which can be folded longitudinally in an overlapping relation to the adjacent tissue sheet(s). In some embodiments, each sheet is folded twice such that each tissue sheet comprises an upper layer, a middle layer, and a lower layer. The lower layer of each intermediate tissue sheet can be partially interposed between the middle and upper layers of one adjacent sheet while the upper layer is interposed between the lower and middle layers of the other adjacent tissue sheet. In some embodiments, the amount of overlap between sheets can range from about 10 percent to about 50 percent of the length of the sheet.

In another aspect, the present disclosure is directed to such a rolled tissue product on a disposable core which can serve as refills for the dispenser.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best or preferred mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figure in which:

FIG. 1 is a perspective view of an embodiment of a dispenser in accordance with the present disclosure;

FIG. 2 is a perspective view of one embodiment of a base made in accordance with the present disclosure;

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

FIG. 4 is a perspective view of an embodiment of a top made in accordance with the present disclosure;

FIG. 5 is a perspective view of an embodiment of a dispenser in accordance with the present disclosure;

FIGS. 6A-6F illustrate one embodiment of the folded and rolled tissue sheets according to the present disclosure;

FIG. 7 is a perspective view of one embodiment of a base and rolled tissue product formed in accordance with the present disclosure; and

FIG. 8 is a perspective view of one embodiment of a tissue dispenser and tissue sheet in accordance with the present disclosure.

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

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 dispenser for a rolled tissue product, such as a roll of folded facial tissue sheets. The dispenser can have a small footprint which takes up less space on a table or counter and can also be mounted to a wall or any other desirable surface. Advantageously, in some embodiments, the dispenser can swivel such that it can dispense products in any direction. Additionally, by using a roll of folded tissues rather than a stack, the dispenser can reduce issues of fall back.

The dispenser comprises a base and a top that can interlock with one another to form the dispenser body. The base comprises a bottom portion with a flat surface to facilitate mounting (e.g., via adhesive strips). The top is detachable from the base, allowing a user to remove the top and refill the dispenser without having to dismount the dispenser from any surface it is mounted to. The dispenser is configured to accept a rolled tissue product, such as a roll of folded tissue sheets. For example, in some embodiments, the tissue sheets can be rolled onto a disposable core which can be slid onto a spindle detachably retained in the dispenser.

The base comprises an upper portion and a lower portion. The upper portion can be generally hemispherical in shape and mount to the lower portion via a joint. The lower portion has the generally flat surface by which the dispenser can be mounted. In some embodiments, the flat surface is generally circular. However, the flat surface can be any other suitable shape as well, such as a square, rectangle, triangle, or the like, or any other shape that can be mounted to a surface. Additionally, the upper portion of the base does not need to be hemispherical and can have any other shape which has an interior volume which can accept a spindle and a roll of tissues within it.

As used herein, generally spherical or hemispherical means that the dispenser, base, or top has a convex rounded surface and at least one circular cross-section such that a projection of the surface would have ratio of the long diameter to the short diameter of about 1.0 to about 1.5. As such, generally spherical or hemispherical shapes can be egg-shaped or have one or more flat surfaces and still be considered generally spherical. For example, the upper portion of the base may be generally spherical even if it has a flat bottom surface.

The top of the dispenser has a lower portion that interfits with the upper portion of the base. For example, the lower portion of the top can have a rim which interfits with a rim on the upper portion of the base. For example, in some embodiments, the outer surface of the rim of the top is sized to fit just inside the inner surface of the rim of the base. In other embodiments, the outer surface of the rim of the base can be sized to fit just inside the inner surface of the rim of the top.

Alternatively, the rims of both the base and the top can be similarly sized such that they butt together. When the rims of the top and bottom butt together, they can include other means to detachably interlock the top to the base. For example, in one embodiment, the top comprises at least one tab which extends below the rim and has a protrusion extending parallel to the rim. The base can then have an L-shaped slot which extends below the rim of the base and is spaced such that the protrusion on the tab of the top can fit into the lower groove of the L-shaped slot on the base, which similarly runs parallel to the rim, thereby interlocking the top to the base.

In some embodiments, the top is hemispherical in shape and has a rim with a circular cross-section that meets with a hemispherical base section also having a rim with a circular cross section. While this is a preferred embodiment, as the top can be rotated with respect to the base to lock the top and base together via a tab and slot as described above while keeping the rims aligned with each other, the rims can also have non-circular cross sections and other means for detachably interlocking the top and base.

For example, if the dispenser were shaped as a cube instead of a sphere, the top and bottom rims could have square cross-sections that interfit with each other or butt together with a separate interlocking mechanism, such as a tab and protrusion that fits into a corresponding slot. However, if the rim is not circular, the tab could be formed such that it deflects inward when the top and base are pushed together and then snaps into the slot, rather than having to rotate the top with respect to the base. Those skilled in the art can envision many other shapes that such a dispenser can have and mechanisms for detachable interlocking the top to the base.

The various components of the dispenser can be made from any suitable rigid or semi-rigid material that can bend or flex with applied force but otherwise retains its shape. Suitable materials can include polyethylene, polyester, polypropylene, polystyrene, ABS, polyvinyl chloride, polyamide, silicone, rubber, elastomeric materials, metal, wood, and glass amongst other suitable alternatives. The materials used should be capable of withstanding multiple use cycles of opening and refilling the dispenser.

Materials can be chosen that provide the desired degree of flexibility for the interlocking mechanism to join the top to the base and for the mechanism to detachably retain the spindle. For example, when a tab needs to be deflected and then locked into a slot, the tab should have enough flexibility to deflect with minimal force but enough rigidity to remain locked in the slot afterward. Additionally, when the spindle and/or the sidewalls of a slot need to deflect enough for the spindle to slide through the slot and then be locked into a bottom portion of the slot, the materials of the slot and/or sidewalls should have enough flexibility to temporarily deflect and then revert to their original shape in order to detachably retain the spindle. Those skilled in the art can select materials accordingly.

One embodiment of the dispenser is illustrated by FIG. 1. FIG. 1 shows a generally spherical dispenser 10 including a base 20 and a top 30. The base 20 includes an upper portion 21 and a lower portion 22. The lower portion 22 includes a generally flat surface 23. The top 30 includes an upper portion 31 and a lower portion 32. The upper portion 31 includes a circular opening 33. The dispenser also includes a spindle 40 retained in the upper portion 21 of the base 20. While the opening shown in FIG. 1 is circular, it should be understood that it may take any shape suitable for dispensing a tissue from the interior to the exterior of the dispenser, such as an ovular or elliptical shape.

In some embodiments, a mounting mechanism can be attached to the generally flat surface 23. For example, in some embodiments, an adhesive strip can be attached in order to stick the dispenser to a table, countertop, wall, or similar flat surface. Alternatively, the generally flat surface may be attached to a bracket with holes for attaching the dispenser to a surface via screws, nails, or a similar fastener.

The upper portion 21 of the base 20 may be attached to the lower portion 22 of the base 20 in a manner that allows the upper portion 21, and therefore the rest of the dispenser body, to rotate relative to the lower portion 22. For example, the upper portion 21 may be attached to the lower portion 22 via a ball-and-socket joint. The ball component of the joint may be part of either the upper portion 21 or the lower portion 22 of the base 20, while the other portion contains the socket component. Alternatively, any other means for allowing the upper portion to rotate with respect to the lower portion may be used, for example, bearings or bushings. In a preferred embodiment, the joint between the upper portion and lower portion of the base allows the dispenser body to freely rotate 360°.

One embodiment of the base 20 is illustrated by FIG. 2. As shown, the base 20 includes L-shaped slots 50 and spindle slots 60. The L-shaped slots 50 are configured to interlock with tabs extending from the top 30 (shown in FIG. 4). The L-shaped slots 50 are formed as recesses in the upper portion of the base and extend below a rim 25 of the base. The recesses have an upper groove 51 and a lower groove 52 which extends parallel to the rim 25 in a clockwise direction (when viewing the dispenser from above). The bottom of the lower groove may be defined by a ledge 26 which extends parallel to the rim 25.

Spindle slots 60 are configured to detachably retain a spindle. They are also formed by recesses in the upper portion of the base and include round bottom sections 61, middle sections 62, and upper sections 63. They each contain two sidewalls 64. The slots 60 are shaped with convex sidewalls 64 such that the width of the middle sections 62 are narrower than the upper sections 63 and the lower sections 61. For example, the width of the lower sections 61 and upper sections 63 can be slightly wider than the diameter of a spindle which is to be retained in the slots 60. The width of the middle sections 62 is preferably equal to, or slightly narrower than, the diameter of the spindle, such that the spindle can be placed in the upper portion of the slot 63 and then pressed firmly through the middle section 62 until it snaps into the lower rounded section 61. In order to remove the spindle, a user can pull the spindle upward firmly through the middle portion 62 of the slot 60 to dislodge it. It can then be removed by continuing to pull it through the upper portion 63 of the slot 60.

In some embodiments, the spindle is stationary and does not spin, while the tissue roll or core spins on the spindle. However, it is also possible that the spindle itself can be mounted such that it can rotate as the rolled tissue product is dispensed. Additionally, in some embodiments, the spindle can be disposable. For example, a refill tissue roll cartridge may include a spindle that can be attached to the dispenser. However, it is preferable that the spindle is reused and refill tissue roll cartridges are mounted on the reusable spindle.

Another embodiment of a base is shown in FIG. 3. In the base shown in FIG. 3, slots 50 are the same as in FIG. 2. However, instead of slots 60 for retaining a spindle, in this embodiment, the base contains L-shaped slots 70. The L-shaped slots contain an upper groove 71 and a lower groove 72. The L-shaped slots are formed by recesses in the upper part 21 of the base 21. As shown in FIG. 3, they can be formed such that the top openings of the upper grooves 71 of the L-shaped slots 70 are recesses in the ledge 26. In this embodiment, the spindle can be inserted through the upper grooves 71 of the L-shaped slots 70 and then slid horizontally into the lower grooves 72 of the L-shaped slots 70 to secure the spindle. In this embodiment, a non-round spindle can also be used. For example, the spindle can have a square cross-section.

The spindle can have any suitable diameter but is typically from about 0.25 in to about 1.5 in in diameter, such as from about 0.5 in to about 1 in. In some embodiments, the top 63 and bottom 61 sections of the spindle slots 60 shown in FIG. 2 or the top 71 and bottom 72 grooves of the L-shaped slots 70 in FIG. 3 can have a width of about 0.025 in to about 0.25 in larger than the diameter of the spindle. The width of the middle of the spindle slot in FIG. 2 can range from the same size as the diameter of the spindle to about 0.125 in smaller than the diameter of the spindle, in order to retain it.

Although FIGS. 2 and 3 show the slots for retaining the spindle in the base of the dispenser, it should be understood that they can also be formed in the top or even partially in the base and partially in the top such that the spindle is retained between a recess in the rim of the top and a recess in the rim of the base and retained by interlocking the top to the base.

FIG. 4 shows one embodiment of a top. The top 30 has an upper portion 31, a lower portion 32, an opening 33 in the upper portion 31, a rim 34, and two tabs 35. The two tabs 35 extend below the rim 34. The tabs each contain a protrusion 36. The protrusions 36 are spaced apart from the rim 34 such that when the top 30 is placed on the base 20 shown in either FIG. 2 or FIG. 3, the rim 34 of the top 30 will butt against the rim 25 of the base 20 and the bottoms 37 of the tabs 35 will sit on the ledge 26 of the base 20. The top 30 can be slid onto the base 20 by aligning the protrusions 36 with the upper grooves 51 of the L-shaped slots 50. Once the top 30 is slid onto the base 20 such that the rim 34 of the top sits flush with the rim 25 of the base 20, the top 30 can be rotated clockwise with respect to the base 20 in order to slide the protrusions 36 into the lower grooves 52 of the L-shaped slots 50, thereby locking the top 30 to the base 20. In this regard, the distance between the rim 34 and the protrusions 36 on the top 30 is about the same as the distance between the rim 25 and the bottom grooves 52 of the L-shaped slots 50 on the base 20. In some embodiments, for example, this distance can range from about 0.25 in to about 1.5 in. Additionally, the distance between the rim 34 of the top 30 and the bottoms of the tabs 37 is about the same as the distance between the rim 25 of the base 20 and the ledge 26. In some embodiments, for example, this distance can range from about 0.5 in to about 2 in.

While the top is described as having an upper portion and a lower portion, it should be understood that the upper and lower portions are not necessarily separate components and preferably they are integral with each other and formed from a single piece of material.

FIG. 5 shows an embodiment of the dispenser wherein the opening 33 in the top 30 has an insert 80 to facilitate the separation of the interfolded tissue sheets. The insert 80 has an aperture 81. For example, when a roll of folded tissues is contained in the dispenser, a user can pull the top tissue from the roll through the aperture, and the friction between the aperture 81 of the insert 80 and the next tissue in the roll can hold the next tissue in the aperture 81 while the user pulls out the top tissue. Although FIG. 5 shows the aperture 81 in the insert 80 as being circular, it can have any suitable shape. For example, it can have an ovular shape, or the insert can comprise multiple flaps which meet at the middle of the opening, such as a cross or X-shaped configuration. The insert 80 can be made of any suitable material but is preferably a polymer, such as silicone. The insert 80 can be attached to either the inner or outer surface of the opening 33 perimeter or can straddle both the inner and outer surfaces of the opening perimeter.

The present disclosure is also directed to a rolled tissue product, such as a roll of folded facial tissues. The rolled tissue product can comprise a series of interfolded sheets rolled onto a core. The core can be a disposable tube, such as a cardboard tube. The core can be formed such that the inner diameter of the core is larger than the diameter of the spindle, allowing the spindle to be inserted through the core before being mounted to the dispenser. For example, in some embodiments, the diameter of the core is from about 0.5 in to about 1.75 in, such as from about 0.75 in to about 1.25 in. When all the tissues have been used, a user can remove the spindle from the dispenser, dispose of the core, and insert another roll of folded tissues into the dispenser via the spindle.

FIGS. 6A-6F show the folds of a roll of folded tissues in detail. As shown in FIG. 6A, a tissue sheet 100 is folded lengthwise about a third of the way from the bottom of the sheet along a first fold line 104 so that the bottom third 101 is folded over the middle third (not shown as it is underneath bottom third 101 in FIG. 6A). As used herein, the terms “top third,” “middle third,” and “bottom third” are used to describe the sections of the tissue sheets before they are folded. While the term “third” is used, it should be understood as an approximation and the sheet does not need to be folded precisely into thirds. The terms “upper layer,” “middle layer,” and “lower layer” are used to describe the same portions of each tissue sheet after it is folded. For example, with respect to the first tissue sheet 100, the bottom third 101 becomes the middle layer, the middle third becomes the lower layer, and the top third 103 becomes the upper layer after folding.

As shown in FIG. 6B, the next tissue sheet 110 is placed such that its top third 113 partially overlaps with the bottom third 101 (middle layer) of the first sheet 100 at an overlapping section 140. The top third 103 (upper layer) of the first sheet 100 is then folded over the top third (lower layer) of the second sheet 110 at fold line 105, as shown in FIG. 6C. As shown in FIG. 6D, the bottom 111 and middle 112 thirds of the second sheet 110 are then folded over the top third 103 (upper layer) of the first sheet 100 at a fold line 114. Then, as shown in FIG. 6E, a third sheet 120 is placed so that its top third 123 partially overlaps the middle third 112 (middle layer) of the second sheet 110 at a second overlapping section 150. The bottom third 111 (top layer) of the second sheet 120 can then be folded over the top third 123 of the third sheet 120. The process continues until a desired number of sheets are interfolded together. The interfolded sheets are then wound around a core 160, as shown in FIG. 6F. The number of tissues wound on the roll can vary depending on the size of the dispenser but is typically in the range of about 15 to about 100, in some embodiments from about 20 to 50.

FIG. 7 shows a roll of interfolded tissues 200 wound around a spindle (not shown) and inserted into a base 20 of a dispenser 10. One tissue sheet 201 is shown partially unwound from the roll 200. FIG. 8 shows the dispenser 10 after the top 30 is attached to the base 20. Tissue sheet 201 can be seen partially pulled through an aperture 81 in an insert 80.

Each tissue sheet can have any desired length and width but will normally range from about 6 inches to about 12 inches in both length and width. As such, when the tissue sheet is folded twice lengthwise into approximately thirds, each tissue will have a width of from about 2 inches to about 4 inches. Accordingly, in some embodiments, the length of the spindle can range from about 2.5 inches to about 8 inches, such as from about 3 inches to about 5 inches. In this regard, the diameter of the dispenser can range from about 3 inches to about 10 inches, such as from about 4 inches to about 8 inches, depending on the size of the tissue sheets and the number of tissues desired to fit within the dispenser. While the dispenser is taught as being suitable for facial tissues, it should be understood that the dispenser can also be used to dispense other paper products as well and can accordingly be adjusted to any desirable size.

The process described above produces a roll of folded sheets wherein each intermediate sheet (meaning every sheet but the first and last in the roll) is folded twice to produce an upper layer, middle layer, and lower layer. The lower layer of each intermediate tissue sheet is partially interposed between the middle and upper layers of one adjacent sheet and the upper layer of each intermediate sheet is interposed between the lower and middle layers of the other adjacent sheet. For example, with reference to FIGS. 6A-6F, tissue sheet 110 is an intermediate sheet. After folding is complete, its lower layer 111 (top third) is partially interposed between the middle layer (bottom third) and upper layer 103 (top third) of tissue sheet 100 and its upper layer 113 is interposed between the lower layer 123 (top third) of tissue sheet 120 and the middle layer 122 of tissue sheet 120.

As used herein, interfolded tissues are those in which each tissue is at least partially folded with the adjacent tissue(s). Interfolding the tissues creates a beneficial feature in that as the first tissue is pulled up out of the opening, it will cause the next tissue to start to follow the first tissue out of the dispenser. It should be noted that each tissue can be folded in either its machine direction or in its cross-direction. The orientation of the tissue relative to its machine direction or cross-direction will depend upon the equipment used to fold the tissue.

It should be understood that while the above process is one way of interfolding a series of individual tissue sheets together, it is not the only way. Those skilled in the art can determine other suitable ways to fold tissue sheets together such that they can be rolled on a core. For example, the sheets can be folded in half instead of into thirds, or the sheets can be folded into thirds in a different configuration to that described above.

The amount of overlap between sheets can be selected as desired. In some embodiments, the amount of overlap between each sheet and the next is about 10% to about 50% of the length of each individual sheet. In some embodiments, the amount of overlap is from about 1 to about 4 inches (e.g., about 3 inches). Such an overlap typically allows the sheets to be sufficiently linked together so that they can be rolled onto a core while also separating easily from each other when being pulled against the friction from the opening or insert (e.g., silicone insert) within the opening.

The folds can be made in any suitable manner. For example, they can be done by hand and manually wound around a core. Alternatively, the folding and rolling operations may be performed by machines. For example, the tissues can be folded and rolled by a multifolder or interfolder and a flexwinder or a machine combining the folding and rolling operations.

It should also be understood that the dispenser can be used for any rolled tissue product and is not limited to being used with the roll of folded tissues described herein. For example, the dispenser is also suitable for dispensing a spirally wound tissue product containing a tissue sheet with perforations separating each tissue sheet.

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 either 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.