Note: Descriptions are shown in the official language in which they were submitted.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
Stack of paper sheets, dispenser having such a stack and
method for forming such a stack
TECHNICAL FIELD
The present disclosure relates to a stack of folded paper
sheets, particularly a stack of interfolded paper sheets and
even more particular tissue paper sheets. The disclosure
further relates to a dispenser having such a stack and a
method for forming such a stack, particularly for folding of
the individual sheets and their interfolding. The present
disclosure is particularly applicable to table napkins, more
particular dispenser napkins, but may also be employed for
other applications such as paper towels.
BACKGROUND
One such stack is disclosed in US 2014/0057069 Al. The folded
sheets of the stack disclosed therein are first folded in
half along a longitudinal centerline. Subsequently, the
sheets are folded along two parallel folding lines which are
perpendicular to the longitudinal centerline in opposite
directions so as to obtain a Z-folding. The Z-folding is used
for interfolding the consecutive sheets within the stack. In
particular, one of the two parallel folding lines separates
the sheets in two panels and one panel of a consecutive sheet
is sandwiched or disposed between the two panels of previous
sheet, whereby the interfolding is obtained. The other one of
the two parallel folding lines forms a starter fold enabling
easier grabbing of a sheet not already protruding from a
dispensing opening.
The above stack or particularly the folded sheets thereof use
three folds about three folding lines achieving 1/4 of the
size of the base sheet.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
2
Yet, the opening of the sheets is perceived less than
optimum. In particular, when gripping the starter fold and
withdrawing the sheet from a dispenser, the sheet only opens
along the two parallel folding lines used for interfolding
and, therefore, only doubles in size.
SUMMARY
In view of the aforesaid, it is desired to provide a stack of
folded paper sheets, a dispenser and a method wherein the
individual sheets are easily unfolded when being withdrawn
from the stack. In particular embodiments, the individual
sheets have a size after being unfolded corresponding to more
than twice the times their size before withdrawal from the
stack (i.e. compared to the folded sheet).
It is also desired to obtain easier unfolding while
maintaining interfolding of the individual folded sheets and
presenting a starter fold.
Also, it is desired to provide a stack, a dispenser having a
stack and a method for forming a stack, the stack having a
relatively small footprint, without impairing interfolding of
the individual folded sheets, presenting a starter fold
and/or easy unfolding of the individual folded sheets when
being withdrawn from the stack.
At least one of the above objects is solved by a stack of
folded paper sheets as defined in claim 1, a dispenser having
such a stack as defined in claim 10 and a method for forming
a stack of folded paper sheets as defined in claim 11.
According to an aspect a stack of folded paper sheets is used
as table napkins, more particular dispenser napkins. In this
context, dispenser napkins are to be understood as napkins
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
3
which are presented to a user via a dispenser, wherein the
napkins are withdrawn from the dispenser one by one. Yet,
other applications for examples as towels are conceivable as
well. In particular embodiments, tissue paper (see also ISO
12625-1) is used as material for the folded sheets. The stack
comprises a plurality of individual sheets. Each folded sheet
may have a rectangular shape. Each folded sheet may be folded
from a base sheet. The base sheet is to be considered as a
sheet of one or more paper layers or plies without any fold.
The base sheet may as well have a rectangular shape. In this
context, rectangular includes quadratic as well as rectangles
having rounded corners. Each base sheet may be constituted
from one or more plies. Further, each base sheet may be
folded a plurality of times to form the folded sheet. The
term "folded sheet" is to be understood as the completely
folded sheet in the stack. According to this aspect, each of
the folded sheets is at least folded along a first folding
line so that a part of a free edge opposite to the first
folding line is located inward of the outer peripheral edges
and on an outer surface of the folded sheet, whereby a
starter fold is formed. In one embodiment, the part of the
free edge is located on a top surface of the folded sheet in
the stack or, to put it differently, on a top surface of the
folded sheet facing upwards in the stack. A starter fold is
to be understood as a fold having a free edge presented to a
consumer for instance via a dispensing opening to facilitate
initial removal of the sheets from a dispenser. For example,
the starter fold may provide a free edge located on the top
of each folded sheet centrally or offset to the outline of
the folded sheet. According to an embodiment, the width of
the starter fold perpendicular to the first folding line is
at least 10 mm or at least 20 mm. The maximum width is mainly
governed by the total width of the folded sheet in a
direction perpendicular to the first folding line. According
to an embodiment, the maximum width is chosen to allow for at
least 10 or at least 20 mm of ,free surface" on top of the
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
4
folded sheet other than the starter fold to provide
sufficient space for the fingers gripping the free edge. As
regards the terminology "first folding line", "second folding
line", etc, it is to be understood that first, second, etc.
does not indicate the order in which the folds are made
during the manufacturing process but only serves to
differentiate between different folding lines. Moreover and
according to this aspect, each folded sheet is further folded
along one or more second folding lines non-parallel to the
first folding line. Preferably, the second folding line/-s
intersect/-s the starter fold. As a result, also the starter
fold is folded along or about the second folding line/-s. If
one second folding line is present, the folded sheet is
separated in two panels connected at the second folding line.
It is to be understood, that each folded sheet may be folded
along two of the second folding lines forming a Z-shape and
having three panels or even more than two of the second
folding lines forming an accordion like shape and having more
than three panels. If only one second folding line is
present, the second folding line separates the sheet in only
two panels which are connected at the second folding line
forming a U-shape. Considering a Z-shape, two second folding
lines are present, wherein one of the second folding lines
separates the sheet in a first panel and a second middle
panel and the other one of the second folding lines separates
the sheet in the second middle panel and a third panel.
Moreover, two consecutive folded sheets in the stack are
interfolded or interleaved so that at least one panel of one
sheet is disposed between two panels of the previous and/or
consecutive sheet. Comfortable withdrawing of the folded
sheets from a dispenser is enabled by interfolding the
consecutive sheets. In particular, when the consumer pulls a
folded sheet out of a dispensing opening of the dispenser,
the immediate next (consecutive) folded sheet is also subject
to a pulling force making the immediate next folded sheet
partially protrude from the dispensing opening and being
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
partially unfolded. The next user can then easily access this
protruding sheet.
According to this aspect, it is possible to use the first and
5 second folding line to reduce the footprint of each folded
sheet compared to the base sheet and, thereby the stack. At
the same time, because the first and second folding line are
non-parallel, unfolding of each folded sheet after being
withdrawn from the stack or dispenser is simplified and
enhanced compared to the prior art in that the at least
partially unfolded sheet is more than double the size of the
folded sheet after being withdrawn from the stack. Even
further, the used folding lines have a double function,
namely the first folding line additionally serves for
creating the starter fold and the second folding line
additionally serves for interfolding the consecutive folded
sheets within the stack.
According to an embodiment, the first folding line may extend
perpendicular to the second folding line. The use of
perpendicular folding lines for this purpose provides for
ease of manufacture. In this manner, one of the folding lines
may be formed during the manufacturing process in the machine
direction (MD), i.e. parallel to the machine direction,
whereas the other one of the folding lines may be formed in
the cross machine direction (CD), i.e. transverse to the
machine direction. As a consequence, the combination of
standard machinery or elements thereof may be used to fold
the sheets and form the stack.
As explained earlier, the second folding line may intersect
the starter fold. According to an embodiment, the second
folding line intersects the starter fold at a longitudinal
center of the starter fold (the longitudinal direction is
parallel to the free edge and the first folding line). The
latter is particularly the case if only one second folding
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
6
line is present centrally separating the folded sheet in only
two panels. Further, the starter fold may extend along the
two panels on surfaces of the panels facing away from each
other. This is particularly the case if the starter fold is
formed by folding the sheet about the first folding line
before folding the sheet about the second folding line for
interfolding with the starter fold being located on top of
the sheet and the folding about the second folding line is
performed towards the back of the sheet.
Moreover, each folded sheet may be further folded along a
third folding line parallel to the first folding line forming
a backfold, the backfold and the starter fold being located
on opposite sides of the sheet particularly before folding
the sheet about the second folding line. As the starter fold,
the second folding line may intersect the backfold. In
particular, the second folding line may intersect the back
fold at a longitudinal center of the backfold, the
longitudinal direction being parallel to the third folding
line. The folded sheets of the stack form a number of plies
or layers in the height direction of the stack, wherein one
sheet has a plurality of plies or layers in the height
direction at least because of the folding process. The
backfold provides for the advantage, that the number of plies
or layers of the stack is the same at the edge of the first
folding line and the edge of the third folding line.
Accordingly, the stack is more stable. In addition, this
simplifies compression of the stack, if compression thereof
is desired. Furthermore, if the folded sheet is already
protruding from the dispensing opening, the user has two
possibilities to grip the sheet, because the starter fold and
the backfold somewhat protrude in opposite directions forming
a "Z" at the protruding edge. Accordingly, the folded sheet
is easy to grip and unfold. The backfold further reduces the
footprint of the folded sheet.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
7
In certain embodiments, a width of the starter fold
perpendicular to the first folding line and a width of the
backfold perpendicular to the third folding line sum up to a
total width between and perpendicular to the first folding
line and the third folding line. Accordingly, the same number
of plies over the height of the stack may be achieved not
only at the outer edges corresponding to the first and third
folding line, but over the entire area (in plan view) of the
stack.
Further, the backfold may extend along the two panels on
surfaces of the panels facing each other. To put it
differently, the starter fold can be located at one side
(e.g. outer side) of the folded sheet, i.e. the sheet folded
about the second folding line, whereas the backfold is
located at another opposite side (e.g. inner side) of the
folded sheet. To put it differently, the intermediately
folded sheet, that is the sheet before being folded about the
second folding line, has two opposite surfaces. The starter
fold is located on one of the two surfaces and the backfold
is located on the other of the two surfaces. After folding
about the second folding line, the starter fold is located on
an outer side, that is surfaces of the panels facing away
from each other, and the backfold is located on an inner
side, that is surfaces of the panels facing towards each
other. Accordingly, the backfold does not interfere with the
starter fold. Hence, the freedom of design of the starter
fold is enhanced and it can be ensured that a user can easily
grab the free edge of the starter fold. In addition, once a
sheet protrudes from the dispensing opening the user has two
possibilities for gripping the sheet at either the starter
fold or the backfold for unfolding to the "full" area or at
least a larger area.
Moreover, the free edge of the starter fold may be formed by
a fourth folding line. Thus, the fourth folding line is
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
8
parallel to the first folding line. Because of the fourth
folding line, the footprint of the stack may be further
reduced as compared to folded sheets having only two or only
three folding lines. Moreover, using the fourth folding line
as the free edge of the starter fold provides for a starter
fold consisting of at least two layers or plies connected at
the fourth folding line, i.e. the free edge of the starter
fold. Thus, a more stable starter fold can be obtained which
can be gripped more easily. Also the appearance of the
starter fold is enhanced as compared to a two ply starter
fold wherein the two plies are unconnected at the free edge.
If a backfold is present, the backfold may be formed by two
plies or layers. In this case, the layers may be unconnected
at the free edge of the backfold.
In one embodiment, the fourth folding line is a half fold of
the base sheet. Yet, the fourth folding line may well be a
quarter fold of the base sheet. In this context a
half/quarter fold is a fold by which the base sheet is folded
so as to have only half/quarter of its original completely
unfolded size.
Furthermore, the fourth folding line may be parallel to the
first folding line and the optional third folding line. Thus,
two/three of the three/four folding lines can be manufactured
in the machine direction enabling manufacture at short cycle
time.
An even further aspect concerns a dispenser having a housing
accommodating a stack as described above and a dispensing
opening, the free edge of the starter fold of the first
(uppermost or top) folded sheet in the stack being accessible
via the dispensing opening. In a particular example, the free
edge of the starter fold is visible through the dispensing
opening. Thus, it can be ensured that the first folded sheet
of a new stack can be readily extracted from the dispenser
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
9
through the dispensing opening and because of the
interfolding apply a pulling force to the consecutive folded
sheet, whereby the consecutive folded sheet is pulled out of
the dispensing opening automatically. Accordingly, the
consecutive folded sheet protrudes from the dispensing
opening and is readily accessible for the next user. As the
dispensers are usually refilled even in cases before all of
the folded sheets are dispensed, it may happen that two or
more of the stacks are contained in the container, the two
stacks being not interfolded at their interface. Thus, the
folded sheets are folded identically so that each of the
folded sheets of the stack has the starter fold. Thus, at the
interface between an upper and a lower stack, where the first
folded sheet of the lower stack is not automatically pulled
out of the dispensing opening when withdrawing the last
folded sheet of the upper stack, the user can again use the
starter fold of the first folded sheet of the lower stack for
withdrawing the first folded sheet of the lower stack through
the dispensing opening.
An even further aspect relates to a method for forming a
stack of folded paper sheets for use as table napkins or
other applications as mentioned above. The stack may have the
configuration as described above. As a result, any features
described with respect to the stack and/or the dispenser
above may also be combined with the following method. The
method comprises a) folding a plurality of sheets to form a
plurality of intermediate folded sheets, each folded along a
first folding line so that a free edge opposite and parallel
to the first folding line is located inward of the outer
peripheral edges of the intermediate folded sheet, wherein a
starter fold is formed. Inward of the outer peripheral edges
of the intermediate folded sheet in this context means that
the free edge is located in a distance to the outline of the
intermediate folded sheet in a plan view. In an example, the
free edge may be located at a center between opposite
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
peripheral edges or off-center. After the step a)
intermediate folded sheets are obtained. The method further
comprises, after step a), the step b): subsequently folding
the intermediate folded sheets along a second folding line
5 non-parallel to the first folding line forming a folded
sheet, whereby a part of the free edge of the starter fold is
located inward of the outer peripheral edges of and on an
outer surface of the folded sheet, wherein the second folding
line separates the folded sheet in two panels connected at
10 the second folding line and step c): interfolding two
consecutive folded sheets so that at least one panel of one
folded sheet is disposed between the two panels of the
previous and/or consecutive folded sheet. The steps b) and c)
may be performed concurrently, wherein consecutive folded
sheets, folded about the second folding line, are
concurrently interfolded, or one after the other. Commonly
used technologies for making a stack of interfolded or
interleaved paper sheets include where the second folding
line is parallel with the machine direction (length folding)
or perpendicular with the machine direction (cross folding).
The preferred technology for the invention is cross folding
which facilitates introduction of the first, third and fourth
folding lines through length folding. Cross folding to
achieve interfolding is often denoted by Interfold, Multifold
or Single-fold. Also if there is some ambiguity as to the
definitions of these terms, interfold often refers to when
two webs are interleaved and multifold when only a single web
is used. Single-fold refers to when the folded paper sheet
has only one second folding line. Single-fold was
historically made on interfold lines using two webs but
recently technologies were introduced that are capable of
producing single-fold also from a single web. With two webs
the webs are cut separately to generate two streams of sheets
of equal length and the cut is positioned so as not to
coincide between the two webs and combined into one stream.
The stream of cut sheets is folded alternatingly so as to
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
11
form a stack of separate sheets where one or more panels of
each sheet are interleaved with the panels of an adjacent
sheet. With a single web, the web is cut in sheets of
commonly equal length which are made to partially overlap
through a retardation and displacement of the trailing edge
of one sheet relative to the leading edge of the following
thus generating a stream of sheets partially overlapping. The
overlapping can be so that the trailing edge sheet always
ends up on the same side of the leading edge sheet or that it
ends up on alternating sides. That stream is then folded
alternatingly to so as to form a stack of separate sheets
where one or more panels are interleaved. With one or two
webs any number of panels can be made. And also can the first
or last panel be made smaller than the other. With only two
panels is normally required either a solution with two webs
or a single web solution where the displacement of the
trailing edge of the stream of sheets is alternatingly
located as described above. This is a prerequisite to achieve
an interleaving.
The method may also comprise the step of folding the sheets
about a third folding line parallel to the first folding line
for forming a backfold as described above. The backfold and
the starter fold are located on opposite sides of the sheet
after folding and before step b). The step of folding the
sheets about a third folding line may be performed before or
after the step a), but before the step b).
The method may further comprise the step of folding the
sheets along a fourth folding line before the step a). As
explained above, the fourth folding line may be parallel to
the first folding line and the optional third folding line.
Further, the fourth folding line may be a half fold or a
quarter fold of the base sheet.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
12
For ease of manufacture, the web for producing the sheets or
sheets are fed in a machine direction and the first folding
line, the optional third folding line and the optional fourth
folding line are parallel to (extend along or in) the machine
direction and the second folding line is (extends) transverse
(perpendicular) to the machine direction (in the cross
machine direction).
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, embodiments and examples are explained in
the following detailed description referring to the
accompanying drawings. The drawings show in:
Figure 1 A-C: a process of folding a sheet and forming a
stack according to a first embodiment;
Figure 2: a perspective view of one folded sheet of the stack
of figure 1;
Figure 3 A-D: a process of folding a sheet and forming a
stack according to a second embodiment;
Figure 4: a perspective view of one folded sheet of the stack
of figure 3;
Figure 5: a perspective view of one folded sheet of a stack
according to a third embodiment;
Figure 6: a perspective view of one folded sheet of a stack
according to a fourth embodiment;
Figure 7: a perspective view of one folded sheet of a stack
according to a fifth embodiment;
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
13
Figure 8: a perspective view of one folded sheet of a stack
according to a sixth embodiment;
Figure 9: a perspective view of one folded sheet of a stack
according to a seventh embodiment; and
Figure 10: a schematic side view of the folded sheets of
Figure 9 showing the interfolding.
DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS
The same reference numerals have been used for the same or
similar elements throughout the various embodiments disclosed
in figures 1A to 10. In order to avoid repetition these
elements have not always been described anew in all of the
embodiments. Further it is noted that folding lines extending
in the machine direction (MD) are perpendicular to folding
lines extending in the cross machine direction (CD) in the
embodiments.
Figures 1A-C and 2 show a first embodiment. Each folded sheet
of the first embodiment is '/4 in size compared to the
completely unfolded sheet (in the following referred to as
base sheet 10).
Figure 1A shows a perspective of the base sheet 10. The base
sheet 10 has a rectangular shape having a first pair of
parallel peripheral edges 111 and 112 and a second pair of
parallel peripheral edges 121 and 122. The base sheet may
consist of one or more paper plies.
The base sheet 10 is folded about a first folding line 13
indicated by the broken line in figure 1A. In particular, the
left hand peripheral edge 121 is folded about the first
folding line 13 towards an upper surface 14 of the base sheet
10 as indicated by the arrow.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
14
As a result, a starter fold 16 is formed on the upper surface
14 of the base sheet 10 and later the outer side of the
folded sheet 30. The starter fold 16 has a free edge
corresponding to the left hand peripheral edge 121 and is
connected to the remainder of the base sheet 10 at the first
folding line 13. The free edge of the starter fold 16 is
located within the outline of the thus obtained intermediate
folded sheet 20.
Further, the base sheet 10 is folded about a third folding
line 15 indicated by the broken line in figure 1A. In
particular, the right hand peripheral edge 122 is folded
about the third folding line 15 towards a lower surface of
the base sheet 10 (opposite to the upper surface 14) as
indicated by the arrow.
As a result, a backfold 17 is formed on the back surface of
the base sheet 10 and later the inner side of the folded
sheet 30. The backfold 17 is connected to the remainder of
the base sheet 10 at the third folding line 15. A free edge
of the backfold corresponds to the right hand peripheral edge
122 of the base sheet 10.
It is also clear from the above, that the first folding line
13 and the third folding line 15 are parallel to the
peripheral edges 121 and 122.
In a particular embodiment of the manufacturing process a web
having a total width W corresponding to the length of the
peripheral edges 111 and 112 is fed in a machine direction
(MD) parallel to the peripheral edges 121 and 122.
Subsequently, a plurality of sheets may be formed by cutting
the web in a cross machine direction (CD) to form the
peripheral edges 111 and 112. The folding about the first
folding line 13 and the third folding line 15 may be achieved
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
in the machine direction (MD) either concurrently, before or
after the mentioned cutting.
Thus, one obtains an intermediate folded sheet 20 as shown in
5 figure 1B.
Subsequently and as shown in figure 1B, the intermediate
folded sheet 20 is folded about a second folding line 18
towards the back in figure 1B as shown by the arrow. In the
10 manufacturing process, this folding about the second folding
line 18 is performed in the cross machine direction (CD).
Thereby, the intermediate folded sheet 20 is separated into a
first panel 19 and a second panel 21 by the second folding
line 18.
Accordingly a folded sheet 30 as shown in figure 2 is
obtained. At this stage, the peripheral edges 111 and 112 may
be congruent in plan view. Thus, the outline of the folded
sheet 30 is delimited by the first folding line 13, the
second folding line 15 parallel thereto, the second folding
line 18 perpendicular to the first folding line and the
second folding line as well as the peripheral edges 111 and
112 parallel to the second folding line. Particularly
considering figure 2 it becomes apparent that the free edge
of the starter fold 16 formed by the peripheral edge 121 is
situated inward of the outer peripheral edges 13, 15, 18,
111/2, i.e. the outline of the folded sheet 30. Thus, the free
edge may easily be gripped by a user as will be explained in
more detail below.
Further, the upper surface 14 of the base sheet 10 forms the
outer surface of the folded sheet 30. The lower surface
opposite to the upper surface 14 forms the inner surface of
the folded sheet 30. Thus, the two panels 19, 21, connected
at the second folding line 18, form a U-shape.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
16
The back fold 17 is located on an inner surface side. In
particular, outer surfaces 22 of the backfold 17 facing away
from the back surface of the base sheet 10 face each other
but are located on an inner surface side of the folded sheet
30.
The starter fold 16 is located on an outer surface side. In
particular, outer surfaces 23 of the starter fold 16 facing
the upper surface 14 of the base sheet 10 face away from each
other.
The folding of the intermediate folded sheet 20 about the
folding line 18 is used to interfold a plurality of
consecutive folded sheets 30 to form a stack 40 as shown in
figure 1C.
In particular and as indicated in figure 2, the two panels 21
and 19 sandwich another panel 19' of a consecutive folded
sheet 30' (the panel 19' of the consecutive folded sheet 30'
has been indicated only schematically in figure 2). In turn,
the consecutive folded sheet 30' sandwiches the panel 19 of
the folded sheet 30 and the panel 21" (not shown) of a
further consecutive folded sheet 30" (not shown) between its
panels 19' and 21'. This is repeated to form the stack 40 of
a plurality of folded sheets 30.
Moreover, the width W1 of the starter fold 16, that is the
length of a line perpendicular to and connecting the first
folding line 13 and the peripheral edge 121 and the width W2
of the backfold 17, that is the length of a line
perpendicular to and connecting the third folding line 15 and
the peripheral edge 122 sum up to the width W3 of the
remainder of the base sheet 10, that is the length of a line
perpendicular to and connecting the first folding line 13 and
the third folding line 15 (W1+W2=W3). It is to be understood
that in other embodiments the width W1 and W2 do not need to
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
17
sum up to the width W3. Accordingly, the planar size of the
intermediate folded sheet 20 is 50% as compared to the planar
size of the base sheet 10. Further, in particular
embodiments, the free edge of the starter fold 16 and the
free edge of the backfold 17 are congruent in plan view. As a
result, the number of layers formed by the plurality of
folded sheets 30 over the height H of the stack 40 is the
same over the whole planar area of the stack 40. In
particular, the number of layers per folded sheet in the
height direction is four over the entire planar area.
Thereby, a stable and easily compressible stack 40 is
achieved.
As will be apparent from figure 1A, the width W1 is smaller
than the width W2. Accordingly, the free edge of the starter
fold 16 formed by the peripheral edge 121 will be located
closer to the peripheral edge (formed by the first folding
line 13) of the intermediate folded sheet 20 than to the
opposite peripheral edge (formed by the third folding line
15) of the intermediate folded sheet 20. Accordingly, the
free edge is off-centered. If the width W1 and W2 is the same
and W1+W2=W3 and/or if the width W1 is half the width W3, the
free edge is centered.
Further, by folding the intermediate folded sheet 20 about
the folding line 18, which is disposed in the center of the
intermediate folded sheet 20, the planar size of the folded
sheet is reduced to 50% of the planar size of the
intermediate folded sheet 20 and to 25% of the planar size of
the base sheet 10. Thus, a stack 40 with a relatively small
footprint in plan view can be obtained, which in the present
example is only i/4 of the original planar size of the base
sheet 10. This size reduction is however mainly achieved by
folding lines having a further function, namely the function
of forming the starter fold 16 (the first folding line 13)
and the function of interfolding the consecutive folded
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
18
sheets 30 (the second folding line 18). Thus, these folding
lines have a double function.
The stack may be accommodated in a dispenser 41 as
schematically indicated in figure 1C. The dispenser 41 has a
dispensing opening 42, which in the present example may be
situated at an outer edge of the dispenser 41 in a plan view.
The dispenser 41 as shown in figure 1C may have been refilled
with a stack 40 recently so that no folded sheet 30 protrudes
from the dispensing opening 42. Yet, the free edge of the
starter fold 16 formed by the peripheral edge 121 is visible
and accessible through the dispensing opening 42. If a user
intends to withdraw a folded sheet 30 from the dispenser 41,
the user can thus readily grab the free edge of the starter
fold 16 and withdraw the folded sheet 30 through the
dispensing opening 42 and from the dispenser 41. Because of
friction forces between the panel 19' of the consecutive
folded sheet 30'and the inner surfaces of the panels 19 and
21 of the folded sheet 30, the panel 19' of the consecutive
folded sheet 30' is entrained by the withdrawal of the folded
sheet 30. As a result, after complete withdrawal of the
folded sheet 30, the panel 19' of the consecutive folded
sheet 30' protrudes from the dispensing opening 42. Thus, the
consecutive folded sheet 30' can be withdrawn even more
easily. This process is continued as long as the folded
sheets 30 are interfolded. If more than one stack 40 is
disposed within the dispenser 41, with the last sheet of the
first stack and the first folded sheet of the second stack
not being interfolded, the first folded sheet of the second
stack will again not protrude from the dispensing opening 42.
Yet, in this case, the user can again grab the starter fold
16 of the first folded sheet of the second stack as explained
above.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
19
In addition, when withdrawing the folded sheet 30 from the
dispenser 41, the folded sheet 30 is automatically unfolded
about the first folding line 13, the second folding line 18
and the third folding line 15. By unfolding about the second
folding line 18, the folded sheet 30 already doubles its size
again to the intermediate folded sheet 20. The unfolding
about the first folding line 13 and the third folding line 50
again doubles the size of the intermediate folded sheet 20 to
the full size of the base sheet 10. Accordingly, the user can
automatically get the benefit of the full area of the base
sheet 10 without having to manually unfold the sheet/napkin.
Figures 3A-D and 4 show a second embodiment. Each folded
sheet 30 of the second embodiment is 1/8 in size compared to
the completely unfolded base sheet 10.
The main difference between the first and second embodiment
is, that the base sheet 10 is in a first step, shown in
figure 3A, folded about a fourth folding line 50 in half as
shown by the arrow. Thus, the planar size of the thus folded
intermediate folded sheet 1 is reduced by 50% compared to the
planar size of the base sheet 10. In the manufacturing
process, the fourth folding line 50 is as well created in the
machine direction (MD), yet before the formation of the first
folding line 13 and the third folding line 15.
The intermediate folded sheet 1 shown in figure 3B is in
principle similar to the base sheet 10 in figure 1A except
that it is double layered because of the folding about the
fourth folding line 50. As a result, the free edge of the
starter fold 16 is formed by the fourth folding line 15. As a
consequence, the starter fold 16 is double layered (see
figure 4) and the free edge is "closed" in that the two
layers of the starter fold 16 are connected by the fourth
folding line 50. This configuration provides for a more
stable starter fold 16 which is easy to grab.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
To the contrary, the free edge of the backfold 17 is formed
by the aligned peripheral edges 121-and 122 of the base sheet
10. Hence, also the backfold 17 is double layered, but the
5 free edge thereof is "open" in that the two layers are
unconnected.
After folding about the first folding line 13 and the third
folding line 15, one obtains a further intermediate folded
10 sheet 20 as shown in figure 3C in principle corresponding to
the intermediate folded sheet 20 of figure 1B. The further
intermediate folded sheet 20 is because of W1+W2=W3 only 50%
in planar size of the intermediate folded sheet 1 and hence
only 25% in plan a size of the base sheet 10.
In a next step and as explained with respect to the first
embodiment above, the further intermediate folded sheet 20 is
then folded about a second folding line 18 extending in the
cross machine direction (CD). Thus, the size of the further
intermediate folded sheet 20 is further reduced by 50% to
obtain the folded sheet 30. In total, the folded sheet 30 is
accordingly only 12.5% in planar size of the base sheet 10 in
this embodiment.
In addition and as in the first embodiment, the folding about
the second folding line 18 serves to interfold a plurality of
folded sheets 30 to form a stack 40 as shown in figure 3D.
Again because of the configuration of the width W1, W2 and
W3, the number of layers over the height H of the stack is
the same. In the particular example, the number of layers per
sheet is eight over the whole planar area of each folded
sheet 30.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
21
The remainder of the second embodiment is the same as that of
the first embodiment and reference is made to the above
description.
A third embodiment is shown in figure 5. The embodiment in
figure 5 differs over the first embodiment only in that the
backfold 17 is omitted. To put it differently, the base sheet
is only folded once about the first folding line 13 and no
folding about the third folding line 15 is performed. The
10 width W1 of the starter fold 16 may be increased compared to
the first and second embodiment to half the width W3 of the
remainder of the base sheet 10. Accordingly, the free edge
formed by the peripheral edge 121 is located in the center of
the folded sheet 30 in plan view, that is centrally between
the folding line 13 and the peripheral edge 122.
In this example, the planar size of the base sheet 10 is
reduced by 1/3 when folding the base sheet 10 about the first
folding line 13 for forming the starter fold 16. Accordingly,
the size of the intermediate folded sheet 20 in this
embodiment is about 66% of that of the base sheet 10.
Afterwards, the intermediate folded sheet 20 is again folded
about the second folding line 18 used for interfolding as in
the first and the second embodiment. Thereby, the planar size
of the folded sheet 30 is only 50% of the planar size of the
intermediate folded sheet 20 and only 1/3 (about 33,3%) of
the planar size of the base sheet 10.
A fourth embodiment is shown in figure 6. As explained with
respect to the second embodiment, in this embodiment the
starter fold 16 is double layered to provide for a more
stable starter fold 16 which is hence easier to be grabbed.
The fourth embodiment explains an alternative to achieve such
a starter fold 16 even without first folding the base sheet
10 into half as in figure 3A of the second embodiment.
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
22
Similar to the first embodiment one starts from a base sheet
10, folding the base sheet 10 about a first folding line 13
and a third folding line 15. The first folding line 13 and
the third folding line 15 separate the base sheet 10 into 3
portions of equal width W1=W2=W3.
Subsequently, the portion folded about the first folding line
13 is again folded in half about a fifth folding line 51 in
an opposite direction. The fifth folding line 51 is parallel
to the first folding line 13 and hence also the third folding
line 15. Accordingly, a starter fold 16 having a width
W4=0.5*W1 is formed.
The free edge of the starter fold 16 is formed by the fifth
folding line 51. Hence, the free edge is, as in the second
embodiment, "closed" in that the two layers forming the
starter fold 16 are connected at the fifth folding line 51.
In this embodiment, the free edge of the starter fold 16 is
again centered relative to the outline between the first
folding line 13 and the third folding line 15.
Further and different to the first embodiment, the backfold
17 extends over the entire inner side of the panels 19, 21.
That is, the width W2 of the backfold 17 is the same as the
width W3 of the remainder of the folded sheet 30.
The planar size of the folded sheet 30 is, in this
embodiment, 1/6 of the size of the base sheet 10.
A fifth embodiment is shown in figure 7. The fifth embodiment
differs from the fourth embodiment only in that also the
backfold 17 is folded in half similar to the starter fold 16
in the fourth and the fifth embodiment. For this purpose, the
backfold 17 is after being folded about a third folding line
15 folded in half about a sixth folding line 52 in an
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
23
opposite direction. Accordingly, the width W5 of the backfold
17 is 0.5*W2 (W5=0.5*W2). The benefit of this fifth
embodiment compared to the fourth embodiment is that the same
number of layers may be achieved over the height H of the
stack and over the entire planar area thereof. In particular
and considering figure 7, the number of layers per sheet 30
is six over the whole width W3. To the contrary, the number
of layers in the fourth embodiment in figure 6 is six in the
left portion of the width W3 and four in the right portion of
the width W3 (the left and right portion are divided in the
center of the width W3). Accordingly, the stack formed from
sheets 30 as shown in the fifth embodiment would be more
stable and can be more easily compressed as compared to the
one shown in the fourth embodiment.
The planar size of the folded sheet 30 is, in this embodiment
again, 1/6 of the size of the base sheet 10.
A sixth embodiment is shown in figure 8. The sixth embodiment
differs from the first embodiment in that the intermediate or
middle portion having the width W3 of the base sheet 10 is
folded about a seventh folding line 53 and an eighth folding
line 54 to 1/3 of its size. In particular, the seventh
folding line 53 and the eighth folding line 54 separate the
middle portion of the base sheet 10 in three portions of
equal width (W3=3*W6). Accordingly and as compared to the
first embodiment, the footprint of the folded sheet 30 can be
further reduced. In particular, the planar size of the folded
sheet 30 is only 1/8 of the planar size of the base sheet 10.
That remainder of the sixth embodiment is the same as that of
the first embodiment.
Moreover and as will be apparent from the comparison of the
first and second embodiments above, any of the third to sixth
embodiment may additionally include first folding the base
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
24
sheet 10 into half along the fourth folding line 50 and only
subsequently starting with the folding process described in
these embodiments.
In addition, it is to be understood that in view of the
description above the first folding line 13 may be selected
so that the free edge of the starter fold 16 is centered or
off-centered in all of the above embodiments. Further and if
a backfold 17 is present, the width of the backfold 17 can be
adjusted as desired. Yet, to achieve the same number of
layers over the height H of the stack 40, the width of the
backfold 17 is the same as the width of the starter fold 16.
In particular embodiments, the free edges of the starter fold
16 and the backfold 17 are aligned or congruent in plan view.
Moreover, the interfolding has been explained with respect to
a U-folded sheet 30. Yet, the interfolding can also be
achieved when the intermediate folded sheet 20 is folded in
opposite directions about parallel but distanced second
folding lines 18, whereby a Z-folded sheet is obtained
similar to that described in US 2014/0057069 Al. Such an
embodiment is shown in figures 9 and 10. This embodiment is
similar to the one described with respect to figures 3 and 4
with the exception that the intermediate folded sheet 20
shown in figure 3C is folded twice about two parallel second
folding lines 18. Accordingly and considering the folded
sheet 30, a part of the outer surface 23 and, hence, of the
free edge 50 of the starter fold 16 is located on the top of
the folded sheet 30 in the stack and hence faces upward in
the stack. In other words, the free edge 50 of the starter
fold 16 is located on top of the top panel 62. The remainder
of the starter fold 16, i.e. of the outer surface 23 and the
free edge 50, are located on an inner side surface of the
folded sheet 30 between the intermediate panel 60 and the
bottom panel 61. Similar, the backfold 17 or more
particularly its outer surface 22 is located on an inner side
CA 03033043 2019-02-05
WO 2018/054455 PCT/EP2016/072329
surface of the folded sheet 30 between the top panel 62 and
the intermediate panel 60 whereas the remainder of the
backfold 17 is located on an outer side surface of the folded
sheet 30, namely the bottom surface of the bottom part 61 and
5 the facing downward in the stack.
The interfolding of such folded sheets 30 is shown in figure
10. In particular, one panel, namely the bottom panel 62, of
one folded sheet 30 is sandwiched between 2 panels, namely
10 the top panel 61 and the intermediate panel 60 of the
consecutive folded sheet 30 and so on. Yet, the interfolding
can also be performed as shown in US 2014/0057069 Al we see
intermediate panel 60 and the bottom panel 62 of one folded
sheet 30 being sandwiched between the top panel 61 and the
15 intermediate panel 60 of the consecutive folded sheet 30 and
so on.
The remainder of this embodiment is the same as that shown in
figures 3 and 4. Of course also the embodiment in figures 1
20 and 2 and the embodiments in figures 5 to 8 may be embodied
in combination with a Z-fold about two second folding lines
18 as shown in figures 9 and 10.
In view of the above, the described embodiments are not
25 considered exclusive but may be modified and even combined in
various ways.
