U.S. patent application number 14/942866 was filed with the patent office on 2016-05-19 for compressed hollow coreless re-formable roll products.
The applicant listed for this patent is Georgia-Pacific Consumer Products LP. Invention is credited to Thomas J. Daul, Sarah A. Lemke, Pamela S. Mueller, Douglas E. Robinson.
Application Number | 20160137398 14/942866 |
Document ID | / |
Family ID | 55961045 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160137398 |
Kind Code |
A1 |
Lemke; Sarah A. ; et
al. |
May 19, 2016 |
Compressed Hollow Coreless Re-Formable Roll Products
Abstract
A compressed hollow coreless roll of absorbent paper sheet
produced by way of providing a roll of absorbent paper sheet by
winding the sheet about a forming core member having a diameter in
the range of 30 mm to 50 mm; removing the forming core member such
that there is provided a hollow coreless roll of absorbent paper
sheet with an axial cavity having a diameter in the range of 30 mm
to 50 mm and compressing the hollow coreless roll such that the
axial cavity is substantially collapsed. The compressed hollow
coreless rolls are readily re-formed into cylindrical shape.
Space-saving packages of the rolls are overwrapped with tubular
polymer film to provide a flexible reconfigurable package of a
series of individually encased rolls. Volume reductions of about 10
to about 20%, about 14% to about 20%, 30%, 40% and more as compared
with conventional products are realized.
Inventors: |
Lemke; Sarah A.; (Appleton,
WI) ; Robinson; Douglas E.; (Appleton, WI) ;
Daul; Thomas J.; (Oneida, WI) ; Mueller; Pamela
S.; (Neenah, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Georgia-Pacific Consumer Products LP |
Atlanta |
GA |
US |
|
|
Family ID: |
55961045 |
Appl. No.: |
14/942866 |
Filed: |
November 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62080822 |
Nov 17, 2014 |
|
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|
Current U.S.
Class: |
206/386 ;
206/391; 242/160.4; 53/438 |
Current CPC
Class: |
B65D 2571/00018
20130101; B65H 18/28 20130101; B65D 71/063 20130101; B65D 77/02
20130101; B65D 85/07 20180101; B65D 85/671 20130101; B65D
2571/00012 20130101; B65B 63/02 20130101; B65D 2571/00037 20130101;
B65D 71/0092 20130101 |
International
Class: |
B65D 85/671 20060101
B65D085/671; A47K 10/16 20060101 A47K010/16; B65D 77/02 20060101
B65D077/02; B65D 65/02 20060101 B65D065/02; B65D 71/00 20060101
B65D071/00; B65D 71/06 20060101 B65D071/06; B65H 18/28 20060101
B65H018/28; B65B 63/02 20060101 B65B063/02 |
Claims
1. A compressed hollow coreless roll of absorbent paper sheet
produced by way of providing a roll of absorbent paper sheet by
winding the sheet about a forming core member having a diameter in
the range of 30 mm to 75 mm; removing the forming core member such
that there is provided a hollow coreless roll of absorbent paper
sheet with an axial cavity having a diameter in the range of 30 mm
to 75 mm and compressing the hollow coreless roll such that the
axial cavity is substantially collapsed.
2. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the forming core member has a
diameter of from about 35 mm to 50 mm such that the axial cavity of
the roll has a diameter of from 35 mm to 50 mm prior to compression
of the roll.
3. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the forming core member has a
diameter of from about 37.5 mm to 42.5 mm such that the axial
cavity of the roll has a diameter of from 37.5 mm to 42.5 mm prior
to compression of the roll.
4. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the forming core member is a tubular
paperboard core.
5. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the compressed hollow coreless roll
is overwrapped with a polymeric film in order to maintain the
compressed hollow coreless roll in the substantially collapsed
configuration.
6. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the hollow coreless tissue roll has a
diameter of from about 80 mm to 230 mm prior to compression, and a
thickness after compression such that its axial cavity is
substantially collapsed, of no more than about 60% of the diameter
of the roll prior to compression.
7. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the hollow coreless tissue roll has a
diameter of from about 80 mm to 230 mm prior to compression, and a
thickness after compression such that its axial cavity is
substantially collapsed, of no more than about 50% of the diameter
of the roll prior to compression.
8. The compressed hollow coreless roll of absorbent paper sheet
according to claim 1, wherein the hollow coreless tissue roll has a
diameter of from about 100 mm to 200 mm prior to compression and a
thickness after compression such that its axial cavity is
substantially collapsed of no more than about 80% of the diameter
of the roll prior to compression.
9. A package containing a plurality of the compressed hollow
coreless rolls according to claim 1, which are overwrapped with a
polymeric film, wherein the polymeric film is effective to maintain
the axial cavities of the plurality of hollow coreless rolls in the
substantially collapsed configuration.
10. The package according to claim 9, wherein the package contains
a re-usable tubular dispensing core which has a diameter smaller
than the forming core member upon which the roll was wound.
11. The package according to claim 10, wherein the tubular
dispensing core has a diameter of from 25 mm to 32 mm.
12. A method of making and packaging a compressed hollow coreless
roll of absorbent paper sheet comprising: providing a roll of
absorbent paper sheet by winding the sheet about a forming core
member having a diameter in the range of 30 mm to 50 mm; removing
the forming core member such that there is provided a hollow
coreless roll of absorbent paper sheet with an axial cavity having
a diameter in the range of 30 mm to 50 mm; compressing the hollow
coreless roll such that the axial cavity is substantially
collapsed; and packaging the compressed hollow coreless roll so
that the axial cavity of the compressed hollow coreless roll is
maintained in the substantially collapsed configuration.
13. The method according to claim 12, wherein the forming core
member has a diameter of from about 35 mm to 45 mm such that the
axial cavity of the roll has a diameter of from 35 mm to 45 mm
prior to compression of the roll.
14. The method according to claim 12, wherein the forming core
member has a diameter of from about 37.5 mm to 42.5 mm such that
the axial cavity of the roll has a diameter of from 37.5 mm to 42.5
mm prior to compression of the roll.
15. The method according to claim 12, wherein the forming core
member is a tubular paperboard core.
16. The method according to claim 12, wherein the compressed hollow
coreless roll is overwrapped with a polymeric film in order to
maintain the compressed hollow coreless roll in the substantially
collapsed configuration.
17. The method according to claim 12, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 150 mm prior to
compression, and a thickness, after compression such that its axial
cavity is substantially collapsed, of no more than about 60% of the
diameter of the roll prior to compression.
18. The method according to claim 12, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 150 mm prior to
compression, and a thickness, after compression such that its axial
cavity is substantially collapsed, of no more than about 50% of the
diameter of the roll prior to compression.
19. The method according to claim 12, wherein the hollow coreless
tissue roll has a diameter of from about 100 mm to 130 mm prior to
compression and a thickness after compression such that its axial
cavity is substantially collapsed, of no more than about 60% of the
diameter of the roll prior to compression.
20. The method according to claim 12, wherein a plurality of the
compressed hollow coreless rolls are overwrapped with a polymeric
film to form a package of the plurality of rolls, wherein the
polymeric film is effective to maintain the axial cavities of the
plurality of hollow coreless rolls in the substantially collapsed
configuration.
21. The method according to claim 20, wherein the package contains
a re-usable tubular dispensing core which has a diameter smaller
than the forming core member upon which the roll was wound.
22. The method according to claim 21, wherein the tubular
dispensing core has a diameter of from 25 mm to 32 mm.
23. A method of delivering absorbent paper sheets comprising:
providing a roll of absorbent paper sheet by winding the sheet
about a forming core member having a diameter in the range of 30 mm
to 50 mm; removing the forming core member such that there is
provided a hollow coreless roll of absorbent paper sheet with an
axial cavity having a diameter in the range of 30 mm to 50 mm;
compressing the hollow coreless roll such that the axial cavity is
substantially collapsed; packaging the compressed hollow coreless
roll so that the axial cavity of the compressed hollow coreless
roll is maintained in the substantially collapsed configuration;
re-forming the compressed roll by expanding the substantially
collapsed axial cavity; mounting the re-formed compressed roll
about a spindle; and dispensing absorbent sheet from the outer
periphery of the re-formed roll.
24. The method according to claim 23, further comprising inserting
a tubular dispensing core into the reformed hollow coreless roll
prior to mounting the roll about the spindle wherein the tubular
dispensing core has a diameter smaller than the core member upon
which the roll was wound.
25. The method according to claim 24, wherein the tubular
dispensing core has a diameter of from 25 mm to 32 mm.
26. The method according to claim 23, wherein the forming core
member has a diameter of from about 35 mm to 45 mm such that the
axial cavity of the core has a diameter of from 35 mm to 45 mm
prior to compression of the roll.
27. The method according to claim 23, wherein the forming core
member has a diameter of from about 37.5 mm to 42.5 mm such that
the axial cavity of the core has a diameter of from 37.5 mm to 42.5
mm prior to compression of the roll.
28. The method according to claim 23, wherein the forming core
member is a tubular paperboard core.
29. The method according to claim 23, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 150 mm prior to
compression, and a thickness, after compression such that its axial
cavity is substantially collapsed, of no more than about 60% of the
diameter of the roll prior to compression.
30. The method according to claim 23, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 150 mm prior to
compression, and a thickness after compression such that its axial
cavity is substantially collapsed, of no more than about 50% of the
diameter of the roll prior to compression.
31. The method according to claim 23, wherein the hollow coreless
tissue roll has a diameter of from about 100 mm to 130 mm prior to
compression and a thickness after compression such that its axial
cavity is substantially collapsed of no more than about 60% of the
diameter of the roll prior to compression.
32. A method of making and packaging a compressed hollow coreless
roll of absorbent tissue comprising: providing a roll of absorbent
paper sheet by surface winding tissue to form a first coreless
cylindrical roll of tissue having a diameter in the range of 30 mm
to 50 mm; providing a slip interface about the first coreless
cylindrical roll of tissue, surface winding tissue over the first
coreless cylindrical roll to provide a tissue roll having a
diameter of between about 80 to 230 mm around said interface that
promotes mutual sliding removing a first coreless cylindrical roll
of tissue having a diameter in the range of 30 mm to 50 mm such
that there is provided a hollow coreless roll of absorbent paper
sheet with an axial cavity having a diameter in the range of 30 mm
to 50 mm; compressing the hollow coreless roll such that the axial
cavity is substantially collapsed; and packaging the compressed
hollow coreless roll in a polymeric film so that the axial cavity
of the compressed hollow coreless roll is maintained in the
substantially collapsed configuration.
33. The method according to claim 32, wherein the first coreless
cylindrical roll of tissue has a diameter of from about 35 mm to 45
mm such that the axial cavity of the roll has a diameter of from 35
mm to 45 mm prior to compression of the roll.
34. The method according to claim 32, wherein the first coreless
cylindrical roll of tissue has a diameter of from about 37.5 mm to
42.5 mm such that the axial cavity of the roll has a diameter of
from 37.5 mm to 42.5 mm prior to compression of the roll.
35. The method according to claim 32, wherein first coreless
cylindrical roll of tissue comprises tissue substantially identical
to the tissue in the tissue roll having a diameter of between about
80 to 230 mm wound around said interface that promotes mutual
sliding.
36. The method according to claim 32, wherein the compressed hollow
coreless roll is overwrapped with a polymeric film in order to
maintain the compressed hollow coreless roll in the substantially
collapsed configuration.
37. The method according to claim 32, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 230 mm prior to
compression, and a thickness after compression such that its axial
cavity is substantially collapsed, of no more than about 80% of the
diameter of the roll prior to compression.
38. The method according to claim 32, wherein the hollow coreless
tissue roll has a diameter of from about 80 mm to 230 mm prior to
compression, and a thickness after compression such that its axial
cavity is substantially collapsed, of no more than about 60% of the
diameter of the roll prior to compression.
39. The method according to claim 32, wherein the hollow coreless
tissue roll has a diameter of from about 100 mm to 200 mm prior to
compression and a thickness, after compression such that its axial
cavity is substantially collapsed, of no more than about 80% of the
diameter of the roll prior to compression.
40. The method according to claim 32, wherein a plurality of the
compressed hollow coreless rolls are overwrapped with a polymeric
film to form a package of the plurality of rolls, wherein the
polymeric film is effective to maintain the axial cavities of the
plurality of hollow coreless rolls in the substantially collapsed
configuration.
41. A package of absorbent paper product comprising a plurality of
compressed hollow coreless rolls of absorbent paper having a length
"L", a width "w", the width of each roll being substantially equal
to the width of the web comprising said roll, and a maximum
transverse dimension "d" in the direction normal to the width and
length of said compressed hollow coreless roll, each said hollow
coreless roll of absorbent paper comprising a web having a
generally uniform width and being disposed in a first hollow
polymeric tube having a first end and a second end, the length of a
portion of said first hollow polymeric tube between at least one
roll in said tube and another adjacent roll being a distance of at
least about d, at least one line of weakness and at least one
sealed region being formed in the portion of said tube between said
at least one roll and said other adjacent roll.
42. The package of claim 41 wherein in the portion of the first
polymeric tube between said one roll and the adjacent other roll is
formed at least one additional sealed region and wherein said line
of weakness is formed between said sealed regions.
43. The package as in claim 41, wherein the volume of the package
is at least 10% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
44. The package as in claim 41, wherein the volume of the package
is at least 15% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
45. The package as in claim 41, wherein the volume of the package
is at least 20% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
46. The package as in claim 41, wherein the volume of the package
is at least 25% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
47. The package as in claim 41, wherein the volume of the package
is at least 30% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
48. The package as in claim 41, wherein the volume of the package
is at least 35% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
49. The package as in claim 41, wherein the volume of the package
is at least 40% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
50. The package of claim 41, wherein the volume of the package is
at least 20% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
51. The package of claim 41, wherein the volume of the package is
at least 30% less than the volume of a package of cored
uncompressed rolls having the same caliper, basis weight, and total
sheet area.
52. A corrugated carton having a length of between 17 and 19
inches, a width between 13 and 15 inches and a height between 7 and
9 inches, having packed therein a plurality of rolls of compressed
hollow coreless re-formable roll products, each said roll having a
width of substantially 4 inches, said rolls being arrayed in a
configuration, chosen from the group of configurations consisting
of: (a) 3 rolls by 7 rolls by 2 rolls of bath tissue having a
caliper of from about 0.065 to about 0.165 inches, wherein the
volume of said array is at least 25% less than the volume of a
comparable cored roll of uncompressed tissue of the same caliper
and length; (b) 3 rolls by 5 rolls by 2 rolls of bath tissue having
a caliper of from about 0.065 to about 0.165 inches, wherein the
volume of said array is at least 20% less than the volume of a
comparable cored roll of uncompressed tissue of the same caliper
and length; and (c) 5 rolls by 2 rolls by 2 rolls of bath tissue
having a caliper of from about 0.65 to about 0.165 inches, wherein
the volume of said array is at least 20% less than the volume of a
comparable cored roll of uncompressed tissue of the same caliper
and length.
53. A corrugated carton having a length of between 17 and 19
inches, with the between 13 and 15 inches and a height between 7
and 9 inches, having packed therein a plurality of rolls of
compressed hollow coreless re-formable roll products, each said
roll having a width of substantially 4 inches, said rolls being
arrayed in a configuration, chosen from the group of configurations
consisting of: (a) 3 rolls by 3 rolls by 1 roll of kitchen roll
towel having a caliper of from about 0.065 to about 0.165 inches,
wherein the volume of said array is at least 35% less than the
volume of a comparable cored roll of uncompressed toweling of the
same caliper and length; (b) 3 rolls by 2 rolls by 1 roll of
kitchen roll towel having a caliper of from about 0.065 to about
0.165 inches, wherein the volume of said array is at least 30% less
than the volume of a comparable cored roll of uncompressed toweling
of the same caliper and length; and (c) 2 rolls by 2 rolls by 1
roll of kitchen roll towel having a caliper of from about 0.065 to
about 0.165 inches, wherein the volume of said array is at least
30% less than the volume of a comparable cored roll of uncompressed
toweling of the same caliper and length (d) 5 rolls by 1 roll by 1
roll of kitchen roll towel having a caliper of from about 0.065 to
about 0.165 inches, wherein the volume of said array is at least
30% less than the volume of a comparable cored roll of uncompressed
toweling of the same caliper and length; (e) 2 rolls by 2 rolls by
1 roll of kitchen roll towel having a caliper of from about 0.065
to about 0.165 inches, wherein the volume of said array is at least
15% less than the volume of a comparable cored roll of uncompressed
toweling of the same caliper and length; and (f) 4 rolls by 4 roll
by 1 roll of kitchen roll towel having a caliper of from about
0.065 to about 0.165 inches, wherein the volume of said array is at
least 30% less than the volume of a comparable cored roll of
uncompressed toweling of the same caliper and length.
54. A pallet comprising a base having a length of substantially 48
inches, a width of substantially 40 inches, bearing thereupon a
plurality of poly wrap packs of 12 rolls of compressed hollow
coreless re-formable roll products arrayed in a 3.times.3.times.2
configuration, each of said poly wrap packs having a length of
substantially 12 inches a height of substantially 81/4 inches and a
width of substantially 8 inches, said poly wrap packs being
disposed in 12 layers, each said layer containing 20 poly wrap
packs of compressed hollow coreless re-formable roll products with
12 of said packs having their long edge parallel to the 40 inch
width of said pallet, 8 of said poly wrap packs having their long
edge parallel to the 48 inch width of said pallet, said poly wrap
packs being retained on said pallet by an overwrap of polymeric
film.
55. A pallet comprising a base having a length of substantially 46
7/16 inches, a width of substantially 365/8 inches, bearing
thereupon a plurality of corrugate cartons, each carton containing
3 poly wrap packs of 30 rolls of compressed hollow coreless
re-formable roll products arrayed in a 3.times.5.times.2
configuration, said cartons being disposed in 4 layers, each said
layer containing 6 cartons with 2 of said cartons having their long
edge parallel to the 46 7/16 inch width of said pallet, 4 of said
cartons having their long edge parallel to the 365/8 inch length of
said pallet, each of said poly wrap packs having a length of
substantially 18 inches, having a width of substantially 133/4
inches and a height of substantially 8 inches, each of said cartons
having a width of substantially 133/4 inches a length of
substantially 18 inches and a depth of substantially 24 inches,
said cartons being retained on said pallet by an overwrap of
polymeric film.
56. A pallet comprising a base having a length of substantially 48
inches, a width of substantially 41 inches, bearing thereupon a
plurality of corrugate cartons, each carton containing corrugate
cartons in layers, each carton containing 2 poly wrap packs of 6
compressed hollow coreless re-formable roll kitchen roll towel
products; each poly wrap pack comprising 3 columns of kitchen roll
towels in a 3.times.2 array of rolls with the long side of each
roll aligned with the 3 deep dimension of the array; each corrugate
carton containing 2 poly wrap packs in a vertical array with the
axis of each roll being horizontal; each layer comprising 9 cartons
in a 3.times.3 columnar array with 6 cartons having a long side
being parallel to said long axis of said pallet occupying the 1,1;
2,1; 1,2; 3,2; 2,3 and 3,3 positions of the array and 3 cartons
having a long side perpendicular to said long axis of said pallet,
these 3 cartons occupying the 1,3; 2,2 and 3,1 positions of the
array.
57. A pallet comprising a base having a length of substantially 45
inches, a width of substantially 40 inches, bearing thereupon a
plurality of corrugate cartons, in layers, each carton containing 2
poly wrap packs of 6 compressed hollow coreless re-formable kitchen
roll towel product; each poly wrap pack comprising 6 rolls in a
3.times.2 array with a long side of each roll aligned with the 3
deep dimension of the array; each corrugate container containing 2
poly wrap packs in a side by side array with the axis of each roll
being vertical; each layer comprising 7 cartons in an array with 3
cartons in line having long side by long side with each long side
also being parallel to long axis of said pallet, two pair of
cartons having a long side thereof normal to said long axis of said
pallet, with a long side of one carton of each pair abutting
interior short sides of said 3 cartons in line, interior short
sides of these 2 pairs of cartons being spaced apart from each
other, and, the other carton of each pair having one long side
facing outwardly from said layer of cartons.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on U.S. Provisional Patent
Application No. 62/080,822, filed Nov. 17, 2014, which is
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to roll products and, in a
preferred embodiment, to compressed and hollow coreless rolls of
absorbent paper products such as tissue and toweling, commonly
referred to as tissue, in flexible packaging that enables the
manufacturer to ship a larger usable area of tissue in a given
volume while enabling the end user to store tissue in nooks and
crannies that might not be suitable for tissue packaged in
conventional configurations.
BACKGROUND
[0003] Transportation costs add substantially to the cost of
absorbent paper products sold for consumer use as the volume of
these products is such that when the entire allowable space in a
trailer or container is filled with product, the weight is
typically far less than the load carrying capacity of the trailer
or container. Prime contributors to the excessive volume of these
products are the central void which is typically around 40 mm or so
and also to a lesser extent the generally cylindrical external
shape of the overall product. In practice, when an array of
absorbent products is packaged in a polyethylene overwrap, the
exteriors of the roll are flattened to some extent, increasing the
packability of the array of rolls over that which would be
predicted based solely on the uncompressed roll diameter. It seems
that consumers do not find such rolls objectionable, most likely
due to substantial recovery of the cylindrical shape resulting from
the resilient nature of absorbent paper products. However, efforts
to eliminate the excess volume contributed by the hollow center
void have been less successful in consumer markets, as rolls that
have been compressed sufficiently to eliminate the hollow center
space apparently do not recover their overall cylindrical shape
sufficiently to satisfy consumers' aesthetic demands.
[0004] It is known to compress rolled goods to reduce volume which
is advantageous for transportation and storage. There is disclosed,
for example, in U.S. Pat. No. 864,975 to Luce, a method and
apparatus for baling cotton in sheet form. The method includes
baling the cotton around a mandrel, removing the mandrel, followed
by compressing the annular bale so formed. So also, U.S. Pat. No.
3,537,226 to Le Van et al. discloses a method of packaging batts of
textile fibers, including: (a) wrapping the initial batt onto a
rigid core to form a cylindrical structure; (b) encasing the
structure with a bag of an air impervious material and removing the
core; (c) evacuating air from the bag to contract the structure and
to increase the initial batt density; and then (d) wrapping the
contracted structure with a wrapper of sufficient tensile strength
to maintain substantially the contracted state.
[0005] U.S. Pat. No. 5,480,060 to Blythe shows a system for
dispensing wipers which includes a bi-directionally compressed
hollow coreless roll of wipers configured for center-feed
dispensing.
[0006] Bath tissue is sometimes produced in hollow coreless roll
form, typically with a very small axial central cavity (see U.S.
Pat. No. 4,487,378 to Kobayashi) to minimize volume, or with a
larger central cavity when the tissue roll is configured for
center-feed dispensing. See U.S. Pat. No. 5,849,357 to Andersson.
Such products have not been popular with consumers who prefer
rolled bath tissue with a relatively large core, outer roll-feed
for home use where the product is mounted about a spindle.
Typically bath tissue rolls are provided with a core having a
diameter of 40 mm or so consisting of a paperboard tube which adds
cost, weight and volume to the product. Production efficiency
deficits are also associated with tissue having a large core which
are often formed on center wind equipment operating at lower
winding speeds than surface winders often employed to produce
hollow coreless products.
[0007] U.S. Pat. No. 4,886,167 to Dearwester discloses compressed
rolls of absorbent sheet with conventional paperboard tubular
cores. It has been found that this type of product often does not
recover well from compression; as re-shaping to cylindrical roll
form can be quite difficult, possibly due, in part, to the
difficulty of removing creases from the paperboard core after it
has been flattened.
[0008] U.S. Pat. No. 7,992,818 to Maddaleni relates to a technique
for forming rolls of tissue having a large central opening on high
speed winders without the expense of a board tube. Rather by
providing a discontinuity or low friction interface between
adjacent layers in the wound roll, it becomes possible to remove a
central plug or small diameter roll of tissue located interiorly to
the discontinuity or low friction interface after the roll has been
formed. The central plug is a product usable in its own right after
removal from the larger roll, particularly where a small, easily
carried around supply of tissue is desirable as in a lady's purse
for example.
SUMMARY OF INVENTION
[0009] There is provided in accordance with the invention
compressed hollow coreless rolls of absorbent paper sheet having a
substantially collapsed central axial cavity. Prior to use, the
roll is re-formed into cylindrical shape and subsequently mounted
about a spindle for dispensing. Optionally, a tubular dispensing
core with a diameter smaller than the original cavity before
collapse is provided which may be inserted into the hollow coreless
roll after it is re-formed into cylindrical shape and prior to
dispensing. Such a core can suitably be 2-50% smaller, preferably
10-50% smaller, more preferably 15 to 40% smaller than the original
cavity before collapse and is preferably re-usable, although single
use or several use adaptors are employable as well.
[0010] A particularly significant aspect of the invention is the
reduced volume of a package as compared with a package of
conventional rolls of cored product with the same weight and sheet
count. Volume reductions of about 10 to about 20%, about 14% to
about 20%, 30%, 40% and more are realized while delivering the same
quality and quantity of product without incurring excessive
aesthetic objections. In one particularly popular format, we have
found that we can increase the amount of tissue (rolls of specified
width and length) which can be loaded into a 96'' wide trailer
having a length of 608'' and a height of 104'' can be increased by
over 35% by use of compressed hollow coreless re-formable roll
products of the present invention as compared to conventional
cylindrical cored products.
[0011] The central cavity of the hollow coreless roll, prior to
compression of the roll, is typically cylindrical with a diameter
in the range of 25-75 mm. The invention is superior to core-in
compressed products in terms of reduced weight and in terms of
re-formability of the central cavity as will be appreciated from
the discussion provided hereinafter.
[0012] In contrast to conventional hollow coreless products with
small central axial cavities, the invention product has a
relatively large central cavity and the product is much more
compressible, making available the benefits in terms of volume
reduction and product shape. Conventional hollow coreless products
are also difficult to re-shape after compression to a stable
"round" shape.
[0013] Moreover, the present invention makes it possible to
overcome consumer negatives associated with producing desirable
combinations of sheet count and caliper without needing to achieve
specific roll diameter requirements. Current rolled products have
desired roll diameters for specific characterizations like "Regular
Roll", "Large Roll", Big Roll", "Giant Roll", Mega Roll", "Super
Roll", "Double Roll" and similar other size related descriptions.
As sheet counts are reduced, it becomes more and more difficult to
achieve the desired roll diameter, whether by increasing base sheet
caliper, finished product caliper (i.e., through more emboss,
higher basis weight, high bulk forming), or through winding the
roll in a way that results in a large diameter, but low overall
fiber weight, roll.
[0014] By compressing a hollow coreless roll, the need to balance
the sheet count, forming, caliper, embossing, and roll winding
process to achieve the desired roll diameter is eliminated, as
compressed rolls will not have the same roll diameter requirements
as conventional rolled product. This will result in more cost
effective papermaking and converting processing of the base sheet
and finished product, as well as more efficient transportation of
these compressed rolls.
[0015] The present invention also provides for multiple packaging
options for a plurality of rolls. Packages of multiple rolls in
accordance with the invention require less storage space and can be
configured to fit into spaces not suitable for conventional
products; making it possible to better utilize available storage
areas in the home or in a business establishment. Significantly,
the tissue rolls in the compressed configurations also adapt well
to limited storage and display spaces found in retail environments.
Savings in transportation costs can be of immense importance
commercially.
[0016] In one particularly attractive embodiment, each roll of
compressed absorbent paper product may be wrapped in a polyethylene
film formed from a tube flattened and heat sealed between rolls so
that each roll is ensconced in its own separate sub package while a
linear array of wrapped rolls may be manipulated like a string of
sausages to adapt to storage in oddly sized or configured spaces
that may be available. In many cases, it will be convenient to
provide two heat sealed regions separated by one line of weakness
in the portion of the tube between adjacent rolls so that the rolls
may be easily separated from the linear array while remaining
individually sealed from the environment. Preferably the distance
between at least some of adjacent rolls will be at least
substantially equal to the transverse dimension (width) of the
compressed roll to make it convenient to dispose the rolls in
serpentine configurations.
[0017] In some embodiments, each individualized roll will bear a
transverse circumferential band to stabilize the compression. Such
a band may comprise paper, a similar nonwoven or a polymeric film.
In most cases it will be expedient to secure the transverse band by
interposing pressure sensitive adhesive between overlapping ends
thereof. In other cases, particularly where the hollow compressed
rolls are packaged in a long polymeric tube as described above,
that packaging will itself be sufficient to retain the rolls in the
compressed configuration.
[0018] In some cases, it may be expedient to compress the rolls
using opposed pistons. In other cases, the rolls may be compressed
by forcing them through a suitably shaped chute.
[0019] Still further features and advantages will become apparent
from the discussion which follows.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The invention is described in detail below with reference to
the drawings wherein like numerals designate similar parts.
[0021] FIG. 1A is a photograph showing a compressed hollow coreless
roll of bath tissue of the invention.
[0022] FIG. 1B is a photograph showing a compressed roll of bath
tissue with a paperboard core prepared by the same method of
compression as the roll of FIG. 1A.
[0023] FIG. 2A illustrates a re-formed hollow coreless roll of bath
tissue in accordance with the invention.
[0024] FIG. 2B illustrates a re-formed roll of bath tissue with a
paperboard core.
[0025] FIGS. 3A, 3B and 3C are views in perspective of a re-usable
core which may be used for dispensing tissue from the roll of FIG.
2A.
[0026] FIG. 4 illustrates a package which contains four rolls
disposed in a 1.times.4 planar array with the collapsed axial
cavities of the compressed rolls arranged in parallel and the
longer sides of the compressed rolls arranged in facing
relationship.
[0027] FIG. 5 illustrates a package which contains four compressed
rolls disposed in a 2.times.2 planar array with the collapsed axial
cavities of the compressed rolls arranged in parallel.
[0028] FIG. 6 illustrates a package which contains four compressed
rolls, two of which are disposed centrally with their collapsed
axial cavities arranged in parallel between two other outer rolls
wherein the collapsed axial cavities of the outer rolls are
arranged perpendicularly with respect to the collapsed axial
cavities of the centrally located compressed rolls.
[0029] FIG. 7 illustrates a package which contains four compressed
rolls disposed in a stacked 2.times.2 array with the collapsed
axial cavities of two pairs of stacked compressed rolls arranged
coaxially and wherein the longer side of the compressed rolls
arranged in facing relationship to each other.
[0030] FIG. 8 illustrates a package which contains four rolls
disposed in a 1.times.4 array with the collapsed axial cavities of
the compressed rolls coaxially arranged.
[0031] FIG. 9 illustrates a package which contains four rolls
disposed in a 1.times.4 array with the collapsed axial cavities of
the compressed rolls arranged in parallel and wherein the shorter
sides of the compressed rolls are arranged in facing
relationship.
[0032] FIGS. 10A through 10G are schematic diagrams which
illustrate volume savings of the invention products as compared
with uncompressed product having a paperboard tubular core packaged
in a 2.times.2 planar array. It can be appreciated that savings in
volume extend over a wide variety of configurations from single
rolls up to over-wrapped pre-packaged store displays holding
hundreds of rolls of tissue in any of a variety of subpacks on a
single pallet that can be simply positioned on the retail floor and
sold individually after removal of the overwrap.
[0033] FIGS. 11A through 11D illustrate schematically how a hollow
roll of tissue, having its core previously removed, may be
uniaxially compressed using opposed pistons producing an elliptical
void wherein the long walls of the ellipse are nearly planar and
parallel to each other, preferably touching, or nearly so, along
most of their length.
[0034] FIG. 12 is a schematic illustration of a four pack of hollow
compressed tissue rolls encased in a hollow polymeric tube which
has been heat sealed between the hollow compressed rolls to form a
flexible pack which can be disposed in a very large number of
configurations.
[0035] FIG. 13 is another schematic illustration of a four pack of
hollow compressed tissue rolls encased in a hollow polymeric tube
which has been disposed in another configuration.
[0036] FIG. 14 is another schematic illustration of how three four
packs of hollow compressed tissue rolls encased in a hollow
polymeric tube may be disposed in an overall configuration forming
a twelve pack.
[0037] FIG. 15 is another schematic illustration of how six four
packs of hollow compressed tissue rolls encased in a hollow
polymeric tube may be disposed in an overall configuration forming
a twenty-four pack.
[0038] FIG. 16 is a schematic illustration of how twelve hollow
compressed rolls of tissue may be disposed in a single elongated
polymeric tube to form a flexible package which can be configured
in a large number of postures. The length of the portions of the
hollow polymeric tube between adjacent rolls has been exaggerated
to more clearly show the heat sealed regions and lines of weakness
formed in that portion of hollow polymeric tube between rolls.
[0039] FIG. 17 is another schematic illustration of how three four
packs of hollow compressed tissue rolls encased in a hollow
polymeric tube may be disposed in an overall configuration forming
a twelve pack.
[0040] FIG. 18 is another schematic illustration of how six four
packs of hollow compressed tissue rolls encased in a hollow
polymeric tube may be disposed in another overall configuration
forming a twenty-four pack.
[0041] FIGS. 19A through 19F schematically illustrate an expandable
spindle suitable for use in a home tissue dispenser which may be
inserted into the cavity of hollow compressed tissue rolls to urge
them into a more rounded shape.
[0042] FIGS. 20A through 20D schematically illustrate the interior
workings of an expandable spindle suitable for use in a home tissue
dispenser which may be inserted into the cavity of hollow
compressed bath tissue rolls to urge them into a more rounded
shape.
[0043] FIGS. 21A through 21C schematically illustrate a packing
scheme in which poly-wrapped 12 packs of compressed bath tissue are
palletized without cartons yielding a particularly efficient
truckload of tissue.
[0044] FIGS. 22A through 22E schematically illustrate a packing
scheme in which poly-wrapped 30 packs of compressed bath tissue are
packed 3 to a carton and palletized yielding a particularly
efficient truckload of tissue.
[0045] FIGS. 23A through 23H schematically illustrate a variety of
configurations of poly-wrapped bath tissue rolls particularly
suitable for e-commerce.
[0046] FIGS. 24A through 24C schematically illustrate a Prior Art
packing scheme in which poly-wrapped 24 roll packs of cored
un-compressed kitchen roll toweling are palletized in cartons.
[0047] FIGS. 25A through 25E schematically illustrate a packing
scheme in which poly-wrapped 6 roll packs of un-cored compressed
kitchen roll towel are palletized in cartons yielding another
particularly efficient truckload of tissue.
[0048] FIGS. 26A through 26D schematically illustrate a packing
scheme in which poly-wrapped 6 roll packs of un-cored compressed
kitchen roll towel are palletized in cartons yielding another
particularly efficient truckload of tissue.
DETAILED DESCRIPTION
[0049] The invention is described in detail below in connection
with the various Figures for purposes of illustration, only. The
invention is defined in the appended claims. Terminology used
throughout the specification and claims herein are given their
ordinary meanings as supplemented immediately below.
[0050] When we refer to the axial cavity of the product as
"substantially collapsed", the reference is to a flattened form as
shown in FIG. 1A. Preferably, the gap between opposing sides of the
cavity in the substantially collapsed configuration is less than 25
mm, preferably less than 10 mm, more preferably less than 5 mm and
still more preferably less than 2 mm on average. In a preferred
embodiment, opposing sides of the collapsed cavity are in contact
over a major portion of their area, preferably over at least about
60%, more preferably over at least about 70%, even more preferably
over at least about 80%, and most preferably at least about 90%,
when rolls are in the compressed state in which they are
shipped.
[0051] "Tissue" rolls or similar terminology refers to cellulosic
fiber tissue products, while "bath tissue" rolls must be flushable
and are typically manufactured without a substantial amount of
permanent wet strength resin; as opposed to paper toweling, or
kitchen roll towel, which has a substantial amount of wet strength
resin. Moreover, the most preferred bath tissue is predominantly
(over 50% dry weight) composed of hardwood fiber such as eucalyptus
fiber, although many grades, particularly commercial and economy
grades, have ever increasing recycled content of uncertain origin.
Bath tissue generally has a basis weight of anywhere from 8 to 35
lbs per 3000 square foot ream, with 2 and 3 ply products typically
having a basis weight of from 20 to 35 lbs per 3000 square foot
ream. Details and various properties of bath tissue are presented
in U.S. Pat. No. 8,287,986 to Huss et al. As mentioned previously,
similar savings and advantages are also realizable with kitchen
roll towel as well as any absorbent paper product sold in roll
form. Preferably, the invention is employed with respect to
absorbent papers in which the sheets are not spoiled or defaced by
the compression process. Accordingly, the invention can be employed
with bath tissue, kitchen roll towel, other paper toweling formats,
or even napkin stock.
[0052] In the various packaging configurations hereinafter
described and shown in the drawings, relative orientation of the
compressed rolls in the package is specified, in part, by reference
to a central axis of the collapsed axial cavities of the compressed
rolls which corresponds to the axis of the forming core member upon
which the sheet is wound during manufacture and/or converting.
Relative orientation is also sometimes specified by reference to
either a longer or shorter sides of the compressed rolls.
[0053] Referring to FIG. 1A, there is shown a compressed hollow
coreless roll 10 of absorbent paper sheet produced by way of
providing a roll of absorbent paper sheet by winding the sheet
about a forming core member having a diameter in the range of 25 mm
to 50 mm; removing the forming core member such that there is
provided a hollow coreless roll of absorbent paper sheet with an
axial cavity having a diameter in the range of 25 mm to 50 mm and
compressing the hollow coreless roll such that the axial cavity is
substantially collapsed. When we refer to a "hollow" compressed
roll, we are referring to a roll of tissue from which either a
conventional cylindrical board stock tube has been removed or a
roll of tissue from which the central portion of the roll has been
removed leaving a hollow cavity therethrough. Note the absence of
any hollow cylindrical board stock core in central cavity 12 of the
compressed hollow coreless roll 10 of FIG. 1A.
[0054] Prior to compression, central plugs are preferably removed
from substantially hollow coreless rolls using the procedures such
as those described in U.S. Pat. No. 7,992,818 to Maddaleni, Aug. 9,
2011 (incorporated herein by reference). Subsequent to core
removal, hollow coreless roll 8 may be compressed by action of
opposed pistons 70, 72 bearing against lateral surfaces of the
rolls as illustrated in FIGS. 11A through 11D, resulting in
compressed hollow coreless roll 10. Alternatively, a single piston
bearing against a roll restrained by a fixed wall may be used.
[0055] Typically, the plug removed has a diameter of from about 15
mm to 45 mm such that the axial cavity of the roll has a diameter
of from 15 mm to 45 mm prior to compression of the roll, and in
some embodiments the forming core member has a diameter of from
about 37.5 mm to 42.5 mm such that the axial cavity of the roll has
a diameter of from 37.5 mm to 42.5 mm prior to compression of the
roll.
[0056] The forming core member may be a tubular paperboard core or
any other suitable collapsible core member, but the forming core is
preferably removed prior to completion of roll compression in order
to facilitate both compression and re-forming as will be
appreciated from the Figures. In some cases, initial compression of
the roll while still retaining the core may facilitate removal of
the core, particularly if the roll is formed around a conventional
paperboard core rather than being formed directly on a mandrel or
on a collapsible mandrel. In the cases in which the product of the
present invention is formed from a substantially hollow coreless
roll, it will generally be preferable to remove the central plug
from the roll prior to compression thereof. However, advantageously
there is no necessity to remove the central plug prior to sawing of
individual rolls prior to the log saw.
[0057] In FIG. 1A, compressed hollow coreless roll 10 maintains a
flattened shape having: a substantially collapsed central cavity
12, a pair of longer sides 14 which may be relatively flattened and
may have a central portion which approaches being generally planar;
a pair of shorter sides 16, which, at least after initial
compression, are more rounded and may even approach being generally
semi-cylindrical. The compressed hollow coreless roll 10 is
characterized largely by a thickness 18 measured from the
perpendicular longer sides 14 through the central axis 20 of the
substantially collapsed central cavity 12 which corresponds to the
central axis of the forming core member about which the absorbent
sheet was wound.
[0058] There is shown in FIG. 1B compressed roll 30 of bath tissue
which was compressed with tubular forming core 32 remaining in
place, otherwise following the same procedure as was used to
compress hollow coreless roll 10. It is seen in FIG. 1B that
compressed roll 30 does not maintain a flattened shape nearly as
well as compressed hollow coreless roll 10 and that forming core 32
appears creased around its lateral edges, especially at edge 34 and
36. On the other hand, compressed hollow coreless roll 10 maintains
a flatter shape which is much more desirable in terms of volume
reduction, and package consistency, package compressibility, and
residual force the roll might exert upon a package after
wrapping.
[0059] In FIGS. 2A and 2B there is shown the rolls of FIGS. 1A and
1B, respectively, after re-forming by simple application of hand
pressure, principally on the shorter sides of the rolls. It can be
seen that compressed hollow coreless roll 10 recovers a much more
cylindrical shape than compressed roll 30, which presents a far
more irregular shape largely occasioned by the easily visible
resistance of forming core 32 to re-shaping. If desired by the
consumer, cavity 12a may be further re-shaped by hand prior to
mounting on a spindle for dispensing or a by dispensing core, such
as re-useable core 40 shown in FIGS. 3A though 3C, which may be
inserted prior to mounting the roll on a spindle.
[0060] In FIGS. 3A though 3C, re-usable core 40 is a tubular core
of a length, L, corresponding to the length of the bath tissue
roll, preferably slightly longer, and has a diameter, D, which is
typically smaller than the diameter of the forming core member
about which compressed hollow coreless roll 10 was originally
formed. In this regard, the forming core member about which
compressed hollow coreless roll 10 was originally formed may be a
paperboard core (such as forming core 32, FIG. 2B) which may have a
diameter of about 1.6 inches (41 mm), while the diameter, D, of
re-useable core 40 may be in the range of from 1 to 1.25 inches (or
about 25-40 mm) The forming core may be tubular, cylindrical or
other suitable shape, in which case "diameter" refers to the
maximum lateral dimension of the forming core member. As is
conventional, re-usable core 40 is placed around a spindle or rod
having spring loaded retractable end pieces 42 to enable re-usable
core 40 with a roll of tissue about it to be mounted in
conventional holders. Expandable spindles adapted to urge the
central cavity toward a more cylindrical shape such as that shown
in FIGS. 19A through 19F may be used particularly by homemakers
concerned about the aesthetic appearance of the product in the roll
holder.
[0061] The compressed products of the invention have significantly
less volume than corresponding products provided with a core and
may be packaged in various individually wrapped sub packaged
configurations, preferably overwrapped with a polymeric film
effective to maintain the compressed roll in a substantially
collapsed configuration, as shown in FIG. 1A. While any convenient
polymeric film having sufficient strength may be used, preferably
the film may be a polyethylene or polypropylene film, if so
desired. The invention is particularly suitable for bath tissue and
kitchen roll towel rolls from which the central plug has been
removed.
[0062] A hollow coreless tissue roll of the present invention
suitably has a diameter of from about 80 mm to 230 mm prior to
compression, and a thickness after compression such that after its
axial cavity is substantially collapsed, it has a thickness of no
more than about 90%, preferably no more than about 85%, preferably
no more than about 80%, preferably no more than about 70% and more
preferably no more than about 60%, still more preferably no more
than about 55% of the diameter of the roll prior to compression and
still more preferably, a thickness after compression of no more
than about 50% of the diameter of the roll prior to compression. A
particularly preferred hollow coreless tissue roll has a diameter
of from about 100 mm to 230 mm prior to compression and a thickness
after compression such that its axial cavity is substantially
collapsed to no more than about 60% of the diameter of the roll
prior to compression. The tissue, whether kitchen roll towel or
bath tissue, may be 2-ply or 3-ply product or, if a suitable
high-bulk forming method is used even single ply.
[0063] The products of the invention are typically provided in a
package containing a plurality of the compressed hollow coreless
rolls which are overwrapped with a polymeric film, wherein the
polymeric film is effective to maintain the axial cavities of the
plurality of hollow coreless rolls in the substantially collapsed
configuration. Optionally, the package contains a re-usable tubular
dispensing core such as re-usable core 40 which has a diameter
smaller than the forming core member upon which the roll was wound.
Re-usable core 40 may have a diameter of from 25 mm to 32 mm, or
from 2 to 50% less than the axial cavity, and may, if so desired,
be perfumed, or may be manufactured from a water-dispersible
material. In some embodiments, the tubular dispensing core is
colored with a pigment or die, wherein the pigment or dye is of a
color selected from red, yellow, blue, green, cyan, magenta and
combinations thereof, or white if pigmented with TiO.sub.2.
[0064] Packages of product in accordance with the invention,
consisting of rolls of absorbent sheet overwrapped with a polymeric
film, occupy much less space than corresponding conventional cored
products and also have less weight due to the absence of a core.
Weight benefits are of anywhere from 5 to 15% or even 25%, over
conventional products, saving transportation costs. The benefits
with respect to decreased occupied volume are much more dramatic
ranging anywhere from 25 to 45%, as can be appreciated from FIGS. 4
through 10G.
[0065] The product of the invention provides dramatic volume
reductions in comparison with conventional 2.times.2 package
dimensions of 24.times.12.times.20. This can be appreciated from
the variety of packaging arrangements having drastically different
package dimensions illustrated in FIGS. 10A through 10G.
[0066] FIG. 4 illustrates a package 50 which contains four
compressed hollow coreless rolls 10 disposed in a 1.times.4 planar
array with collapsed axial central cavities 12 of compressed hollow
coreless roll 10 arranged in parallel and the longer sides of the
compressed rolls arranged in facing relationship. The rolls are
overwrapped with polymer film 52. It can be appreciated from FIG.
10A that this configuration provides a volume savings of 42% with
respect to a conventional four roll package.
[0067] FIG. 5 illustrates a package 54 which contains four
compressed hollow coreless rolls 10 disposed in a 2.times.2 planar
array with the collapsed axial central cavities 12 of the
compressed rolls arranged in parallel. The rolls are overwrapped
with polymer film 52. FIG. 10B demonstrates that this configuration
provides a volume savings of 37% with respect to a conventional
four roll package.
[0068] FIG. 6 illustrates a package 56 which contains four
compressed rolls, two of which 23 are disposed centrally with their
collapsed axial cavities (not visible) arranged in parallel between
two outer rolls 21, wherein the collapsed axial central cavities 12
of the outer rolls 21 are arranged perpendicularly with respect to
the collapsed axial cavities of the centrally located compressed
rolls 23. The rolls are overwrapped with polymer film 52. A similar
arrangement is shown in FIG. 10C wherein it can be seen the package
configuration provides a volume savings of 32% as compared with a
conventionally packaged four roll ensemble.
[0069] FIG. 7 illustrates a package 57 which contains four
compressed hollow coreless rolls 10 disposed in a stacked 2.times.2
array with the collapsed axial central cavities 12 of two pairs of
stacked compressed hollow coreless rolls 10 arranged coaxially and
wherein the longer side 14 of the compressed hollow coreless rolls
10 arranged in facing relationship to each other. The rolls are
overwrapped with polymer film 52. It is seen in FIG. 10D that this
package also provides a volume savings of 32% as compared with
conventionally packaged product.
[0070] FIG. 8 illustrates a package 58 which contains four
compressed hollow coreless rolls 10 disposed in a 1.times.4 array
with the collapsed axial central cavities 12 of the compressed
hollow coreless rolls 10 coaxially arranged. The rolls are
overwrapped with polymer film 52. It can be seen in FIG. 10E that
this package likewise provides a 32% volume savings compared with
conventionally packaged rolls.
[0071] FIG. 9 illustrates a package 59 which contains four
compressed hollow coreless rolls 10 disposed in a 1.times.4 array
with collapsed axial central cavities 12 of the compressed hollow
coreless rolls 10 arranged in parallel and wherein shorter sides 16
of compressed hollow coreless rolls 10 are arranged in facing
relationship. The rolls are overwrapped with polymer film 52. Here,
the volume savings is 34% compared with conventional packaging as
demonstrated in FIG. 10F.
[0072] Still yet another package configuration is shown in FIG. 10G
wherein a 2.times.2 stacked array of compressed rolls with
collapsed axial cavities of two pairs of stacked rolls arranged
coaxially and the shorter sides of the compressed rolls are
arranged in facing relationship to each other. Here, again, a 34%
volume savings is realized.
[0073] FIG. 12 illustrates four compressed hollow coreless rolls 10
encased in a hollow polymeric tube 53 in which each compressed
hollow coreless roll 10 is arrayed side-by-side with the other
compressed hollow coreless rolls 10 in a serpentine fashion which
allows the user to rearrange the four rolls to fit in a convenient
storage spot while retaining the sealed character of the package
encasing each individual compressed hollow coreless roll 10.
Polymeric tube 53 is heat-sealed just before and just after each
compressed hollow coreless roll 10 as indicated by heat sealed
regions 80. Thus if there are four compressed hollow coreless rolls
10 in a particular polymeric tube 53, eight heat sealed regions 80
will be present. In addition a number of lines of weakness 82 are
provided so that each individual compressed hollow coreless roll 10
may be removed from the package while retaining its sealed
character. Thus each individual compressed hollow coreless roll 10
of tissue has disposed one heat seal region 80 at each end of
polymeric tube 53. An individual roll may be removed from the
package by tearing along line of weakness 82. It can be seen that
the four compressed hollow coreless rolls 10 can be easily arranged
in a 2.times.2 configuration or with all four compressed hollow
coreless rolls 10 aligned in a straight line. Conveniently, larger
packages can be easily manufactured using four roll packs as
building blocks as described hereinafter with the assemblages of
four roll packs overwrapped by a polyethylene film.
[0074] FIG. 13 illustrates a similar four roll package 57
comprising four compressed hollow coreless rolls 10 in a serpentine
polymeric tube 53. However, heat seal regions 80 are provided only
between the interior two compressed hollow coreless rolls 10 of
tissue, allowing for a material savings between the first and
second and also between the third and fourth rolls in the tube
wherein only a line of weakness 82 is interposed. This package may
be preferred for retail establishments in the case of four packs as
the configuration is relatively stable on the shelf as compared to
a stacked four pack in which two rolls of tissue are placed above
two other rolls of tissue. For manufacturing convenience, constant
spacing between rolls may be preferred.
[0075] FIG. 14 illustrates how a tissue twelve pack of compressed
hollow coreless rolls 10 may be easily formed comprising three
fours packs as illustrated in FIG. 12. In this case the polymeric
overwraps are not shown. FIG. 15 is a twenty-four pack of
compressed hollow coreless rolls 10, made up similarly.
[0076] FIG. 16 illustrates how a very long serpentine pack
comprising a total of twelve rolls can be assembled. The length of
polymeric tube 53 between each compressed hollow coreless roll 10
is exaggerated to more clearly illustrate how two heat sealed
regions 80 and line of weakness 82 are provided between each roll
and its neighbor so that a single roll can be removed while
maintaining the sealed character and protection from dirt and
contamination provided to each other roll in the serpentine pack.
In most cases, a polymeric overwrap (not shown) would be provided
over the assemblage to stabilize the package for display on a store
shelf.
[0077] FIG. 17 illustrates another tissue twelve pack of compressed
hollow coreless rolls 10 which can be assembled either by stacking
four three packs side-by-side or by stacking three of the four
packs illustrated in FIG. 12 on top of each other. Similarly FIG.
18 illustrates a tissue twenty-four pack of compressed hollow
coreless roll 10 which can be easily assembled from two of the
twelve packs of FIG. 17.
[0078] FIGS. 19A through 19F and 20A through 20D illustrate an
expandable spindle which may be used with the hollow compressed
tissue rolls of the present invention to restore the compressed
tissue roll to a generally cylindrical configuration. In the
spindles, frustoconical surfaces 88 are mounted upon shafts 86
which are urged apart by spring 84. Leaf segments 90 having mating
frustoconical surfaces 92 formed therein are forced outwardly when
the two shafts 86 are forced together to insert the tissue roll
thereabout into a conventional holder.
[0079] FIGS. 21 A through 21C illustrate one particularly
advantageous method of packing compressed hollow coreless
re-formable roll products of the present invention on pallets 200
of poly-wrap 12 pack tissue ensembles (poly pack) 202. Each poly
pack ensemble 202 has 4 columns 204 of rolls 206 in a 2.times.2
array of 3 rolls 206 with each roll 206 lying on its longer side
208 as shown in FIG. 21A with 2 other similarly oriented rolls 206
in the same column 204. Poly packs 202 are palletized as shown in
FIG. 21B and fitted into standard trailer 210 as shown in FIG. 21C.
Axis 212 of each roll 206 in poly pack 202 is parallel to axis 212
of every other roll 206 in poly pack 202 and axis 212 of each roll
206 is collinear with axis 212 of one other roll 206. Poly-packs
202 are palletized in 12 layers 214 wherein each layer 214
comprises 2 rows 216 of 6 poly packs 202 with long side 218 of each
poly pack 202 being parallel to shorter axis 222 of pallet 200 and
2 rows 211 of 4 poly packs 202 wherein long side 218 of each poly
pack 202 is parallel to long axis 226 of pallet 200 and wherein
each layer 214 is arrayed similarly but rotated 180.degree.
relative to layers 214 immediately above and below it. Pallet 200
with 12 layers 214 of poly wrapped tissue packs 202 is
shrink-wrapped in another layer (not illustrated) of polyethylene,
desirably of a sufficiently heavier gauge polyethylene to provide
for a pallet having dimensional stability and sufficient durability
to survive commercial transportation practices. In Figures in this
application, where dimensions appear alongside a figure, it is to
be understood that those are linear dimensions in inches. When the
trailer is loaded, it will often be convenient to turn two of the
pallets 200t with their long directions parallel to the length of
the trailer. Although this is not required to obtain the benefits
of the invention, it can help restrict longitudinal movement of
pallets 200.
[0080] Table 1 sets forth the relevant parameters concerning the
shipping efficiency of this configuration. It is considered
particularly significant that the cubic efficiency of this
packaging configuration is almost 85%.
TABLE-US-00001 TABLE 1 53 ft Trailer 636.0 .times. 101.0 .times.
110.0 Unit Load Bottle (OD} Shipper (OD} (Incl. Pal} Vehicle Load
Ln: 6.000 in 12.000 in 48.00 in 608.00 in Wd: 2.750 in 8.000 in
40.00 in 96.0 in Ht: 4.000 in 8.250 in 104.00 in 104.0 in Net: 0.00
oz 0.00 lb 0.00 lb 0.00 lb Grs: 0.00 oz 0.45 lb 153.33 lb 4600.00
lb Cube: 51.815 in.sup.3 0.458 ft.sup.3 115.556 ft.sup.3 3512.889
ft.sup.3 Width Vert Height Vert Bottle: 12 2880 86400 Shipper: 240
7200 Unit Loads: 30 Area Efficiency: 100.00% 100.00% 89.67% Cubic
Efficiency: 78.51% 99.00% 84.78% Cases per layer: 20 7200 UL per
layer: 30 Layers/load: 12 1 Pattern : 2 .times. 2 .times. 3
Interlock Interlock Density (gr/cc): 0.0158 0.0150
[0081] FIGS. 22A through 22E illustrate a packaging configuration
in which pallets 300 carry cartons 301 cartons in layers 314, in
which each carton 301 contains 3 poly wrap packs 302 of 30
compressed hollow coreless re-formable rolls 306 of the present
invention. Each poly wrap pack 302 comprises 15 columns 304 of
rolls 306 in a 5.times.3 array of 2 rolls 306 with long side 308 of
each roll 306 aligned with the 3 deep dimension of the array. Each
corrugate carton 301 contains 3 poly wrap packs 302 in a vertical
array with axis 312 of each roll 306 being vertical. Each layer 314
comprises 4 cartons 301 in a 2.times.2 array with long side 318 of
each carton being normal to long axis 326 of pallet 300 and 2
cartons 301 having long side 318 parallel to long axis 326 of
pallet 300, these 2 cartons 301 being spaced apart from each other,
each having one long side 318 generally coplanar with exterior
short sides 327 of 4 cartons 301 in the same layer 314 therewith as
well as coplanar with exterior short sides 327 of 4 cartons 301 in
a layer 314 immediately thereabove or therebelow. When the trailer
is loaded, it will often be convenient to turn two of the pallets
300t with their long directions parallel to the length of the
trailer. Although this is not required to obtain the benefits of
the invention, it can help restrict longitudinal movement of
pallets 300.
[0082] Table 2 sets forth the relevant parameters concerning the
shipping efficiency of this configuration. It is considered
particularly significant that the cubic efficiency of this
packaging configuration is again almost 85%.
[0083] Recent years have seen retail marketing move from
`brick-and-mortar stores" to e-commerce with more and more products
becoming available on-line for shipment direct to the customer's
home or office every day. In the past e-commerce was largely
limited to small, compact relatively high value items; but as this
channel of commerce is developed, merchandisers have found ways to
economically offer more and more products. Towel and tissue
products however present unusual difficulties for e-commerce in
that their volume to cost ratio is rather lower than the more
conventional products. We have found that these compressed hollow
coreless re-formable roll products provided much more attractive
product for e-commerce due to their greatly reduced volume. Tables
3 and 4 set forth configurations of products which are particularly
suitable for e-commerce illustrating the reduction in volume for
each configuration tabulated.
[0084] For e-commerce applications, it is particularly important to
have electronically sortable unit size package to control cost of
handling. One particularly common unit size package is
18''.times.14''.times.8''. Table 3 sets forth the length, width and
height for a number of product configurations which are well-suited
for this size. It should be noted that each configuration provides
a volume savings of at least 22% while the 3 roll by 7 roll by 2
roll configuration using regular length rolls provides a savings of
29%. In Table 3, the "Roll Orientation" column refers to FIGS. 23 A
through 23H, the figures illustrating how each roll is arrayed
relative to the others. In Tables 3 and 4, a double roll has twice
the length of a regular roll while a giant or jumbo roll has a
length which is 2.2 or 2.3 times that of a single roll,
respectively.
[0085] Table 4 sets forth a number of other product configurations
for kitchen roll tell (paper towel) which are also suitable for use
in this unit size package. It is particularly important to note
that most of these configurations provide a savings of over 30% in
volume compared to conventional kitchen roll towel.
[0086] Table 5 presents the possible savings and efficiency of
trailer volume utilization achievable with other product
configurations of compressed hollow coreless re-formable roll
products of the present invention.
TABLE-US-00002 TABLE 2 53 ft Trailer 636.0 .times. 101.0 .times.
110.0 Battle Carton Shipper Shipper Shipper Shipper Unit load
Vehicle (OD) (OD) (D) (OD) Slack Bulge (Incl. Pal) Load Ln:: 6.000
in 18.000 in 18.000 in 18.313 in 0.000 in 0.000 in 46.44 in 608.00
in Wd: 2.750 in 13.750 in 13.750 in 14.063 in 0.000 in 0.000 in
36.63 in 96.0 in Ht.: 4.000 in 8.000 in 24.000 in 24.625 in 0.000
in 0.000 in 103.50 in 103.5 in Net: 0.00 oz 0.00 lb 0.00 lb 0.00 lb
0.00 lb Grs: 0.00 oz 0.77 lb 4.041 b 142.00 lb 4259.86 lb Cube
51.815 in.sup.3 1980.000 in.sup.3 3.438 ft3 3.670 ft3 101.869 ft3
3496.000 ft3 Height Vert Height Vert Height Vert Unit Loads: 30
Area 100.00% 80.47% 89.67% Efficiency: Cubic 100.00% 79.27% 84.37%
Efficiency: UL per layer 30
TABLE-US-00003 TABLE 3 Retail Bath Tissue (Sortable Unit Size 18''
.times. 14'' .times. 8'') Percent Volume of Space Cored, Non
Savings vs. Roll Compressed Cored, Non Arrangement in Same
Compressed Product in Pack Length Width Height Volume Roll
Orientation in same Description (L .times. W .times. H) (in) (in)
(in) (in3) Orientation (in3) orientation Regular Roll 3 .times. 7
.times. 2 rolls 15 14 8 1680 23A 2363 29 (EQ = 1) Double Roll 3
.times. 5 .times. 2 rolls 18 14 8 2016 23B 2595 22 (EQ = 2)
Giant/Jumbo 5 .times. 2 .times. 2 rolls 18 12.5 8 1800 23C 2305 22
Roll (EQ = 2.2/2.3)
TABLE-US-00004 TABLE 4 Retail Paper Towel Percent Volume of Space
Cored, Non Savings vs. Roll Compressed Cored, Non Arrangement in
Same Compressed Product in Pack Length Width Height Volume Roll
Orientation in same Description (L .times. W .times. H) (in) (in)
(in) (in.sup.3) Orientation (in.sup.3) orientation Regular Roll 3
.times. 3 .times. 1 roll 15 7.5 11 1238 23D 2005 38 (EQ = 1.0) Big
Roll 3 .times. 2 .times. 1 roll 18 6.5 11 1287 23E 1925 33 (EQ =
1.33) Giant Roll 2 .times. 2 .times. 1 roll 13 6.5 11 930 23F 1430
35 (EQ = 1.5) Giant Roll 5 .times. 1 .times. 1 roll 16.25 6.5 11
1162 23G 1787 35 (EQ = 1.5) XL Roll 2 .times. 2 .times. 1 roll
13.25 8.8 11 1283 23F 1584 19 (EQ = 2.0) XL Roll 4 .times. 1
.times. 1 roll 17.67 6.625 11 1288 23H 1980 35 (EQ = 2.0)
TABLE-US-00005 TABLE 5 Coreless Compressed Quilted Northern Ultra
Plush .RTM. Double Roll Truck Load Efficiencies Percent Number
Number Increase of Rolls Secondary of Rolls from Un- Pack
Configuration per Pack Packaging per Truck compressed Brick - 2
.times. 3 12 4 packs 62,208 Un- roll in two layers per case
compressed w/core Brick - 2 .times. 3 12 4 packs 69,120 11 roll in
two layers per case Brick on Side - 2 .times. 3 12 4 packs 71,280
15 roll in two layers per case Brick - 2 .times. 3 12 none 77,760
25 roll in two layers Brick on Side - 2 .times. 3 12 none 86,400 39
roll in two layers Brick - 3 .times. 5 30 none 54,000 Un- rolls in
two layers compressed w/core Brick - 3 .times. 5 30 none 64,800 20
rolls in two layers Brick - 2 .times. 5 30 none 79,200 47 rolls in
three layers Brick - 3 .times. 5 30 3 packs 54,000 Un- rolls in two
layers per case compressed w/core Brick - 3 .times. 5 30 3 packs
64,800 20 rolls in two layers per case
TABLE-US-00006 TABLE 6 Coreless Compressed Big Roll Truck Load
Efficiencies Number Number Percent of Rolls Secondary of Rolls
Increase Pack Configuration per Pack Packaging per Truck from
Current Brick - 2 .times. 3 6 4 packs 17,280 current rolls in one
layer** per case Brick - 2 .times. 3 6 2 packets 20,160 17 rolls in
one layer per case Brick on Side - 2 .times. 3 6 2 packs 22,680 31
roll in one layer per case **product with core, non-compressed
TABLE-US-00007 TABLE 7 53 ft Trailer 636.0 .times. 101.0 .times.
110.0 Bottle Carton Shipper Shipper Shipper Shipper Unit Load
Vehicle (OD) (ID) (ID) (OD) Slack Bulge (Incl. Pal) Load (Ln: (Ln:
6.000 in 18.000 in 18.000 in 18.313 in 0.000 in 0.000 in 47.94 in
621.13 in Wd: 3.250 in 11.000 in 11.000 in 11.313 in 0.000 in 0.000
in 40.94 in 96.0 in Ht: 11.000 in 6.500 in 13.000 in 13.625 in
0.000 in 0.000 in 100.38 in 100.4 in Net: 0.00 oz 0.00 lb 0.00 lb
0.00 lb 0.00 lb Grs: 0.00 oz 0.56 lb 2.15 lb 180.69 lb 5420.78 lb
Cube: 168.442 in3 1287.000 in3 1.490 ft3 1.633 ft3 113.993 ft3
3463.635 ft3 Width Vert Height Vert Height Vert Unit 30 Loads Area
100.0% 97.1% 91.8% Efficiency: Cubic 100.0% 92.6% 83.7% Efficiency:
UL per 30 layer:
TABLE-US-00008 TABLE 8 53 ft Trailer 636.0 .times. 101.0 .times.
110.0 Bottle Carton Shipper Shipper Shipper Shipper Unit Load
Vehicle (OD) (OD) (ID) (OD) Slack Bulge (Incl. Pal) Load Ln: 6.000
in 18.000 in 18.000 in 18.313 in 0.000 in 0.000 in 44.94 in 608.00
in Wd: 3.250 in 6.500 in 13.000 in 13.313 in 0.000 in 0.000 in
39.94 in 96.0 in Ht: 11.000 in 11.000 in 11.000 in 11.625 in 0.000
in 0.000 in 98.00 in 98.0 in Net: 0.00 oz 0.00 lb 0.00 lb 0.00 lb
0.00 lb Grs: 0.00 oz 0.48 lb 2.05 lb 159.69 lb 4790.85 lb Cube:
168.442 in.sup.3 1287.000 in.sup.3 1.490 ft.sup.3 1.640 ft.sup.3
101.782 ft.sup.3 3310.222 ft.sup.3 Height Vert Height Vert Height
Vert Unit 30 Loads: Area 100.0% 88.9% 89.7% Efficiency: Cubic
100.0% 82.7% 79.9% Efficiency: UL per 30 layer:
[0087] FIGS. 24A-C illustrate a prior art packaging configuration
in which pallets 400 carry cartons 401 cartons in layers 414, in
which each carton 401 contains 4 poly wrap packs 402 of
conventional uncompressed kitchen roll towel products 406. Each
poly wrap pack 402 comprises 6 rolls 406 in a 2.times.3 array. Each
corrugate container 401 contains 4 poly wrap packs 402 in a
horizontal array with axis 412 of each roll 406 being vertical.
Each layer 414 comprises 6 cartons 406 in a 3.times.2 array with
long side 418 of each carton being normal to long axis 426 of
pallet 400.
[0088] FIGS. 25A-D illustrate a packaging configuration in which
pallets 500 carry cartons 501 in layers 514, in which each carton
501 contains 2 poly wrap packs 502 of 6 compressed hollow coreless
re-formable roll kitchen roll towel products 506 of the present
invention. Each poly wrap pack 502 comprises 3 columns 504 of rolls
506 in a 3.times.2 array of rolls 506 with long side 508 of each
roll 506 aligned with the 3 deep dimension of the array. Each
corrugate container 501 contains 2 poly wrap packs 502 in a
vertical array with axis 512 of each roll 506 being horizontal.
Each layer 514 comprises 9 cartons 506 in a 3.times.3 columnar
array with 6 cartons 501 having long side 518 of each carton being
parallel to long axis 526 of pallet 500 occupying the 1,1; 2,1;
1,2; 3,2; 2,3 and 3,3 positions of the array and 3 cartons 501
having long side 518 perpendicular to long axis of pallet 500,
these 3 cartons 506 occupying the 1,3; 2,2 and 3,1 positions of the
array. FIG. 25E illustrates the nomenclature for the array. The
same benefits can be obtained when 6 cartons 501 having long side
518 of each carton being parallel to long axis 526 of pallet 500
occupy the 1,2; 1,3; 3,2; 3,1; 2,2 and 2,3 positions, which can be
referred to as left handed and the first conformation can be
referred to as right handed. In each case, it will be noted that
there will be two voids 511 in each layer. Further, left-handed and
right-handed layers can be intermixed or alternated without any
loss of the benefits. When the trailer is loaded, it will often be
convenient to turn two pallets 500t with their long directions
parallel to the length of the trailer. Although this is not
required to obtain the benefits of the invention, it can help
restrict longitudinal movement of pallets 500.
[0089] FIGS. 26A-D illustrate a packaging configuration in which
pallets 600 carry cartons 601 cartons in layers 614, in which each
carton 601 contains 2 poly wrap packs 602 of 6 compressed hollow
coreless re-formable roll products 606 of the present invention.
Each poly wrap pack 602 comprises 6 rolls 606 in a 3.times.2 array
with long side 608 of each roll 606 aligned with the 3 deep
dimension of the array. Each corrugate container 601 contains 2
poly wrap packs 602 in a side by side array with axis 612 of each
roll 606 being vertical. Each layer 614 comprises 7 cartons 606 in
an array with 3 cartons 601 in line having long side 618 by long
side 618 with each long side 618 also being parallel to long axis
626 of pallet 600, two pair of cartons 601 having long side 618
thereof normal to long axis 626 of pallet 600, with a long side 618
of one carton 601 of each pair abutting interior short sides 627 of
said 3 cartons 601 in line, interior short sides 627 of these 2
pairs of cartons 606 being spaced apart from each other, and, the
other carton 601 of each pair having one long side 618 facing
outwardly from said layer of cartons 601. When the trailer is
loaded, it will often be convenient to turn two pallets 600t with
their long directions parallel to the length of the trailer.
Although this is not required to obtain the benefits of the
invention, it can help restrict longitudinal movement of pallets
600.
[0090] In view of the foregoing discussion, relevant knowledge in
the art and references discussed above in connection with the
Background and Detailed Description, the disclosures of which are
all incorporated herein by reference, further description is deemed
unnecessary. In addition, it should be understood that aspects of
the invention and portions of various embodiments may be combined
or 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 invention.
* * * * *