US20160213204A1

US20160213204A1 - Toilet Paper Sheets Having Alternating Sidewall Indentations

Info

Publication number: US20160213204A1
Application number: US14/604,142
Authority: US
Inventors: David R. Morris
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-01-23
Filing date: 2015-01-23
Publication date: 2016-07-28
Also published as: WO2015112867A1

Abstract

Toilet paper rolls are provided with alternating indentions in the left and right sides of the toilet paper sheet wherein the opposite side will retain the straight shape of a normal toilet paper roll. When multiple sheets are folded, the effective area is the same as “normal” toilet paper width. From this, toilet paper sheets may be produced with less material while maintaining wiping performance. For use as a covering for an oval toilet seat, coverage is improved.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/930,563 filed on Jan. 23, 2014, and U.S. Provisional Application No. 62/017,526 filed on Jun. 26, 2014.

BACKGROUND OF THE INVENTION

Toilet paper is used by billions of people around the world. Modern commercialization began in the 1800s and minor changes have taken place since. Currently, toilet paper is sold as long sheets of tissue paper most often about 4 inches (approximately 10 cm) in width, usually wound around a hollow cardboard or compressed-paper cylindrical core into toilet paper rolls for convenience. As sold, these rolls are often wound to about 4 inches in diameter to fit into standard toilet paper dispensers. Typically, toilet paper is most often perforated across the width of the sheet, parallel to the axis of the core, at approximately 4-inch intervals. These perforations help to yield individual sheets of toilet paper measuring approximately 4 inches by 4 inches square, when torn off the toilet paper roll by the user at the outermost exposed perforation. Many users tear the tissue paper at a more-interior perforation, yielding a longer sheet of toilet paper, termed herein a “multiple sheet,” containing one or more remaining perforation lines that may be used to help fold the multiple sheet when in use by the user.
The commercial production of toilet paper rolls often begins with a wet paste of wood or recycled paper. This paste is dried and made into very long, wide sheets of tissue paper. These long sheets are then perforated and/or embossed by running the sheets of paper between one more sets of large embossing drums that imprint patterns and/or create perforations. Afterwards, these long, wide sheets are wound around cylindrical cardboard tubes or compressed tissue paper cores into “logs” of the desired diameter. These logs, which can measure ten feet in width, are then crosscut into individual rolls of the proper size (e.g., 4 inches wide, 4 inches in diameter) for commercial sale.
The shape of toilet paper sheets under current designs promotes inefficient use for two reasons. First, in order to provide sufficient hand protection during wiping, one or more single or multiple sheets are often required, folded or bunched together for use. Within these toilet paper sheets, the central or ‘inner’ area (i.e., the area interior from the sidewalls of each toilet paper roll) does the majority of cleaning. Consequently, the outer areas of toilet paper may be essentially wasted during layering of material.
Second, a user may place a layer of toilet paper on a toilet seat before sitting. Because the toilet seat is oval or circular and sheets of toilet paper form squares or long rectangles (i.e., when using multiple sheets of toilet paper), the toilet paper must outline the curved seat with a cornered shape (a square, pentagon, hexagon, etc.). This wastes toilet paper due to the impossibility of covering an oval shape with square or rectangular sheets without overlap.
The prior art represents limited progress towards a more efficient shape for sheets of toilet paper. For instance, U.S. Pat. No. 8,221,864 describes making angled rather than straight cuts (i.e., not perpendicular to the cylindrical core axis) on the tissue paper log when cutting the log into individual rolls during the production process. These angled cuts are parallel to each other (or not if desired). In other words, if the left sidewall of the resultant roll has an acute cut of −5 degrees (i.e., as measured by its deviation from a perpendicular cut) then the right sidewall would have an obtuse cut of +5 degrees. This imparts a parallel wavy shape (or non-parallel if desired) of the toilet paper roll when it is unrolled. Still, one sidewall is necessarily obtuse when the other sidewall is cut acutely and vice versa. This allows a multiple sheet of toilet paper when folded over itself to give a larger effective area, allowing for an actual reduction in paper width and a concomitant reduction in the amount of paper used in manufacture. Some drawbacks to this prior art design, however, include difficulty in tearing out the toilet paper when used in standard dispensers and an overall appearance of reduced toilet paper width that is apparent to the user.
The subject invention is an improved shape for toiler paper that allows for, when folded, a more effective width of tissue using less overall material that results in more efficient use of material for the primary purposes of: (1) wiping; and (2) toilet-seat covering. In addition, aspects of the subject invention include methods of using and preparing the same.

SUMMARY OF THE INVENTION

Some embodiments of the present invention include a length of toilet paper having parallel sidewalls defining a sidewall width of said paper, wherein said sidewalls are perpendicular at least one perforation spanning the distance between each side, comprising a first indentation in one side of said length of toilet paper. Some embodiments include a second indentation in the side opposite the one containing the first indentation. In some embodiments, the second indentation does not overlap the first indentation if the length of toilet paper is folded in half parallel to the sidewalls of said paper. In some embodiments, the length of toilet paper further comprises a plurality of indentations that do not overlap if the length of toilet paper is folded in half parallel to the sidewalls of said roll.
In some embodiments, the indentations have an overall concave shape. In yet other embodiments two or more perforations equally spaced from and parallel to each other. In other embodiments, an endpoint of at least one indentation occurs at or about the intersection of a perforation and said endpoint. In others, an endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper. In some embodiments, the endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper and both endpoints intersect with a perforation.
In some embodiments, two or more perforations are spaced on said length of toilet paper at equal intervals to form individual sheets of toilet paper; in others, two or more perforations are spaced at about 4 inch intervals. In some embodiments, the first indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets. In some embodiments, the second indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets. In some embodiments, a plurality of indentations each span: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three individual sheets.
Some embodiments of the present invention include a toilet paper roll having parallel sidewalls defining a sidewall width of said roll, wherein said sidewalls are perpendicular to the long axis of a central core of said toilet paper roll, comprising a length of toilet paper with sidewalls congruent to the sidewalls of said roll, comprising a first indentation in one side of said length of toilet paper. In some embodiments, the roll includes a second indentation in the side of said length of toilet paper opposite the one containing the first indentation. In others, the second indentation does not overlap the first indentation if said length of toilet paper is folded in half parallel to the sidewalls of said paper. In some embodiments, the length of toilet paper further comprises a plurality of indentations that do not overlap if the length of toilet paper is folded in half parallel to the sidewalls of said roll.
In some embodiments of the present invention, the roll includes indentations that have an overall concave shape. In some embodiments, the roll includes a length of toilet paper further comprising two or more perforations equally spaced from and parallel to each other. In others, an endpoint of at least one indentation occurs at or about the intersection of a perforation and said endpoint. In some embodiments, an endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper; in others, the endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper and both endpoints intersect with a perforation.
In some embodiments of the roll, two or more perforations are spaced on said length of toilet paper at equal intervals to form individual sheets of toilet paper; in others, two or more perforations are spaced at about 4 inch intervals. In some embodiments, the first indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets. In others, the second indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets. In other embodiments, a plurality of indentations each span: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three individual sheets.
Some embodiments of the present invention include a sheet of tissue paper capable of being formed into individual rolls or lengths of toilet paper, comprising a plurality of cut out areas where the cut out areas intersect lines of separation into individual rolls. In some embodiments, one or more endpoints of each cutout area occur at or about lines of perforation perpendicular to said lines of separation into individual rolls or lengths of toilet paper. In some embodiments, the cut out areas intersecting adjacent lines of separation are offset from one another. In other embodiments, each cut out area is intersected by: at least two, at least three, at least four, or more than four perpendicular lines of perforation.
Some aspects of the present invention include a method of producing toilet paper rolls or lengths of toilet paper, comprising: providing a sheet of tissue paper capable of being formed into individual rolls or lengths of toilet paper, comprising a plurality of cut out areas where the cut out areas intersect lines of separation into individual rolls. In other aspects, one or more endpoints of each cutout area occur at or about lines of perforation perpendicular to said lines of separation into individual rolls or lengths of toilet paper. In some aspects, cut out areas intersecting adjacent lines of separation are offset from one another. In other aspects, each cut out area is intersected by: at least two, at least three, at least four, or more than four perpendicular lines of perforation.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the present invention will be better understood from the following detailed description taken in conjunction with the accompanying drawings, all of which are given by way of illustration only, and are not limitative of the present invention, in which:

FIGS. 1A-1C present views of an example of a “normal” or typical toilet paper roll, where: FIG. 1A is a perspective view of a normal roll; FIG. 1B a plan view; and FIG. 1C presents a frontal view of a multiple sheet unrolled from a normal roll.

FIGS. 2A-2D present views of an example toilet paper roll as described in U.S. Pat. No. 8,221,864, where: FIG. 2A is a perspective view; FIG. 2B a plan view; FIG. 2C a frontal view of an unrolled multiple sheet; and FIG. 2D a plan view of a detached and folded multiple sheet.

FIGS. 3A-3D present views of an example embodiment of the subject invention, where: FIG. 3A is a perspective view; FIG. 3B a plan view; FIG. 3C a frontal view of an unrolled multiple sheet; and FIG. 3D a plan view of a detached and folded multiple sheet.

FIGS. 4A-4D present views of another example embodiment of the subject invention, where: FIG. 4A is a perspective view; FIG. 4B a plan view; FIG. 4C a frontal view of an unrolled multiple sheet; and FIG. 4D a plan view of a detached and folded multiple sheet.

FIGS. 5A-5D present views of another example embodiment of the subject invention, where FIG. 5A is a perspective view; FIG. 5B a plan view; FIG. 5C a frontal view of an unrolled multiple sheet; and FIG. 5D a plan view of a detached and folded multiple sheet.

FIGS. 6A-6C present example embodiments of tissue paper sheet patterns of the subject invention, which may, in some embodiments, be rolled and cut to form individual toilet paper rolls.

DETAILED DESCRIPTION OF THE INVENTION

Toilet paper is typically not used one sheet at a time for the wiping function. Generally, the user employs a folding or scrunching method of multiple sheets in order to have sufficient material between his or her hand and the surface requiring wiping. Inefficient use of material results, as described above, from the current design due to the squared shape of the sheets.
Embodiments and/or aspects of the subject invention may call for indentations to be alternately formed or cut out of the sides of the sheets so that less paper can be used to make a roll of toilet paper without a loss of effectiveness.

DEFINITIONS

The contents of each of the patent documents and other references cited herein are herein incorporated by reference in their entirety.
Throughout the application, a line or other object or shape “intersects” a second line, object or shape if it passes through the second line, object or shape, which includes passing through, at or about one or more of the the second line, object or shape's endpoints.
Geometrical terms such as, e.g., “perpendicular” or “parallel” include the concepts of “nearly” perpendicular or parallel, including but not limited to shapes or lines produced within the normal tolerances and variability associated with various mechanical processes, and lines or shapes that approach perpendicular or parallel lines.
The terms “approximately,” “nearly,” “about” modify descriptive geometrical, numerical, or mathematical terms and concepts listed herein to imply a rough, but not exact correspondence.
The term “length” of toilet paper is defined herein as one or more sheets (i.e., a single or multiple sheet) of toilet paper that may be attached, detached from a toilet paper roll or otherwise exist apart from a toilet paper roll. A “single sheet” of toilet paper is defined as the length of toilet paper between two perforations; this definition includes sheets that may be partially or completely torn at one or more of the perforations to produce a single sheet detached from a roll or length of toilet paper or the end or outermost sheet on a roll or length of toilet paper. A “multiple sheet” is a length of toilet paper that contains one or more internal perforations, i.e., composed of more than one undetached single sheets.
A “sidewall” of a toilet paper roll corresponds to the side of a toilet paper roll formed when a length of toilet paper is wound about itself in the standard way with no areas of non-overlapping toilet paper protruding from the roll.
In the context of a length of toilet paper, a “sidewall” of a length of toilet paper is the side formed by the lateral (long) edges of a length of toilet paper perpendicularly folded over itself in such a way so that areas of maximum toilet paper width are superimposed upon each other with no areas of non-overlap. As stated below, the sidewall and actual side of a length of toilet paper may differ, especially in indented areas.
A “sidewall line” corresponds to the location of the sidewall on an unrolled or unfolded length of toilet paper, i.e., where a sidewall would be when the length of toilet paper is folded or rolled.
A “width of a length of toilet paper” is measured at any point across the length of toilet paper perpendicularly to the sidewall of the length of toilet paper, and may vary along the length of toilet paper. A “sidewall width” corresponds to the distance between a sidewall of a toilet paper roll or length of toilet paper and the opposite sidewall, and in this context, is identical to the maximum width of that length of toilet paper or any other length of toilet paper in that roll.
An “indentation” is an area on a length of toilet paper wherein the width of the toilet paper is narrower than the maximum width (i.e., the sidewall width) of that length of toilet paper. An indentation can also be characterized as an area where at least one side of the length of toilet paper is indented from the sidewall (i.e., closer to the center of the sheet). The “endpoint” of an indentation occurs where the width of the length of toilet paper has returned to its maximum width and/or at least one side of the length of toilet paper is no longer indented from the sidewall.
The “side” of a length of toilet paper is the actual vertical side of the length of toilet paper (if the length of toilet paper is held so that the perforations, if any, are orientated horizontally). In some areas of a length of toilet paper, the side and sidewall line will be congruent. However, in an area where a side is indented, the indented side will be located internal to the line formed by the sidewall between the endpoints of the indentation, where the side and sidewall line will again be congruent.
A “cut out” area in a sheet of tissue paper is a void or hole in the sheet of tissue paper and may be formed by any conventional methods, such as stamping, laser cutting, sonic cutting, water-based cutting methods and other methods known to persons of skill in the art. The “endpoints” of a cut-out area include points of inflection in the outer perimeter of said cutout, and/or points of maximum vertical or horizontal extent in the cutout when the tissue paper is viewed in a vertical orientation.
FIG. 1A depicts a typical roll of toilet paper 100 in current use as seen in perspective from an off-center view in order to show the front of the roll as well as right sidewall 104 of roll 100. The sidewalls (e.g., 104) are formed by wound paper material around core 103. (Toilet paper is sometimes sold, in particular for institutional use, without a cardboard core and instead tightly wound and/or compressed in the center of the roll to maintain the shape of the roll during dispensing. This variation can be accommodated by the subject invention.) A single sheet of toilet paper 102 is delineated by perforations 106, which serves to facilitate removal of a single sheet or multiple sheet from roll 100.
As seen in FIG. 1B, the right sidewall 104 of roll 100 is parallel to the left sidewall 107. Further, the right sidewall 104 is formed such that it is perpendicular to the long axis 108 of the cylindrical cardboard core 103; in other words, the angle θ (marked as 120) between the right sidewall 104 and long axis 108 is 90°. (Note that the angle between left sidewall 107 and long axis 108 is also 90°.) FIG. 1C depicts a multiple sheet of toilet paper as dispensed from roll 100; note that the width 130 of the sheet is approximately equal to the distance between perforations 106 (e.g., about 4 inches).
FIG. 2A depicts an example of the modified toilet paper roll 200 described in U.S. Pat. No. 8,221,864. As noted above, the toilet paper log is cut at an angle, thus providing a toilet paper roll differing in a number of ways from the “normal” roll of toilet paper described in FIGS. 1A-1D. Right sidewall 204 is cut at an acute angle relative to the long axis of cylindrical cardboard core 203. Thus, sides 213 and 214 of the length of toilet paper extended or pulled from the body of roll 200 are wavy, rather than straight as in FIG. 1A. Thus, sheet 212 is also wavy. Perforations 206 continue to be perpendicular to the axis of cylindrical cardboard core 203.
As seen in FIG. 2B, right sidewall 204 and left sidewall 207 are parallel to each other, but slanted with respect to the axis 208 of cylindrical cardboard core 203. Thus, angle θ₁(230) between the right sidewall 204 and long axis 208 is an obtuse angle, greater than 90°; similarly, angle θ₂(231) between the left sidewall 204 and long axis 208 is an acute angle, less than 90°.
FIG. 2C depicts a multiple, two-sheet view of toilet paper as dispensed from roll 200. Single sheets 221 and 222 are separated by perforations 206 from each other and adjacent sheets. The oblique sidewalls of roll 200 create a parallel sinuous, wavy shape to sides 213, 214 of the multiple sheet. The wave in toilet paper side 214, for example, may be characterized by a wavelength 240 of two sheets in length (i.e. the length of sheet 221 plus sheet 222), plus amplitude 235, which characterized the deviation from a straight or “normal” multiple sheet of toilet paper when unrolled. The actual width of the toilet paper sheet 233 is less than the effective width 232.
When sheets 222 and 221 are placed over each other, as can be seen in FIG. 2D, the actual width of each sheet, 233, is increased to an effective width of 232, also creating a central area 225 with two layers of material for use by the user.
Note that if the sheets are folded over each other (e.g., at perforation 206) central area 225 would necessarily be narrower than as depicted in FIG. 2D, since the attachment of sheets 221 and 222 would not allow as wide an area of superimposition as shown in FIG. 2D. Further, as noted above, certain other drawbacks may occur with this prior art design, including difficulty in tearing out the toilet paper when used in standard dispensers. Further, in regular use, there is an overall appearance of reduced or “flimsy” toilet paper width when used in standard dispensers, since effective width 232 must fit within the confines of a standard dispenser opening in order to be dispensable; thus, the actual width of the paper 233 must be significantly smaller than a standard dispenser opening. In addition, since the process of winding a toilet paper roll is essentially a spiraling process (i.e., more and more toilet paper is required to complete a single wind/rotation around the roll as it grows in size), an oblique cut through a roll will not result in a constant wavelength 240 as the toilet paper is unwound in use, although amplitude 235 remains constant. Thus, the most convenient place for folding or tearing two superimposable sheets for use will not always align with perforations 206, or requires a non-constant spacing between perforations 206 that differs between interior and exterior portions of the roll.
Embodiments of the present invention overcome the limitations of the prior art. In general, indentations are formed or cut out of the sides of the toilet paper sheet that alternate from one side to another, such that one side is straight while the other, opposite side is indented, as the roll is unrolled during use. The alternating indentations remove unnecessary material allowing for less waste in manufacture, while the opposite straight side preserves the traditional shape of the toilet paper roll and allows for easy dispensing with standard dispensers. In some embodiments, the indentations are oriented such that they align or nearly align with horizontal perforations so that individual sheets may be easily detached or folded over each other allowing for superimposition of sheets to create a thicker center region and thinner outer region for wiping. In other embodiments, the indentations are curved or concave in shape allowing for multiple or single sheets of toilet paper to be more easily draped over a toilet seat than standard shapes of toilet paper. Other indentation shapes are possible, such as, for example, scalloped, square, triangular, wavy, etc.
An example embodiment of the present invention is shown in FIG. 3A. A toilet paper roll 300 is shown with right sidewall 300 and left sidewall 331 (dotted lines). In some embodiments, a concave indentation 327 with a length of two sheets may be cut out of the right side of a length of toilet paper within roll 300. The cut reaches its apex 336 at the perforation 326 between these two sheets. The beginning of the indentation is aligned with perforation 306; at this point the width of the toilet paper is unchanged from typical toilet paper. The resulting shape is the concave indentation that removes material from the right sidewall with normal toilet-paper width at the beginning and end and the deepest portion of the indentation (the “apex”) at the perforated portion between the two sheets. As a consequence, adjacent perforations, e.g., 326 and 306 are no longer uniform in length.
In this example embodiment, offset indentations 328 and 329 begin in the left side of the length of toilet paper at the ends of indentation 327. In this embodiment, these indentations have the same shape (i.e. same curvature, length and amplitude) as 327. The pattern of alternating offset indentations shown in FIG. 3A, may be continued throughout the entire length of the toilet paper roll. In effect, there are mirroring concave indentations cut or otherwise formed from each sidewall, offset from each other. By cutting out or otherwise removing excessive sidewall material in an alternating, concave pattern, the resulting product is less wasteful. Indentations within the same roll may be of different shape from each other, as well as form shapes that differ from concave or have a different concave shape than is shown here as an example embodiment of the invention.
As shown in FIG. 3B, the toilet paper roll of the present invention retains the same outer shape of typical toilet paper rolls, while using less material. FIG. 3B presents a plan view of the embodiment shown in FIG. 3A. As in typical toilet paper (see, e.g., FIG. 1B), the sidewalls remain perpendicular to the axis 308 of cylindrical cardboard core 303, since each sidewall 330, 331, retains straight portions along with the indented portions (shown here with dotted lines). Thus, the angles θ (marked as 320) between sidewalls 330, 331 and long axis 308 remain 90°.
FIG. 3C shows an example embodiment of a length of toilet paper 301, with the same overall characteristics of the portion of toilet paper roll 300 shown in FIGS. 3A and 3B. As in FIGS. 3A-B, alternating, offset concave indentations 328 and 329 are cut out or otherwise removed from the sidewalls 330, 331 of toilet paper length 301.
Although less material is used to manufacture a roll of the improved toilet paper, the product functions as effectively as toilet paper of the current ordinary design. When folded, the central wiping area of the paper is the same area as a normal fold of toilet paper while the outer area is lessened. Further, the semi-circular shape of the concave-segment sidewall cut is, when place in two-sheet segments, more practical for covering an oval toilet seat.
To illustrate, FIG. 3D shows a schematic plan view of a multiple sheet of the example toilet paper shown in FIGS. 3A and 3C, both unfolded, and folded. The leftmost diagram shows a multiple sheet unfolded. Adjacent two- sheet segments 340 and 342 are given different shadings to illustrate their orientation when folded. Segment 340 is bounded by two long perforations 306, with a shorter perforation 326 in the middle of the two-sheet segment; concave indentation 327 is formed or cut out of the right side of this segment. Similarly, segment 342 is bounded by two long perforations 306, with a shorter perforation 327 in the middle of the two-sheet segment; concave indentation 328 is formed or cut out of the left side of this segment.
When segment 342 is folded on top of segment 340 (folded such that sidewall 330 of each segment is superimposed upon itself, and sidewall 331 is also superimposed upon itself, although other orientations are certainly possible), as the rightmost diagram in FIG. 3D shows, it creates a sheet 343 that is the same effective area as normal, folded-over toilet paper while saving material. Here, the cutout indentation of 342 is on the top, exposing a portion of segment 340; the indentation of segment 340 is hidden by the straight side of 342. Thus, its central area has two layers while the outer areas have alternating indentations and therefore only one layer.
The length of indentations may extend over two adjacent sheets, as shown in FIGS. 3A-3D, or extend over one, three or any number of adjacent sheets.
FIGS. 4A-4D illustrate an example embodiment where the indentations extend over three sheets. In FIG. 4A, concave indentation 446 on the right side of a toilet paper sheet spans three adjacent single sheets, beginning and ending at long perforations 406, with maximum amplitude at interior perforations 448. Similar indentations 445 and 449 begin on the left side of the toilet paper sheet at long perforations 406. The pattern of alternating offset indentations shown in FIG. 4A, may be continued throughout the entire length of the toilet paper roll. As noted above, alternating differing shapes are possible in some embodiments, as well as shapes that differ from concave or have a different concave shape.
FIG. 4B presents a plan view of the embodiment shown in FIG. 4A. As in typical toilet paper (see, e.g., FIG. 1B), the sidewalls 430, 431 remain perpendicular to the axis 408 of cylindrical cardboard core 403, since each sidewall retains straight portions along with the indented portions (shown here with dotted lines). Thus, the angles θ (marked as 420) between sidewalls 430, 431 and long axis 408 are 90°.
FIG. 4C shows an example embodiment of a length of toilet paper 401, with the same overall characteristics of the portion of toilet paper roll 400 shown in FIGS. 3A and 3B. As in FIGS. 4A-B, alternating, offset concave indentations are cut out or otherwise formed from the sidewalls 430, 431 of toilet paper length 401.
FIG. 4D shows a schematic plan view of a multiple sheet of the example toilet paper shown in FIGS. 4A and 4C, both unfolded, and folded. The leftmost diagram shows a multiple sheet unfolded. Adjacent three- sheet segments 451 and 452 are given different shadings to illustrate their orientation when folded. Segment 451 is bounded by two long perforations 406, with two shorter perforations 448 in the middle of the three-sheet segment; concave indentation 446 is formed or cut out of the right side of this segment. Similarly, segment 452 is bounded by two long perforations 406, with shorter perforations 444 in the middle of the three-sheet segment; concave indentation 449 is formed or cut out of the left side of this segment.
When segment 451 is folded on top of segment 452, as the rightmost diagram in FIG. 4D shows, it creates a sheet 453 that is the same effective area as normal, folded-over toilet paper while saving material. The indentation of 451, indentation 446, may be on the top, exposing a portion of segment 452; the cutout indentation of 452 will then be hidden by the straight side of 451. Thus, its central area has two layers while the outer areas have alternating indentations and therefore only one layer.
FIGS. 5A-5D illustrate an example embodiment where the indentations extend over one sheet. In FIG. 5A, concave indentation 554 on the right side of a toilet paper sheet spans a single sheet, beginning and ending at adjacent perforations 506; maximum amplitude of the indentation occurs at 548, in the middle of a single sheet. Similar indentations 553 and 555 begin on the left side of the toilet paper sheet at perforations 506 adjacent to indentation 554. Another left-side indentation 556 is adjacent to right-side indentation 555. The pattern of alternating offset indentations shown in FIG. 5A, may be continued throughout the entire length of the toilet paper roll. As noted above, alternating differing shapes are possible in some embodiments, as well as shapes that differ from concave.
FIG. 5B presents a plan view of the embodiment shown in FIG. 5A. As in typical toilet paper (see, e.g., FIG. 1B), the sidewalls remain perpendicular to the axis 508 of cylindrical cardboard core 503, since each sidewall retains straight portions along with the indented portions (shown here with dotted lines). Thus, the angles θ (marked as 520) between sidewalls 530, 531 and long axis 508 are 90°.
FIG. 5C shows an example embodiment of a length of toilet paper 501, with the same overall characteristics of the portion of toilet paper roll 500 shown in FIGS. 5A and 5B. As in FIGS. 5A-B, alternating, offset concave indentations are cut out or otherwise formed from the sidewalls 530, 531 of toilet paper length 501.
FIG. 5D shows a schematic plan view of a multiple sheet of the example toilet paper shown in FIGS. 5A and 5C, both unfolded, and folded. The leftmost diagram shows a multiple sheet unfolded. Adjacent single sheets 561 and 562 are given different shadings to illustrate their orientation when folded. Sheet 561 is bounded by perforations 506; concave indentation 555 is formed or cut out of the left side of this sheet. Similarly, sheet 462 is bounded by perforations 506; concave indentation 556 is formed or cut out of the right side of this sheet.
When sheet 561 is folded on top of segment 562, as the rightmost diagram in FIG. 5D shows, it creates a sheet 463. The indentation of 561 may be on the top, exposing a portion of segment 562; the cutout indentation of 562 will thus be hidden by the straight side of 561. Thus, its central area has two layers while the outer areas have alternating indentations and therefore only one layer.
Although less material is used to manufacture a roll of the improved toilet paper, the product functions as effectively as toilet paper of the current ordinary design. When folded, the central wiping area of the paper is the same area as a normal fold of toilet paper while the outer area is lessened. Further, the semi-circular shape of the concave-segment sidewall cut is, when place in two-sheet segments, more practical for covering an oval toilet seat.
Other aspects of the present invention include methods of making the toilet paper rolls of the present invention. In one aspect, the improvement represented by this invention can be made with an addition to currently used embossing or perforation processes, as described below. As will be apparent to those of skill in the art, other methods of manufacture, such as forming the indentations during the paper forming stage may also be used, such as with drying trays with areas of the proper shape (e.g., properly shaped raised areas, such as “bumps”, or “islands” in the drying trays, orientated and spaces to give the indentations of the present invention) that serve to exclude paper pulp from the tissue paper sheet as it is initially formed prior to rolling and cutting operations.
Other possible methods of cutting, such as cutting with lasers, water jets and the like may be used as well. See, e.g., European Patent App. No. 1529477.
A preferred method of manufacture is described with reference to FIGS. 6A-6C. In one aspect, teeth or stamps of the appropriate shape, spacing and orientation may be added to an embossing drum. During the embossing process, the toilet paper travels between two drums that imprint a given design. A sharp pattern which has the desired shape will cut the paper to produce the alternating pattern shown in e.g., FIG. 3A, 4A or 5A.
For example, FIG. 6A shows examples of the various cutting or forming shapes that are possible. Cutting or forming shapes may be double or single-sized; double-sized shapes may cut out indentations in two adjacent toilet paper rolls at the same time; single-sized shapes cut out indentations in a single toilet paper roll. In some aspects, teeth are shaped in a double-sized lens shape with width 664 and length 666. The lens is orientated such that the long axis of the lens is centered on a toilet paper log cut line 680, and the endpoints will correspond to three adjacent perforations 606, which may be formed on the same embossing drum or different embossing drums. The length 666 of this lens creates a final indentation two sheets in length on two adjacent toilet paper rolls. As shown, lens height 664 and length 666 may create the two-sheet side indentation shapes shown in e.g., FIGS. 3A-3D.
Similarly a double-sized lens may have a length 669 that spans four adjacent perforations 606, creating an indentation that spans three adjacent sheets. The height 667 of the lens may be any desired height; as shown, lens height 667 and length 669 may create the three-sheet side indentation shapes shown in e.g., FIGS. 4A-4D.
Similarly a double-sized lens may have a length 670 that spans two perforations 606 and one sheet. The height 672 of the lens may be any desired height; as shown, lens height 672 and length 670 may create the one-sheet side indentation shapes shown in e.g., FIGS. 5A-5D.
The same indentation shapes may also be formed in toilet paper rolls of the present invention with single-sized shapes, as seen in half- lenses 665, 668 and 671. (As will appreciated by persons of skill the art, twice the number of lenses will be needed to create the same number of rolls as with double- sized lenses 664, 667 and 670.)
Shapes other than concave may also be created during the embossing step, such as the double-sized scalloped shapes shown in 673 and single-sized half-scalloped shape at 674. Such shapes may have a height 675 that spans one sheet, or may span multiple sheets in other embodiments and aspects.
FIG. 6B shows one example the orientation and spacing required to emboss the shapes of the current invention on multiple toilet paper rolls at the same time. The pattern shown in FIG. 6B will create, for example, the two-sheet indentations shown in FIGS. 3A-3D.
The toilet paper sheet over FIG. 6B may be cut at the lines 680 labeled with V shapes at the edges of the diagram. Double-sized lens shapes with two-sheet height 666 and width 664 are oriented such that their ends occur on every other perforation 606, and with maximum heights at perforations 626 and 637. Perforations may be made prior to, at the same time, or after the lens-shaped cuts are formed. The lens shapes are centered on cut lines and adjacent lenses are offset two sheets to create the pattern required to form multiple rolls with the shapes shown in FIGS. 3A-3D.
An additional example pattern is shown in FIG. 6C, which will create the example single-sheet indentation embodiments shown in FIGS. 5A-5D. Double-sized lens shapes have a length that span one sheet and end at adjacent perforations 606. Lenses are offset one sheet from each other and are centered on cut lines 680 such that a toilet paper roll with have indentations that alternate from the left side to the right side on adjacent sheets, as shown in FIGS. 5A-5D.
Because these teeth on one drum may grind on the other drum, the drum without teeth may have a rubber covering in order to allow this cut without damage to the equipment. Alternatively, during the perforation process, the concave-segment-shaped shape can be cut at the same time perforation lines are added. A rubber covering on the non-cutting drum may also be desired or required. In either case, there will be waste material (e.g., the cut-out lenses) produced which can be collected and recycled.
The present invention includes formation of individual rolls or lengths of toilet paper (such as lengths of prefolded toilet paper) of any size and shape. Additional embodiments of the present invention include embossing or printing verbal or pictorial instructions for use, e.g. similar to FIG. 3D, 4D, or 5D, on the toilet paper of the current invention itself.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The foregoing description and figures, given for purposes of illustration, are not to be construed as limiting the scope of this invention, which is defined by the following claims and all equivalents thereto.

Claims

1. A length of toilet paper having parallel sidewalls defining a sidewall width of said paper, wherein said sidewalls are perpendicular at least one perforation spanning the distance between each side, comprising a first indentation in one side of said length of toilet paper.

2. The paper of claim 1, comprising a second indentation in the side opposite the one containing the first indentation, further comprising two or more perforations equally spaced from and parallel to each other, and wherein said two or more perforations define at least one individual sheet of toilet paper.

3. The paper of claim 2, wherein the second indentation does not overlap the first indentation if the length of toilet paper is folded in half parallel to the sidewalls of said paper.

4. (canceled)

5. The paper of claim 2, wherein the indentations have an overall concave shape.

6. (canceled)

7. The paper of claim 5, wherein an endpoint of at least one indentation occurs at or about the intersection of a perforation and said endpoint.

8. The paper of claim 5, wherein an endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper.

9. (canceled)

10. (canceled)

11. (canceled)

12. The paper of claim 2 wherein the first indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets.

13. (canceled)

14. (canceled)

15. A toilet paper roll having parallel sidewalls defining a sidewall width of said roll, wherein said sidewalls are perpendicular to the long axis of a central core of said toilet paper roll, comprising a length of toilet paper with sidewalls congruent to the sidewalls of said roll, where said length of toilet paper comprises a first indentation in one side of said length of toilet paper.

16. The roll of claim 15, comprising a second indentation in the side of said length of toilet paper opposite the one containing the first indentation, where the length of toilet paper further comprises two or more perforations equally spaced from and parallel to each other, and wherein said two or more perforations define at least one individual sheet of toilet paper.

17. The roll of claim 16, wherein the second indentation does not overlap the first indentation if said length of toilet paper is folded in half parallel to the sidewalls of said paper.

18. (canceled)

19. The roll of claim 16, wherein the indentations have an overall concave shape.

20. (canceled)

21. The roll of claim 16, wherein an endpoint of at least one indentation occurs at or about the intersection of a perforation and said endpoint.

22. The roll of claim 21, wherein an endpoint of said first and an endpoint of said second indentations are located about perpendicular to each other on opposite sides of said length of toilet paper.

23. (canceled)

24. (canceled)

25. (canceled)

26. The roll of claim 16, wherein the first indentation spans: one individual sheet, two adjacent individual sheets, three adjacent individual sheets, or more than three adjacent individual sheets.

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. A method of producing toilet paper rolls or lengths of toilet paper, comprising:

providing a sheet of tissue paper capable of being formed into individual rolls or lengths of toilet paper, comprising a plurality of cut out areas where the cut out areas intersect lines of separation into individual rolls.

34. The method of claim 33, wherein one or more endpoints of each cutout area occur at or about lines of perforation perpendicular to said lines of separation into individual rolls or lengths of toilet paper, and wherein each cut out area is intersected by: at least two, at least three, at least four, or more than four perpendicular lines of perforation.

35. The method of claim 33, wherein cut out areas intersecting adjacent lines of separation are offset from one another.

36. (canceled)