Interfolded Paper Stack with Starter Fold for Enhanced Unfolding
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Solution Overview
Problem
Existing stacks of folded paper sheets, such as tissue paper, do not allow for easy unfolding when withdrawn from a dispenser, as they only double in size along the parallel folding lines used for interfolding, resulting in a less than optimal opening and gripping experience.
Innovation Solution
A stack of folded paper sheets is designed with a starter fold formed by a first folding line and additional folding lines that intersect to create a more stable and easily grippable sheet, allowing the sheet to unfold to more than double its original size after withdrawal, while maintaining a small footprint and interfolding capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If sheets are folded along three folding lines to achieve 1/4 size reduction, then the footprint is reduced, but the unfolding capability is limited to only doubling in size
Solution Approach 1:
The sheet is divided into multiple panels (first panel, second panel, third panel) separated by different types of folds. The first and second folding lines create panel separations for interfolding, while the third folding line creates a starter fold that segments the sheet to enable progressive unfolding beyond the limited double-size expansion of conventional designs.
Solution Approach 2:
The invention introduces a third folding line that is non-parallel to the first two folding lines, adding a new dimensional aspect to the folding pattern. This third fold creates a starter fold that extends in a different direction, allowing the sheet to unfold in multiple directions and achieve more than double its original size when pulled from the dispenser.
2Ease of manufacture
If parallel folding lines are used for interfolding, then the stacking and interfolding is simplified, but the sheet opening is perceived as less than optimum
Solution Approach 1:
The sheet structure is segmented into distinct functional zones: the first and second folding lines create panel separations for interfolding, while the third folding line creates a starter fold that segments the sheet to enable progressive unfolding beyond the limited double-size expansion of conventional designs.
Solution Approach 2:
The third folding line serves multiple functions: it creates the starter fold for easy gripping, enables additional unfolding beyond the parallel folds, and maintains compatibility with the existing interfolding structure. This multi-functional element enhances sheet opening without complicating the manufacturing process.
3Area of stationary object
If the stack is made compact with limited unfolding, then storage efficiency is improved, but the user experience of gripping and opening is degraded
Solution Approach 1:
The third folding line is pre-configured during manufacturing to create a starter fold that protrudes from the compact stack. This preliminary action ensures that when a user pulls a sheet from the dispenser, the starter fold is already positioned for easy gripping and begins the unfolding process automatically, enhancing user experience without increasing the compact stack footprint.
Solution Approach 2:
The third folding line introduces a new dimensional aspect to the folding pattern, creating a starter fold that extends in a different direction from the parallel folds. This allows the sheet to unfold in multiple directions when pulled, achieving more than double its original size while maintaining a compact footprint when stacked.
Data Source
Figure 1A~2
Figure 3A~4
Figure 5~8
AI summary
The present disclosure concerns a stack of paper sheets particularly for use as dispenser napkins, the stack comprising a plurality of folded sheets (30), each folded sheet (30) being folded along a first folding line (13) so that a part of a free edge opposite to the first folding line (13) is located on an outer surface of the folded sheet (30) and inward of the outer peripheral edges of the folded sheet (30), whereby a starter fold (16) is formed, each folded sheet (30) being further folded along a second folding line (18) non-parallel to the first folding line (13), the second folding line (18) separating the folded sheet (30) in two panels connected at the second folding line (18), wherein two consecutive folded sheets (30) are interfolded so that one panel (19) of one folded sheet (30) is disposed between two panels (19, 21) of the consecutive folded sheet (30). The present disclosure further concerns a method for manufacturing such a stack and folding the sheets included in the stack as well as a dispenser containing such a stack.