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.

What is claimed is: 
     
         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 3×3×2 configuration, each of said poly wrap packs having a length of substantially 12 inches a height of substantially 8¼ 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 36⅝ 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 3×5×2 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 36⅝ inch length of said pallet, each of said poly wrap packs having a length of substantially 18 inches, having a width of substantially 13¾ inches and a height of substantially 8 inches, each of said cartons having a width of substantially 13¾ 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 3×2 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 3×3 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 3×2 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.