Improved sheet products for use in a pop-up dispenser and method for forming

An improved method is disclosed for forming a strata of overlapping sheets suitable for use in a pop-up dispensing system. The sheets are cut from ribbons having at least one side edge which has a knee-like protrusion, with the opposing side edge being either, substantially parallel to the longitudinal axis of the ribbon, or having one or more knee-like protrusions formed on the opposing edge. The ribbons are then phased so that the knee-like protrusion on one edge aligns with either the essentially parallel edge of an adjoining ribbon or a knee-like protrusion on the side edge of the adjoining ribbon. Phasing can be accomplished by either, aligning knee-like protrusions on the side edges of adjoining ribbons, or reversing the orientation of the side edges of alternating ribbons. After phasing, the ribbons are overlapped creating a series of predetermined, areas of greatest overlap adjoining areas of least overlap such that successive ribbons are bonded only by the interfacial interaction between ribbons. By overlapping multiple ribbons in this manner a strata is formed which is then folded to interleave the ribbons. A resulting stack of interleaved ribbons is cut to form blocks of individual interleaved sheets. The process can be accomplished manually or in a continuous production process.